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TITLE PAGE FINAL PROJECT

PRELIMINARY DESIGN OF TERTIARY BUTYL ALCOHOL PLANT FROM ISOBUTYLENE AND WATER CAPACITY OF 80,000 TONS/YEAR

Submitted In Partial Fulfillment of the Requirement for the Degree of Bachelor in Chemical Engineering by: Desi Ratnasari D 500 112 002

Supervisor: 1. Ir. Herry Purnama, M.T., PhD 2. Tri Widayatno, S.T., M.Sc., Ph.D

DEPARTMENT OF CHEMICAL ENGINEERING FACULTY OF ENGINEERING UNIVERSITAS MUHAMMADIYAH SURAKARTA 2016

ABSTRACT ABSTRAK

Pabrik Tertiary Butyl Alcohol (TBA) memiliki kapasitas 80.000 ton per tahun. Pabrik direncanakan untuk beroperasi selama 330 hari pertahun. Proses pembuatan TBA dilakukan dalam reaktor gelembung fase cair-gas, non-adiabatis dan isotermal. Proses berlangsung pada suhu 70°C dan tekanan 1.4 atm dalam reaksi irreversible dan eksotermis. Pabrik ini dikategorikan pabrik beresiko rendah. Setiap tahun, kebutuhan bahan baku isobutilen adalah 58.192,4872 ton dan air sebanyak 21.880,5938 ton. Unit pendukung proses (Utilitas) meliputi air pendingin, air sanitasi, air umpan boiler, air proses, steam, listrik, bahan bakar, dan udara tekan. Kebutuhan air total sebanyak 88.334,4799 kg/jam diambil dari Sungai Cimanuk. Kebutuhan steam sebanyak 9.388,1468 kg/jam dan didapatkan dari boiler. Bahan bakar untuk boiler digunakan minyak sebnyak 1.4710 m3/jam. Kebutuhan udara tekan sekitar 50m3/jam. Kebutuhan listrik dipenuhi oleh Perusahaan Listrik Negara (PLN) sebanyak 321.62 kW dan generator yang digunakan sebagai cadangan tenaga sebanyak 550 kW dengan menggunakan bahan baku solar sekitar 1.76 m3/jam. Pabrik didirikan di area industri Indramayu, Jawa Barat. Total area tanah adalah 27,030 m2. Bahan baku isobutilene didapatkan dari UP VI Balongan, Indramayu, Jawa Barat. Jumlah karyawan sebanyak 125 orang. Pabrik TBA membutuhkan Rp 480.322.499.166,48 sebagai modal tetap dan Rp 145.074.950.600,34 sebagai modal kerja. Berdasarkan analisis ekonomi, pabrik ini akan mendapatkan keuntungan sebelum pajak sebesar Rp 271.474.519.769,99. Pabrik akan mendapatkan keuntungan setelah pajak 30% sebesar Rp 190,032,163,838.99 per tahun. Jumlah persen dari Return of Investment (ROI) sebelum pajak dan sesudah pajak adalah 56.52% dan 39.56% berturut-turut. Pay Out Time (POT) sebelum pajak dan sesudah pajak sekitar 1.5 tahun dan 2 tahun. Break Even Point (BEP) adalah 42.92% dan Shut Down Point adalah 28.46%. Internal Rate of Return (IRR) adalah 33%. Berdasarkan dari kelayakn ekonomi, disimpulkan bahwa pabrik TBA layak untuk dibangun.

Kata kunci: Tertiari Butil Alkohol, isobutilen, reaktor gelembung

ABSTRACT The Tertiary Butyl Alcohol (TBA) plant has a capacity of 80,000 tons per year. The plant is planned to operate for 330 days per year. TBA making process is carried out in a bubble reactor liquid-gas phase, non-adiabatic and isothermal. The process takes place at a temperature of 70°C and a pressure of 1.4 atm in irreversible and exothermic reaction. This plant is classified low risk plant. Each year, the need for raw materials isobutylene is 58,192.4872 tons and water is 21,880.5938 tons. Process supporting units (Utilities) consist of cooling water, sanitary water, boiler feed water, process water, steam, electricity, fuel, and compressed air. Total water needed is about 88,384.4799 kg/hour supplied from Cimanuk River. Steam supply is about 9,388.1468 kg/hour then obtained from the boiler. The fuel for boiler is used fuel oil as much as 1.4710 m3/hour. Compressed air needs is about 50 m3/hr. Electricity is supplied by State Electricity Company (PLN) as much as 321.62 kW and generator for backup power is about 550 kW by using diesel fuel of 1.76 m3/hr. The plant was established in the industrial area of Indramayu, West Java. Total land area is 27,030 m2. Isobutylene raw material is obtained from UP VI Balongan, Indramayu, West Java. The number of employees are 125 people. TBA plant needs 480,322,499,166.48 IDR of fixed capital and 145,074,950,600.34 IDR of working capital. Based on the economic analysis, the plant will get 271,474,519,769.99 IDR of profit before tax. The plant will get 190,032,163,838.99 IDR of profit after 30% of tax per year. Number of percent Return of Investment (ROI) before tax and after tax is 56.52% and 39.56% respectively. Pay Out Time (POT) before tax and after tax is about 1.5 years and 2 years. Break Even Point (BEP) is 42.92% and shut down point is 28.46%. Internal Rate of Return (IRR) is 33 %. Based on the economic feasibility, it is concluded that the TBA plant is feasible to be built.

Keyword: tertiary butyl alcohol, isobutylene, bubble reactor

MOTTO

“YOU ARE WHAT YOU THINK!”

DEDICATION Every challenging work needs self efforts as well as guidance of older especially those who were very close to our heart. My humble effort I dedicate to my sweet and loving

Father & Mother,

Whose affection, love, encouragement and prays of day and night make me able to get such success and honor,

Along with all hard working and respected Teachers

PREFACE

Assalamu’alaikum Wr. Wb. Alhamdulillah, Praise due to Allah SWT for blessing and guidance of His mercy I can finish this final project. This report is one of requirements to pass the Bachelor’s in Chemical Engineering.

In this opportunity, the author would like to thank to everyone who has helped and guide, in completing this report. 1. Allah AWT who has given the opportunity to complete this final project. 2. Prophet Muhammad S.A.W. who has given exemplary to do best 3. Ir. Herry Purnama, M.T., PhD as first supervisor of final project 4. Tri Widayatno, S.T., M.Sc., Ph.D as second supervisor of final project 5. Rois Fatoni, S.T., MSc. Ph.D as Head of Chemical Engineering Department, Faculty of Engineering, Universitas Muhammadiyah Surakarta 6. Father, mother, and brother, who has given support, and a lot of love to the author. 7. All lecturer of Chemical Engineering Department, UMS 8. All employees of Administration in Chemical Engineering Department, UMS, has helped all the needs of the technical administration in the preparation of this final project. 9. Everyone who has supported the author to carry out this final project very well. The author realizes this report is not perfect due to our limited knowledge and experience, therefore advice and suggestion are welcome. Author wish this report to be beneficial to those may concern. Wassalamu'alaikum Wr. Wb. Surakarta, October 2016 Author

Preliminary Design of Tertiary Butyl Alcohol Plant from Isobutylene and Water Capacity of 80,000 Tons/Year

LIST OF CONTENTS

TITLE PAGE ........................................................................................................... i VALIDATION ........................................................................................................ ii STATEMENT OF AUTHENTICITY ................................................................... iii ABSTRACT ABSTRAK ....................................................................................... iv MOTTO ................................................................................................................. vi DEDICATION ...................................................................................................... vii PREFACE ............................................................................................................ viii LIST OF CONTENTS .......................................................................................... vii LIST OF TABLE .................................................................................................. xii TABLE OF FIGURES ......................................................................................... xiv CHAPTER I INTRODUCTION ............................................................................ 1 1.1. Background of the Study ............................................................................. 1 1.2. Design Capacity .......................................................................................... 1 1.3. Location ....................................................................................................... 2 1.4. Literature Review ........................................................................................ 4 1.4.1. Process Selection .................................................................................. 4 1.4.2. The Use of the Product ......................................................................... 5 1.4.3. Physical and Chemical Characteristic of Raw Materials and Products 5 1.4.4. Process Review .................................................................................... 9 CHAPTER II PROCESS DESCRIPTION ........................................................... 10 2.1. Specification of the Raw Materials and Product ........................................ 10 2.1.1. Specification of the Raw Materials ...................................................... 10 2.1.2. Product Specification ........................................................................... 11 2.2. Reaction Concept ...................................................................................... 11 2.2.1. Basis of Reaction ................................................................................ 11

Desi Ratnasari D 500 112 002

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2.2.2. Operational Condition ........................................................................ 12 2.2.3. Thermodynamic Review .................................................................... 12 2.2.4. Kinetics Review ................................................................................. 14 2.2.5. Process Step........................................................................................ 15 2.3. Flowchart ................................................................................................... 17 2.4. Mass Balance............................................................................................. 20 2.5. Heat Balance ............................................................................................. 22 2.6. Layout of Plant and Equipment ................................................................. 27 2.6.1. Layout of the Plant ............................................................................. 27 2.6.2. Layout of the Equipment .................................................................... 31 CHAPTER III EQUIPMENT SPECIFICATIONS .............................................. 33 3.1. Reactor ........................................................................................................ 33 3.2. Distillation Column -01 ............................................................................. 33 3.3. Distillation Column -02 ............................................................................. 34 3.4. Flash Drum ................................................................................................ 35 3.5. Accumulator .............................................................................................. 35 3.5.1. Accumulator – 01 ............................................................................... 35 3.5.2. Accumulator – 02 ............................................................................... 36 3.5.3. Accumulator – 03 ............................................................................... 37 3.5.4. Accumulator – 04 ............................................................................... 37 3.6. Condenser .................................................................................................. 38 3.6.1. Condenser – 01 ................................................................................... 38 3.6.2. Condenser – 02 ................................................................................... 39 3.7. Cooler ........................................................................................................ 39 3.7.1. Cooler – 01 ......................................................................................... 39


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3.7.2. Cooler – 02 ......................................................................................... 40 3.8. Reboiler ..................................................................................................... 41 3.8.1. Reboiler – 01 ...................................................................................... 41 3.8.2. Reboiler – 02 ...................................................................................... 42 3.9. Heat Exchanger ......................................................................................... 43 3.9.1. Heat Exchanger – 01 .......................................................................... 43 3.9.2. Heat Exchanger – 02 .......................................................................... 44 3.9.3. Heat Exchanger – 03 .......................................................................... 44 3.10. Vaporizer ................................................................................................... 45 3.11. Tank ......................................................................................................... 46 3.11.1. Tank – 01 ............................................................................................ 46 3.11.2. Tank – 02 ............................................................................................ 46 3.11.3. Tank – 03 ............................................................................................ 47 3.11.4. Tank – 04 ............................................................................................ 48 3.12. Pump ......................................................................................................... 48 3.12.1. Pump – 01........................................................................................... 48 3.12.2. Pump – 02........................................................................................... 49 3.12.3. Pump – 03........................................................................................... 50 3.12.4. Pump – 04........................................................................................... 51 3.12.5. Pump – 05........................................................................................... 51 3.12.6. Pump – 06........................................................................................... 52 3.12.7. Pump – 07........................................................................................... 53 3.12.8. Pump – 08........................................................................................... 54 3.12.9. Pump – 09........................................................................................... 54 3.12.10. Pump – 10 ........................................................................................ 55 Desi Ratnasari D 500 112 002

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3.12.11. Pump – 11 ........................................................................................ 56 3.12.12. Pump – 12 ........................................................................................ 57 CHAPTER IV PROCESS SUPPORT AND LABORATORY ........................... 58 4.1. Process Support Unit ................................................................................. 58 4.2. Water Provider .......................................................................................... 58 4.2.1. Steam Provider Unit ........................................................................... 64 4.2.2. Electricity Provider Unit .................................................................... 66 4.2.3. Fuel Support Unit ............................................................................... 69 4.2.4. Compressed Air .................................................................................. 70 4.2.5. Waste Support Unit ............................................................................ 70 4.2.6. Laboratory .......................................................................................... 71 CHAPTER V PLANT MANAGEMENT ............................................................ 87 5.1. Corporate Form ......................................................................................... 87 5.2. Organizational Structure ........................................................................... 87 5.3. Duties and Power ...................................................................................... 90 5.3.1. Shareholders ....................................................................................... 90 5.3.2. The Board of Commissioner .............................................................. 90 5.3.3. President Director ............................................................................... 90 5.3.4. Expert Staff ........................................................................................ 90 5.3.5. Manager of Engineering and Production ........................................... 91 5.3.6. Manager of Finance ............................................................................ 91 5.3.7. Secretary ............................................................................................. 91 5.3.8. Research, development, and quality control ...................................... 91 5.3.9. Head of Department ........................................................................... 92 5.3.10. Head of General ................................................................................. 92


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5.3.11. Head of Health Safety and Environment............................................ 93 5.4. Employees System .................................................................................... 94 5.5. Working Hours .......................................................................................... 94 5.6. Details of Duties and Skill ........................................................................ 96 5.6.1. Distribution of Position ...................................................................... 96 5.7. Total Employee ......................................................................................... 97 5.7.1. The salary system ............................................................................... 98 5.8. Employees social safety ............................................................................ 98 5.9. Production Management ........................................................................... 99 CHAPTER VI ECONOMIC ANALYSIS ......................................................... 100 6.1. Fixed Capital Investment ........................................................................ 105 6.2. Working Capital ...................................................................................... 106 6.3. Manufacturing Cost ................................................................................. 106 6.4. General Expenses .................................................................................... 107 6.5. Economic Analysis .................................................................................. 107 REFERENCE ...................................................................................................... 113 ATTACHMENT ................................................................................................. 115


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LIST OF TABLE

Table 1.2.1 Data Import of TBA in Indonesia ........................................................ 2 Table 2.4.1 Total Mass Balance ............................................................................ 20 Table 2.4.2 Mass Balance in Reactor .................................................................... 20 Table 2.4.3 Mass Balance in Flash Drum ............................................................. 21 Table 2.4.4 Mass Balance in Distillation Column 1 (D-100) ............................... 21 Table 2.4.5 Mass Balance in Distillation Column 2 (D -110) .............................. 22 Table 2.5.1 Heat Balance on Heat Exchanger – 01 (E-110) ................................. 22 Table 2.5.2 Heat Balance on Heat Exchanger – 02 (E-111) ................................. 23 Table 2.5.3 Heat Balance on Heat Exchanger – 03 (E-112) ................................. 23 Table 2.5.4 Heat Balance on Vaporizer -01 (E-112) ............................................ 24 Table 2.5.5 Heat Balance on Reactor (R-100) ...................................................... 25 Table 2.5.6 Heat Balance on Flash Drum (H – 100)............................................. 26 Table 2.5.7 Heat Balance on Distillation Column – 01 (D-110) .......................... 26 Table 2.5.8 Heat Balance on Distillation Column – 02 (D-111) .......................... 27 Table 2.6.1 Total area of TBA plant capacity of 80,000 tons/year ....................... 29 Table 4.2.1 List of Consumption of Water for cooling ......................................... 59 Table 4.2.2 Sanitation Water Consumption .......................................................... 60 Table 4.2.3 Steam Requirement ............................................................................ 61 Table 4.2.4 Total of Water Consumption ............................................................. 61 Table 4.2.5 Electricity Consumption for Process.................................................. 66 Table 4.2.6 Electricity Consumption for Utility support unit ............................... 67 Table 5.5.1 Daily schedule and working hours for shift employees ..................... 95 Table 5.7.1 Total employee................................................................................... 97 Table 5.9.1 Cost Index Chemical Plant Data ...................................................... 101 Table 6.1.1 Fixed Capital Investment ................................................................. 105 Table 6.2.1 Working Capital ............................................................................... 106 Table 6.3.1 Manufacturing Cost.......................................................................... 106 Table 6.4.1 General Expenses ............................................................................. 107


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Table 6.5.1 Fixed Cost ........................................................................................ 109 Table 6.5.2 Variable Cost ................................................................................... 109 Table 6.5.3 Regulated Cost ................................................................................. 109 Table 6.5.4 Comparisons between Calculation and Reference ........................... 111


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TABLE OF FIGURES Figure 2.3.1 Diagram of Quantitative ................................................................... 18 Figure 2.3.2 Diagram of Qualitative ..................................................................... 19 Figure 2.6.1 Layout of TBA Plant ........................................................................ 30 Figure 4.2.1 Water Treatment Unit ....................................................................... 86 Figure 5.2.1 Organization Structure ...................................................................... 89 Figure 5.7.1 Relationships Between Year Vs Cost Index ................................... 102 Figure 6.5.1 Economic Analysis ......................................................................... 111


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