Perancangan Pabrik Urea Formaldehyde Concentrate – 85 dari Metanol dan Udara dengan Kapasitas 10.000 Ton/Tahun

Abstract

The Urea Formaldehyde Concentrate-85 plant gives very good prospect, considering the requirement of Urea Formaldehyde Concentrate-85 in Indonesia which progressively increase. Preliminary design of Urea Formaldehyde Concentrate-85(UFC-85) plant from methanol and air is planned to be built in Bontang, the province of East Borneo, in the land area of 27,586 m2 with production capacity of 10,000 tons/year. This chemical plant will be operated for 330 days a year and 24 hours a day with total 145 employees. Raw materials needed are methanol 62,630.3189 tons/year and air 270,804.8685 tons/year. The production process will be operated at temperature of 240°C and pressure about 1,4 atm using a fixed bed reactor and as a reactor cooler is used cooler coil. The convert reaction is 99%, resulting product formaldehyde and water. This plant needs 197.027,4442 kg/hour of water from Sangatta river which proceed in utility unit, 112.080,3864 kg/hour of fuel, 176.543,8272 kg/hour of steam, and 70 kVA of electricity power provided by PLN and also need a generator as reserve. A parameter of appropriatness uses an economic analysis with total capital investment Rp 116.583.547.843,56 and USD 8.967.965,22 consist of Rp 210.669.061.233,63 and USD 16.205.312.,40 as a Fixed Capital Investment, and Rp 22.652.126.075,96 and USD 1,742,471,24 as a Working Capital Total Cost Rp 116. 583.547.843,56 and Annual Sales Rp 169.000.000.000,00, thus it can get profit Rp 52.416.452.156,44 before taxes, and Rp 26.208.226.078,22 after taxes. A result of parameter after taxes is percentage of Return On Investment (ROI) 12,44%, Pay Out Time (POT) 2.87 year, Discounted Cash Flow (DCF) 18.70 %, Break Event Point (BEP) 46,28 %, while Shut Down Point (SDP) 16,94 %. From the analyses above it shows that the result is satisfied so the plant are interesting and appropriate to be built.