PRARANCANGAN PABRIK POLYSTYRENE DARI STYRENE MONOMER DENGAN KAPASITAS 50.000 TON / TAHUN

LUTFI INDRA RAMADHAN, Ir. Imam Prasetyo, M.Eng., Ph.D.

2013 | Skripsi | TEKNIK KIMIA

Polystyrene adalah senyawa polimer dengan bahan baku styrene monomer yang dapat dibentuk berbagai macam produk seperti pembuatan casing, isolator, pembungkus makanan dan juga resin. Peluang berkembangnya industri polystyrene di Indonesia cukup besar, mengingat pada tahun 2011 nilai impor Indonesia terhadap produk polystyrene sendiri mencapai 45.309 ton. Pabrik ini direncanakan beroperasi selama 330 hari/tahun dengan kapasitas produksi polystyrene 50.000 ton/tahun. Bahan baku utama yang dibutuhkan adalah styrene monomer sebanyak 50.468,2840 ton/tahun, ethylbenzene sebanyak 1.286,1804 ton/tahun dan benzoyl peroxide sebanyak 58,6389 ton/tahun. Proses pembuatan Polystyrene terjadi melalui reaksi polimerisasi adisi dan dilakukan dengan metode solution polymerization. Secara umum, tahapan proses pembuatan polystyrene adalah sebagai berikut: (i) reaksi antara styrene monomer, ethylbenzene dan benzoyl peroxide dalam reaktor alir tangki berpengaduk, (ii) pemisahan produk polystyrene melalui proses distlasi tingkat satu (iii) proses pemadatan polystyrene menggunakan extruder. Sebagai penunjang, unit utilitas menyuplai kebutuhan air pendingin sebanyak 53.628,2688 kg/jam, listrik sebanyak 914,98 kVA dan steam sebanyak 1856,0295 kg/jam. Pabrik ini akan didirikan di kota Cilegon, propinsi Banten, dengan pertimbangan raw material oriented. Kawasan Cilegon dekat dengan industri styrene monomer, dan dekat dengan pelabuhan sehingga mempermudah pemasaran produk polystyrene. Lokasi pabrik dekat dengan sungai, sehingga sumber air untuk unit utilitas berasal dari air sungai. Perhitungan evaluasi ekonomi memberikan hasil modal tetap yang dibutuhkan adalah sebesar $24.060.164,71 dan modal kerja sebesar $16.402.314,40. Pada kapasitas 80% produksi, diperoleh ROI before tax sebesar 31,01%, ROI after tax sebesar 15,51%. POT before tax sebesar 2,44 tahun, POT after tax sebesar 3,92 tahun dengan BEP sebesar 47,48%, SDP sebesar 27,29%, dan DCFRR sebesar 25,57%. Berdasarkan pertimbangan hasil evaluasi tersebut, maka pabrik polystyrene dengan kapasitas 50.000 ton/tahun ini layak untuk dikaji lebih lanjut.

Polystyrene is a polymer substance made from monomer styrene which leads to production of casing, insulator, food-wrapper and resin. The opportunity of polystyrene industry to develop in Indonesia is quite big, by considering the fact that in 2011, the value of Indonesian product resulted from import activity has reached 45.309 ton in total. The factory is designed to operate for 330 days/year consecutively with polystyrene production capacity of 50.000 ton/year. The main raw material needed is styrene monomer 50.468,284 ton/year, ethylbenzene 1.286,1804 to/year, and benzoyl peroxide 58,6389 ton/year. The production of polystyrene involving a reaction of addition polymerization and is done by polymerization solution method. Generally, polymerization production follows these sequent steps, which are: (i) reaction between styrene monomer, ethylbenzene and benzoyl peroxide inside a continuous stirred tank reactor, (ii) separation of polymerization product by one stage distillation process, and (iii) compaction process of polystyrene by using extruder. As a support for these activities, utility unit will supply the need of cold water 53.628,2688 kg/hour, electricity 914,98 kVA, and steam 1856,0295 kg/hour. The factory will be built in Cilegon which is located in Banten province. This decision made by considering the raw material oriented. Cilegon area is located close to both monomer styrene industry and harbor which will help the distribution of polystyrene production way much easier. Besides, the location of the factory is also close to a river. Therefore the river will supply the water source for the utility unit. The calculation of economy evaluation gives result in $24.060.164,71 of the fixed capital and $16.402.314,40 of the working capital. When the capacity production reaches 80% , the ROI before tax achieved will be 31,01% and ROI after tax 15,51%; POT before tax 2,44 year and POT after tax 3,92 year with BEP 47,48%, SDP 27,29% and DCFRR 25,57%. By considering this evaluation result, thus, the polystyrene factory with production capacity of 50.000 ton/year is worth for a further research.

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