Pra Rancangan Pabrik Pembuatan Fenol dari Tongkol Jagung dengan Kapasitas 18.000 Ton/Tahun dan Tugas Khusus Rancangan Keteknikan Detail Evaporator

Abstract

Corncobs are the largest part of corn waste with 40-50% of the total mass of corn fruit with cobs being the weight of corncobs. Corncob contains phenolic phytochemical compounds which can be used as a source of active antioxidant ingredients. Corncobs can be further processed through a pyrolysis process to produce bio-oil containing phenol which can then be extracted. The design of a factory for the manufacture of phenol from corncobs through a fast pyrolysis process has a capacity of 18.000 tons/year and will operate for 330 days a year. The main process in this plant design is divided into three stages, namely the raw material pretreatment stage, the pyrolysis stage, the extraction stage and the purification stage. In the pyrolysis stage, a fluidized bed type reactor is used with N2 gas to fluidize at operating conditions of 500°C with a residence time of 2 seconds. The number of corn cobs needed to achieve an annual phenol production capacity of 18.000 tons/year is 27,939.98 kg/hour. The special task which has been completed is the detailed engineering design of evaporator. The selected evaporator is a type of double effect evaporator with the design specification as follows: Specification Equipment Name EV-201 EV-202 D tubes (in) 1 1 Outer Surface Area/ft 0,2618 0,2618 Inner Surface Area/ft 0,1754 0,1754 Solution Height (m) 2,773 2,007 Tank Height (m) 3,882 2,809 Nt (tubes) 245 204 D shell 2,218 1,605 Shell Thickness (in) 5/16 5/16 The factory to produce phenol from corncobs using fast pyrolysis process is planned to be built in Deli Serdang district, North Sumatra Province, with a total area of 17,504 m2. The factory's utility water needs will be supplied from the Snake River as much as 31,456.129 kg/hour. The planned company organizational form is a Limited Liability Company (LLC) with a total of 200 employees. The result of economic calculation analysis at the phenol manufacturing plant from corncobs are as follows: 1. Capital Investment (CI) : IDR 268.043.765.100,52 2. Total Cost (TC) : IDR 477.779.962.756,034 3. Profit Margin (PM) : 53,81% 4. Break Even Point (BEP) : 28,58% 5. BEP Capacity point : 5.716,90 tons 6. Return On Invesment (ROI) : 57,01% 7. Pay Out Time (POT) : 1,75 Year 8. Return On Network (RON) : 95,02% 9. Internal Rate of Return (IRR) : 30,44% Based on the results of the analysis of economic calculations that have been carried out, it can be concluded that a factory for manufacturing phenol from corn cobs through a fast pyrolysis process with a production capacity of 18,000 tonnes/year is feasible to establish.