2/10/2013

TK 4103
Ekonomi dan Manajemen Proyek Teknik Kimia

Pabrik Caprolactam
Process Flow Diagram
Sumber : Hydrocarbon Processing Edisi Maret 1997

Deskripsi Singkat :

Lisensor Teknologi : SNIA Viscosa Process

Produksi caprolactam dari nitro grade toluene
Keterangan PFD :
1 Oxidation Reactor
2 Fractionator
3 Hydrogenation CSTR
4 Caprolactam Reactor
5 Dillution Vessel
6 Crystallizer
7 Extractor
8 Fractionator
9 Storage Tank

Kapasitas Pabrik

90,000 ton/tahun

Joseph
Lugas
Edi

13010001
13010025
13010029

Chemical Engineering Cost Index

Sumber : www.che.com/pci
CE Indeks dari literatur

CE Indeks dari literatur

Tahun

CE Indeks

Tahun

CE Indeks

1976

192.1

1995

381.1

1977

204.1

1996

381.7

1978

218.8

1997

386.5

1979

238.7

1998

389.5

1980

261.2

1999

390.6

1981

297

2000

394.1

1982

314

2001

394.3

1983

316.9

2002

395.6

1984

322.7

2003

402

1985

325.3

2004

444.2

1986

318.4

2005

468.2

1987

320

2006

499.6

1988

342.5

2007

525.4

1989

355.4

2008

575.4

1990

357.6

2009

521.9

1991

361.3

2010

550.8

1992

358.2

2011

585.7

1993

359.2

2012

584.6

1994

368.1

2013

569.9

LAMPIRAN 1

Perhitungan Total Capital Investments

Hijau

Literatur

Perhitungan no 1 sampai dengan 7 mengacu pada persamaan 6.7 pada buku Coulson & Richardson's ChE Vol. 6
Perhitungan no 8 mengacu pada persamaan 6.15 pada buku Towler & Sinnot's Chemical Engineering Design
Referensi :(1) Coulson Richardson Chemical Engineering Vol. 6 Chapter 6 Economic Evaluation dan
(2) Towler & Sinnot's Chemical Engineering Design
Basis Tahun 2004
No

Major Equipment
1

Oxidation Reactor

Jenis

Reactor
Agitator

Vertikal
Kapasitas (m3)
4000
Propeller Duty (kW) 750
Jumlah
2
Diameter (m)
3
Tinggi (m) 22
Vertikal
Material S.S.
Pressure (bar)
1.5
Diameter (m)
3
Sieve material S.S.
Tray
18
Vertikal
Kapasitas (m3)
3500
3-blade
Duty (kW) 800
Jumlah
2
Vertikal
Kapasitas (m3)
3600
3-blade
Duty (kW) 900
Jumlah
2
Diameter (m)
3
Panjang (m)12
Horizontal
Material S.S.
Pressure (bar)
1.5
Vertikal
Kapasitas (m3)
3000
Propeller Duty (kW) 800
Diameter (m)
3
Jumlah
2
Vertikal Tinggi (m) 22

Vessel
2

Fractionator
Tray

Hydrogenation Reactor

Reactor
Agitator

Caprolactam Reactor

Reactor
Agitator

Dillution Vessel

Extractor

Fractionator

Keterangan

Equipment

Vessel
Reactor
Agitator

Vessel

Konstanta

Index

31000
1900

0.45
0.5

Figure 6.5
Figure 6.5
2
1
Figure 6.7
1.7
31000
1900

0.45
0.5

31000
1900

0.45
0.5

Figure 6.6
Figure 6.6
2
1
31000
1900
Figure 6.5

0.45
0.5
-

Figure 6.5

Biru

Hasil Perhitungan

Merah

Nilai yang Diinput

Faktor Cepci
Harga lama
Harga lama
(US$)
total (US$)
2,590,113
2,590,113
104,067
104,067

220,000

220,000

2,210

39,780

2,439,059
107,480

2,439,059
322,441

2,470,176
114,000

2,470,176
342,000

100,000

100,000

2,275,602
107,480

2,275,602
107,480

220,000

220,000

Fractionator

Vessel

Vertikal

220,000
Material S.S.
Pressure (bar)
1.5

No

Major Equipment
7

Fractionator

Crystallizer

Storage Tank

Equipment

Jenis

Tray

Sieve

Keterangan
Diameter (m)
2
material S.S.
Tray
20

Scraped Surface Crystallizer Length (m) 16

Tank

Jumlah 4
Floating Roof
Volume (m3)7000

2
1

Konstanta

Index

Figure 6.7
1.7

41000
40000
4350

Harga lama
(US$)

0.7
0.55

220,000

Harga lama
total (US$)

2,380

47,600

319,576

319,576

566,622

2,266,487

TOTAL
$ 17,787,731
Untuk menghitung Capital Investments yang dibutuhkan, maka terdapat beberapa faktor
perhitungan yang perlu dimasukkan. Berdasarkan Guthrie (1969) faktor-faktor tersebut diantaranya ialah :
No

Item
Fluids Processing
Major Equipment, total purchase cost
f1, Equipment erection
0.4
f2, Piping
0.7
f3, Instrumentation
0.2
f4, Electrical
0.1
f5, Buildings, process
0.15
f6, Utilities
0.5
f7, Storages
0.15
f8, Site development
0.05
f9, Ancillary buildings
0.15

No

Item
Fluids Processing
Total physical plant cost (PPC)
2
PPC = PCE (1+f1+f2++f9)
= PCE x
3.4
Physical Plant Cost (PPC)
$ 60,478,287
f10, Design and Engineering0.3
3
f11, Contractor's fee
0.3
f12, Contingency
0.1
FIXED CAPITAL = PPC (1+f10+f11+f12)
= PPC x
1.7
FIXED CAPITAL (FCI) $ 102,813,087
Working Capital 20% dari
$ Fixed
20,562,617
Capital Working Capital
TOTAL CAPITAL INVESTMENT

(TCI) = $ 123,375,705

20%

sil Perhitungan

LAMPIRAN 1 (Harga Alat)

ai yang Diinput

1.28
Harga Baru (US$)
$
$

3,323,065
133,516

282,256

51,037

$
$

3,129,266
413,685

$
$

3,169,187
438,779

128,298

$
$

2,919,553
137,895

282,256

Figure 6.5

282,256

Harga Baru (US$)

$

61,070

410,010

2,907,859

Figure 6.6

Figure 6.7

a.
No.
1
2
3
4
5
6
7

Manufacturing Cost = DMC + FMC + GME

Direct Manfacturing Cost (DMC)
Referensi Harga Senyawa : www.alibaba.com
Raw Materials
Material
Toluen
Katalis Co
Katalis Pd
Hidrogen
NOHSO4
NH3
Oleum

Jumlah (ton/tahun)
90,000
35
4,000
12,000
115,000
148,000
475,000
Total

Crm =
b.

c.

d.

Waste Treatment
Wast Disposal (Solid & Liquid)
Non-hazardous

US $ / ton
Harga US $
$
1,200 $
$
16,000 $
$
14,000 $
$
1,800 $
$
200 $
$
400 $
$
60 $
$

296,860,000.00

kapasitas Produksi
Biaya per ton

90,000 ton/tahun
Biaya Aktual
Total Biaya/ tahun
36
3,240,000 $
3,240,000

Referensi Harga utilitas : Turton, 2009. Analysis, Design, and Design of Chemical Process, Chapter 8 page 233
Utilities
kapasitas Produksi
90,000
Kebutuhan Utilitas
Dari Referensi HP Processing Jumlah aktual
Steam (kg/ tahun)
110
9,900,000
Electricity (kWh)
40
3,600,000
Water Cooling (m3/ tahun)
10
900,000
Fuel Gas (Nm3/tahun)
25
2,250,000
TOTAL
Operating Labor
Equipment Type
1 Oxidation Reactor

108,000,000
560,000
56,000,000
21,600,000
23,000,000
59,200,000
28,500,000
296,860,000

Jumlah Equipment

Nnp
2

ton/tahun
Biaya/ tahun
$
$
$
$
$

277,200
216,000
60,300
945,000
1,498,500

2
3
4
5
6
7
8
9

Fractionator
Hydrogenation CSTR
Caprolactam Reactor
Dillution Vessel
Crystallizer
Extractor
Fractionator
Storage Tank

1
2
2
1
1
2
1
4
TOTAL

P=
NOL =
Operating Labor = 4.5* NOL
Labor Cost per year =
Total Labor Cost per year =
e.

f.

g.

h.

Direct Supervisory and Clerical Labor

(Direktur Utama, Direktur, dll.) --> (0,18*Col)
Total =

$
$

1
6 Jumlah operator per shift
29
54,000 Referensi : Buku Turton hal. 230
1,568,621

18%
282,351.78

Maintenance and Repairs

Besar biaya per tahun adalah 6 % dari Fixed Capital Investment (FCI)
Total =
$

6%
6,168,785

Operating supplies
Besar biaya per tahun adalah 0,9 % dari FCI atau setara 15 % dari Maintenance
Total =
$
Laboratory charges
Besar biaya per tahun adalah 15 % dari Operating Labor Cost
Total =

1
2
2
1
1
2
1
4
16

0.9%
925,318

15%
235,293.15

i.

Patent and royalties

Referensi Harga Senyawa : www.alibaba.com
Paten dan royalti bernilai 1 % dari penjualan produk
No. Produk
1 Caprolactam
2 Ammonium Sulfat
Total product cost
Patent and royalties total =
DMC =

a.

b.

c.

a.

b.

Fixed Manufacturing Cost (FMC)

Depreciation
Depresiasi dihitung sebesar 10 % dari FCI
Nilai depresiasi =
Local taxes and insurances
Besarnya pajak adalah 2 % dari FCI
Tax =
Besarnya biaya asuransi adalah 1 % dari FCI
Insurances =

1%
Produksi per tahun (ton)
Harga per ton
Harga Jual
90,000 $
3,100.00 $
500,000 $
320.00 $
$
$
4,390,000
$
315,168,869

$
$

10%
10,281,309

2%
2,056,262
1%
1,028,131

Plant overhead costs

Besarnya cost dari kepala operating labor dan direct supervisory & clerical labor 60 % dari Col
POC =
$
3,870,682.21
FMC =
$
17,236,384
General Manufacturing Expenses (GME)
Administration costs
Administration costs dihitung sebesar 15% dari labor cost
Distribution and selling costs
Distribution and selling costs dihitung sebesar
5% dari total product cost
Biaya =

279,000,000
160,000,000
439,000,000

15% labor cost

967,670.55

5%
21,950,000

60%

c.

Research and Development

R&D Cost dihitung sebesar 10% dari total product cost
R&D Cost =
GME =

Cost of Manufacture = DMC + FMC + GME =

$
$
$

10%
43,900,000
66,817,671
FCI=
399,222,923 Revenue =

$
$

102,813,087
39,777,077

Utilitas
Harga
Steam
0.028 USD/kg
Electricity
0.06 USD/kWh
Water Cooling 0.067 USD/ton
Fuel Gas
0.42 USD/Nm3
Referensi : buku Turton halaman 233

Profitability Analysis
Joseph B. (13010001)
Lugas Raka A. (13010025)
Edi Yusuf H. (13010029)

Biaya-biaya Proyek Pabrik Caprolactam

Fungsi RoundUp

Harga Tanah (C L)=

$
5,000,000
Total Fixed Capital Investment (FCI)=
$ 102,813,087 dibulatkan menjadi
$ 103,000,000
Asumsikan pembangunan memakan waktu 2 tahun
FCI pada tahun ke-1 =
$ 63,000,000
FCI pada tahun ke-2 =
$ 40,000,000
Pabrik mulai berjalan di akhir tahun ke-2
Working capital =
20% dari FCI =
$ 20,600,000
Fungsi RoundUp
Sales Revenue dan Cost of Manufacturing (COM)
Revenue tiap tahun (setelah beroperasi)=
$ 439,000,000 per tahun
Biaya Manufaktur (setelah beroperasi) =
$ 399,222,923 per tahun
$ 400,000,000
Taxation Rate =
35%
Salvage Value =
$
3,000,000
Depresiasi =
10 tahun dengan Garis Lurus (SL method)
Asumsikan usia proyek ialah 10 tahun
Interest Rate=
10%

Non-Discounted
225.00
200.00
175.00
150.00

Cash Flow (dalam juta USD)

Tahun
0
0
1
2
2
3
4
5
6
7
8
9
10
11
12
12

Diagram Cash Flow

Cummulative Cash Flow
Cash Flow
Dalam juta USD
$
0.00
$ (5,000,000) -5.00
$ (68,000,000) -68.00
$ (108,000,000) -108.00
$ (128,600,000) -128.60
$ (99,750,000) -99.75
$ (70,900,000) -70.90
$ (42,050,000) -42.05
$ (13,200,000) -13.20
$ 15,650,000 15.65
$ 44,500,000 44.50
$ 73,350,000 73.35
$ 102,200,000 102.20
$ 131,050,000 131.05
$ 161,850,000 161.85
$ 187,450,000 187.45

125.00
100.00
75.00
50.00
25.00
0.00
-25.00

-50.00
-75.00
-100.00
-125.00
-150.00

Tahun ke-

10

11

12

13

Tabel Perhitungan Cash Flow

keterangan : angka dalam kurung berarti negatif

End of Year (k)

0
1
2
3
4
5
6
7
8
9
10
11
12

Invesment
$
(5,000,000)
$ (63,000,000)
$ (60,600,000)
$
$
$
$
$
$
$
$
$
$
25,600,000

dk
$
$
$
$
$
$
$
$
$
$
$
$
$

10,000,000
10,000,000
10,000,000
10,000,000
10,000,000
10,000,000
10,000,000
10,000,000
10,000,000
10,000,000

Depresiasi tiap tahun (dk) =

Land + Working Capital =

FCIL-dk
$ 103,000,000
$ 103,000,000
$ 103,000,000
$
93,000,000
$
83,000,000
$
73,000,000
$
63,000,000
$
53,000,000
$
43,000,000
$
33,000,000
$
23,000,000
$
13,000,000
$
3,000,000
$

10,000,000

R
$
$
$
$
$
$
$
$
$
$
$
$
$

439,000,000
439,000,000
439,000,000
439,000,000
439,000,000
439,000,000
439,000,000
439,000,000
439,000,000
442,000,000

COMd
$
$
$
$ 400,000,000
$ 400,000,000
$ 400,000,000
$ 400,000,000
$ 400,000,000
$ 400,000,000
$ 400,000,000
$ 400,000,000
$ 400,000,000
$ 400,000,000

(R-COMd-dk)*(1-t)+dk
$
$
$
$ 28,850,000
$ 28,850,000
$ 28,850,000
$ 28,850,000
$ 28,850,000
$ 28,850,000
$ 28,850,000
$ 28,850,000
$ 28,850,000
$ 30,800,000
$

9,813,829 $

33,057,851

$
(25,600,000) untuk payback period, dicari waktu kapan cashflow terhitung harga tersebut
$
(22,024,793) untuk discounted payback period, dicari kapan terhitung harga tersebut
Non Discounted Criterion
Discounted Criterion
CCP =
$ 187,450,000
NPV =
$ 42,927,668
CCR =
2.458
PVR =
1.382
PBP =
3.57 tahun
DPBP =
5.00 tahun
ROROI =
28.20%
DCFROR=
16.83%

Discounted (10%)

Cash Flow (dalam juta USD)

Tahun
0
0
1
2
2
3
4
5
6
7
8
9
10
11
12
12

Diagram Cash Flow

Cummulative Cash Flow
Cash Flow
Dalam Juta USD
$
0.00
$
(5,000,000) -5.00
$ (62,272,727) -62.27
$ (95,330,579) -95.33
$ (112,355,372) -112.36
$ (90,679,940) -90.68
$ (70,975,002) -70.98
$ (53,061,422) -53.06
$ (36,776,349) -36.78
$ (21,971,737) -21.97
$
(8,512,999) -8.51
$
3,722,217 3.72
$
14,845,141 14.85
$
24,956,890 24.96
$
34,770,719 34.77
$
42,927,668 42.93

60.00
50.00
40.00
30.00
20.00
10.00
0.00
-10.00 0
-20.00
-30.00
-40.00
-50.00
-60.00
-70.00
-80.00
-90.00
-100.00
-110.00
-120.00
-130.00

Tahun ke-

10

11

12

13

keterangan : angka dalam kurung berarti negatif

Cash Flow
End of Year (k)
0
1
2
3
4
5
6
7
8
9
10
11
12

Interest Rate
10%
12%
14%
16%
18%

NonDiscounted

$
$
$
$
$
$
$
$
$
$
$
$
$

(5,000,000)
(63,000,000)
(60,600,000)
28,850,000
28,850,000
28,850,000
28,850,000
28,850,000
28,850,000
28,850,000
28,850,000
28,850,000
56,400,000

Cummulative Cash Flow

Discounted

$
$
$
$
$
$
$
$
$
$
$
$
$

(5,000,000)
(57,272,727)
(50,082,645)
21,675,432
19,704,938
17,913,580
16,285,073
14,804,612
13,458,738
12,235,216
11,122,924
10,111,749
17,970,778

NonDiscounted

$
$
$
$
$
$
$
$
$
$
$
$
$

(5,000,000)
(68,000,000)
(128,600,000)
(99,750,000)
(70,900,000)
(42,050,000)
(13,200,000)
15,650,000
44,500,000
73,350,000
102,200,000
131,050,000
187,450,000

Discounted

$
$
$
$
$
$
$
$
$
$
$
$
$

(5,000,000)
(62,272,727)
(112,355,372)
(90,679,940)
(70,975,002)
(53,061,422)
(36,776,349)
(21,971,737)
(8,512,999)
3,722,217
14,845,141
24,956,890
42,927,668

DCFROR dicari melalui besaran interest rate yang menghasilkan NPV=0

dengan trial and error
NPV
16%
0 14.62
$
42,927,668
=
18% 16%
5.015 14.62
$
27,461,174
$
14,618,635
DCFROR=
16.88%
$
3,920,739
$
(5,015,645)
Atau dapat dicari dengan metode goal seek solver pada Excel
Goal seek akan mencari nilai Interest Rate saat NPV=0
Dari hasil pencarian goal seek, diperoleh :
DCFROR =
16.83%
hasil yang diperoleh sama

CFD Non-Discounted dan Discounted (10%)

Non-discounted

Discounted 10%

225.00
200.00
175.00

Cash Flow (dalam juta USD)

150.00
125.00
100.00
75.00
50.00
25.00
0.00
-25.00 0

-50.00
-75.00
-100.00
-125.00
-150.00

Tahun ke-

10

11

12

13

Sensitivity Analysis
Tujuan :

Mengetahui efek perubahan variabel-variabel asumsi terhadap NPV dan IRR

Variabel yang diubah :

1
2
3
4
5
6
7

Revenue
Investment
Biaya Produksi
Tax Rate
Interest Rate
Working Capital
Harga Tanah

Lowest
-8%
$ 403,880,000
$
94,760,000
$ 368,000,000
32.20%
9.20%
18.40%
$
4,600,000

Low
-4%
$ 421,440,000
$ 98,880,000
$ 384,000,000
33.60%
9.60%
19.20%
$
4,800,000

Middle-Low
-2%
$ 430,220,000
$ 100,940,000
$ 392,000,000
34.30%
9.80%
19.60%
$ 4,900,000

Base Case
0%
$ 439,000,000
$ 103,000,000
$ 400,000,000
35.00%
10.00%
20.00%
$ 5,000,000

Middle-High
2%
$ 447,780,000
$ 105,060,000
$ 408,000,000
35.70%
10.20%
20.40%
$
5,100,000

High
4%
$ 456,560,000
$ 107,120,000
$ 416,000,000
36.40%
10.40%
20.80%
$
5,200,000

Highest
8%
$ 474,120,000
$ 111,240,000
$ 432,000,000
37.80%
10.80%
21.60%
$
5,400,000

High

Highest

Analisis Sensitivitas dilakukan hanya untuk discounted saja karena proyek/ pabrik caprolactam
termasuk 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/ DCFROR

Nilai NPV
1
2
3
4
5
6
7

Revenue
Investment
Biaya Produksi
Tax Rate
Interest Rate
Working Capital
Harga Tanah

Lowest

Low

-8%

-4%
-2%
0%
2%
4%
8%
-$15,034,389
$13,946,640
$42,927,668
$71,908,697
$100,889,725
$158,851,782
$46,018,797
$44,473,233
$42,927,668
$41,382,104
$39,836,540
$36,745,411
$95,740,476
$69,334,072
$42,927,668
$16,521,264
-$9,885,140
-$62,697,948
$45,002,782
$43,965,225
$42,927,668
$41,890,112
$40,852,555
$38,777,442
$46,386,353
$44,640,601
$42,927,668
$41,246,874
$39,597,553
$36,390,751
$43,346,108
$43,136,888
$42,927,668
$42,718,448
$42,509,228
$42,090,788
$43,063,942
$42,995,805
$42,927,668
$42,859,531
$42,791,394
$42,655,121

-$72,996,446
$49,109,926
$148,553,285
$47,077,895
$49,979,118
$43,764,548
$43,200,216

Middle-Low

Base

Middle-High

Nilai IRR/ DCFROR

1
2
3
4
5
6

Revenue
Investment
Biaya Produksi
Tax Rate
Working Capital
Harga Tanah

Lowest

Low

Middle-Low

Base

Middle-High

High

Highest

-8%
-4.83%
18.23%
30.91%
17.45%
17.05%
16.91%

-4%
7.36%
17.51%
24.24%
17.14%
16.94%
16.87%

-2%
12.32%
17.17%
20.65%
16.99%
16.89%
16.85%

0%
16.83%
16.83%
16.83%
16.83%
16.83%
16.83%

2%
21.01%
16.51%
12.74%
16.68%
16.78%
16.82%

4%
24.92%
16.19%
8.28%
16.52%
16.73%
16.80%

8%
32.14%
15.57%
-2.35%
16.21%
16.63%
16.76%

$200.00

NPV (DALAM JUTA USD)

$150.00

$100.00
$50.00
$0.00
-$50.00
-$100.00
-10%

-8%

-6%

-4%

-2%

0%

2%

4%

6%

8%

10%

% PERUBAHAN PARAMETER

Nilai NPV
1
2
3
4
5
6
7

Revenue
Investment
Biaya Produksi
Tax Rate
Interest Rate
Working Capital
Harga Tanah

Revenue

Investments

Manufacturing Cost

Interest Rate

Working Capital

Harga Tanah

Tax Rate

Lowest

Low

Middle-Low Base

Middle-High

High

Highest

-8%
-$73.00
$49.11
$148.55
$47.08
$49.98
$43.76
$43.20

-4%
-$15.03
$46.02
$95.74
$45.00
$46.39
$43.35
$43.06

-2%
$13.95
$44.47
$69.33
$43.97
$44.64
$43.14
$43.00

2%
$71.91
$41.38
$16.52
$41.89
$41.25
$42.72
$42.86

4%
$100.89
$39.84
-$9.89
$40.85
$39.60
$42.51
$42.79

8%
$158.85
$36.75
-$62.70
$38.78
$36.39
$42.09
$42.66

0%
$42.93
$42.93
$42.93
$42.93
$42.93
$42.93
$42.93

35.00%

INTERNAL RATE OF RETURN (%)

30.00%
25.00%
20.00%

15.00%
10.00%
5.00%
0.00%
-5.00%
-10.00%
-10%

-8%

-6%

-4%

-2%

0%

2%

4%

6%

8%

10%

% PERUBAHAN PARAMETER
Revenue

Nilai IRR/ DCFROR

1
2
3
4
5
6

Revenue
Investment
Biaya Produksi
Tax Rate
Working Capital
Harga Tanah

Investment

Manufacturing Cost

Tax Rate

Working Capital

Harga Tanah

Lowest

Low

Middle-Low Base

Middle-High

High

Highest

-8%
-4.83%
18.23%
30.91%
17.45%
17.05%
16.91%

-4%
7.36%
17.51%
24.24%
17.14%
16.94%
16.87%

-2%
12.32%
17.17%
20.65%
16.99%
16.89%
16.85%

2%
21.01%
16.51%
12.74%
16.68%
16.78%
16.82%

4%
24.92%
16.19%
8.28%
16.52%
16.73%
16.80%

8%
32.14%
15.57%
-2.35%
16.21%
16.63%
16.76%

0%
16.83%
16.83%
16.83%
16.83%
16.83%
16.83%