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FINAL PROJECT DESIGNING A CHLOROFORM PLANT USING ACETONE AND CHLORINE WITH CAPACITY 19,000 TONNES PER ANNUM By : MUHAMMAD FAHMI HAKIM D 500 112 007 Supervisor : 1. Muhammad Mujiburrohman, S.,T. M.,Eng. Phd 2. Emi Erawati, S.,T. M.,Eng CHEMICAL ENGINEERING DEPARMENT ENGINEERING FACULTY UNIVERSITY MUHAMMADIYAH OF SURAKARTA 2015
Transcript
Page 1: FINAL PROJECT DESIGNING A CHLOROFORM PLANT USING ACETONE …eprints.ums.ac.id/39715/22/NASKAH PUBLIKASI.pdf · acetone as the main raw material which is obtained from PT. Smartlab

FINAL PROJECT

DESIGNING A CHLOROFORM PLANT

USING ACETONE AND CHLORINE

WITH CAPACITY 19,000 TONNES PER ANNUM

By :

MUHAMMAD FAHMI HAKIM

D 500 112 007

Supervisor :

1. Muhammad Mujiburrohman, S.,T. M.,Eng. Phd

2. Emi Erawati, S.,T. M.,Eng

CHEMICAL ENGINEERING DEPARMENT

ENGINEERING FACULTY

UNIVERSITY MUHAMMADIYAH OF SURAKARTA

2015

Page 2: FINAL PROJECT DESIGNING A CHLOROFORM PLANT USING ACETONE …eprints.ums.ac.id/39715/22/NASKAH PUBLIKASI.pdf · acetone as the main raw material which is obtained from PT. Smartlab
Page 3: FINAL PROJECT DESIGNING A CHLOROFORM PLANT USING ACETONE …eprints.ums.ac.id/39715/22/NASKAH PUBLIKASI.pdf · acetone as the main raw material which is obtained from PT. Smartlab

ABSTRACT

The growth of the world population continues to rise and leads to increases

in the need for particular goods. This affects development and establishment of

new industries in the world, including in Indonesia.Chloroform is one of

industries have been good prospect. For need chloroform, indonesia still

importing from the other countries, so manufacturing chloroform in Indonesia is

good solusion to minimmize need of importing from other countries.

Chloroform used as an anesthetic and a non-polar solvent in laboratories

or by industries. From many factors as availbillity raw materials, transportation,

need of chloroform in indonesia and overseas, can determine capacity otimmum

to produce chlorofprm is 40,000 tonnes/annum. With reacted between chlorine

and aceton in ratio 27,522 kg of acetone and 2,752 kg of chlorine in batch reactor

( T=50oC and P=1 atm) during 2 hours, will be produce chloroform and

byproducts like as calcium acetate Ca(CH3COO)2, calcium hydroxide (Ca(OH)2),

calcium chloride (CaCl2).

Plant will be build at 2017 in the Cilegon,banten with area is 48.732 m2

.

From the calculate, get the value of BEP is 40.9 % (at range 40% - 60%) and for

POT is 0.5 years (maksimmum 2 years). So if this plant will be build so many

advantages and very profitably.

Keywords : Chloroform, Acetone, Chlorine.

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CHAPTER I

OVERVIEW

1.1 BACKGROUND

The growth of the world population continues to rise and leads to increases

in the need for particular goods. This affects development and establishment of

new industries in the world, including in Indonesia. Indonesia, which so far

largely relies on imports to meet the need of the population, is actually able to

satisfy it without imports from other countries, i.e. by establishing the

manufacturers in Indonesia.

Chloroform is one of the chemicals whose demand is continuously

increasing in Indonesia and therefore establishment of chloroform manufacturers

will have a pretty good prospect so as to meet the need of chloroform both at

home and overseas. The establishment of chloroform manufacturers in Indonesia

will reduce imports and diversify products with high economic values which add

to state revenues and provide employment.

1.2 PURPOSE

Manufacture of chloroform plant have ad purpose, as :

1.1 To meet the need of chloroform both at home and overseas

2.1 The establishment of chloroform manufacturers in Indonesia will

reduce imports and diversify products with high economic values

which add to state revenues and provide employment.

Page 5: FINAL PROJECT DESIGNING A CHLOROFORM PLANT USING ACETONE …eprints.ums.ac.id/39715/22/NASKAH PUBLIKASI.pdf · acetone as the main raw material which is obtained from PT. Smartlab

CHAPTER II

LITERATURE REVIEW

2.1 The Designed Production Capacity

The maximum amount of production done within a particular unit of time is

called production capacity. There is many factors that inffluences to determine

production capacity are :

a Availability of Raw Materials

Acetone & chlorine is the main raw materials of chloroform manufacture.

acetone as the main raw material which is obtained from PT. Smartlab

Indonesia costs IDR 145,000 while production of chlorine through the

interaction between chlorine gas and calcium hydroxide which is obtained

from PT Asahimas Chemical costs IDR 15,000. All of raw materials near

with plant design (Cilegon,Banten).

b Minimmum Design Capacity

In indonesia, there is no chloroform plant.This is design capacity of

chloroform plant in overseas :

Chloroform Plant Capacity

(ton/years)

1.Dow Chemical Company, Freeport, Texas

2.Dow Chemical Company, Plaquemine, Louisiana

3.Hanlin Group Inc., Moundsville, West Virginia

4.Vulcan Materials Company, Geismar, Louisiana

5.Vulcan Materials Company, Wichita, Kansas

60.750

90.000

18.000

40.500

72.000

From this factors, can be detrmine the capacity optimmum to get high

profit is 40,000 tonnes/annum and for location manufacture this plant will be

build in the Cilegon,Banten. With the assumptions that it will:

1. Be able to export chloroform as the world demand for chloroform keeps

on increasing

2. Boost state revenues through exports to other countries

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2.2 Types of The Process

There is many types to prododuce chloroform, like :

a Methane Chlorination

In methane chlorination reactions can produce yield ranges from 90 to

95%, but use of fixed bed reactors requires that the cantilever construction

made is strong enough to support the catalyst.

b Photochemical Chlorination

Yield will be produce are 90% and this reactions can reduce impurities in

the resulting chloromethane, but The capacity per reactor is low so very

slow reactions.

c Reaction between Acetone and Chlorine

2 CH3COCH3(l)+ 6 CaOCl2.H2O(s) 2 CHCl3(l) + Ca(CH3COO)2(s) +

2 Ca(OH)2 (s) +3 CaCl2(s)+ 6 H2O(l)

This reaction will be produce crude chloroform in the batch reactors and

will be purification with destillation process. Yield from this reaction is 86

- 91 %. But the process include conventional process.

So to produce chloroform in optimmum condition, reaction between

acetone and chlorine choose for the reaction.

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CHAPTER III

RESEARCH METHODOLOGY

3.1 Thermodynamics Review

Review of thermodynamics aims at finding out the properties of a reaction,

including exothermic or endothermic as well as the direction of its reaction

including reversible or irreversible. The determination of exothermic or

endothermic reaction is considered from the calculation of standard reaction heat

(Hr).

Tabel 3.1 data of ∆Ho

f every component at 298K

No. Componen Ho

f( kJ/mol )

1 CH3COCH3 - 217,848

2 CaOCl2.H2O - 1.103,766

3 CHCl3 103,246

4 Ca(CH3COO)2 - 1.491,757

5 Ca(OH)2 - 986,762

6 CaCl2 - 796,329

7 H2O - 286,025

Based from ∆Ho

f, so we can get value of Hr use this formula :

Hr= Ho

f produk - Ho

f reaktan

Hr= -305,634 kJ/mol

Because the value of Hr is negative, the reaction of chloroform forming is

exothermic. To find out the direction of a reaction in thermodynamics aspect, it

needs the principles of chemistry equilibrium. Use this formula :

Go = - R.T.lnK

dT

Kd ln=

2

r

TR

H

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And for the data of gibbs free energy use :

No. Component G

o298

(kJ/mol)

1 CH3COCH3 - 153,304

2 CaOCl2.H2O 0

3 CHCl3 70,405

4 Ca(CH3COO)2 0

5 Ca(OH)2 - 899,040

6 CaCl2 - 748,608

7 H2O - 237,304

And get this value : Go = - R.T.lnKo

lnKo = - TR

oG

lnKo = 298 .314,8

310.020.5

lnKo = 2.026,302

3.2 Review Kinetics

Can get from the value :

t =

XA = 0,91

a = 2

b = 6

k = 1,81.10-8

L/kmol.detik

t=

t= 1.831 hours ≈ 2 hours

)1(

0

ln

).(.

1

AXM

AXa

bM

Aa

bMCk

)91,01(561,0

91,02

6561,0

8ln

)2

6561,0(013,010.81,1

1

x

x

xx

Page 9: FINAL PROJECT DESIGNING A CHLOROFORM PLANT USING ACETONE …eprints.ums.ac.id/39715/22/NASKAH PUBLIKASI.pdf · acetone as the main raw material which is obtained from PT. Smartlab

3.3 Main Equipment Process

a Reactor Batch

Code : R-110

Function : Reaction between chlorine and acetone,

will produce chloroform for 2 hours.

Type : Batch reactors are equipped stirrer and

heating coil

Volume : 70.979 m3

Total : 4 buah (parallel)

Dimension : Height = 8.312 m

Diameter = 5.791 m

Thick head = 0.00635 m

Thick shell = 0.00793 m

Agitator : Turbin

Diameter : 1.524 m

Height : 0.305 m

Width agitator : 0.381 m

Width baffle : 0.457 m

rpm : 45 rpm

motor power : 22 HP

Material Construction : Stainless stell SA 167 type 304

b Mixer 01

Code : M-110

Function : Mix between chlorine and water

Type : Vertical cylinder with head and bottom

shaped torispherical

Amount : one

Tank : Diameter (D) : 4.110 m

Height (H) : 4.918 m

Thick : 0,00794 m

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Agitator : Type marine propeller with 3 blades and 4 baffle

Diameter : 1.370 m

Rpm : 53.705 rpm

Tenaga motor : 6 HP

Materials : Carbon steel grade CSA-285

c Coloumn Destillation

Code :D-110

Function :Make a pure chloroform.

Type : plate coloumn with sieve tray

Temperature : Feed = 62.2oC

Top = 60.4oC

Bottom= 94.0oC

Shell Diameter :Top = 0.941 m

Bottom= 0.941 m

Thick :Top = 0,0048 m

Bottom= 0,0048 m

Material :Stainless stell SA 167 type 304

Height Shell : 20.56 m

Column Height : 17.515 m

Top section : 12.419 m

Bottom section : 5.096 m

Support : 3,048 m

Head Type : Torispherical dishedhead

Thick head : Top =0,0048 m

Bottom = 0,0048 m

Height head : Top = 0,2068 m

Bottom = 0,8683 m

Plate Type : Sieve tray

Amount plate : 25

Feed plate ke : 7

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Plate spacing : 0,60 m

d Decanter

Code : H-110

Function : Separating the main product of byproducts

use density.

Total : 12

Diameter tank : 2.190 m

Length tank (L) : 6.571 m

Material Construction : Stainless stell SA 167 type 30

3.4 Operational Value

Chloroform production process by making a reaction between acetone and

chlorine in principle consists of some stages, i.e :

raw materials preparation stage

reaction stage

product purification stage

The product produced from batch reactor is in the form of side products and

chloroform which are then flown into (H-110) to separate chloroform and side

products based on the size of particle and density. The low result of decanter is in

the form of calcium acetate, calcium hydroxide, calcium chloride which are flown

to waste processing unit. The result of decanter in the form of chloroform is flown

into distillation column for purification. Upper product which is produced from

distillation column is in the form of chloroform with the purification of 99%.

Page 12: FINAL PROJECT DESIGNING A CHLOROFORM PLANT USING ACETONE …eprints.ums.ac.id/39715/22/NASKAH PUBLIKASI.pdf · acetone as the main raw material which is obtained from PT. Smartlab

CHAPTER IV

RESULT OF RESEARCH

BEP in the manufacture of chlororfom with capacity 40,000 tonnes/annum is

40.90 % with POT befor tax is 0.36 years and after tax is 0.5 years. ROI before

tax can get value is 270.72 % and after tax is 189.509%. This number can shown

chloroform plant feseable to building in Cilegon,Indonesia. If the BEP value more

decrease and value of ROI will be increase, so profit will be get the plant also

increase.

Discount cash flow minimmum is 25% from the bank, and chloroform plant

can get 55.51%, this is also can shown that chloroform plant feseable to build in

indonesia.

Figure 6.2 Graph of Feasibility Analysis

0

5

10

15

20

25

30

35

40

45

50

0 10 20 30 40 50 60 70 80 90 100

Fa VaRa SaSDP BEP

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CHAPTER V

CONCLUSION

A. Conclusion

We can get the conclusion from Plant Design of Chloroform from acetone

and chlorine in capacity 40,000 tonnes/years :

1. Precent Return On Invesment (ROI) before tax is 270.727 %

2. Precent Return On Invesment (ROI) after tax is 189.509 %

3. Pay Out Time (POT) before tax is 0.36 years

4. Pay Out Time (POT) after tax is 0.5 years

5. Break-even Point (BEP) is 40.90 %

6. Shoutdown Point (SDP) is 34.35 %

7. Discounted Cash Flow (DCF) is 55.51%.

So this plant Feasible to build in the Cilegon,Banten.

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