Maulana, Triyaldi Fakhry and Rachmawati, Hanif (2021) Pra Desain Pabrik Metanol Dari Batubara Kelas Rendah. Undergraduate thesis, Institut Teknologi Sepuluh Nopember.
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Abstract
Sumber daya gas alam ketersediaannya kini semakin menipis, dimana kebutuhunnya semakin meningkat untuk industri kimia, hal ini mendorong agar penggunaan gas alam dapat digantikan oleh alternatif lainnya. Salah satunya adalah batubara yang dapat diolah menjadi syngas. Berdasarkan Kementerian Energi dan Sumber Daya Mineral (ESDM), jumlah potensi cadangan batubara yaitu mencapai 37,6 miliar ton per Desember 2019. Maka batubara dapat dijadikan alternatif gas alam dan diproses menjadi berbagai produk, seperti metanol.
Sejalan dengan perkembangan ekonomi dalam negeri, metanol ditaksir akan terus mengalami kenaikan kebutuhannya sebagai bahan baku berbagai industri kimia seperti formaldehida, MTBE, biodiesel, dan yang lainnya. Selain itu, Program Mandatori B30 yang digagas pemerintah untuk memproduksi B30 dengan bahan baku metanol akan turut menambah jumlah kebutuhan metanol di Indonesia.
Konsumsi metanol dalam negeri hingga 2020 hanya dipasok oleh produsen tunggal yaitu PT. Kaltim Methanol Industri (KMI) dengan kapasitas 650.000 ton/tahun dengan produk yang dihasilkan pure methanol grade AA (kadar min. 99,85%). Dengan proporsi sebanyak 70% metanol yang dihasilkan ditujukan untuk ekspor, dan sisanya hanya sebanyak 30% untuk memasok kebutuhan metanol dalam negeri.
Maka dari itu, pabrik metanol dari batubara kelas rendah ini didirikan dengan tujuan untuk membantu masalah tersebut, dimana pabrik ini akan dioperasikan secara kontinu 24 jam selama 330 hari per tahunnya dan berkapasitas produksi 640 KTPA. Dari kapasitas tersebut dibutuhkan bahan baku batubara sebesar 195 ton/jam; process water sebanyak 83.571,43 kg/jam; cooling water sebanyak 13.740.266,11 kg/jam; oksigen sebanyak 151.927,2 kg/jam; saturated steam sebanyak 189.059,05 kg/jam; superheated steam sebanyak 1.090.491,57 kg/jam. Selain iti, proses ini juga menghasilkan solid waste sebanyak 10.573,64 kg/jam; Waste water sebanyak 30.965,9 kg/jam; purge sebanyak 350.704,68 kg/jam; flare sebanyak 4.377,89 kg/jam; dengan kebutuhan daya listrik sebesar 44.440 kW. Pasokan bahan baku batubara berasal dari PT. Bukit Asam, Tbk. yang berada di Tanjung Enim, Sumatera Selatan.
Pendirian pabrik metanol ini direncanakan dimulai di tahun 2022 dan dapat selesai tahun 2024. Dimana proses produksi metanol dari batubara kelas rendah ini terdiri dari dua proses inti, antara lain : Gasifikasi (proses produksi syngas dari batubara) dan Sintesa metanol (proses konversi syngas atau mereaksikan CO dan CO2 dengan H2 menjadi CH3OH).
Dari perhitungan analisa ekonomi didapatkan laju pengembalian modal (IRR) pabrik metanol ini sebesar 26,8% dengan tingkat suku bunga bank 9,95% per tahun dan laju inflasi rata-rata 1,94% per tahun. Sementara itu, waktu pengembalian modal (POT) adalah 4 tahun 7 bulan dan titik impas (BEP) sebesar 32,23%. Untuk dapat memproduksi metanol grade AA dengan kapasitas 640.000 ton/tahun, dibutuhkan biaya produksi total per tahunnya sebanyak Rp. 3.488.925.879.353,62 dengan biaya investasi total (TCI) sebanyak Rp. 3.854.287.975.819,96 Jika dipertimbangkan dari aspek analisa ekonomi serta teknis, pabrik metanol dari batubara kelas rendah ini layak didirikan.
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The availability of natural gas resources is now dwindling, where the need is increasing for the chemical industry, this encourages the use of natural gas to be replaced by other alternatives. One of them is coal which can be processed into syngas. Based on the Ministry of Energy and Mineral Resources (ESDM), the number of potential coal reserves reached 37.6 billion tons as of December 2019. So coal can be used as an alternative to natural gas and processed into various products, such as methanol.
In line with the development of the domestic economy, it is estimated that the demand for methanol will continue to increase as a raw material for various chemical industries such as formaldehyde, MTBE, biodiesel, and others. In addition, the B30 Mandatory Program initiated by the government to produce B30 with methanol as raw material will also increase the amount of methanol demand in Indonesia.
Domestic methanol consumption until 2020 will only be supplied by a single producer, namely PT. Kaltim Methanol Industry (KMI) with a capacity of 650,000 tons/year with pure methanol grade AA (min. 99.85%). With a proportion of 70% of the methanol produced is intended for export, and the remaining 30% is for supplying domestic methanol needs.
Therefore, this low grade coal methanol plant was established with the aim of helping this problem, where this plant will be operated continuously 24 hours for 330 days per year and a production capacity of 640 KTPA. From this capacity, 195 tons/hour of coal raw materials are needed; process water as much as 83,571.43 kg/hour; cooling water as much as 13,740,266.11 kg/hour; oxygen as much as 151,927,2 kg/hour; saturated steam as much as 189,059.05 kg/hour; superheated steam as much as 1,090,491.57 kg/hour. In addition, this process also produces 10,573.64 kg/hour solid waste; Waste water as much as 30,965.9 kg/hour; purge as much as 350,704.68 kg/hour; flares as much as 4,377.89 kg/hour; with an electrical power requirement of 44,440 kW. The supply of coal raw materials comes from PT. Bukit Asam, Tbk. which is located in Tanjung Enim, South Sumatra.
The establishment of this methanol plant is planned to start in 2022 and be completed in 2024. Where the methanol production process from low grade coal consists of two core processes, namely: Gasification (the syngas production process from coal) and Methanol synthesis (the syngas conversion process or reacting CO and CO2 with H2 become CH3OH).
From the calculation of the economic analysis, the rate of return on capital (IRR) of this methanol plant is 26.8% with a bank interest rate of 9.95% per year and an average inflation rate of 1.94% per year. Meanwhile, the payback period (POT) is 4 years 7 months and the break-even point (BEP) is 32.23%. To be able to produce AA grade methanol with a capacity of 640,000 tons/year, a total annual production cost of Rp. 3,488,925,879,353.62 with a total investment cost (TCI) of Rp. 3,854,287,975,819.96 If considered from the aspect of economic and technical analysis, this low grade coal methanol plant is feasible to build.
| Item Type: | Thesis (Undergraduate) |
|---|---|
| Uncontrolled Keywords: | Coal, Gasification, Lurgi, Methanol, Batubara, Gasifikasi, Lurgi, Metanol |
| Subjects: | T Technology > TP Chemical technology > TP155.5 Chemical plants--Design and construction |
| Divisions: | Faculty of Industrial Technology and Systems Engineering (INDSYS) > Chemical Engineering > 24201-(S1) Undergraduate Thesis |
| Depositing User: | Hanif Rachmawati |
| Date Deposited: | 19 Aug 2021 01:49 |
| Last Modified: | 19 Aug 2021 01:49 |
| URI: | http://repository.its.ac.id/id/eprint/87891 |
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