Rajendra, Rafi (2026) ASETILENA DARI KALSIUM KARBIDA DAN AIR DENGAN PROSES HIDROLISIS BASAH KAPASITAS 75.000 TON/TAHUN. Undergraduate thesis, UPN Veteran Jawa Timur.
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Abstract
The preliminary design of an acetylene plant with a production capacity of 75,000 tons/year utilizes calcium carbide (CaC₂) and water (H₂O) as raw materials through a wet hydrolysis process. The plant is planned to be located in the JIIPE Industrial Estate, Manyar District, Gresik Regency, East Java, Indonesia. The plant location was selected based on several considerations, including raw material availability, proximity to markets, ease of transportation and distribution, utility availability, labor availability, and environmental aspects. The establishment of this acetylene plant is driven by domestic demand for acetylene, which is used as a raw material and auxiliary material in various industries. Therefore, an increase in domestic production capacity is necessary to meet this demand. Acetylene is produced through the hydrolysis reaction of calcium carbide with water, yielding acetylene (C₂H₂) and calcium hydroxide (Ca(OH)₂). The production process consists of raw material storage and preparation, calcium carbide feeding into the acetylene generator, hydrolysis with water, separation of acetylene gas from calcium hydroxide slurry, cooling and condensation, drying, gas purification, compression, and product storage. The resulting acetylene gas is purified to remove impurities such as phosphine (PH₃), hydrogen sulfide (H₂S), ammonia (NH₃), and other contaminants before being compressed and stored as the final product. The by-product, calcium hydroxide, and waste generated during the purification process are subsequently handled by appropriate waste treatment units according to their characteristics. Based on the analyses conducted, the establishment of this plant is considered technically and operationally feasible and has the potential to meet domestic acetylene demand. The results of the calculations and discussions lead to the following conclusions: Production Capacity: 75,000 tons/year Business Entity: Limited Liability Company Organizational Structure: Line and Staff Organization Total Number of Employees: 226 people Operating Schedule: 330 days/year, 24 hours/day Plant Location: JIIPE Industrial Estate, Gresik, East Java, Indonesia Operating System: Continuous Operating Period: 330 days/year Economic Analysis: a. Construction Period: 2 years b. Fixed Capital Investment (FCI): IDR 1,356,089,816,114 c. Working Capital Investment (WCI): IDR 55,905,266,972,682 d. Total Capital Investment (TCI): IDR 57,261,356,788,796 e. Annual Raw Material Cost: IDR 30,319,686,206,416 f. Annual Utility Cost: IDR 52,876,610,185 g. Annual Sales Revenue: IDR 184,226,885,201,495 h. Bank Loan Interest Rate: 7.74% i. Rate on Investment (ROI) Before Tax: 29.3% j. Rate on Investment (ROI) After Tax: 22.6% k. Payback Period (POT): 3 years and 0.53 months l. Internal Rate of Return (IRR): 15.53% m. Break-Even Point (BEP): 31.77%
| Item Type: | Thesis (Undergraduate) | ||||||||||||
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| Subjects: | Q Science > QD Chemistry | ||||||||||||
| Divisions: | Faculty of Engineering > Departement of Chemical Engineering | ||||||||||||
| Depositing User: | Rafi Rajendra | ||||||||||||
| Date Deposited: | 12 Oct 2026 03:41 | ||||||||||||
| Last Modified: | 12 Oct 2026 06:37 | ||||||||||||
| URI: | https://repository.upnjatim.ac.id/id/eprint/60666 |
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