| dc.description.abstract | The establishment of a fatty alcohol factory with a capacity of 70,000 tons/year
aims to meet the demand for surfactants in the agriculture, paper & pulp, and
cosmetics sectors as well as to be used as a stabilizer and emulsifier agent in the
detergent and soap industry so as to reduce import activities and build domestic
economic growth. This factory was established in the Wilmar integrated industrial
area (KITW) Serang-Banten with 169 employees employed. Fatty alcohol is
produced using methyl ester as raw material obtained from fatty acids methyl ester
(FAME) which is separated using a distillation tower where the methyl ester
obtained is then hydrogenated at a temperature of 250˚C and a pressure of 50 bar
using the help of a catalyst in the form of copper-manganese with a conversion of
98% in a packed bed trickle reactor which takes place in three phases namely, solidliquid-gas.
The
output
of
the
reaction
in
the
reactor
is
in
the
form
of
gas
and
liquid
phases
where the gas phase which was first released with the assumption that the
pressure is also released along with the output of the gas phase, then when the
conditions inside the reactor are at atmospheric pressure the liquid fluid output is
just released. At the output the liquid fluid contains fatty alcohol which is the main
product in this factory. While the output of the gas phase contains excess hydrogen
and methanol which will then be purified by excess hydrogen to be recycled using
a flash drum and the separated methanol is used as a by-product. The required raw
material for methyl ester is 10,197.217 kg/hour with hydrogen as much as
22,523.396 kg/hour to produce a fatty alcohol capacity of 70,000 tons/year. The
water utility needs of this factory is 71,425.22 Kg/hour with details of using Cooling
Water: 84,241.11; Steam Water: 232,209.92; Domestic Water: 26,617.5798; and
Air Service 500 (all in units of Kg/hour). Based on the economic evaluation of the
establishment of a fatty alcohol factory, the results are as follows: Return on
Investment (ROI) before tax is 55.80%, Return on Investment after tax is 41.85%,
Pay Out Time before tax is 1.57 years, Pay Out Time after tax is 2.01 years, Break
Even Point 53.8%, Shut Down Point 42%, and Discounted Cash Flow Rate of
Return 23.15%. The design of the fatty alcohol factory from methyl ester and
hydrogen with a capacity of 70,000 tonnes/year is classified as a high risk plant
based on process reviews, operating conditions, raw material and product
characteristics, and the origin of the raw materials. But the factory design is
economically feasible to establish and has good potential to be developed both in
the national and international markets. | en_US |
