TITLE PAGEFINAL PROJECT Preliminary Design of Tertiary Butyl Alcohol Plant from Isobutylene and Water, Capacity of 80,000 Tons/Year.

TITLE PAGE FINAL PROJECT

PRELIMINARY DESIGN OF TERTIARY BUTYL ALCOHOL
PLANT FROM ISOBUTYLENE AND WATER
CAPACITY OF 80,000 TONS/YEAR

Submitted In Partial Fulfillment of the Requirement for the
Degree of Bachelor in Chemical Engineering
by:
Desi Ratnasari
D 500 112 002

Supervisor:
1. Ir. Herry Purnama, M.T., PhD
2. Tri Widayatno, S.T., M.Sc., Ph.D

DEPARTMENT OF CHEMICAL ENGINEERING
FACULTY OF ENGINEERING
UNIVERSITAS MUHAMMADIYAH SURAKARTA
2016

ABSTRACT
ABSTRAK

Pabrik Tertiary Butyl Alcohol (TBA) memiliki kapasitas 80.000 ton per
tahun. Pabrik direncanakan untuk beroperasi selama 330 hari pertahun. Proses
pembuatan TBA dilakukan dalam reaktor gelembung fase cair-gas, non-adiabatis
dan isotermal. Proses berlangsung pada suhu 70°C dan tekanan 1.4 atm dalam
reaksi irreversible dan eksotermis. Pabrik ini dikategorikan pabrik beresiko rendah.
Setiap tahun, kebutuhan bahan baku isobutilen adalah 58.192,4872 ton dan air
sebanyak 21.880,5938 ton.
Unit pendukung proses (Utilitas) meliputi air pendingin, air sanitasi, air
umpan boiler, air proses, steam, listrik, bahan bakar, dan udara tekan. Kebutuhan
air total sebanyak 88.334,4799 kg/jam diambil dari Sungai Cimanuk. Kebutuhan
steam sebanyak 9.388,1468 kg/jam dan didapatkan dari boiler. Bahan bakar untuk
boiler digunakan minyak sebnyak 1.4710 m3/jam. Kebutuhan udara tekan sekitar
50m3/jam. Kebutuhan listrik dipenuhi oleh Perusahaan Listrik Negara (PLN)
sebanyak 321.62 kW dan generator yang digunakan sebagai cadangan tenaga
sebanyak 550 kW dengan menggunakan bahan baku solar sekitar 1.76 m3/jam.
Pabrik didirikan di area industri Indramayu, Jawa Barat. Total area tanah adalah
27,030 m2. Bahan baku isobutilene didapatkan dari UP VI Balongan, Indramayu,

Jawa Barat. Jumlah karyawan sebanyak 125 orang.
Pabrik TBA membutuhkan Rp 480.322.499.166,48 sebagai modal tetap dan
Rp 145.074.950.600,34 sebagai modal kerja. Berdasarkan analisis ekonomi, pabrik
ini akan mendapatkan keuntungan sebelum pajak sebesar Rp 271.474.519.769,99.
Pabrik akan mendapatkan keuntungan setelah pajak 30% sebesar Rp
190,032,163,838.99 per tahun. Jumlah persen dari Return of Investment (ROI)
sebelum pajak dan sesudah pajak adalah 56.52% dan 39.56% berturut-turut. Pay
Out Time (POT) sebelum pajak dan sesudah pajak sekitar 1.5 tahun dan 2 tahun.
Break Even Point (BEP) adalah 42.92% dan Shut Down Point adalah 28.46%.
Internal Rate of Return (IRR) adalah 33%. Berdasarkan dari kelayakn ekonomi,
disimpulkan bahwa pabrik TBA layak untuk dibangun.

Kata kunci: Tertiari Butil Alkohol, isobutilen, reaktor gelembung

ABSTRACT
The Tertiary Butyl Alcohol (TBA) plant has a capacity of 80,000 tons per
year. The plant is planned to operate for 330 days per year. TBA making process is
carried out in a bubble reactor liquid-gas phase, non-adiabatic and isothermal. The
process takes place at a temperature of 70°C and a pressure of 1.4 atm in irreversible
and exothermic reaction. This plant is classified low risk plant. Each year, the need

for raw materials isobutylene is 58,192.4872 tons and water is 21,880.5938 tons.
Process supporting units (Utilities) consist of cooling water, sanitary water,
boiler feed water, process water, steam, electricity, fuel, and compressed air. Total
water needed is about 88,384.4799 kg/hour supplied from Cimanuk River. Steam
supply is about 9,388.1468 kg/hour then obtained from the boiler. The fuel for
boiler is used fuel oil as much as 1.4710 m3/hour. Compressed air needs is about 50
m3/hr. Electricity is supplied by State Electricity Company (PLN) as much as
321.62 kW and generator for backup power is about 550 kW by using diesel fuel of
1.76 m3/hr. The plant was established in the industrial area of Indramayu, West
Java. Total land area is 27,030 m2. Isobutylene raw material is obtained from UP
VI Balongan, Indramayu, West Java. The number of employees are 125 people.
TBA plant needs 480,322,499,166.48 IDR of fixed capital and
145,074,950,600.34 IDR of working capital. Based on the economic analysis, the
plant will get 271,474,519,769.99 IDR of profit before tax. The plant will get
190,032,163,838.99 IDR of profit after 30% of tax per year. Number of percent
Return of Investment (ROI) before tax and after tax is 56.52% and 39.56%
respectively. Pay Out Time (POT) before tax and after tax is about 1.5 years and 2
years. Break Even Point (BEP) is 42.92% and shut down point is 28.46%. Internal
Rate of Return (IRR) is 33 %. Based on the economic feasibility, it is concluded
that the TBA plant is feasible to be built.

Keyword: tertiary butyl alcohol, isobutylene, bubble reactor

MOTTO

“YOU ARE WHAT YOU THINK!”

DEDICATION
Every challenging work needs self efforts as well as guidance
of older especially those who were very close to our heart.
My humble effort I dedicate to my sweet and loving

Father & Mother,

Whose affection, love, encouragement and prays of day and
night make me able to get such success and honor,

Along with all hard working and respected
Teachers

PREFACE

Assalamu’alaikum Wr. Wb.
Alhamdulillah, Praise due to Allah SWT for blessing and guidance of His
mercy I can finish this final project. This report is one of requirements to pass the
Bachelor’s in Chemical Engineering.

In this opportunity, the author would like to thank to everyone who has
helped and guide, in completing this report.
1. Allah AWT who has given the opportunity to complete this final project.
2. Prophet Muhammad S.A.W. who has given exemplary to do best
3. Ir. Herry Purnama, M.T., PhD as first supervisor of final project
4. Tri Widayatno, S.T., M.Sc., Ph.D as second supervisor of final project
5. Rois Fatoni, S.T., MSc. Ph.D as Head of Chemical Engineering Department,
Faculty of Engineering, Universitas Muhammadiyah Surakarta
6. Father, mother, and brother, who has given support, and a lot of love to the
author.
7. All lecturer of Chemical Engineering Department, UMS
8. All employees of Administration in Chemical Engineering Department, UMS,
has helped all the needs of the technical administration in the preparation of this

final project.
9. Everyone who has supported the author to carry out this final project very well.
The author realizes this report is not perfect due to our limited knowledge
and experience, therefore advice and suggestion are welcome. Author wish this
report to be beneficial to those may concern.
Wassalamu'alaikum Wr. Wb.
Surakarta, October 2016
Author

Preliminary Design of Tertiary Butyl Alcohol Plant from Isobutylene and Water
Capacity of 80,000 Tons/Year

LIST OF CONTENTS

TITLE PAGE ........................................................................................................... i
VALIDATION ........................................................................................................ ii
STATEMENT OF AUTHENTICITY ................................................................... iii
ABSTRACT ABSTRAK ....................................................................................... iv
MOTTO ................................................................................................................. vi
DEDICATION ...................................................................................................... vii

PREFACE ............................................................................................................ viii
LIST OF CONTENTS .......................................................................................... vii
LIST OF TABLE .................................................................................................. xii
TABLE OF FIGURES ......................................................................................... xiv
CHAPTER I INTRODUCTION ............................................................................ 1
1.1. Background of the Study ............................................................................. 1
1.2. Design Capacity .......................................................................................... 1
1.3. Location ....................................................................................................... 2
1.4. Literature Review ........................................................................................ 4
1.4.1. Process Selection .................................................................................. 4
1.4.2. The Use of the Product ......................................................................... 5
1.4.3. Physical and Chemical Characteristic of Raw Materials and Products 5
1.4.4. Process Review .................................................................................... 9
CHAPTER II PROCESS DESCRIPTION ........................................................... 10
2.1. Specification of the Raw Materials and Product ........................................ 10
2.1.1. Specification of the Raw Materials ...................................................... 10
2.1.2. Product Specification ........................................................................... 11
2.2. Reaction Concept ...................................................................................... 11
2.2.1. Basis of Reaction ................................................................................ 11

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Preliminary Design of Tertiary Butyl Alcohol Plant from Isobutylene and Water
Capacity of 80,000 Tons/Year

2.2.2. Operational Condition ........................................................................ 12
2.2.3. Thermodynamic Review .................................................................... 12
2.2.4. Kinetics Review ................................................................................. 14
2.2.5. Process Step........................................................................................ 15
2.3. Flowchart ................................................................................................... 17
2.4. Mass Balance............................................................................................. 20
2.5. Heat Balance ............................................................................................. 22
2.6. Layout of Plant and Equipment ................................................................. 27
2.6.1. Layout of the Plant ............................................................................. 27
2.6.2. Layout of the Equipment .................................................................... 31
CHAPTER III EQUIPMENT SPECIFICATIONS .............................................. 33
3.1. Reactor ........................................................................................................ 33

3.2. Distillation Column -01 ............................................................................. 33
3.3. Distillation Column -02 ............................................................................. 34
3.4. Flash Drum ................................................................................................ 35
3.5. Accumulator .............................................................................................. 35
3.5.1. Accumulator – 01 ............................................................................... 35
3.5.2. Accumulator – 02 ............................................................................... 36
3.5.3. Accumulator – 03 ............................................................................... 37
3.5.4. Accumulator – 04 ............................................................................... 37
3.6. Condenser .................................................................................................. 38
3.6.1. Condenser – 01 ................................................................................... 38
3.6.2. Condenser – 02 ................................................................................... 39
3.7. Cooler ........................................................................................................ 39
3.7.1. Cooler – 01 ......................................................................................... 39
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Preliminary Design of Tertiary Butyl Alcohol Plant from Isobutylene and Water
Capacity of 80,000 Tons/Year

3.7.2. Cooler – 02 ......................................................................................... 40
3.8. Reboiler ..................................................................................................... 41
3.8.1. Reboiler – 01 ...................................................................................... 41
3.8.2. Reboiler – 02 ...................................................................................... 42
3.9. Heat Exchanger ......................................................................................... 43
3.9.1. Heat Exchanger – 01 .......................................................................... 43
3.9.2. Heat Exchanger – 02 .......................................................................... 44
3.9.3. Heat Exchanger – 03 .......................................................................... 44
3.10.Vaporizer ................................................................................................... 45
3.11.Tank ......................................................................................................... 46
3.11.1. Tank – 01 ............................................................................................ 46
3.11.2. Tank – 02 ............................................................................................ 46
3.11.3. Tank – 03 ............................................................................................ 47
3.11.4. Tank – 04 ............................................................................................ 48
3.12.Pump ......................................................................................................... 48
3.12.1. Pump – 01........................................................................................... 48
3.12.2. Pump – 02........................................................................................... 49
3.12.3. Pump – 03........................................................................................... 50
3.12.4. Pump – 04........................................................................................... 51

3.12.5. Pump – 05........................................................................................... 51
3.12.6. Pump – 06........................................................................................... 52
3.12.7. Pump – 07........................................................................................... 53
3.12.8. Pump – 08........................................................................................... 54
3.12.9. Pump – 09........................................................................................... 54
3.12.10. Pump – 10 ........................................................................................ 55
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Preliminary Design of Tertiary Butyl Alcohol Plant from Isobutylene and Water
Capacity of 80,000 Tons/Year

3.12.11. Pump – 11 ........................................................................................ 56
3.12.12. Pump – 12 ........................................................................................ 57
CHAPTER IV PROCESS SUPPORT AND LABORATORY ........................... 58
4.1. Process Support Unit ................................................................................. 58
4.2. Water Provider .......................................................................................... 58
4.2.1. Steam Provider Unit ........................................................................... 64
4.2.2. Electricity Provider Unit .................................................................... 66
4.2.3. Fuel Support Unit ............................................................................... 69
4.2.4. Compressed Air .................................................................................. 70
4.2.5. Waste Support Unit ............................................................................ 70
4.2.6. Laboratory .......................................................................................... 71
CHAPTER V PLANT MANAGEMENT ............................................................ 87
5.1. Corporate Form ......................................................................................... 87
5.2. Organizational Structure ........................................................................... 87
5.3. Duties and Power ...................................................................................... 90
5.3.1. Shareholders ....................................................................................... 90
5.3.2. The Board of Commissioner .............................................................. 90
5.3.3. President Director ............................................................................... 90
5.3.4. Expert Staff ........................................................................................ 90
5.3.5. Manager of Engineering and Production ........................................... 91
5.3.6. Manager of Finance ............................................................................ 91
5.3.7. Secretary ............................................................................................. 91
5.3.8. Research, development, and quality control ...................................... 91
5.3.9. Head of Department ........................................................................... 92
5.3.10. Head of General ................................................................................. 92

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Preliminary Design of Tertiary Butyl Alcohol Plant from Isobutylene and Water
Capacity of 80,000 Tons/Year

5.3.11. Head of Health Safety and Environment............................................ 93
5.4. Employees System .................................................................................... 94
5.5. Working Hours .......................................................................................... 94
5.6. Details of Duties and Skill ........................................................................ 96
5.6.1. Distribution of Position ...................................................................... 96
5.7. Total Employee ......................................................................................... 97
5.7.1. The salary system ............................................................................... 98
5.8. Employees social safety ............................................................................ 98
5.9. Production Management ........................................................................... 99
CHAPTER VI ECONOMIC ANALYSIS ......................................................... 100
6.1. Fixed Capital Investment ........................................................................ 105
6.2. Working Capital ...................................................................................... 106
6.3. Manufacturing Cost ................................................................................. 106
6.4. General Expenses .................................................................................... 107
6.5. Economic Analysis .................................................................................. 107
REFERENCE ...................................................................................................... 113
ATTACHMENT ................................................................................................. 115

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Preliminary Design of Tertiary Butyl Alcohol Plant from Isobutylene and Water
Capacity of 80,000 Tons/Year

LIST OF TABLE

Table 1.2.1 Data Import of TBA in Indonesia ........................................................ 2
Table 2.4.1 Total Mass Balance ............................................................................ 20
Table 2.4.2 Mass Balance in Reactor .................................................................... 20
Table 2.4.3 Mass Balance in Flash Drum ............................................................. 21
Table 2.4.4 Mass Balance in Distillation Column 1 (D-100) ............................... 21
Table 2.4.5 Mass Balance in Distillation Column 2 (D -110) .............................. 22
Table 2.5.1 Heat Balance on Heat Exchanger – 01 (E-110) ................................. 22
Table 2.5.2 Heat Balance on Heat Exchanger – 02 (E-111) ................................. 23
Table 2.5.3 Heat Balance on Heat Exchanger – 03 (E-112) ................................. 23
Table 2.5.4 Heat Balance on Vaporizer -01 (E-112) ............................................ 24
Table 2.5.5 Heat Balance on Reactor (R-100) ...................................................... 25
Table 2.5.6 Heat Balance on Flash Drum (H – 100)............................................. 26
Table 2.5.7 Heat Balance on Distillation Column – 01 (D-110) .......................... 26
Table 2.5.8 Heat Balance on Distillation Column – 02 (D-111) .......................... 27
Table 2.6.1 Total area of TBA plant capacity of 80,000 tons/year ....................... 29
Table 4.2.1 List of Consumption of Water for cooling ......................................... 59
Table 4.2.2 Sanitation Water Consumption .......................................................... 60
Table 4.2.3 Steam Requirement ............................................................................ 61
Table 4.2.4 Total of Water Consumption ............................................................. 61
Table 4.2.5 Electricity Consumption for Process.................................................. 66
Table 4.2.6 Electricity Consumption for Utility support unit ............................... 67
Table 5.5.1 Daily schedule and working hours for shift employees ..................... 95
Table 5.7.1 Total employee................................................................................... 97
Table 5.9.1 Cost Index Chemical Plant Data ...................................................... 101
Table 6.1.1 Fixed Capital Investment ................................................................. 105
Table 6.2.1 Working Capital ............................................................................... 106
Table 6.3.1 Manufacturing Cost.......................................................................... 106
Table 6.4.1 General Expenses ............................................................................. 107

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Preliminary Design of Tertiary Butyl Alcohol Plant from Isobutylene and Water
Capacity of 80,000 Tons/Year

Table 6.5.1 Fixed Cost ........................................................................................ 109
Table 6.5.2 Variable Cost ................................................................................... 109
Table 6.5.3 Regulated Cost ................................................................................. 109
Table 6.5.4 Comparisons between Calculation and Reference ........................... 111

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Preliminary Design of Tertiary Butyl Alcohol Plant from Isobutylene and Water
Capacity of 80,000 Tons/Year

TABLE OF FIGURES
Figure 2.3.1 Diagram of Quantitative ................................................................... 18
Figure 2.3.2 Diagram of Qualitative ..................................................................... 19
Figure 2.6.1 Layout of TBA Plant ........................................................................ 30
Figure 4.2.1 Water Treatment Unit ....................................................................... 86
Figure 5.2.1 Organization Structure ...................................................................... 89
Figure 5.7.1 Relationships Between Year Vs Cost Index ................................... 102
Figure 6.5.1 Economic Analysis ......................................................................... 111

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