PRELIMINARY

1.1 COMPANY HISTORY

PT. Indo Acidatama Tbk was originally named PT. Indo Alcohol Utama with
PMDN status was established in 1983 and was established in an area of16 hectares in
Kemiri Village, Kebakkramat District, Karanganyar Regency, Central Java. Factory
construction began in June 1985, and the entire construction was completed in June
1989. In 1986 it changed its name to PT. Indo Acidatama Chemical Industry. This
factory is developing production as well as changing the name of the factory to PT. Indo
Acidatama Tbk in 1989 and was inaugurated by President Soeharto on July 20, 1989
with the status of a limited liability company.On October 24, 2005, PT. Indo Acidatama
Tbk changed its name to PT. Sarasa Nugraha Tbk. And this industry again changed the
name PT. Indo Acidatama Tbk on June 30, 2006 until now.
Process units in PT. Indo Acidatama Tbk is a unit of alcohol, acetaldehyde, acetic
acid and ethyl acetate. The alcohol unit began operating in November 1988 with the
largest capacity in Indonesia and has achieved international standard quality. The other
units, namely the aldehyde unit, acetic acid unit and ethyl acetate unit alternately start
operating. The acetic acid and ethyl acetate unit started production in June 1989 and was
the first in Indonesia, the expansion started functioning in March 1995. PT. Indo
Acidatama Tbk has set up a fertilizer plant unit with POMI and Alfinase fertilizer
products which was inaugurated on August 8, 2007.

1.2 COMPANY LOCATION

PT. Indo Acidatama Tbk. located in Kemiri Village, Kebakkramat District,
Karanganyar Regency, ± 15 km to the northeast of Surakarta City or 2 km from the Palur
– Sragen highway.
1.3 RAW MATERIALS AND MANUFACTURED PRODUCTS
1.3.1 Raw material
The raw materials in the acetaldehyde unit are the basic materials used for the
manufacture of acetaldehyde. The materials used consist of main raw materials and
supporting materials.

1.3.2 Main Raw Materials

The main raw materials used for the manufacture of acetaldehyde are ethanol and air.
Ethanol is obtained from the Ethanol Unit (Area 300), while air is obtained from the
surrounding environment.

a. Ethanol
- Specification
- Form :liquid (1 atm, 30°C)
- appearance :clear
- Smell and Taste :Specific
- Rate : min 95.5% volume
- Density (25°C) : 0.8160 – 0.7937 g/cm3
- Viscosity : 1.32-1.22 cp
- Composition
- Fussel oil : max 0.2 mg/100 ml
- Acetaldehyde : max 0.2 mg/100 ml
- Acetic acid : max 0.4 mg/100 ml
- Acetic Acid and methyl ester : max 2.0 mg/100 ml
- Ash : max 0.5 mg/100 ml
b. Free air
Air is a source of oxygen for the process of making acetaldehyde. To
meet this need, a compressor equipped with a filter has been installed to filter out
dust and solid particles.
The specifications of free air used in the manufacture of acetaldehyde are
as follows:
- Form : gas ( T= 30°C, P = 1 atm )
- appearance :colorless
- Smell :no smell
- Density : 1.225-1.315 g/cm3
 - Average composition :
- N2 : 76-79%
- O2 : 18-21%
- Dust : 3-4%
- Humidity : 80-83%
1.3.3 Supporting material
Supporting materials used in the Acetaldehyde unit include: catalyst, steam, and
nitrogen gas (N2). The catalyst used is solid pure silver (Ag). The catalyst was
purchased directly from KRUPP Industrie Technic GMBH, West Germany. Steam
is mostly used in the distillation process, as heating power. Steam in the
acetaldehyde unit is supplied by the utility division of PT. Indo Acidatama Tbk.
While N2 is used for inerization and heating of the reactor at start up. N2 is
supplied by PT. Aneka Gas and PT. Samator Gas.
Specifications of supporting materials used in the acetaldehyde unit of
PT.Indo Acidatama Tbk. Are as follows :
1. Ag catalyst
 Specification
- Type :silver, Aug
- Shape :powder, solid
- Diameter : 0.5-1.0 mm and 1.0-2.0 mm
- Density : 10.79 kg/m3
 Composition
- Aug : ≥ 99.99 % - Rev : ≤ 5 µg/g
- Au : ≤ 10µg/g - Pt : ≤ 5 µg/g
- Mrs : ≤ 10 µg/g -S : ≤ 5 µg/g
- Cu : ≤ 25 µg/g - Se : ≤ 5 µg/g
- Fe : ≤ 10 µg/g - Th : ≤ 5 µg/g
- Pb : ≤ 10 µg/g -Cl : ≤ 5 µg/g
2. Steam
o Form : superheated steam (P = 102 kg/c m2, T = ± 600ºC )
superheated steam ( P = 42 kg/ , T = ± 450ºC )c m2
saturated steam ( P = 3.5 kg/ , T = ± 250ºC )c m2
o appearance : colorless
o Smell : no smell
 3. Nitrogen
o Form : liquid (5.08 Bar ; -180ºC)
o Purity : 99.999 %
o Impurity : maximum oxygen 3 ppm
o appearance : colorless, tasteless, colorless

1.3.4 Product
The product produced by Acetaldehyde Unit ( Area 400 ) is acetaldehyde
(CH3CHO) with a capacity of 40,000 kg/day. The product specifications for
acetaldehyde are as follows:
 Specifications:
- Form : liquid (30ºC ; 2.5 atm)
- appearance : clear
- Smell : sharp
- Density : 0.779g/c m2
- Rate : 99.9 % by weight
- Composition
o Ethanol : max 0.08 % by weight
o Water : max 0.05 % by weight
o Acetone : max 0.05 % by weight
o Acetic acid : max 0.05 % by weight
o Iron : max 1 ppm
o Evaporation residue : max 10 ppm
o Color : max 10 ppm
o Mercury and chloride :-
 CHAPTER II

PROCESS DESCRIPTION

2.1 Process Concept

The process of making acetaldehyde from ethanol and air is based on an oxidation
reaction. The reaction takes place in the gas phase with a solid catalyst, is irreversible and
exothermic.

The reaction is as follows :

Aug
1
C2H5OH(g)+ O 2(g)CH3CHO(g)+ H2O(g)∆H298= -43 kcal/mol
2 T=500-530ºC

P=1.3-1.5 Bars

The manufacture of acetaldehyde is a catalytic reaction, so the reaction occurs

according to the following mechanism:

a. Adsorption of reactants on the surface of the catalyst

The ethanol and oxygen molecules will collide with the catalyst surface, resulting in
an adsorption process on the catalyst surface. The reaction is as follows:
C2H5OH(g) C2H5OH (ads)
O2(g) O2 (ads)

b. Adsorbed reactant activation

The reaction is as follows:
C2H5OH(g) C2H5OH* (ads)
O2(g) O2* (ads)

c. The reactants react activated to activated products on the surface of the catalyst
In this stage, a reaction occurs between activated ethanol and activated oxygen to
form activated acetaldehyde and activated water.
1
C2H5OH - kat(ads)* + O2- kat(ads)* CH3COH - kat(ads)* + H2O - kat(ads)*
2

d. Adsorbed product deactivation

 Adsorbed acetaldehyde results from deactivation of acetaldehyde* And adsorbed
water results from deactivation of water*. The reaction is as follows:
CH3COH - kat(ads)* CH3COH - kat(ads)
H2O - kat(ads)* H2O - kat(ads)

e. Desorption of adsorbed products on the surface of the catalyst

Free acetaldehyde is generated from the desorption of adsorbed acetaldehyde. And
free water is generated from the desorption of adsorbed water. The reaction is as follows:
CH3COH - kat(ads) CH3COH + kat
H2O - kat(ads) H2O + kat

The ethanol oxidation reaction was carried out in a fixed bed reactor which was
operated at the following operating conditions:
- temperature : between 500-530°C
- Pressure : between 1.3-1.5 bars

The operating conditions are selected based on the following considerations:

1. If the temperature and pressure are increased, it can damage the catalyst, causing the
conversion to decrease.
2. Conversely, if the temperature and pressure are lowered, the reaction will run slowly,
this is not desirable because the production of acetaldehyde is carried out
continuously and it is required to immediately provide acetaldehyde as a raw material
in the acetic acid unit.

The reaction temperature is kept at around 500-530°C and the reaction is exothermic.
For this reason, the reactor is designed in such a way that the heat of reaction can be used
to heat other operations.
The acetaldehyde product was determined by the ratio of the ethanol and feed air
compositions. The ratio of ethanol and air to be fed to the reactor is determined by setting
the flow of ethanol and air vapor in the saturator. The operating conditions in the saturator
must be maintained at 75°C and a pressure of 1.6 bar. If the reaction temperature
continues to increase, the resulting acetaldehyde decomposes into methane gas and
carbon monoxide.
The reaction is as follows:
 O = C ˗ CH3 CH4 + C = O
Acetaldehyde methane carbon monoxide

In addition, excessive oxidation can cause the acetaldehyde that is formed to be

oxidized to carbon dioxide and water vapor. The reaction is as follows:
CH3CHO + 5/2 O2 2H2O +2CO2

Besides, the acetaldehyde produced can also undergo further oxidation to form acetic
acid. The reaction is as follows:
1
CH3CHO + O2 CH3COOH
2
For this reason, the operating conditions in the saturator must be maintained properly
because the conditions in the saturator greatly determine the operating conditions in the
reactor.
2.2 Process Flow Chart

2.3 Process Steps

Production of acetaldehyde at PT. Indo Acidatama Tbk. Using ethanol oxidation
process with the help of pure silver catalyst. The process is divided into three stages,
namely:
1. Ethanol purification stage
2. Reaction stage
3. Acetaldehyde purification stage
1. Ethanol Purification Stage
At this stage a DA-401 distillation column is used to obtain ethanol vapor with a
composition of approximately 90% by weight.
In this column there are four feed currents, namely:
 - The first feed is fresh ethanol from tank FB-603 A, which is pumped with P-401 to
be pumped to the top of the DA-401 column, but previously heated in HE-401. This
heat exchanger utilizes heat from the lutter water that comes out of the HE-405
which comes from the bottom of the DA-401
- The second feed is from the bottom yield of the DA-403 column which was
previously pumped with P-404 and heated in HE-405. Before entering the DA-401
column, the feed is mixed with the bottom product from the FA-402 saturator, only
then the mixture is fed to the DA-401 column.
- The third feed is from the top yield of the DA-401 column which is condensed on
the HC-401. Some is fed to the FA-402 saturator and some as reflux in the DA-401.
- The fourth feed is from the bottom yield of the DA-404 column. The feed is
pumped with P-407 and directly fed to column DA-401.
In this DA-401 column, the top product of the column is ethanol vapor with a
concentration of 90% by weight and the bottom product is wateri lutter which is an
impurity. The results from column DA-401 are partially condensed in HC-401 to be
returned to column DA-401 as reflux and some in the form of ethanol vapor is fed to
the FA-402 saturator.
2. Reaction Stage
This process aims to react ethanol vapor from the DA-401 column with O2
from the air. The main equipment of this unit is the FA-402 saturator and two RA-
401A and RA-401B fixed bed reactors arranged in parallel.
A. Saturator FA-402
This saturator functions to mix ethanol vapor and air in a certain composition
in order to obtain ethanol and air in the gas phase, as feed in the reactor.
The saturator contains steam and part of it is liquid ethanol±50% saturation
volume. The liquid is pumped out of the saturator with a P-408 pump and mixed with
the bottom product from DA-403 and then fed to DA-401.
Ethanol vapor originating from DA-401 is fed to the FA-402 saturator and will
be mixed with air to obtain a certain composition as reactor feed. The air used comes
from the compressor.
The gas mixture entering the reactor is regulated in the saturator by setting the
temperature and pressure in the saturator. Because this greatly determines the
temperature and pressure of the reactor. The temperature setting on the saturator is
 regulated by adjusting the ethanol vapor flow. Meanwhile, the pressure in the
saturator is regulated by adjusting the air flow.
Any increase in temperature in the saturator will result in a decrease in the
temperature in the reactor and if the pressure in the saturator rises at a constant
temperature, the temperature of the RA-401 A/B reactor will increase. With a
temperature of 75°C and a pressure of 1.6 bar in the saturator, you will get a gas
composition with a ratio of ethanol: air: water = 45%: 40%: 15%.
The gas mixture before entering the RA-401 A/B reactor is heated first with
the AE-402 superheater as the heater used steam. The gas that comes out of AE-402 is
then fed to the RA-401 A/B reactor. The composition and operating conditions in the
saturator must be maintained in such a way as to avoid the explosive range of ethanol
in air.
B. RA-401 A/B reactor
This reactor functions to react the gas mixture originating from the FA-402
saturator. This type of reactor is a fixed bed reactor consisting of two reactors
arranged in parallel and containing a pure silver catalyst. The catalyst stack is placed
on top of the bed. These two reactors can function one or both depending on needs.
This fixed bed reactor consists of two parts, the upper part functions to react
the gas mixture using a pure silver catalyst while the lower part is a cooling section
with a cooling circuit system.
At startup, the upreactor is heated and inert with nitrogen. At first - nitrogen
gas is heated with an electric heater EH-401, then flowed into the reactor to heat the
pure silver catalyst. The warm-up lasts for±4 hours (up to reactor
temperature±200°C), then heating is stopped by stopping the flow of N2 gas, the
reactant gas is then fed to the reactor to start the reaction to produce acetaldehyde.
Because the reaction is exothermic, the heat of reaction will increase so that it will
reach a reaction temperature of 500-530°C at a pressure of 1.3-1.5 bar.
The temperature and pressure in the reactor must be maintained by adjusting
the flow rate of air and ethanol entering the FA-402 saturator. At a temperature of
500-530°C and a pressure of 1.3-1.5 bar, the reactant gas will react with the help of a
pure silver catalyst to form acetaldehyde. Under these operating conditions a
conversion of around 25-35% will be obtained.
The gases resulting from the reaction after coming out of the catalyst bed then
enter the cooling chamber and are cooled with liquid coolant originating from the
 DA-404 column with a cooling circuit system. This heat is utilized by the DA-404
column.
After being cooled the gases from the reaction come out with a temperature of
120-130°C. The gas resulting from the reaction is acetaldehyde as a product and by
products are H2O, O2, residue, residual ethanol, CO2, CH4, CO2, and CH3COOH.
Furthermore, the gases resulting from the reaction flowed into column DA-402.

3. Acetaldehyde Purification Stage

At this stage the aim is to obtain acetaldehyde product with a grade±99.9 %
bw. The main tools in this process are quencher column (DA-402B) and absorber
column (DA-402A), scrubber column (DA-403), and acetaldehyde purification
column (DA-404).
A. Quencher Column and Absorber (DA-402)
The DA-402 column consists of two parts, the lower part is the DA-402B
quencher and the upper part is the DA-402A absorber column which is equipped with
twelve HEs arranged in series.
Column quencher DA-402B is a device for condensing reaction steam by
sudden cooling. So that the gases resulting from the reaction coming from the reactor
will condense in the quencher. The coolant used comes from the DA-402B column
itself and the condensation of HC-403. The bottom result of column DA-402B is
divided into two streams:
The first flow is pumped with the P-403 pump flowed to HE-402 to be cooled
and then flowed back to the top of the DA-402B quencher column as coolant.
The second stream is pumped with a pump with a P-405 pump supplied to the
previously heated column DA-404 with HE-404
The DA-402A absorber column aims to capture non-condensable gases in the
quencher. The gases that escape will be absorbed in the DA-402A column, because
these gases still contain acetaldehyde and ethanol. The absorbent used is ethanol-
water which has ethanol content±45% of the weight coming from the DA-404 bottom
is channeled to the top of the DA-402A column. The gas mixture will be absorbed and
then cooled at 12 HE which is along the absorber column so that the ethanol and
acetaldehyde will condense and go down to the quencher. Meanwhile, the gases that
are not absorbed will enter the DA-403 scrubber column.
B. Column Scrubber (DA-403)
 This column serves to absorb ethanol that is still present in the mixture
originating from the DA-402 column. The liquid used to absorb the ethanol is process
water
The gas mixture from the DA-402A absorber column flows into the DA-403
column and is absorbed with process water. Ethanol will be absorbed and fall down
the column and come out of the bottom DA-403 with ethanol content±18% by weight,
then flowed into the DA-401 column with the P-404 pump while the gas that is not
absorbed will be discharged into the atmosphere as exhaust gas or off gas consisting
of CO2, CO, CH4, and N2
C. Acetaldehyde Purification Column (DA-404)
This column is a distillation tower DA-404 which consists of 40 trays and
functions to separate acetaldehyde from ethanol-water and a small amount of acetic
acid. There are two heat sources used in this tower, the first is steam and the second is
the coolant coming out of the cooling circuit in the RA-401 A/B reactor.
This DA-404 column feed is a liquid coming out of the DA-402B quencher
which contains acetaldehyde, ethanol, water and a small amount of acetic acid. This
liquid is then heated in HE-404 where the heating comes from the DA-404 column
The operating conditions of the DA-404 column are as follows:
Bottom : P =±3.5 bars ; T =±120°C
On :P=±3.25 bars ; T=±56°C
The bottom yield of the DA-404 tower is graded ethanol±45% and divided
into two streams:
- The first flow is channeled into the reactor with the P-406 pump through a
cooling circuit which is used as a cooling medium in the reactor by absorbing
the heat generated from the reactions that occur. Exiting the cooling circuit,
the liquid flows back into the DA-404 column as a column heater.
- The second stream with the P-407 pump is divided into two streams. The first
stream is flowed into the DA-401 column to take the unconverted ethanol.
Meanwhile, the second current is channeled into column DA-402A, but
previously cooled in HE-404 with cooling liquid coming from the bottom DA-
402B, then cooled back in HE-403 with cooling water, then flowed into the
absorber column DA-402A
The top yield from column DA-404 is acetaldehyde of purity±99.9% by
weight which is then condensed in multilevel condensers arranged in series,
namely HC-402 and HC-403 with the cooling medium used is cooling water.
Part of the condensate from HC-403 flows into column DA-402B as a coolant,
while some of it is mixed with the condensate from HC-402. Then the
condensed mixture with the help of the P-409 pump is partially returned to the
DA-404 column as reflux, while some is cooled in HC-404. The acetaldehyde
product that comes out of HC-404 then flows into the FC-451 A/B storage
tank
 CHAPTER III

UTILITY START UP

UTILITY

The utility department is the department responsible for supporting the production
process. The utility department is in charge of providing water, steam, fuel, biogas, power
stations, and compressed air.

The utility department at PT. INDO ACIDATAMA Tbk consists of several units,
including:

2.1. WATER SUPPLY UNIT

This unit is tasked with supporting the production process in terms of providing
cooling water, process water, soft water and service water.

The main water source comes from underground water (ABT) with a well depth
of 150-200 meters. This is intended to maintain the quality of water produced and large
debits. In addition, it is also to ensure that it does not disturb the cycle of surface water
(wells, rivers, ponds, etc.) around the company's environment.

The water produced is generally impure because there are impurities or unwanted
impurities. To drain water from a depth of 200 meters, a water pump (Deep Well or Well
pump) with a capacity of 11 kW is used and will produce a discharge of between 20-30
m3/hour. The water is then flowed into the Sand Filter to undergo a filtering process
using silica sand media.

The system used at PT. Indo Acidatama Tbk is:

 Pre Treatment can be done in a short time,

 Can remove bacteria and turbidity to the greatest extent possible,
 Fast screening time,
 Use a little washing water
 As the first step in the water process which continues to the process of softening the
water (soft water).
 PT. INDO ACIDATAMA Tbk has 3 units of sand filters, namely FB 721, FB
722, and FB 723 with a capacity of ± 3,000 L. Sand filters are operated in batches. The
pressure in the sand filter is maintained at 1.5 bar. If the manometer shows a pressure
above 1.5 bar, then more sediment is retained in the filter and the filtration rate will
decrease. This can interfere with or hinder the filtering process itself. So that the sand
filter tank needs to be cleaned by backwashing and aeration with the intention of
removing sediment from the sand filter tank.

After passing through the sand filter, the water will be collected in a water pit
with a capacity of 500 m3. From this water pit, water is then divided into functions to
meet water needs in the factory area. The functions of the water include:

2.1.1 Cooling water.

Cooling wateris water that is used as a medium for exchanging or absorbing heat
for the media of the equipment in the plant (HE, column, etc.) and then cooled back in
the cooling tower unit. The cooling water re-cooling scheme in the cooling tower can be
seen in Figure 2.1.

Water return from plant

Water to plant
Penguapan oleh udara

Hot basin Cold basin Cold basin

filter area

Pompa sirkulasi Pompa distribusi

Figure 2.1Water Cooling Scheme in Cooling Tower

PT. INDO ACIDATAMA Tbk has 2 cooling towers with an open cooling system.
Cooling tower 1 is equipped with 4 fan units and cooling tower 2 is equipped with 3 fan
units. The cooling tower is equipped with 2 basins, namely a cold basin which holds
 cooling water and a hot basin which collects water returns from the plant. The
distribution pump used has a minimum power of 37.5 kW and the largest has a power of
90 kW.

The way this cooling tower works is as follows, cooling water from the plant is
channeled into the hot basin. Water in the hot basin will be flowed upward using a 30
kW circulation pump to the top deck of the cooling tower and dropped. This aims to
form water droplets due to colliding with the wooden lattice. Outside air will be sucked
in by a 55 kW fan through the grille. Then there will be a heat transfer process between
the hot water and the cooler outside air. So that the water cools down and is stored in a
cold basin to be distributed to the plant again.

2.1.2. Process water.

Process wateris the water needed in the plant for the benefit of the process.
Process water is taken directly from the water pit without undergoing further processing.
Water from the water pit is channeled by means of pumps P 708.1, P 708.2 and P 708.3
into the W1 holding tank in area 300 and W3 holding basin in area 450 without being
returned to the water treatment unit.

FC 701 To Feed Water Boiler

From Well Pump

Service Water To All Area

FC 702

SAND
FILTER
SOFTENER

WATER PIT

W1
PROCESS WATER
W2-3

Figure 2.2Water Pit Treatment Scheme

2.1.3. Softwater.

Softwaterused specifically for boiler feed. Besides that, soft water is also used for
processes in area 500, expansion of diesel tanks, compressors, cooling towers from
Micro Lab, Cooling Tower Mini Compressors.

The treatment process starts with water coming from the Water Pit flowing into
the softener tank. Inside the softener tank there is a Na+ Resin which aims to bind Ca
(calcium) and Mg (magnesium) which are components of the nineral CaCO3 crust which
will stick to the walls of the boiler thereby inhibiting the formation of heat. If too much
concentration of Ca and Mg is bound by the Na+ resin then saturation will occur or no
trace or the water will become hard (Total Hardness CaCO3) above 4 ppm. Then a
regeneration process must be carried out with NaCl table salt (salt solution) ± 700 kg /
regeneration. After going through a chemical process in the softener tank, the water is
called Soft Water and is accommodated in the FC 701 tank.

Ion Exchange Chemical Reactions

CaSO4 + 2R-Na R2Ca + Na2SO4

MgSO4 + 2R-Na R2Mg + Na2SO4

Regeneration

R2Ca + 2NaCl 2R-Na + CaCl2

R2Mg + 2NaCl 2R-Na + MgCl2

Another use of Soft Water is A 500, Diesel Expansion Tank, Compressor,

Cooling Micro Lab, Cooling Tower Mini Compressor.

2.1.4. Service water.

Service wateris water for cleaning, MCK, cooking, and others. Service water does
not undergo further processing but is directly channeled with the P 709.1 and P 709.2
pumps to the FC 702 tank and then distributed by gravity throughout the plant area.
2.2. Steam Supply Unit (Boiler)

Boiler unit at PT Indo Acidatama Tbk. serving as a steam provider, there are 5
boiler units available. PT. Indo Acidatama uses a fire tube type boiler.

In general, the working principle of a fire tube boiler is the development of a fire
tunnel boiler with the addition of fire pipes in it. The hot gas from combustion in the
combustion chamber flows in the fire tunnel and fire pipe so that it heats the water
around the fire tunnel and fire pipe.

The soft water that is put into the boiler plant is first put into the economizer / pre
heater unit, which is a heat exchanger used to increase the heat efficiency of the boiler.
This economizer is used to utilize wasted gas from the boiler. Boiler heating in the form
of fire in the pipes. Meanwhile, the space between the pipes is filled with soft water. The
residual gas from the combustion of the economizer is put into the chimney to be
discharged into the open air. In general, this economizer can raise the water temperature
between 20-25°C. In accordance with its function, the economizer unit is installed in the
middle between the boiler and the chimney.

2.3 Fuel Supply Unit

This area is tasked with providing fuel which, among other things, is used by
boilers and heavy transportation equipment. PT. INDO ACIDATAMA

Tbk. using several types of fuel, including:

 Coal
Required coalboilersNo. 2 and boiler No. 3 each is 30 tons/day.

 Methane
Required methane gasboilersNo. 1 to operate around 916 Kg/Hour.

 Solar
Solar is used as fuel for transportation equipment.
 Biogas Plant

Biogas is a by-product of waste treatment from area 300 which is accommodated

in an anaerobic tank which has been covered with an HDPE polymer membrane. The gas
produced by the anaerobic tub is methane gas which is useful as a substitute for fuel from
boiler No. 1. The methane gas produced has a pressure of 1.54 bar at 34oC. The yield of
methane gas used is ± 48,000 m3/day.

2.4 Power Station Units

This unit is in charge of providing the electrical power needed by the plant.
Electric power that is in the power station, among others:

1.1.1 Electricity from PLN : 2 x 1090 kW = 2180 kW

1.1.2 Electric power from Genset : 3 x 900 kW = 2,700 kW
Total electric power in PT. INDO ACIDATAMA Tbk. is 4,880 kW which is then
distributed to each COS (Change Over Switch). The distribution of electric power to user
units is regulated by the COS (Change Over Switch) code which is divided into 8 COS
Panels in the Central Power room. The equipment in this room is 2 transformers,
Cubicle, several COS power panels which contain an ACB (Air Circuit Breaker) which
functions as a liaison and breaker for electrical power.

2.5 Compressed Air Supply Unit

This unit is tasked with providing compressed air for the production process in
areas A 400, A 450 and compressed air / instruments for pneumatic propulsion of
equipment in all areas where the largest user is the plant.

There are two types of compressors, namely:

1. Turbo Compressor
There are 2 units each with an installed air capacity of 4,800 kg/hour, driven by a
motor with a power of 500 kW/unit. The air in this compressor undergoes compression
treatment up to 3 times by the turbo where after each time it is compressed the air will
become hot and cooled in Inter Cooler while the most recent air cooler is after cooler.
This is done in order to obtain compressed air with pressure, temperature and flow
according to the needs of the plant.
2. Piston Compressors
There are 4 units with an installed air capacity of 1,250 kg/hour per unit. This
compressor is equipped with a 160 kW motor that drives 2 pistons horizontally, namely
the Low Pressure (LP) Piston and High Pressure (HP) Piston.
The process in the air supply unit is as follows: air from the atmosphere through the
filter will enter Low Pressure at level 1. From Low Pressure it will be compressed so that
the pressure rises to 2-2.5 bar abs. the temperature also rose to 190-200°C. then cooled
with an Inter Cooler (pre-cooler) compressed again to High Pressure (high pressure
device) at level II, until the pressure rises to 7.5 bar abs. From High Pressure and then
cooled in the After Cooler then enters the air holding tank. From this tank, the air is
ready as process air. For instrument air, it must be dried first in the Air Dryer.
 CHAPTER IV

TROUBLESHOOTING

For safety purposes, the acetaldehyde factory is equipped with an interlock system which
basically closes the incoming air at the saturator section. Another safety is the Pressure
Safety Valve (PSV) which works automatically when the interlock system is not working.
The explosive limits of an alcohol-air mixture are between 4-17%, so it is very dangerous
to work in that area. Therefore, to ensure safety, the composition of 45% alcohol, 15%
water, and 40% air was taken with an operating temperature of 75oC and a pressure of
1.65 bar.

The interlock system only works to save explosives if there is a change in the process.
What causes an explosion is as follows:

1. The level in the saturator is set at 50% if it drops to 30% then the interlock system
will work automatically to close the air in the saturator.
2. The pressure in the saturator is set to 1.65 bar, if the pressure rises to 1.7 bar, the
interlock system will work automatically to close the air in the saturator.
3. The temperature in the reactor is set at 530oC if there is a rise in temperature to
600oC then the interlock system will work automatically to close the air in the
saturator.
4. The exit temperature of the reactor is 150oC. If it increases to 200oC, the interlock
system will work automatically to close the air in the saturator.

Trouble shooting that is often experienced:

1. The occurrence of liquid entrainment will cause flooding in DA 401 column and
column DA 404, can be overcome by closing or reducing the input valve openings
and enlarging all output valve openings.
2. The saturator drop level is handled by opening the valve condensation from the DA
401 column
which goes to the saturator is magnified.
 3. The product pressure top in the DA 401 column is increasing, so it can be overcome
by enlarging it
fresh feed ethanol valve opening, and vice versa.
4. Pressure on DA 404 products, how to deal with the same as DA 401.
5. DA level 401 drops,so that the bottom yield valve opening is reduced.
CHAPTER IV

CLOSING

4.1 Conclusions and Observations

4.1.1 PT. INDO ACIDATAMA Tbk is the first integrated ethanol plant in Indonesia
which was founded in 1983, located in Kemiri, Kebak Kramat, Karanganyar. The
main raw material used is molasses (sugar cane molasses) originating from sugar
factories in Java and outside Java with a capacity of 892,740 tons per year and
using the Kyowa strain yeast saccharomyces cereviceae catalyst. The products
produced are ethanol with a capacity of 34,400,000 kg of ethanol/year and ethyl
acetate with a capacity of 4,450,000 kg of ethyl acetate/year.
4.1.2 The production process in the ethanol unit goes through 2 stages, namely the
fermentation stage and the purification stage. The fermentation stage goes through
3 processes, namely the yeast seeding process occurs in the seed fermenter tank,
yeast breeding occurs in the pre-fermenter tank, and the fermentation process
occurs in the main fermenter tank. The mash produced from the fermentation unit
is then purified in the ethanol unit to produce alcohol with a higher concentration
of ± 96%.
4.1.3 utility plantresponsible for supporting the production process, namely providing
water, steam, electricity, and compressed air.
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