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
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.
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.
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
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.
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
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
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
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
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%.
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
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.
BIBLIOGRAPHY
Amonette JE, PM Jeffers, O Qafoku, CK, Wietsma, and Truex. 2009. Carbon
Tetrachloride and Chloroform Attenuation Parameter Studies:
Heterogeneous Hydrolytic Reactions. PNNL-18735, Pacific Northwest
National Laboratory, Richland, Washington.
Aries, R.S., and Newton, R.D. 1955. Chemical Engineering Cost Estimation , Mc
Graw-Hill Book Co. Inc, New York.
Badan Pusat Statistik. 2014. Statistik Perdagangan Luar Negeri
Indonesia.Jakarta.
Donald, E.G. 1989. Chemical Engineering Economics. Van Nostrond. New York.
Hani Handoko, T. 1990. Manajemen Personalia dan Sumber Daya Manusia.
Penerbit Liberty, Jogjakarta.
Ketta, Mc. J.J. and Cunningham, W.A. 1992. Encyclopedia of Chemical
Processing and Design. Vol. 40, Marcel Decker, Inc., New York
Keyes, F., and Clark, R.S., 1959, Industrial Chemistry : 4 th
edition. John Wiley
and Sons, Inc, New York.
Kirk, R.E., and Othmer, V.R. 1998. Encyclopedia of Chemical Technology : 4th
ed. John Wiley & Sons Inc., New York
Levenspiel, O.. 1972. Chemical Reaction Engineering : 2nd
ed. John Wiley &
Sons, Inc., New York.
Perry, R.H. and Green, D.W. 1999. Perry’s Chemical Engineer’s Handbook, 7th
ed. McGraw-Hill Book Company, New York
Peter, M.S. and Timmerhaus, K.D. 1980. Plant design and Economic for
Chemical Engineers, 3rd
edition, Mc Graw-Hill Book Company, Tokyo.
Pudjaatmaka, A.H., Setiono, L. 1984. Buku Teks Analisis Anorganik Makro dan
Semimikro. PT Kalman Media Pustaka, Jakarta.
Severn, W.H., Degler, H.E., and Miles, J.C. 1954. Steam, Air and Gas Power : 5th
ed. John Wiley and Sons inc., New York.
Smith, J.M. and Van Ness, H.C. 1996. Introduction to Chemical Engineering
Thermodynamics, Prentice Hall, Englewood Cliffs., New Jersey.
Yaws, C.L., 1999. Thermodynamic and Physical Properties Data. Mc Graw Hill
Book Co., Singapore.