ETHYL ALCOHOL FROM MOLASSES

PLANT DESIGN
WITH CAPACITY 40,000 TON/YEAR

By:
Ambar Tri Wahyuni
D500102001

Supervisors:
1. Rois Fatoni, ST, MSc, Ph.D
2. Dr. Ir. Ahmad M. Fuadi

CHEMICAL ENGINEERING DEPARTMENT

FACULTY OF ENGINEERING
UNIVERSITAS MUHAMMADIYAH SURAKARTA
2017
 ABSTRACT

Ethyl alcohol is the principal type of alcohol in alcoholic beverages. Ethyl

alcohol is mostly produced by the fermentation of sugar by yeast or by
petrochemical processes. Ethyl alcohol is a chemical product primarily used for
antiseptic, antidote, medical solvent, recreational, fuel (engine fuel, rocket fuel, fuel
cells), household heating, feedstock, solvent, and low temperature liquid(used in
laboratories with dry ice or other coolants). The plant of ethyl alcohol from
molasses as raw material will be established in Sukoharjo, Central Java with
capacity 40,000 tons/year and built in year 2020. The raw of molasses is obtained
from some suppliers around Solo – Semarang, Central Java. The production of
ethyl alcohol is carried out in a fermenter where the operating condition of
pressure and temperature are 1 atm and isothermally at 35°C, respectively. Utility
needs to support the process. Used water as much as 187,154.6378 kg/h which is
obtained from river water. Air and compressed air as much as 50 m3/h also needs
to suport the process. The other utilities needs is steam 66,767,052.8459 kg/h and
electricity 350 kw/h.
This ethyl alcohol plant has 330 operational days with Fixed Capital as
much as Rp 74,261,326,185.2297 and known the Working Capital as much as Rp
45,472,670,854.7867. From the economic evaluation that had been calculated
before showed that the Profit before tax is about Rp 25,002,027,285.4679, while the
Profit after tax about Rp 17,501,419,099.8275. From the calculation also known
that the Return On Investment before tax is about 33.6676%, while Return On
Investment after tax is about 23.5673%. The Pay Out Time before tax shown the
number of 2.2900 years with Pay Out Time after tax are 2.9791 years. Break Event
Point is 53.8313% and Shut Down Point is about 41.2793%, and Discounted Cash
Flow as much as 30.2125%. From the results of economic evaluation this Ethyl
alcohol plant is feasibly established and operated.

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 FOREWORD

Assalamu’alaikum Wr. Wb.

Alhamdulillah, all praises be to Allah SWT who has given many mercies
and blessing so the author can finish the Final Project of Chemical Plant Design
without any troubles. Secondly, may peace be upon the prophet Muhammad SAW
who has guided us from the darkness into the brightness.
Title for this Final Project is “Ethyl Alcohol From Molasses Plant Design
With Capacity 40,000 Tons/Year”. Every student in Chemical Engineering at
Universitas Muhammadiyah Surakarta should take plant design as final project to
be able to graduate as bachelor of enginering. With this final project, there is hope
so analitical and teoritical while studying can be applied correctly.
This final asignment completion is supportted by many peopele around
author, so in this opportunity, author would like to express the sincere thanks to all
who helped resolve this research report, especially to :
1. Mr. Rois Fatoni, S.T, M.Sc, PhD as Chemical Engineering Department
Chief and author 1st supervisor.
2. Mrs.Eni Budiati, S.T., M.Eng as final project coordinator.
3. Mr. Dr. Ahmad M. Fuadi as author 2nd supervisor.
4. Ir. Herry Purnama, Ph.D and Ir. Haryanto AR, M.S as evaluator of this final
project.
5. Author parents that always give a lot of love, pray, and support at home. So
author can finish this final project.
6. Author husband Nurohman Sigit H, who have help in process writing and
give some spirit when author get down also give a lot of love so the author
can done this final asignment.
7. All lecturers at Muhammadiyah University of Surakarta.
8. All family that always prays and support author.
9. All help from friends in Muhammadiyah University of Surakarta.

v
 Author is aware this final asignment still have a lot of flaws and it’s far
from perfection. Author expects hopefully this report can be useful for those who
need information about the material covered in this report.
Wassalamu’alaikum Wr. Wb.

Surakarta, April 2017

Author

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 CONTENT

TITLE PAGE .................................................................................................. i

APPROVAL PAGE ........................................................................................ ii
AUTHOR DECLARATION........................................................................... iii
ABSTRACT .................................................................................................... iv
FOREWORD .................................................................................................. v
CONTENT ...................................................................................................... vii
FIGURE CONTENT ....................................................................................... x
GRAPH CONTENT ....................................................................................... x
TABLE CONTENT ........................................................................................ xi
BAB. I INTRODUCTION ........................................................................ 1
1.1. Background .................................................................................. 1
1.2. The Selection of Design Capacity ................................................ 6
1.3. The Selection of Plant Location ................................................... 8
1.4. Theory .......................................................................................... 10
1.4.1 Type of Process .................................................................... 10
1.4.2 Product Usability .................................................................. 12
1.4.3 General Theory ..................................................................... 12
BAB. II PROCESS DESCRIPTION .......................................................... 14
2.1. Raw Material and Product Specification ....................................... 14
2.1.1. Raw Material Specification............................................... 14
2.1.2. Product Specification........................................................ 17
2.1.3. Adjuvant Specification...................................................... 18
2.2. Reaction Concept .......................................................................... 21
2.2.1. Basic Reaction ................................................................... 21
2.2.2. Reaction Characterity ........................................................ 21
2.2.3. Reaction Phase .................................................................. 23
2.2.4. Operating Condition .......................................................... 23
2.3. The Step of The Process ................................................................ 24
2.3.1. Molasses Process ............................................................... 24

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 2.3.2. Molasses Sterilization ....................................................... 24
2.3.3. Yeast Culturization ............................................................ 24
2.3.4. Fermentation ..................................................................... 25
2.3.5. Filtering ............................................................................. 25
2.3.6. Purification Process ............................................................ 26
2.4. Mass Balance And Heat Balance .................................................. 27
2.4.1. Mass Balance .................................................................... 27
2.4.2. Heat Balance ..................................................................... 40
2.5. Plant Layout And Equipment ......................................................... 54
2.5.1. Plant Layout ..................................................................... 54
2.5.2. Equipment Placement ........................................................ 58
BAB. III PROCESS EQUIPMENT ............................................................. 60
BAB. IV UTILITY AND LABORATORY UNITS .................................... 88
4.1. Utility ............................................................................................ 88
4.1.1. Water Processing and Supply Units...................................... 89
4.1.2. Steam Generator Unit........................................................... 96
4.1.3. Compressed Air Supply Unit................................................ 97
4.1.4. Power Generator Unit........................................................... 97
4.1.5. Fuel Supply Unit.................................................................. 100
4.1.6. Waste Processing Unit... ....................................................... 101
4.2. Laboratory .... ................................................................................. 101
BAB. V COORPERATE MANAGEMENT ............................................... 109
5.1. Coorperate Form ........................................................................... 109
5.2. Organization Structure .................................................................. 110
5.3. Task and Authority......................................................................... 113
5.3.1. Shareholder........................................................................... 113
5.3.2. Commisioner Board.............................................................. 113
5.3.3. Director Board...................................................................... 113
5.3.4. Expertise Staff...................................................................... 114
5.3.5. Manager................................................................................ 114
5.3.6. Head Division....................................................................... 116

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 5.3.7. Section Head........................................................................ 116
5.4. Employee Work Hour .................................................................... 116
5.4.1. Non-Shift Employee.............................................................. 116
5.4.2. Shift Employee...................................................................... 117
5.5. Position Classification, Staff Number, and Salary ......................... 118
5.5.1. Position Requirement........................................................... 118
5.5.2. Staff Number and Salary Break Down................................. 119
5.6. Employee Prosperity...................................................................... 120
5.7. Production Management................................................................ 120
5.7.1. Production Planning............................................................ 121
5.7.2. Production Control.............................................................. 122
BAB. VI ECONOMIC EVALUATION ...................................................... 123
6.1. Capital, Manufacturing Cost, General Expanses, and Financial
Analysis ....................................................................................... 123
6.1.1. Total Fixed Capital Investment ............................................ 126
6.1.2. Working Capital.................................................................... 127
6.1.3 Manufacturing Cost................................................................ 127
6.1.4. General Expense ................................................................... 128
6.1.5. Economic Evaluation Calculation .......................................... 128
6.1.6. Apropriateness Analysis......................................................... 128
BAB. VII CONCLUSION.............................................................................. 133
REFERENCE
ATTACHMENT

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 Figure Content

Figure 1.1. Fossil Fuel Consumption in Indonesia (in KL) ............................ 1

Figure 1.2. Comparation of crude oil need from import and local(mil barrel) 3
Figure 1.3. Fossil fuel consumption in 2011 ................................................... 4
Figure. 1.4. Production of Ethyl Alcohol ........................................................ 11
Figure 2.1. Qualitative Flow Diagram ............................................................ 38
Figure 2.2. Quantitative Flow Diagram .......................................................... 39
Figure 2.3. Plant placement .............................................................................. 57
Figure 2.4. Plant layout .................................................................................... 59
Figure 3.1. Inoculation Tank Scheduling ........................................................ 44
Figure 3.2. Fermentor Reactor Scheduling ..................................................... 46
Figure 4.1. River Water Process as a Support Process .................................... 101
Figure 5.1. Coorperate Structure ..................................................................... 109
Figure 6.1. Equation Graph Cost Index with Year.......................................... 121
Figure 6.2. Economic Evaluation .................................................................... 129

x
 Table Content

Table 1.1. Government Expanding and Subsidy in Quintillion of Rupiah ...... 5

Table 1.2. Ethanol (Ethyl Alcohol) Product Data ............................................ 7
Table 1.3. Data of Ethyl Alcohol plant ........................................................... 8
Table 2.1 Molasses composition ...................................................................... 14
Table 2.2 Mass balance around dilute tank M – 01......................................... 27
Table 2.3 Mass balance around sterilization tank F – 101 ..................……... 27
Table 2.4. Mass balance around storage tank F – 102.................................... 28
Table 2.5. Inoculation tank R – 01 mass balance............................................. 29
Table 2.6. Reactor R – 02 mass balance .......................................................... 30
Table 2.7. Mass balance around filter H – 01. ................................................ 31
Table 2.8. Mass balance around separator D – 01............................................ 32
st
Table 2.9. Mass balance around 1 distillation column D – 02 ........................ 33
Table 2.10. Mass balance around 2nd distillation column D – 03...................... 34
Table 2.11.Overall mass balance ................... ............................................... 35
Table 2.12.Overall mass balance (cont.) ................... ...................................... 36
Table 2.13. Heat balance around dilute tank M – 01 ................... ................. 40
Table 2.14. Heat balance around sterilization tank F – 101 ................... ....... 40
Table 2.15. Heat balance around culturization tank R – 01 ................... ....... 41
Table 2.16. Heat balance around reactor R – 02 ................... ........................ 42
Table 2.17. Heat balance around filter H – 01 ................... ........................... 43
Table 2.18. Heat balance around separator D – 01 ................... .................... 44
Table 2.19.Heat balance around 1st distillation column D – 02 ................... . 45
Table 2.20. Heat balance around 2nd distillation column D – 03 ................... 46
Table 2.21. Heat balance around cooler E-100................................................ 46
Table 2.22. Heat balance around heater E-200.................. ............................. 47
Table 2.23. Heeat balance around cooler E – 103 ........................................ 48
Table 2.24. Heat balance around cooler E – 101................................ ............. 49
Table 2.25. Heat balance around cooler E – 104................................ ............. 50
Table 2.26. Heat balance around cooler E – 105................................ ............. 51

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Table 2.27. Heat balance around cooler E – 106................................ ............. 51
Table 2.28. Overall heat balance................................ ...................................... 52
Table 2.29. Overall heat balance (Cont.)................................ ......................... 53
Table 2.30. Wide of plant area................................ ......................................... 56
Table 3.1. Molasses storage tank F – 100 specification................................... 60
Table 3.2. Molasses storage tank F – 100 specification (Cont.)...................... 61
Table 3.3. Sterilization tank F – 101 specification .......................................... 61
Table 3.4. Sterilization tank F – 101 specification (Cont.) .............................. 62
Table 3.5 Temporary storage tank F – 102 specification ................................. 62
Table 3.6. Storage tank F – 103 specification .................................................. 63
Table 3.7. Dilute tank M – 01 specification ..................................................... 64
Table 3.8. Cooler E – 100 specification ........................................................... 65
Table 3.9. Cooler E – 101 specification ........................................................... 66
Table 3.10. Cooler E – 103 Specification ........................................................ 67
Table 3.11. Cooler E – 104 specification ......................................................... 68
Table 3.12. Cooler E – 105 specification ......................................................... 69
Table 3.13. Cooler E – 106 specification ......................................................... 70
Table 3.14. Heater E – 200 specification ......................................................... 71
Table 3.15. Blower G – 01 specification.......................................................... 72
Table 3.16. Inoculation tank R – 01 specification ........................................... 72
Table 3.17. Inoculation tank R – 01 specification (Cont.) ............................... 73
Table 3.18. Reactor R – 02 specification ......................................................... 75
Table 3.19. Rotary drum filter H – 01 specification ........................................ 77
Table 3.20. Separator D – 01 specification ...................................................... 77
st
Table 3.21. 1 Distilation column D – 02 specification................................... 78
Table 3.22. Condensor E – 301 specification .................................................. 79
Table 3.23. Accumulator F – 201 specification ............................................... 80
Table 3.24. Reboiler E – 401 specification ...................................................... 80
Table 3.25. Reboiler E – 401 specification (Cont.).......................................... 81
nd
Table 3.26. 2 distilation column D – 03 specification................................... 82
Table 3.27. Condensor E – 302 specification .................................................. 83

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Table 3.28. Accumulator F – 202 specification ............................................... 84
Table 3.29. Reboiler E – 402 specification ...................................................... 84
Table 3.30. Reboiler E – 402 specification (Cont.).......................................... 85
Table 3.31. Main pump equipment specification ............................................. 86
Table 3.32. Main pump equipment specification (Cont.) ................................ 87
Table 4.41. Water needs ................................................................................... 91
Table 4.2. Water needs (Cont.) ........................................................................ 92
Table 4.3. Steam needs in plant ....................................................................... 96
Table 4.4. Process power data .. ....................................................................... 98
Table 4.5. Utility power needs ......... ................................................................ 99
Table 4.6. Other electricity needs..................................................................... 100
Table 4.7. Main utility equipment specification................................................ 105
Table 4.8. Main utility equipment specification (Cont.)................................... 106
Table 4.9. Utility pump specification................................................................ 107
Table 4.10. Utility pump specification (Cont.)................................................. 108
Table 5.1. Shift emploee work hour ...... ………………................................. 117
Tabel.5.2. list of position and requirement....................................................... 118
Tabel.5.3. Brake down position, staff number and salary................................ 119
Table 6.1. Chemical plant cost index............................................................... 124
Table 6.2. Total fixed capital investment......................................................... 126
Table 6.3. Working capital investment .......................................................... . 127
Table 6.4. Manufacturing cost ........................................................................ 127
Table 6.5. General expenses ............................................................................ 128
Table 6.6. Fixed cost ....................................................................................... 130
Table 6.7. Variable cost .................................................................................. 130
Table 6.8. Regulated Cost ............................................................................... 130
Table 7.1. Economic feasibility analysis ......................................................... 133

xiii
 MOTTO

 If you can dream you can do it

 Do the best, be good, then you will be the best

 Keep thinking the out of the box, keep executing the inside of the
box
 Presented

 All praises be to Allah SWT who has given many mercies and
blessing so the author can finish the Final Asignment of
Chemical Plant Design without any troubles.
 May peace be upon the prophet Muhammad SAW who has
guided us from the darkness into the brightness.
 Mom and Dad, thanks for the love, pray, and support so I can be
like this. Thanks for all that you have given to me. I just can say
thank you and I love you all.
 My lovely hubby, thank you so much for all that you have given
to me, I love you so much.
 All family that give me support until now.

Hopefully what I studied before can helps others. Aamiin.