Preliminary plant design of ethyl acetate plant using PTSA catalyst with production capacity of 14,787 tons/year

Ethyl acetate is an important industrial chemical used primarily as a solvent for various resins in protective coatings, and also used extensively in formulating printing inks and adhesives. In Indonesia the only company that produces ethyl acetate is PT. Sarasa Nugraha, Tbk. with production capacity of 4,500 tons/year. On the other hand, the demand of ethyl acetate is growing each year. Due to the increasing imports of ethyl acetate, the existance of another ethyl acetate producing company is plausible. The location of the ethyl acetate plant is designed to be built in Driyorejo Industrial Estate, Gresik, East Java The production of ethyl acetate consists of three main unit operations: esterification reaction, product separation, and purification. There are severnl processes to produce ethyl acetate, but the fischer esterification is the best option to produce ethyl acetate. This process has many advantages compared to other processes because the raw materials needed are easily obtained and compared to other methods, Fischer esterification requires the least number of intermediate steps. Also, Fischer esterification process only produces water as side product which is not harmful to the environment. The ethyl acetate plant is planned to operate continuously for 24 hours and 300 days in a year. The plant is designed with following specifications: • Production Capacity : 14,787 tons ethyl acetate/year • Land Area : 7,500 m2 • Number of Employees : 134 persons • • Raw materials and side product: • Raw materials: • Acetic Acid : 10,800 tons / year • Ethanol 95% : 10,080 tons / year • side product: • • Ethyl Acetate 45% : 1,590 tons / year • • Utilities: • Electricity : 400 kW • Gas : 244,467 MMBtu/year • Water : 53,834 m3/year • Zeolite : 7,840 kg/year • NaCl : 697 kg/year Economical analysis: Fixed Capital Investment : Rp. 35,758,240,000,-Working Capital Investment: Rp. 22,168,277,000,-Total Production Cost : Rp. 133,009,663,000,-Annual Revenue : Rp. 141,426,000,000,- 1 Linear Method Rate of Return before taxes : 14.65 % Rate of Return after taxes : 9.59 % Pay Out Time before taxes : 5 years 1 months Pay Out Time after taxes : 6 years 10 months Break: Even Point : 45.97 % 2 Discounted Cash Flow Method Rate of Return before taxes : 19.93 % Rate of Return after taxes : 16.75 % Pay Out Time before taxes : 6 years 2 months Pay Out Time after taxes : 7 years Break: Even Point : 33.99