Prarancangan Pabrik Lauryl Alcohol Ethoxylate dari Lauryl Alcohol dan Etilena Oksida Dengan Kapasitas 40.000 Ton/tahun

Muhammad Zidan Nurilham, Ir. Muhammad Mufti Azis, S.T., M.Sc., Ph.D., IPM.

2026 | Skripsi | TEKNIK KIMIA

Pabrik Lauryl Alcohol Ethoxylate (LAE) dirancang dengan kapasitas 40.000 ton per tahun dan beroperasi selama 330 hari dalam setahun. Bahan baku utama pabrik ini adalah lauryl alcohol (1-dodekanol) dan etilen oksida (EO). Produk LAE, suatu surfaktan nonionik, diperoleh melalui reaksi etoksilasi lauryl alcohol dengan etilen oksida menggunakan katalis basa kalium hidroksida (KOH). Proses dijalankan secara semi-batch menggunakan tiga reaktor yang disusun seri, yaitu reaktor aktivasi katalis, reaktor etoksilasi berkonfigurasi Spray Tower Loop Reactor (STLR) yang beroperasi pada suhu 155 hingga 178 °C dan tekanan 3 hingga 8 atm, serta reaktor netralisasi. Campuran produk kemudian dimurnikan dalam menara distilasi vakum untuk memisahkan air dan lauryl alcohol sisa sehingga dihasilkan LAE dengan derajat etoksilasi rata-rata 3 dan kemurnian produk polydisperse sebesar 99%. Pabrik direncanakan berdiri di atas lahan seluas 144.774,7 m2 dengan luas bangunan 81.164,5 m2 dan 206 karyawan, berlokasi di Kawasan Industri Merak, Kecamatan Puloampel, Kabupaten Serang, Provinsi Banten. Untuk menunjang proses produksi, utilitas yang dibutuhkan meliputi air pendingin sebanyak 833.571,17 kg/jam, steam sebanyak 3.929,52 kg/jam, dan listrik sebesar 0,79 MW. Pabrik didirikan dengan fixed capital investment sebesar $92.802.218,23 dan working capital sebesar $38.347.018,96, sehingga total capital investment mencapai $131.527.551,64, dengan manufacturing cost sebesar $83.218.721,02 per tahun. Berdasarkan analisis produk dan teknologi, pabrik ini tergolong sebagai pabrik berisiko rendah ke menegah (low to medium risk). Analisis ekonomi menunjukkan nilai Faktor Lang sebesar 4,35, return on investment (ROI) sebelum pajak sebesar 26,92?n sesudah pajak sebesar 20,19%, payout time (POT) sebelum pajak selama 3,18 tahun dan sesudah pajak selama 4,05 tahun, kapasitas break even point (BEP) sebesar 35,84%, shut down point (SDP) sebesar 19,74%, serta discounted cash flow rate of return (DCFRR) sebesar 18,87%. Berdasarkan hasil tersebut, dapat disimpulkan bahwa prarancangan Pabrik Lauryl Alcohol Ethoxylate dengan kapasitas 40.000 ton per tahun dinilai menarik dan layak untuk dikaji lebih lanjut.

The Lauryl Alcohol Ethoxylate (LAE) Plant is designed to have a capacity of 40,000 tons per year and will operate for 330 days annually. The main raw materials for this plant are lauryl alcohol (1-dodecanol) and ethylene oxide (EO). The product, LAE, a nonionic surfactant, is obtained by ethoxylating lauryl alcohol with ethylene oxide using a potassium hydroxide (KOH) base catalyst. The process is carried out in a semi-batch mode using three reactors arranged in series which is a catalyst-activation reactor, an ethoxylation reactor configured as a Spray Tower Loop Reactor (STLR) operated at 155 to 178 °C and 3 to 8 atm, and a neutralization reactor. The reaction mixture is then purified in a vacuum distillation column to remove water and unreacted lauryl alcohol, yielding LAE with an average degree of ethoxylation of 3 and a purity of polydisperse product at 99%. The plant is planned to be established on a land area of 144,774.7 m² with a building area of 81,164.5 m² and 206 employees, located in the Merak Industrial Estate, Puloampel District, Serang Regency, Banten Province. To support the production process, the required utilities include cooling water at 833,571.17 kg/hour, steam at 3,929.52 kg/hour, and electricity at 0.79 MW. The plant is established using a fixed capital investment of $93.180.532,69 and working capital of $38.347.018,96, giving a total capital investment of $131.527.551,64, with an annual manufacturing cost of $83.218.721,02. Based on the product and technology analysis, the plant is categorized as a low to medium risk plant. The economic analysis shows a Lang Factor of 4,35, a pre-tax return on investment (ROI) of 29,77% and an after-tax ROI of 22.33%, a pre-tax payout time (POT) of 3,18 years and an after-tax POT of 4,05 years, a break-even point (BEP) of 35,84%, a shut-down point (SDP) of 19,74%, and a discounted cash flow rate of return (DCFRR) of 18,87%. Based on these results, it can be concluded that the preliminary design of the Lauryl Alcohol Ethoxylate Plant with a capacity of 40.000 tons per year is considered attractive and feasible for further study

Kata Kunci : lauryl alcohol ethoxylate, etoksilasi, surfaktan nonionik, etilen oksida, spray tower loop reactor