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%