Gustika, Cinta Ananda (2026) Pra Rancangan Pabrik Asam Format dari Sodium Hidroksida dan Karbon Monoksida dengan Proses Karbonilasi Kapasitas 80.000 ton/tahun. Undergraduate thesis, UPN Veteran jawa Timur.
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Abstract
The Formic Acid Plant using the carbonylation method is designed with a production capacity of 80,000 tons/year and will be established in the Romokalisari Industrial Estate, Surabaya, East Java. The main raw materials used are carbon monoxide (CO) and sodium hydroxide (NaOH), while sulfuric acid (H₂SO₄) is used as an auxiliary material during the acidification stage. The main product is formic acid (HCOOH), while sodium sulfate (Na₂SO₄) is generated as a by-product. The production process consists of several stages, beginning with raw material preparation. Sodium hydroxide is dissolved in water to obtain a NaOH solution with a concentration suitable for the reactor feed. Meanwhile, carbon monoxide is conditioned to meet the required operating conditions before being fed into the reactor. The NaOH solution and CO are then reacted in an Agitated Autoclave Reactor under appropriate operating conditions to produce sodium formate (HCOONa) as an intermediate product. The resulting sodium formate (HCOONa) is subsequently fed into a Continuous Stirred-Tank Reactor (CSTR) for acidification using sulfuric acid (H₂SO₄), producing formic acid (HCOOH) and sodium sulfate (Na₂SO₄). The reaction mixture is then separated using a Rotary Drum Vacuum Filter to separate sodium sulfate from the liquid phase. The sodium sulfate obtained is subsequently dried in a Rotary Dryer and conveyed to the sodium sulfate storage silo, while the liquid phase containing formic acid is forwarded to the purification stage. The purification stage is carried out using a series of distillation units to obtain formic acid at the desired concentration. The final purification section consists of two distillation columns. The first distillation column separates formic acid from water using an entrainer, while the second distillation column separates formic acid from the entrainer. The plant's electricity supply for air conditioning and lighting is obtained from the State Electricity Company (PLN), while electricity for process operations is supplied by a generator set. The water supply is obtained from a river and is treated in the utility unit before being used as process water, cooling water, boiler feed water, and sanitation water. The plant operates as a Limited Liability Company (Perseroan Terbatas, PT), employing a line-and-staff organizational structure. The plant is designed for continuous operation, with an annual operating period of 330 days. Based on the calculations and discussions conducted, the following conclusions can be drawn: 1. General Plant Information 1. Production Capacity: 80,000 tons/year 2. Company Structure: Limited Liability Company (PT) 3. Organizational Structure: Line-and-Staff Organization 4. Number of Employees: 218 5. Operating Time: 330 days/year, 24 hours/day 6. Plant Location: Romokalisari Industrial Estate, Surabaya, East Java 7. Plant Area: 32,314.81 m² 2. Raw Material Requirements a. Sodium Hydroxide: 10,628.9479 kg/h b. Carbon Monoxide: 7,903.5766 kg/h c. Sulfuric Acid: 11,876.5355 kg/h 3. Product Output a. Formic Acid: 9,780.1096 kg/h b. Sodium Sulfate: 16,322.114 kg/h 4. Utility Requirements a. Boiler Feed Water: 81.2067 m³/h b. Cooling Water: 836.5133 m³/h c. Process Water: 28.2325 m³/h d. Sanitation Water: 0.3771 m³/h e. Electricity: 728 kWh f. Fuel: 73 kg/h 5. Economic Analysis a. Construction Period: 2 years b. Equipment Lifetime: 10 years c. Fixed Capital Investment (FCI): IDR 1,441,691,535,507 d. Working Capital Investment (WCI): IDR 632,680,724,305 e. Total Capital Investment (TCI): IDR 2,074,372,259,812 f. Annual Raw Material Costs: IDR 1,559,044,329,921 g. Annual Utility Costs: IDR 89,146,599,947 h. Total Production Cost (TPC): IDR 2,530,722,897,221 i. Sales Revenue: IDR 3,106,808,508,922 j. Bank Loan Interest Rate: 8% k. Rate of Investment (ROI) Before Tax: 21.54% l. Rate of Investment (ROI) After Tax: 16.16% m. Payback Period (PBP): 4 years and 4 months n. Internal Rate of Return (IRR): 11.06% o. Break-Even Point (BEP): 32.53%
| 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: | Cinta Ananda Gustika | ||||||||
| Date Deposited: | 13 Oct 2026 03:25 | ||||||||
| Last Modified: | 13 Oct 2026 07:41 | ||||||||
| URI: | https://repository.upnjatim.ac.id/id/eprint/60685 |
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