Data2/10/13TK 4103Joseph13010001Ekonomi dan Manajemen Proyek Teknik KimiaLugas13010025LAMPIRAN 1Edi13010029Pabrik Caprolactam

Process Flow DiagramSumber : Hydrocarbon Processing Edisi Maret 1997Lisensor Teknologi :SNIA Viscosa ProcessDeskripsi Singkat :Produksi caprolactam dari nitro grade tolueneKeterangan PFD :1Oxidation Reactor2Fractionator3Hydrogenation CSTR4Caprolactam Reactor5Dillution Vessel6Crystallizer7Extractor8Fractionator9Storage Tank

Kapasitas Pabrik 90,000ton/tahun

Chemical Engineering Cost IndexSumber : www.che.com/pciCE Indeks dari literaturCE Indeks dari literaturTahunCE IndeksTahunCE Indeks1976192.11995381.11977204.11996381.71978218.81997386.51979238.71998389.51980261.21999390.619812972000394.119823142001394.31983316.92002395.61984322.72003402 1985325.32004444.21986318.42005468.219873202006499.61988342.52007525.41989355.42008575.41990357.62009521.91991361.32010550.81992358.22011585.71993359.22012584.61994368.12013569.9

Capital CostPerhitungan Total Capital InvestmentsHijauLiteraturBiruHasil PerhitunganMerahNilai yang DiinputLAMPIRAN 1 (Harga Alat)Perhitungan no 1 sampai dengan 7 mengacu pada persamaan 6.7 pada buku Coulson & Richardson's ChE Vol. 6Perhitungan no 8 mengacu pada persamaan 6.15 pada buku Towler & Sinnot's Chemical Engineering DesignReferensi :(1) Coulson Richardson Chemical Engineering Vol. 6 Chapter 6 Economic Evaluation dan(2) Towler & Sinnot's Chemical Engineering DesignBasis Tahun 2004Faktor Cepci1.28NoMajor EquipmentEquipmentJenisKeteranganKonstantaIndexHarga lama (US$)Harga lama total (US$)Harga Baru (US$)1Oxidation ReactorReactorVertikalKapasitas (m3)4000310000.452,590,1132,590,113$3,323,065AgitatorPropellerDuty (kW)75019000.5104,067104,067$133,516Jumlah22Fractionator VesselVertikalDiameter (m)3Figure 6.5-220,000220,000$282,256Tinggi (m)22Figure 6.5-MaterialS.S.2-Pressure (bar)1.51-TraySieveDiameter (m)3Figure 6.7-2,21039,780$51,037materialS.S.1.7-Tray18-Figure 6.73Hydrogenation ReactorReactorVertikalKapasitas (m3)3500310000.452,439,0592,439,059$3,129,266Agitator3-bladeDuty (kW)80019000.5107,480322,441$413,685Jumlah 24Caprolactam ReactorReactorVertikalKapasitas (m3)3600310000.452,470,1762,470,176$3,169,187Figure 6.5Agitator3-bladeDuty (kW)90019000.5114,000342,000$438,779Jumlah25Dillution VesselVesselHorizontalDiameter (m)3Figure 6.6-100,000100,000$128,298Panjang (m)12Figure 6.6-MaterialS.S.2-Pressure (bar)1.51-6ExtractorReactorVertikalKapasitas (m3)3000310000.452,275,6022,275,602$2,919,553AgitatorPropellerDuty (kW)80019000.5107,480107,480$137,8957FractionatorVesselVertikalDiameter (m)3Figure 6.5-220,000220,000$282,256Jumlah2Tinggi (m)22Figure 6.5-MaterialS.S.2-Pressure (bar)1.51-NoMajor EquipmentEquipmentJenisKeteranganKonstantaIndexHarga lama (US$)Harga lama total (US$)Harga Baru (US$)7FractionatorTraySieveDiameter (m)2Figure 6.7-2,38047,600$61,070materialS.S.1.7-Tray20-8CrystallizerScraped Surface CrystallizerLength (m)16410000.7319,576319,576$410,010400009Storage Tank TankFloating RoofJumlah443500.55566,6222,266,487$2,907,859Volume (m3)7000

TOTAL$17,787,731Untuk menghitung Capital Investments yang dibutuhkan, maka terdapat beberapa faktorperhitungan yang perlu dimasukkan. Berdasarkan Guthrie (1969) faktor-faktor tersebut diantaranya ialah :NoItemFluids ProcessingNoItemFluids Processing1Major Equipment, total purchase cost2Total physical plant cost (PPC)f1, Equipment erection0.4PPC = PCE (1+f1+f2++f9)Figure 6.6f2, Piping0.7= PCE x 3.4f3, Instrumentation0.2Physical Plant Cost (PPC)$60,478,287f4, Electrical0.13f10, Design and Engineering0.3f5, Buildings, process0.15f11, Contractor's fee0.3f6, Utilities0.5f12, Contingency0.1f7, Storages0.15FIXED CAPITAL = PPC (1+f10+f11+f12)f8, Site development0.05= PPC x 1.7f9, Ancillary buildings0.15FIXED CAPITAL (FCI)$102,813,087Working Capital 20% dari Fixed Capital$20,562,617Working Capital 20%

TOTAL CAPITAL INVESTMENT(TCI) =$123,375,705

Manufacturing CostManufacturing Cost = DMC + FMC + GMEDirect Manfacturing Cost (DMC)Referensi Harga Senyawa : www.alibaba.coma.Raw MaterialsNo.MaterialJumlah (ton/tahun)US $ / tonHarga US $1Toluen90,000$1,200$108,000,0002Katalis Co35$16,000$560,0003Katalis Pd4,000$14,000$56,000,0004Hidrogen12,000$1,800$21,600,0005NOHSO4115,000$200$23,000,0006NH3148,000$400$59,200,0007Oleum475,000$60$28,500,000Total$296,860,000Crm =$296,860,000.00

b.Waste Treatmentkapasitas Produksi90,000ton/tahunWast Disposal (Solid & Liquid)Biaya per tonBiaya AktualTotal Biaya/ tahunNon-hazardous363,240,000$3,240,000

Referensi Harga utilitas : Turton, 2009. Analysis, Design, and Design of Chemical Process, Chapter 8 page 233c.Utilitieskapasitas Produksi90,000ton/tahunKebutuhan UtilitasDari Referensi HP Processing Jumlah aktualBiaya/ tahunUtilitasHargaSteam (kg/ tahun)1109,900,000$277,200Steam0.028USD/kgElectricity (kWh)403,600,000$216,000Electricity0.06USD/kWhWater Cooling (m3/ tahun)10900,000$60,300Water Cooling0.067USD/tonFuel Gas (Nm3/tahun)252,250,000$945,000Fuel Gas0.42USD/Nm3TOTAL$1,498,500Referensi : buku Turton halaman 233d.Operating Labor

Equipment TypeJumlah EquipmentNnp1Oxidation Reactor222Fractionator113Hydrogenation CSTR224Caprolactam Reactor225Dillution Vessel116Crystallizer117Extractor228Fractionator119Storage Tank44TOTAL16

P =1NOL =6Jumlah operator per shiftOperating Labor = 4.5* NOL29Labor Cost per year = $54,000Referensi : Buku Turton hal. 230Total Labor Cost per year = $1,568,621

e.Direct Supervisory and Clerical Labor(Direktur Utama, Direktur, dll.) --> (0,18*Col)18%Total =$282,351.78

f.Maintenance and RepairsBesar biaya per tahun adalah 6 % dari Fixed Capital Investment (FCI)6%Total =$6,168,785

g.Operating suppliesBesar biaya per tahun adalah 0,9 % dari FCI atau setara 15 % dari Maintenance0.9%Total =$925,318h.Laboratory chargesBesar biaya per tahun adalah 15 % dari Operating Labor Cost15%Total =$235,293.15i.Patent and royaltiesReferensi Harga Senyawa : www.alibaba.comPaten dan royalti bernilai 1 % dari penjualan produk1%No.ProdukProduksi per tahun (ton)Harga per tonHarga Jual1Caprolactam90,000$3,100.00$279,000,0002Ammonium Sulfat500,000$320.00$160,000,000Total product cost$439,000,000Patent and royalties total =$4,390,000DMC =$315,168,869Fixed Manufacturing Cost (FMC)a.DepreciationDepresiasi dihitung sebesar 10 % dari FCI10%Nilai depresiasi =$10,281,309

b.Local taxes and insurancesBesarnya pajak adalah 2 % dari FCI2%Tax =$2,056,262Besarnya biaya asuransi adalah 1 % dari FCI1%Insurances =$1,028,131

c.Plant overhead costsBesarnya cost dari kepala operating labor dan direct supervisory & clerical labor 60 % dari Col60%POC =$3,870,682.21FMC =$17,236,384

General Manufacturing Expenses (GME)a.Administration costs15%labor costAdministration costs dihitung sebesar 15% dari labor cost$967,670.55b.Distribution and selling costsDistribution and selling costs dihitung sebesar5% dari total product cost 5%Biaya =$21,950,000c.Research and DevelopmentR&D Cost dihitung sebesar 10% dari total product cost10%R&D Cost =$43,900,000GME =$66,817,671FCI=$102,813,087Cost of Manufacture = DMC + FMC + GME = $399,222,923Revenue =$39,777,077

Profitability AnalysisProfitability AnalysisTabel Perhitungan Cash Flowketerangan : angka dalam kurung berarti negatifJoseph B. (13010001)keterangan : angka dalam kurung berarti negatifEnd of Year (k)Cash FlowCummulative Cash FlowLugas Raka A. (13010025)End of Year (k)InvesmentdkFCIL-dkRCOMd(R-COMd-dk)*(1-t)+dkNonDiscountedDiscountedNonDiscountedDiscountedEdi Yusuf H. (13010029)0$(5,000,000)0.0$103,000,0000.00.00.00$(5,000,000)$(5,000,000)$(5,000,000)$(5,000,000)1$(63,000,000)0.0$103,000,0000.00.00.01$(63,000,000)$(57,272,727)$(68,000,000)$(62,272,727)2$(60,600,000)0.0$103,000,0000.00.00.02$(60,600,000)$(50,082,645)$(128,600,000)$(112,355,372)Biaya-biaya Proyek Pabrik CaprolactamFungsi RoundUp30.0$10,000,000$93,000,000$439,000,000$400,000,000$28,850,0003$28,850,000$21,675,432$(99,750,000)$(90,679,940)40.0$10,000,000$83,000,000$439,000,000$400,000,000$28,850,0004$28,850,000$19,704,938$(70,900,000)$(70,975,002)Harga Tanah (C L)=$5,000,00050.0$10,000,000$73,000,000$439,000,000$400,000,000$28,850,0005$28,850,000$17,913,580$(42,050,000)$(53,061,422)Total Fixed Capital Investment (FCI)=$102,813,087dibulatkan menjadi$103,000,00060.0$10,000,000$63,000,000$439,000,000$400,000,000$28,850,0006$28,850,000$16,285,073$(13,200,000)$(36,776,349)Asumsikan pembangunan memakan waktu 2 tahun70.0$10,000,000$53,000,000$439,000,000$400,000,000$28,850,0007$28,850,000$14,804,612$15,650,000$(21,971,737)FCI pada tahun ke-1 =$63,000,00080.0$10,000,000$43,000,000$439,000,000$400,000,000$28,850,0008$28,850,000$13,458,738$44,500,000$(8,512,999)FCI pada tahun ke-2 =$40,000,00090.0$10,000,000$33,000,000$439,000,000$400,000,000$28,850,0009$28,850,000$12,235,216$73,350,000$3,722,217Pabrik mulai berjalan di akhir tahun ke-2100.0$10,000,000$23,000,000$439,000,000$400,000,000$28,850,00010$28,850,000$11,122,924$102,200,000$14,845,141Working capital =20%dari FCI =$20,600,000110.0$10,000,000$13,000,000$439,000,000$400,000,000$28,850,00011$28,850,000$10,111,749$131,050,000$24,956,890Fungsi RoundUp12$25,600,000$10,000,000$3,000,000$442,000,000$400,000,000$30,800,00012$56,400,000$17,970,778$187,450,000$42,927,668Sales Revenue dan Cost of Manufacturing (COM)Revenue tiap tahun (setelah beroperasi)=$439,000,000per tahunDepresiasi tiap tahun (dk) = $10,000,000$9,813,829$33,057,851Biaya Manufaktur (setelah beroperasi) =$399,222,923per tahun$400,000,000DCFROR dicari melalui besaran interest rate yang menghasilkan NPV=0Land + Working Capital =$(25,600,000)untuk payback period, dicari waktu kapan cashflow terhitung harga tersebutdengan trial and errorTaxation Rate =35%$(22,024,793)untuk discounted payback period, dicari kapan terhitung harga tersebutInterest RateNPVSalvage Value =$3,000,000Non Discounted CriterionDiscounted Criterion10%$42,927,668Depresiasi =10tahun dengan Garis Lurus (SL method)CCP =$187,450,000NPV = $42,927,66812%$27,461,174Asumsikan usia proyek ialah 10 tahunCCR =2.458PVR =1.38214%$14,618,635DCFROR=16.88%Interest Rate=10%PBP =3.57tahunDPBP =5.00tahun16%$3,920,739ROROI =28.20%DCFROR=16.83%18%$(5,015,645)Atau dapat dicari dengan metode goal seek solver pada ExcelGoal seek akan mencari nilai Interest Rate saat NPV=0Dari hasil pencarian goal seek, diperoleh :DCFROR =16.83%hasil yang diperoleh samaDiagram Cash FlowNon-DiscountedDiagram Cash FlowDiscounted (10%)CFD Non-Discounted dan Discounted (10%)Cummulative Cash FlowCummulative Cash FlowTahunCash FlowDalam juta USDTahunCash FlowDalam Juta USD00.00.0000.00.000$(5,000,000)-5.000$(5,000,000)-5.001$(68,000,000)-68.001$(62,272,727)-62.272$(108,000,000)-108.002$(95,330,579)-95.332$(128,600,000)-128.602$(112,355,372)-112.363$(99,750,000)-99.753$(90,679,940)-90.684$(70,900,000)-70.904$(70,975,002)-70.985$(42,050,000)-42.055$(53,061,422)-53.066$(13,200,000)-13.206$(36,776,349)-36.787$15,650,00015.657$(21,971,737)-21.978$44,500,00044.508$(8,512,999)-8.519$73,350,00073.359$3,722,2173.7210$102,200,000102.2010$14,845,14114.8511$131,050,000131.0511$24,956,89024.9612$161,850,000161.8512$34,770,71934.7712$187,450,000187.4512$42,927,66842.93

Sensitivity AnalysisSensitivity Analysis

Tujuan :Mengetahui efek perubahan variabel-variabel asumsi terhadap NPV dan IRRVariabel yang diubah :LowestLowMiddle-LowBase CaseMiddle-HighHighHighest-8%-4%-2%0%2%4%8%1Revenue$403,880,000$421,440,000$430,220,000$439,000,000$447,780,000$456,560,000$474,120,0002Investment$94,760,000$98,880,000$100,940,000$103,000,000$105,060,000$107,120,000$111,240,0003Biaya Produksi$368,000,000$384,000,000$392,000,000$400,000,000$408,000,000$416,000,000$432,000,0004Tax Rate32.20%33.60%34.30%35.00%35.70%36.40%37.80%5Interest Rate9.20%9.60%9.80%10.00%10.20%10.40%10.80%6Working Capital18.40%19.20%19.60%20.00%20.40%20.80%21.60%7Harga Tanah$4,600,000$4,800,000$4,900,000$5,000,000$5,100,000$5,200,000$5,400,000

Analisis Sensitivitas dilakukan hanya untuk discounted saja karena proyek/ pabrik caprolactamtermasuk proyek besar (large projects) dengan jangka waktu yang panjang.Efek waktu (time value of money) akan sangat menentukan keuntungan yang diperoleh dari pabrik tersebut.Variabel yang ingin dilihat perubahannya ialah NPV dan IRR/ DCFRORNilai NPVLowestLowMiddle-LowBaseMiddle-HighHighHighestNilai NPVLowestLowMiddle-LowBaseMiddle-HighHighHighest-8%-4%-2%0%2%4%8%-8%-4%-2%0%2%4%8%1Revenue-$72,996,446-$15,034,389$13,946,640$42,927,668$71,908,697$100,889,725$158,851,7821Revenue-$73.00-$15.03$13.95$42.93$71.91$100.89$158.852Investment$49,109,926$46,018,797$44,473,233$42,927,668$41,382,104$39,836,540$36,745,4112Investment$49.11$46.02$44.47$42.93$41.38$39.84$36.753Biaya Produksi$148,553,285$95,740,476$69,334,072$42,927,668$16,521,264-$9,885,140-$62,697,9483Biaya Produksi$148.55$95.74$69.33$42.93$16.52-$9.89-$62.704Tax Rate$47,077,895$45,002,782$43,965,225$42,927,668$41,890,112$40,852,555$38,777,4424Tax Rate$47.08$45.00$43.97$42.93$41.89$40.85$38.785Interest Rate$49,979,118$46,386,353$44,640,601$42,927,668$41,246,874$39,597,553$36,390,7515Interest Rate$49.98$46.39$44.64$42.93$41.25$39.60$36.396Working Capital$43,764,548$43,346,108$43,136,888$42,927,668$42,718,448$42,509,228$42,090,7886Working Capital$43.76$43.35$43.14$42.93$42.72$42.51$42.097Harga Tanah$43,200,216$43,063,942$42,995,805$42,927,668$42,859,531$42,791,394$42,655,1217Harga Tanah$43.20$43.06$43.00$42.93$42.86$42.79$42.66Nilai IRR/ DCFRORLowestLowMiddle-LowBaseMiddle-HighHighHighest-8%-4%-2%0%2%4%8%1Revenue-4.83%7.36%12.32%16.83%21.01%24.92%32.14%2Investment18.23%17.51%17.17%16.83%16.51%16.19%15.57%3Biaya Produksi30.91%24.24%20.65%16.83%12.74%8.28%-2.35%4Tax Rate17.45%17.14%16.99%16.83%16.68%16.52%16.21%5Working Capital17.05%16.94%16.89%16.83%16.78%16.73%16.63%6Harga Tanah16.91%16.87%16.85%16.83%16.82%16.80%16.76%Nilai IRR/ DCFRORLowestLowMiddle-LowBaseMiddle-HighHighHighest-8%-4%-2%0%2%4%8%1Revenue-4.83%7.36%12.32%16.83%21.01%24.92%32.14%2Investment18.23%17.51%17.17%16.83%16.51%16.19%15.57%3Biaya Produksi30.91%24.24%20.65%16.83%12.74%8.28%-2.35%4Tax Rate17.45%17.14%16.99%16.83%16.68%16.52%16.21%5Working Capital17.05%16.94%16.89%16.83%16.78%16.73%16.63%6Harga Tanah16.91%16.87%16.85%16.83%16.82%16.80%16.76%