Pra Rancangan Pabrik Formaldehyde Proses Silver Catalyst Kapasitas 130.000 Ton/Tahun

Abstract

Formaldehyde plant development aims to provide domestic need, to reduce Formaldehyde import, to expand domestic employement, and to increase state revenues from the industrial sector. This plant is planned to be built in Bontang, Kalimantan Timur, it covers 11,179 m2 of land and needs 144 employees. It works continually for 24 hours / day or 330 days / year. Process unit requires 73,638.344 ton / year of methanol and 736.383 ton / year of water, whereas utility unit needs 6,315.4251 kg / hour water for cooling, 2,646 kg / hour water for domestic, 34,106.1558 kg / hour of steam, 4,938.464 kVA of electricity, 7,074.8866 kg / hour of fuel oil and 500 kg / hour of pressured air. The preliminary design of formaldehyde for 130,000 ton / year capacities utilizes methanol of raw material to result formaldehyde with purity 99 % mass and 1 % mass of water. The process is oksidasi and silver catalyst to produce formaldehyde in fixed bed reactor at 560 OC and 1,2 atm atmospere. This plant has a high risk because processes at high operation condition (temperature), another raw material and product are flammable. The economic evaluation shows Fixed Capital of Rp 703,615,940,745.01, Working Capital of Rp 155,718,494,401, Profit before taxes Rp 320,320,116,216, Profit after taxes Rp 256,256,092,973. Feasibility studies results in Break Even Point (BEP) of 46.96 % (BEP requisite in Indonesia 40% - 60 %), Shut Down Point (SDP) of 23.39 %, and Discounted Cash Flow Rate of Return (DCFR) of 18.41 %. Meanwhile Return On Investment Before Taxes (ROIb) of 46 % (ROIb requisite for high risk plant > 44 %) and Return On Investment After Taxes (ROIa) of 36 %. Along with Pay Out Time Before Taxes (POTb) of 1.80 years (POTb requisite for high risk plant < 2 years) and Pay Out Time After Taxes (POTa) of 2.15 years in a row. Based on this economic evaluation, it can be concluded that formaldehyde Plant of 130,000 ton / year is economically feasible.