Pra Rancangan Pabrik Pembuatan Resin Novolak dari Fenol dan Formaldehid menggunakan Katalis Asam Klorida Kapasitas 11.000 Ton/Tahun dan Tugas Khusus Rancangan Keteknikan Reaktor

Abstract

Pre-design of a Novolak Resin manufacturing plant from Phenol and Formaldehyde with a capacity of 11,000 tons per year and operates for 330 days per year. The main process in this pre-design plant consists of four stages: raw material storage, raw material preparation, reaction stage, and purification stage. The reaction involves a polycondensation reaction that takes place inside a Continuous Stirred Tank Reactor (CSTR) column with an average temperature of 95°C and a retention time of 27 minutes in the reactor. The specific task accomplished is the engineering design of a Continuous Stirred Tank Reactor with a torispherical dished head and a cooling jacket. The reactor is designed with the following specifications: 23. Type : Continuous Stirred Tank Reactor (CSTR) 24. Number : 1 25. Reactor Volume (m3) : 3.142 Operating Conditions: 26. Temperature : 95°C 27. Pressure : 1 atm 28. Construction Material : Stainless Steel SA-204 Type 316 29. Diameter (m) : 1.227 30. Height (m) : 1.227 31. Shell Thickness (in) : 0.323 32. Head Type : Torispherical Dished Head 33. Head Thickness (m) : 3/16 34. Head Height (in) : 13.184 35. Total Height (m) : 1.923 Cooling: 36. Type : Jacket 37. Cooling Material : Water 38. Jacket Thickness (in) : 1.5 39. Jacket Diameter (in) : 69.875 Mixer 18. Type : Flat Blade Turbine with baffle 19. Quantity : 1 unit 20. Diameter (m) : 0.409 21. Rotation Speed (rpm) : 1 22. Motor (hp) : 0.5 hp The planned location of the factory is in the Special Economic Zone (SEZ) of Sei Mangkei, located in Simalungun Regency, specifically in North Sumatra. The Sei Mangkei SEZ covers an area of 17,982 m2. The workforce required is 183 individuals, and the business entity is a Limited Liability Company (PT) under the leadership of a General Manager. The economic evaluation results for the Novolak Resin Plant from Phenol and Formaldehyde are as follows: 1. Total Investment Capital : Rp. 721,405,745,058.295 2. Total Production Cost : Rp. 621,372,667,274.326 3. Sales Revenue : Rp 821,329,677,203.651 4. Net Profit : Rp. 115,182,516,410.387 5. Profit Margin (PM) : 24.22% 6. Break Even Point (BEP) : 34.90% 7. Return on Investment (ROI) : 19.31% 8. Pay Out Time (POT) : 5.18 years 9. Return on Network (RON) : 32.19% 10. Internal Rate of Return (IRR) : 34.36% From the economic evaluation results, it can be concluded that the Novolak Resin Manufacturing Plant from Phenol and Formaldehyde is feasible to establish