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Executive Summaryrancangan Pabrik Ethylene Dari Natural Gas Proses Lummus Dengan Desain Alat Utama Reaktor Oxidative Coupling Of Methane (R-101)
ABSTRACT
Ethylene is one of the main petrochemical feedstocks with a wide range of industrial applications, including as a raw material for plastics, textiles, polyester fibers, detergents, and various other chemical products. The demand for ethylene in Indonesia continues to increase, while domestic production capacity remains limited at around 900 thousand tons per year. This condition forces Indonesia to import ethylene, with an average volume of 758,445 tons per year and a growth rate of approximately 6%. The high dependence on imports indicates that the construction of new ethylene plants is urgently needed. An ethylene plant is designed using natural gas as the primary raw material. Considering the abundant availability of natural gas, the plant with a capacity of 130,000 tons per year is planned to be built in Prabumulih, South Sumatra. This location was chosen due to its proximity to raw material sources, good transportation access, low earthquake risk, and the availability of supporting utilities.
Ethylene production from natural gas is designed using Lummus technology with the Oxidative Coupling of Methane (OCM) process, which consists of three main stages: feed preparation, product formation, and separation/purification. This process offers advantages by utilizing abundantly available and more economical natural gas compared to naphtha, while also operating at a lower temperature of about 800°C compared to other processes that reach 1000°C. The plant’s water supply is sourced from the Lematang River, located approximately 924 meters from the site, and its electricity demand of 9,121.72 kW is supplied by the PLN Prabumulih Substation with a 5 MW backup system. The plant generates liquid waste that must be treated to meet environmental quality standards before disposal. Instrumentation applied in the plant includes sensors, indicators, controllers, alarms, and recorders to monitor key variables such as temperature, flow rate, pressure, and liquid level.
Profitability analysis shows that the ethylene plant with a capacity of 130,000 tons per year is feasible to be realized, with a Break Even Point (BEP) of 46.96%, an Internal Rate of Return (IRR) of 25.49%, a Net Present Value (NPV) of IDR 4,383,245,722,986, a Payback Period (PBP) of 3 years and 3 months, and a Return on Investment (ROI) of 23.71%. These values meet the feasibility criteria (IRR > 8%, ROI > 20%, PBP < 4 years) with a medium-risk level. Therefore, the construction of this ethylene plant with a capacity of 130,000 tons per year is considered prospective and is expected to reduce Indonesia’s dependence on imported ethylene.
Keywords: Profitability Analysis, Ethylene, Natural Gas, Lummus, OCM
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