FINAL PROJECT

PRELIMINARY DESIGN OF CHEMICAL PLANT

THE PRODUCTION OF LINEAR ALKYLBENZENE

FROM 1-DODECENE AND BENZENE

WITH CAPACITY 20,000 TONS PER YEAR

By

Mr.Mollakarn Kaewsareh

D 500 102 005

Supervisor

Dr.Ahmad M. fuadi

M. Mujiburohman, Ph.D.

Chemical Engineering Department

Universitas Muhammadiyah Surakarta

2015

TESTIMONY

I hereby asset that there is no plagiarism in this project paper, there is no

other work that has been submitted to obtain the bachelor degree and as far as I

am concerned there is no opinion that has been written or published before, except

the written references with referred in this paper and mentioned in the

bibliography.

If any incorrectness is proved in future dealing with my statement above, I

will be responsible.

Surakarta , January 2015

Mollakarn Kaewsareh

iii

ABSTRACT

Linear alkyl benzene industry produces linear alkyl benzene from raw

material of 1-dodecene and benzene with production capacity 20,000 tons per

year. The industry is planned to be established at industrial estate in Cilegon,

Banten, East Jawa with land area of 10000 m2. The production process of linear

alkyl benzene is Detal process by using fixed bed reactor with solid acid catalyst.

The reaction condition is liquid-liquid phase at 80-193˚C temperature, 5 atm

pressure and mol ratio benzene to 1-dodecene is 2:1, the reaction is irreversible

and exothermal. All of materials do not cause any corrosive. Considering by the

reaction conditions the linear alkyl benzene industry is low risk chemical industry.

The linear alkyl benzene production produces 2,560 kilograms product per

hour. The raw materials needed are benzene 1,568 kilogram per hour and 1-

dodecene 1,689 kilograms per hour. To support the process, the linear alkyl

benzene production requires cooling water 39,709 kilograms per hour and steam

725 kilograms per hour, the water is obtained from seawater. The linear alkyl

benzene production requires fuel oil to generate steam and the diesel fuel uses 166

liters per day. The electricity required for all purposes in the industry is 743

kilowatt which is obtained from the state electricity company (PLN). Incase the

electricity is runs out, the electric generator is prepared for 4 days per month with

diesel fuel requirement 75 liters per hour.

The linear alkyl benzene is considered to operate for 330 days per year with

161 employees. The economic analysis result are as follows, the profit before tax

is IDR 35,872,735,199.40 per year and the profit after tax 30% is

IDR 25,110,914,639.58 per year. The return of investment before tax if 49.89%

and the return of investment after tax is 34.92% .The standard return of

investment before tax is between 40% to 60%. The payout time before tax is 1.670

years while the payout time after tax is 2.226 years, payout time before tax is

allowable for maximum 5 years with breakeven point is 48.20% while breakeven

point is expected between 40% -60% for standard chemical industry. Discounted

iv

cash flow is 43.86%. Discount cash flow is allowable when it’s more than 15%

(bank credit interest). From the economic anlysis results above it can be

concluded that the establishment of the linear alkyl benzene industry is feasible.

Key words: Linear alkyl benzene , 1-dodecene , benzene , fixed bed reactor.

v

PREFACE

Alhamdulillah, all praise and Thanksgiving that are uncountable I dedicate

to Allah SWT who has been giving mercy and extraordinary power so that I can

go through a period of the heavy long, tiring in the process of finishing the final

project. I always remember verse of the Qur'an, which inspire me in through all of

this namely "in difficulties there must be a easiness." Cheer and peace and not to

forget to say thank to the our Prophet Muhammad SAW that has brought us from

the Jahilliyah age to the best present age. The project was not free from direction

assistance and guidance from various people. For that, I thank greatness to

1. Rois Fatoni ST., MSc., PhD. As head of chemical engineering department,

University Muhammadiyah of Surakarta.

2. Dr.Ahmad M. Faudi and M. Mujiburohman, Ph.D. As supervisors I & II.

3. All of chemical engineering department lecturers and officers.

4. My family and friends.

Thanks ,January 2015

Mollakarn Kaewsareh

vi

Contents

Chapter page

Title page…………………………………………………………..…. i

Authentication sheet…………………………………………………… ii

Abstract……………………………………………………………..… iii

Prefect………………………………………………………………… v

Contents…………………………………………………………….… vi

Figure contents………………………………………………………… viii

Table contents………………………………………………………… ix

Chapter I Introduction

1.1. Back ground…………………………………………… 1

1.2. Production capacity…………………………………..... 1

1.3. Plant location………………………………………….. 3

1.4. Literature review……………………………………… 3

Chapter II Process description

2.1. Specification of raw materials and product………….. 9

2.2. Process concept…….…………………………………. 11

2.3. Process flow diagram…………………………………. 13

2.4. Mass balances and heat balances…...………………… 15

2.5. Plant location and lay out……………………………... 19

Chapter III Inventory specifications

3.1. Accumulator………………………………………….. 22

3.2. Heat exchanger……………………………………….. 23

3.3. Pumps……...…………………………………………. 28

3.4. Reactor………………………………………………... 38

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3.5. Separator………………………………………………. 39

3.6. Storage tank…..……………………………………....... 40

Chapter IV Supporting unit process (utility) and laboratory

4.1. Supporting unit process.…………………………….… 45

4.2. Laboratory…………………………………………..… 50

Chapter V Company management

5.1. Company entity….……………………………………. 53

5.2 Organization structure……………………………….… 54

5.3 Duties and authorities………………………………..… 56

5.4 The division of employee working hours……………… 62

5.5 Classification of position and Number of employees…. 65

5.6 Employee welfare and facilities……………………..… 69

Chapter VI Economic analysis

6.1 Cost factor specification..……………………………… 70

6.2 Cost estimation ………………….…………………….. 71

6.3 Total investment cost…………………………………… 72

6.4 Production cost………………………………………… 74

6.5 Economic estimation…………………………………… 75

Conclusion……………………………………………………………. 80

References…………………………………………………………..… xi

Attachments……………………………………………………………. xiii

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Figure contents

Figure page

Figure 2.1 : Qualitative flow diagram …………………………….... 13

Figure 2.2 : Quantitative flow diagram ……………………………... 14

Figure 2.3 : Mass flow diagram…………………………………….… 14

Figure 2.4 : Building lay out ………………………………………… 22

Figure 4.1 : Demineralization Plant ……………………………….… 47

Figure 4.2 : Water treatment process diagram…………………….…. 52

Figure 5.1 : Chart of company organization …………………………. 68

Figure 6.1 : Graphic for CEPCI since 1990 until 2016………………. 72

Figure 6.2 : Graphic of economic analysis…...………………………. 79

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Table contents

table page

Table 1.1 : Linear alkylbenzene needs in Indonesia

based on the import data ……………………………...… 2

Table 1.2 : LAB plants capacity that has been established …………. 2

Table 2.1 : Standard conditions ΔH f298 (kJ/mol) and

ΔG f298 (kJ/mol) of each component …………………... 11

Table 2.2 : Stream component…………………………………….… 15

Table 2.3 : Total mass balance ……..……………………………….. 15

Table 2.4 : Total Mass balance around reactor (R-01) …………….. 16

Table 2.5 : Total Mass balance around flash drum (FD-01) ……….. 16

Table 2.6 : Heat transfer around heater-01 (HE-01) …………….... 16

Table 2.7 : Heat transfer around heater-02 (HE-02) …………….... 17

Table 2.8 : Heat transfer around reactor (R-01) ……………........... 17

Table 2.9 : Heat transfer around flash drum-01 (FD-01) ………….... 18

Table 2.10 : Heat transfer around cooler-01 (Cl-01) ……………....... 18

Table 2.11 : Heat transfer around condenser-01 (Cd-01) ………....... 19

Table 2.12 : Heat transfer around cooler-02 (Cl-02) ……………....... 19

Table 2.13 : The details of building …………………………………. 21

Table 2.14 : Location description …………………………………. 22

Table 5.1 : Shift schedule ………………………………………... 64

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Table 5.2 : Classification of employee’s position …………………... 65

Table 5.3 : The number of employees…...…………………………... 67

Table 5.4 : Employee welfare and facilities ….……………………... 69

Table 6.1 : Total fixed capital investment ….……………………... 73

Table 6.2 : Manufacturing cost ……………..……………………... 74

Table 6.3 : Working capital ….……………………………………... 75

Table 6.4 : General expenses ….…………………………………….75

Table 6.5 : Total production cost ….……………………………….. 75

Table 6.6 : Total fixed manufacturing cost ….……………………... 77

Table 6.7 : Total variabel cost ….………………………………….. 77

Table 6.8 : Total regulated cost ….……………………………….... 77

Table 6.9 : The conclusion of economic estimation……………….. 79