Istiawan, Rio Maulana Putra (2026) Pabrik Chloroform dari Aseton dan Bleaching Powder dengan Proses Haloform. Undergraduate thesis, UPN Veteran Jawa Timur.
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Abstract
Chloroform (CHCl₃) is a chemical compound used as a solvent and a chemical intermediate in various chemical, pharmaceutical, laboratory, polymer, and other chemical synthesis applications. The demand for chloroform in Indonesia is still met through imports because no domestic chloroform production facilities are currently available. Based on demand considerations and market opportunities, a chloroform plant is planned to commence operations in 2030, with a production capacity of 59,000 tons per year. The plant is designed to operate for 330 days per year, with a production rate of 7,449.495 kg/h, and will be located in the Sidoarjo Industrial Estate (SiRIE), East Java, Indonesia. The chloroform production process is carried out through the haloform reaction between acetone (CH₃COCH₃) and bleaching powder, in the form of calcium hypochlorite (CaOCl₂·H₂O), with water serving as the solvent medium. This process was selected because the raw materials are relatively readily available, the operating conditions are relatively mild, the processing time is shorter, the reaction occurs under neutral to alkaline conditions, and the process provides a relatively high yield of approximately 80–91%. The initial stage of the process involves raw material storage and preparation. Acetone and bleaching powder are stored at 30°C and 1 atm. Bleaching powder is first mixed with water to form a suspension or solution before being fed into the reactor. The ratio used is approximately 3 lb of bleaching powder per pound of water. A portion of the unreacted water and bleaching powder is recycled from the solids separation unit to reduce raw material consumption. The bleaching powder suspension is then fed into the reactor, while acetone is supplied from its storage tank. The reactor operates at a pressure of 1 atm and a temperature of 43°C, with a residence time of 3 hours and a reaction yield of 88%. The acetone-to-bleaching-powder ratio is 0.1 lb of acetone per 1 lb of bleaching powder. The reaction produces chloroform as the main product, along with calcium acetate, calcium hydroxide, calcium chloride, water, and unreacted reactants. The reactor is equipped with an agitation and cooling system to maintain the required operating conditions throughout the reaction. The reactor effluent is subsequently fed into a rotary vacuum filter to separate the filtrate from the slurry. The liquid filtrate is then fed into a distillation column to separate chloroform from most of the water and other accompanying components. This distillation unit operates at approximately 65°C and 1 atm. The overhead product is crude chloroform, which is subsequently transferred to an acidification/mixing unit operating at 30°C and 1 atm. At this stage, sulfuric acid (H₂SO₄) is added at a ratio of 1 lb of H₂SO₄ per 2 lb of crude chloroform. The addition of sulfuric acid is intended to help remove residual impurities from the crude chloroform. Most of the H₂SO₄ is retained in the system and recycled to reduce the demand for fresh sulfuric acid. The acidified mixture is then transferred to a decanter operating at 30°C and 1 atm. Separation occurs in the decanter based on differences in phase properties and density. The chloroform-rich phase is separated from the phase containing water, sulfuric acid, and residual acetone. The stream containing H₂SO₄, water, and acetone is subsequently fed into an evaporator, while the chloroform-rich phase proceeds to the final purification stage. The chloroform-rich stream from the decanter is then mixed with calcium oxide (CaO) at 30°C and 1 atm. The addition of CaO is intended to bind or remove residual water remaining in the chloroform phase. The reaction between CaO and water produces Ca(OH)₂, allowing water to be removed from the chloroform product. The mixture is subsequently fed into a rotary vacuum filter (RVF) operating at 30°C and a vacuum pressure of 17.9 inHg to separate solid CaO and Ca(OH)₂ from the liquid chloroform phase. The liquid filtrate from the RVF is then fed into the final distillation column, which operates at approximately 61°C and 1 atm. This column serves as the final purification stage, separating chloroform from residual water and acetone based on differences in volatility. Based on the mass balance calculations, the chloroform production rate is approximately 7,449.495 kg/h. The purified chloroform product is then transferred to the storage tank. The main specifications of the proposed chloroform plant are summarized as follows: 1. Production capacity : 59,000 tons/year 2. Type of company : Limited Liability Company (Perseroan Terbatas, PT) 3. Organizational structure : Line and staff organization 4. Number of employees : 175 people 5. Operating schedule : 330 days/year; 24 hours/day 6. Plant location : Sidoarjo Industrial Estate (SiRIE), East Java, Indonesia 7. Plant area : 20,860 m² 8. Raw Materials a. Acetone : 4,108.698 kg/h b. Bleaching powder : 41,086.983 kg/h c. Sulfuric acid : 4,008.893 kg/h d. Calcium oxide : 18.927 kg/h 8. Product a. Chloroform: 7,449.495 kg/h 9. Utilities a. Steam requirement: 22,273.655 kg/h b. Water requirement: 1,15.301 m³/day c. Electricity requirement: 4,444 kWh d. Fuel requirement: 10,489.008 lb/h 10. Economic Analysis a. Construction period: 2 years b. Plant lifetime: 10 years c. Fixed Capital Investment (FCI): IDR 2,130,645,822,236 d. Working Capital Investment (WCI): IDR 4,675,365,231,690 e. Total Capital Investment (TCI): IDR 6,806,020,053,735 f. Annual raw material cost: IDR 7,588,533,413,454 g. Annual utility cost: IDR 1,839,722,293,290 h. Annual sales revenue: IDR 16,277,677,014,837 i. Bank loan interest rate: 10% j. Rate of Investment (ROI) before tax: 29.18% k. Rate of Investment (ROI) after tax: 21.88% l. Payback Period (PBP): 2 years and 11 months m. Internal Rate of Return (IRR): 15.7% n. Break-Even Point (BEP): 35.81%
| Item Type: | Thesis (Undergraduate) | ||||||||||||
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| Subjects: | T Technology > TP Chemical technology > TP155 Chemical engineering | ||||||||||||
| Divisions: | Faculty of Engineering > Departement of Chemical Engineering | ||||||||||||
| Depositing User: | Rio Rio istiawan | ||||||||||||
| Date Deposited: | 13 Oct 2026 02:43 | ||||||||||||
| Last Modified: | 13 Oct 2026 04:56 | ||||||||||||
| URI: | https://repository.upnjatim.ac.id/id/eprint/60650 |
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