Ujian Akhir Semester

TKS 4095 Disain Produk Industri

Basic Chemical Product
Bio-based Adipic Acid

Disusun Oleh :
Annur Fauzi Syaputra (1207113567)

PROGRAM SARJANA TEKNIK KIMIA

JURUSAN TEKNIK KIMIA FAKULTAS TEKNIK
UNIVERSITAS RIAU
Januari 2016

Kata Pengantar
Puji dan syukur penulis ucapkan kehadirat Tuhan Yang Maha Esa atas
rahmat yang telah diberikan sehingga penulis dapat menyelesaikan Ujian Akhir
Semester mata kuliah Disain Produk Industri tentang Basic chemical product.
Disain produk industri merupakan salah satu mata kuliah di Jurusan Teknik Kimia
Universitas Riau. Disain produk industri bertujuan agar mahasiswa dapat balajar
mendisain Sebuah produk yang baru atau mengembangkan produk yang sudah
ada. Disain produk industri ini mengembangkan produk yang sudah ada, yaitu
industrial protective clothing.
Penulis sudah berusaha sebaik mungkin untuk menyelesaikan Ujian Akhir
Semester ini. Penulis mengharapkan kritik dan saran yang membangun dari
segala pihak. Penulis berharap Ujian Akhir Semester ini dapat diterima dan
mendapatkan nilai yang baik.

Pekanbaru, Januari 2016

Penulis
i

Daftar Isi
Kata Pengantar.....................................................................................................i
Daftar Isi..............................................................................................................ii
Daftar Gambar....................................................................................................iii
Daftar Tabel........................................................................................................iv
BAB 1..................................................................................................................1
1.1 BackGround.........................................................................................1
1.2 Purpose.................................................................................................1
1.3 Problems...............................................................................................1
BAB 2..................................................................................................................2
2.1 Project Charter.....................................................................................2
2.2 Peranan dan Tanggung Jawab Anggota Team......................................3
2.3 Innovation Map....................................................................................4
2.4 SGPDP.................................................................................................5
2.5 Concept Stage......................................................................................5
2.6 Feasibility Stage...................................................................................7
2.7 Development Stage.............................................................................8
2.8 Manufacturing Stage............................................................................8
2.9 Product-Introduction Stage..................................................................9
Kesimpulan........................................................................................................10
Daftar Pustaka

Daftar Gambar

Daftar Tabel
Tabel 1 Initial Project Charter.............................................................................2
Tabel 2 Final Project Charter...............................................................................2
Tabel 3,4 Peranan dan Tanggung Jawab Anggota Team.....................................3
Tabel 5 Import Data of Adipic Acid................................................................6
Tabel 6 Global Adipic Acid Producers................................................................6

Chapter I
1.1

Back Ground
Global adipic acid (ADA) demand is estimated at 2.3 mollion metric tons

in 2012 and is growing at 3 5% per year. Nylon 66 accounts for about 85% of
the total adipic acid demand. The other applications are polyurethanes (5%),
adipic esters (4%), and others (6%). Major global producers of ADA are Invista,
Ascend, Honeywell, BASF, Radici, China Senma, and PetroChina. The average
price is $1,600/mt in 2012.
Adipic Acid has traditionally been produced from various petroleumbased feedstocks like phenol, benzene, and cyclohexane, but the most common
way to produce it was using cyclohexane as it was used by about 93% of global
producers.
1.2

Purpose
1. Produce bio-based adipic acid
2. Making a market analysis of bio based adipic acid
3. making a profitable adipic acid plant

1.3

Problems
Polymer was widely used in almost all aspect of modern society so it will

cause major problem in the future as it is aderivative from crude oil, so it will be
needed to come up witn new ideas about how to stop or prevent this problem
happen. Many attempt was made to overcome this problem including making
bio-based polymer or monomer.
Biobased monomer is a monomer derives from natural source, as example
adipic acid, up until now, adipic acid was made out of siklohexanon, a derivative
of crude oil. But, the recent technologies develop by rennovia inc. allow us to
make adipic acid from carbohydrate containing material, such as sugar, corn, etc
Chapter II
2.1

Project Charter
Tabel 1 Initial Project Charter Of Adipic Acid

Project Name
Project Champions
Project Leader

Adipic Acid with Oxidation Reaction

Head of R&D Subur Nanofabric inc.
Annur Fauzi Syaputra

Specific Goal
Specific Goal

Deliverabels

2.1.1

Producing Adipic Acid From Carbohydrate

containing feedstock
In Scope
- Glucaric Acid from Glucose
- Adipic Acid From Glucaric acid
Out Scope
- Adipic acid from Crude oil derivative
Bussiness opportunity
Technical feasebility assessment
Manufacturing capability assessment
Product life-cycle assessment

Final Project Charter

Tabel 2 Final Project Charter Of Adipic Acid

Project Name
Adipic Acid Production in Indonesia
Project Champions
Head Of R & D PT
Project Leaders
Roy Marthin P
Specific Goals
Produce environmental friendly adipic acid
Project Scope
in-scope :
Adipic Acid from carbohydrate
Glucaric Acid from glucose
out-scope :
Based production for nylon 66
Deliverabels
Bussiness opportunity
How large is the bussiness opportunity for
biobased Adipic Acid?
Technical feasebility assessment
Is it technically feasible
Manufacturing capability assessment
Can it manufactured in industrial scale
Product life-cycle assessment
Would it satisfy the current regulatory
requirements?
Time Line
Product prototype for market testing within 12 months

2.2

Peranan dan Tanggung Anggota Team

Dalam pembangunan pabrik asam adipat ini, terdapat dua tim

utama yaitu :

Tabel 3 Development Team

Name
Rio

Field
Chemical Science

Responsibility
Head of Synthetic

Joko

Chemical Science

development team
Physical Properties Engineering

Process

Tabel 4 Production Team

Name
Annur

Field
Chemical Engineering

Priyo W
Industrial Engineering
Roy Acid Civil Engineering
Innovation Map Adipic
Ika
Economic

Produce C6H10O4 in safe environment

Responsibility
Head of Production Process
development team
Economy Analysis
Plant Construction
Produc Introduction

High yield

Lower cost
4

2.3

Innovation Map
C6H10O4 (Adipic Acid)

Costumer
Higher Oxidation Temperature High Selectivity
ProductHeterogeneous Oxidation Catalyst
Technical
Value
Differentiation
Chemocatalytic Conversion

Product
Catalytic Hydrodeoxigenation
Process/
Manufacturing
Technology
Catalytic oxidation

Glucose
Material
Technology

Oxidation

Cyclohexanone

High Peroxide Process

Oxidation

Nitric Acid

Cyclohexane

2.4

SGPDP

Stage Gate Product Development Process (SGPDP)

Concept

Feasibility

Development

Manufacturing

Product
Introduction

Goal
Develop Superior

Prove Feasibility

Finalize Product

Qualify

Product Concept

of Superior

Design

Manufacturing

Base on

product concept
Product Design

enviromental

Launch Product

Final Product

Raw Matrial

Product Launch

Design

Suply Chain

Testing

friendly raw
material
Glucose Oxidation

Base Case Flow

Manufacturing

Manufacturing

Product Pricing

Glucaric Acid

Diagram
Product

options
Detailed Process

Cost
Manufacturing

Product

Hydrodeoxigenation

Prototype

Design

qualification

Marketing

Result of synthesis is

Product

Bio-Based Adipic

Spesification and

Acid

documentation

2.5

Concept Stage

2.5.1 Market Assessment

The added value for this adipic acid product was the
environmental aspect as it was derived from carbohydrate containing
materials, unlike the commercial source of adipic acid that was crude oil.
Who are the customer ? adipic acid was mainly used as a monomer
to produce Nylon 66, a very famous polyamides witch is a main materials
for textile industry because of its properties. As for Indonesia, adipic acid
was mainly imported, the data is given below :
Tabel 5 Import Data of Adipic Acid
Year
Import (ton)/yr
2007
1052.693
2008
2652.987
2009
705.724
2010
652.924
2011
772.54
Average
1167.3
Badan Pusat Statistik, 2011
The overseas competitor data was :
Tabel 6 Acipic Acid producers
Plant / Company
Allied Chemical
Du Rout
El Passo
Monseintro
Thodia ind
Kanto Denka
Hansu Chemical
State Authority
Rhone Poulenc
(Othmer, 1991)

Place / Country
Hopewell, Virginia
Orange, Texas
Odessa, Texas
Pensacola, Florida
Brazil
Shubukawa, Japan
Wakayama, Japan
Peking, China
Chalempe, France

Capacity (Ktone/yr)
11
136
36
282
30
10
5
55
250

2.5.2

Customer Requirement
The customer requirement for this product was to :
1. having the same or better properties compared to petroleum
based adipic acid.
2. Lower production cost than commercial adipic acid.
3. Biodegradable.

2.5.3

Technical Requirement
To produce environmentally friendly adipic acid with 99 mol%

purity using glucose as raw material.

2.5.4 Market Segmentation
The customer for this product was nylon fiber industry and textile
industry which is can be added for value proposition as the product was
biodegradable. The production cost was also set lower because of lower
temperature requirement in producing adipic acid from glucose.
2.5.5 Product Requirement
2.6
Feasibility Stage
This process contain of producing glucose source, in this case
sugar to aadipic acid, the block diagram was :

Glucaric Acid
Oxidation, 90oC, 414kPa
O2
Hidrodeoxigenation, 160oC, 2758kPa

Glucose
Catalyst

The process start with oxidation of glucose by reacting glucose

with oxygen in the presence of an oxidation catalyst, according to the
Adipic Acid

following reaction :

O2
Glucose
Acid out in a fixed bed reactor with
The first
reactionGlucaric
was carried
Catalyst
palatine as the oxidation catalyst and carried out in 90 oC, and 414 kPa,
the glucaric acid yield was about 66 %.

Glucaric Acid

H2, HBr
Catalyst

Adipic Acid

The second reaction was Carried out in a fixed bed reactor with
metal catalyst and carried out in 160oC, and 2758 kPa the adipic acid
Yield is about 89%.
2.6.1 Economic Potential
Bio-based adipic acid using sugar as glucose source, which is
cheaper than commercial cyclohexane, the compared price is shown in
the table 2.3 so in rough calculation, it was promising to producing adipic
acid from glucose.

Commodity
Glucose
Cyclohexane
Adipic Acid
2.7

Assumed Price ($/mt)

300
1250
1600

Development Stage
This stage typically involves detailed design, equipment size,

profitability analysis, and optimization, as well as reconsider the market

and product recycling. After all it is in review, the adipic acid product
will be produced in a pilot plant scale to obtain the desired adipic acid.
2.8
Manufacturing Stage
This stage develops adipic acid production from pilot scale to
industrial scale with reviewing all existing variables. In this process, the
cost of production of adipic acid will re-reviewed and will be minimized.
This phase should also consider the large production with market demand
and make supply of adipic acid for 2 to 3 months to come.
2.9

Product Introduction
At this stage the product of adipic acid are introduced into the

polymer industries so producers of polymers that are interested in using

styrene monomer can find out the price and advantages of styrene
monomer in the production. In addition to introducing the products to the
domestic industry, these products will also be introduced to foreign
industries so that production does not generate losses and sales targets
can be achieved.

10

Conclution
1. The project promising a good opportunity
2. There will be need more work at development, manufacturing, and
introduction dtage
3. The project pas the State GateTM Product Development Process
(SGPDP).

References
Boussie, T. R et al. 2010, Production of adipic acid and derivetives
from carbohydrate-containing materials. US 20100317823A1
Hambet, C. H. & McAlevy, A. 1951. Adipic Acid Process. US
2557282.
Baker, R. S et al. 1966. Adipic acid production by the two step
oxidation of cyclohexane with oxygen. US 3234271
Othmer, Kirk 1998, Encyclopedia of Chemical Technology Volume 1
Fourth Edition.