Prarancangan Pabrik Pembuatan Polivinil Alkohol Berbasis Polivinil Asetat Dan Metanol Dengan Asam Asetat 25% Sebagai Cleaning Agent Melalui Reaksi Alkoholisis Dengan Kapasitas 84.000 Ton/Tahun

Abstract

Polyvinyl alcohol (PVA) is a synthetic polymer of significant commercial importance. PVA is one of the synthetic polymers with diverse potential applications, such as emulsifiers, suspensions, surfactants, fiber treatment agents, various binders, paper treatment agents, adhesives, films, and similar uses. These advantages are attributed to its solubility in water as well as its excellent film properties (strength, oil resistance, film-forming ability, oxygen gas barrier properties, and others). PVA has the molecular formula (CH2CHOH)n , where n represents the degree of polymerization, which defines the chain length of the formed monomers. PVA is not synthesized directly through polymerization of monomers, but rather produced via hydrolysis of polyvinyl acetate (PVAc) in an alcohol solution. PVA is synthesized through an alcoholysis reaction using a strong base catalyst. In this process, alcohol is used as the reactant to react with (CH2CHCOOCH3)n or PVAc. Alcoholysis is a reaction accompanied by the exchange of alcohol in an ester, which can also be referred to as saponification, in which the ester group in polyvinyl acetate is replaced by a hydroxyl group from the alcohol reactant. The operating conditions required for the hydrolysis reaction are a temperature of 40–70 °C and a pressure of 1 atm, resulting in a conversion rate of 93–99.5%. The preliminary design of a polyvinyl alcohol plant is planned with a production capacity of 84,000 tons per year, operating 330 days annually. In the preliminary design of the polyvinyl alcohol plant from polyvinyl acetate with a capacity of 84,000 tons/year, the production process consists of several stages, including: 1. Pre-Treatment Process 2. Proses Alkoholisis Process 3. PVA Purification Process 4. By-Product Purification The plant is planned to be established in the Gresik Industrial Estate (KIG), Roomo Village, Manyar District, Gresik Regency, East Java. The selection of this location is based on strategic considerations, one of which is its proximity to Tanjung Perak Port Surabaya, serving as the main gateway for importing raw materials from China. In addition, the location has direct access to toll roads, availability of utilities (electricity, water, gas, and waste treatment facilities), as well as adequate industrial infrastructure. The required land area is 52,500 m², with a total workforce of 452 employees. The plant will be established as a Limited Perseroan Terbatas (PT) under the leadership of a President Director. The economic evaluation results of the Polyvinyl Alcohol Plant from Polyvinyl Acetate with a capacity of 84,000 tons per year are as follows: • Total Capital Investment : Rp. 7.973.710.849.738,87 • Total Production Cost : Rp. 6.662.291.344.909,61 • Total Sales Revenue : Rp. 8.370.617.280.186,47 • Net Profit : Rp. 1.136.091.746.959,11 • Profit Margin (PM) : 19,388% • Break Even Point (BEP) : 30,070% • Return on Investment (ROI) : 14,248% • Pay Out Time (POT) : 7 tahun • Return on Network (RON) : 23,747% • Internal Rate of Return (IRR) : 12,07% Based on the economic evaluation, it can be concluded that the preliminary design of the Polyvinyl Alcohol Plant from Polyvinyl Acetate with a capacity of 84,000 tons per year is feasible to be established.