| Summary: | Preliminary plant design of polystyrene manufacturing from styrene
monomer studies its feasibility to produce general purpose polystyrene (GPPS)
with production capacity of 60,000 tons/year. The plant continuously operates in
330 days a year and 24 hours a day. In this solution polymerization process,
styrene monomer is needed as main raw material at rate of 87,044.36 tons/year,
and ethyl benzene and benzoyl peroxide are needed as supporting raw material at
rate of 5.70 tons/year and 140.50 tons/year. Raw material is processed in the
continuous stirred tank reactor that is operated under condition atmospheric
pressure and 90oC temperature.
The plant is planned to be established at industrial area in Cilegon, Banten
with 11,500 sqm area. It is supposed to employ about 188 workers. This plant
utilizes water from Cidanau river at rate of 11,887.66 kg/hour before is processed
in utility section. Two thousand four hundred and fifty five kilowatts of electricity
is supplied by generator set. This plant also has steam reforming section,
instrument air section, and waste water treatment section.
Fixed capital of US$ 12,405,503.54 + IDR 70.241.840.874,41 and working
capital of US$ 27,757,580.48are needed to establish the plant. It provides IDR
89.314.843.092,48 as profit before tax or IDR 44.657.421.546,24 as profit after
tax. Based on economic analysis, Return of Investment (ROI) is 42.33% before tax
or 21.17% after tax. Pay Out Time (POT) is 1.91 years before tax or 3,21 years
after tax. Break Even Point (BEP) is 51.67% and Shut Down Point (SDP) is
38.88%. Discounted Cash Flow Rate of Return (DCFRR) is 27.07% per year.
Therefore, further research in polystyrene plant for styrene monomer with
production capacity of 60,000 tons/year should be carried out.
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