FINAL DESIGN PROJECT REPORT

PRELIMINARY DESIGN OF TITANIUM DIOXIDE PLANT

FROM ILMENITE
CAPACITY OF 55,000 TONS/ YEAR

Submitted to Fulfillment the Bachelor’s Degree in Chemical Engineering

By:

Imala Septi Cahyani

D 500 122 005

DEPARTMENT OF CHEMICAL ENGINEERING

FACULTY OF ENGINEERING

UNIVERSITAS MUHAMMADIYAH SURAKARTA

2017
 APPROVAL PAGE

PRELIMINARY DESIGN OF TITANIUM DIOXIDE PLANT

FROM ILMENITE
CAPACITY OF 55,000 TONS/YEAR

SCIENTIFIC PUBLICATIONS

By:

IMALA SEPTI CAHYANI

D 500 122 005

Have been inspected and approved to be examined by:

Supervisor

Dr. Ir. H.A.M. Fuadi, M.T.

NIK: 618

i
 VALIDATION PAGE

PRELIMINARY DESIGN OF TITANIUM DIOXIDE PLANT

FROM ILMENITE
CAPACITY OF 55,000 TONS/YEAR

BY
IMALA SEPTI CAHYANI
D 500 122 005

It has been maintained in front of the Council of Examiners

Faculty of Engineering
Universitas Muhammadiyah Surakarta
On Thursday, March 6th 2017
and declared that is qualified

Council of Examiners:

1. M. Mujiburohman, S.T., M.T., Ph.D. (……………)

(Head of Examiner Council)
2. Rois Fatoni, S.T., M.Sc., Ph.D. (……………)
(Member I of Examiner Council)
3. Dr. Ir. H.A.M. Fuadi, M.T. (……………)
(Member II of Examiner Council)

Dean,

Ir. Sri Sunarjono, M.T., Ph.D.

NIK: 682

ii
 DECLARATION

I hereby declare that the text of this publication there are no works that have
been asked to obtained a degree at a university and all my knowledge also doesnot
have work or opinions ever written or published by another person, except in
writing referred to the text and mentioned in reference.

If it is found there is untruth in my statement above, it will be my truly

responsibility.

Surakarta, 20 April 2017

Author

Imala Septi Cahyani

iii
 PRELIMINARY DESIGN OF TITANIUM DIOXIDE PLANT
FROM ILMENITE
CAPACITY OF 55,000 TONS/YEAR
UNIVERSITAS MUHAMMDIYAH SURAKARTA

Abstrak
Titanium dioksida merupakan senyawa anorganik dengan rumus kimia
TiO2. Pabrik titanium dioksida dirancang dengan kapasitas 55,000 ton/ tahun.
Pabrik ini direncanakan beroperasi selama 330 hari per tahun. Titanium dioksida
akan dibangun pada tahun 2020 di Belitung Timur, Bangka Belitung. Titanium
dioksida digunakan sebagai pigmen putih (dalam cat, plastik, karet dan kertas),
industri keramik, serat, dan kosmetik, juga digunakan sebagai katalis dan
fotokatalis. Produk dari titanium dioksida rencananya akan didistribusikan untuk
kebutuhan dalam negeri. Proses pembuatan titanium dioksida dilakukan dengan
mereaksikan ilmenit dengan gas klorin menghasilkan TiCl4 dengan menggunakan
kokas sebagai agen pereduksi dalam reaktor fluidized bed fase gas-padat. Proses
berlangsung pada suhu 900°C dan tekanan 1 atm. Keluaran dari Reaktor 1
dimurnikan dan diumpankan ke Reaktor Fluidized Bed 2 yang beroperasi pada suhu
1000°C dan tekanan 1 atm dalam reaksi bolak-balik dan eksotermis. Pabrik ini
diklasifikasikan sebagai pabrik beresiko tinggi. Kebutuhan bahan baku ilmenit
sebesar 18,314.8573 kg/h, klorin sebesar 4,578.7143 kg/h, dan kokas sebesar
16,255.0694 kg/h. Utilitas termasuk pendukung proses dengan kebutuhan air total
sebesar for 26,733.6942 kg/hour diperoleh dari air sungai. Kebutuhan dowtherm
sebesar 124,312.4091 kg/h. Kebutuhan bahan bakar minyak sebesar 2.3222
m3/hour. Kebutuhan udara tekan sebesar 122 m3/h. Kebutuhan listrik dipenuhi dari
PLN dan generator sebagai cadangan tenaga sebesar 986.4136 kW, bahan bakar
sebesar 9.2860 m3/h. Total luas tanah adalah 19,770 m2. Ketersediaan bahan baku
ilmenit diperoleh dari PT. Timah Tbk dan gas klorin diimpor dari luar negeri.
Jumlah karyawan sebanyak 201 orang.Pabrik titanium dioksida membutuhkan
Rp588,594,482,703 sebagai modal tetap dan Rp320,860,312,440 sebagai modal
kerja. Berdasarkan analisis ekonomi, pabrik ini akan mendapatkan keuntungan
sebelum pajak sebesar Rp400,433,669,735 per tahun dan keuntungan setelah 30%
pajak sebesar Rp120,130,100,920. Jumlah persen dari Return of Investment (ROI)
sebelum pajak dan sesudah pajak adalah 68% dan 47% berturut-turut. Pay Out Time
(POT) sebelum pajak dan sesudah pajak sekitar 1.28 tahun dan 1.74 tahun. Break
Even Point (BEP) adalah 46% dan Shut Down Point adalah 56%. Internal Rate of
Return (IRR) adalah 56%. Berdasarkan dari kelayakan ekonomi, maka dapat
disimpulkan bahwa pabrik titanium dioksida layak untuk didirikan.

Kata kunci: Titanium dioksida, Ilmenit, Reaktor Fluidized Bed

1
 Abstract
Titanium dioxide is an inorganic compound with chemical formula TiO2.
Titanium dioxide plant is designed with capacity of 55,000 tons per year. The plant
is planned to operate for 330 days per year. Titanium dioxide will be built in 2020
on East Belitung, Bangka Belitung. Titanium dioxide is used as a white pigment (in
paints, plastics, rubber, and paper), industry of ceramics, fiber, and cosmetics, also
used as catalysts and photocatalysts. The product of titanium dioxide is planned to
be distributed for domestic needs. Titanium dioxide-making process is done by
reacting ilmenite with chlorine gas that produce TiCl4 using coke as reducing agent
in a first fluidized bed reactor solid-gas phase. The process takes place at a
temperature of 900°C and a pressure of 1 atm. The output of first Reactor is purified
and fed to second Fluidized Bed Reactor that continuously operates at a temperature
1000°C and a pressure of 1 atm. The processes are irreversible reaction and
exothermic. This plant is classified as high risk plant. The need for raw materials
ilmenite is 18,314.8573 kg/h, chlorine is 4,578.7143 kg/h, and coke is 16,255.0694
kg/h. Utilities include water supply process support for 26,733.6942 kg/hour is
obtained from river water. Dowtherm supply is 124,312.4091 kg/h. Diesel fuel is
2.3222 m3/hour. Compressed air requirement is 122 m3/h. Electricity demand is
obtained from the PLN and generator for backup power is 986.4136 kW, fuel is
9.2860 m3/h. Total land area is 19,770 m2. The availability of raw material of
ilmenite is obtained from PT. Timah Tbk. and chlorine gas is imported from abroad.
The number of employees is 201 people.The titanium dioxide plant needs
588,594,482,703 IDR of fixed capital. Titanium dioxide needs 320,860,312,440
IDR of working capital. Based on the economic analysis, the plant will get
400,433,669,735 IDR of profit before tax. The plant will get 120,130,100,920 IDR
of profit after 30% of tax per year. Number of percent Return of Investment (ROI)
before tax and after tax is 68% and 47%, respectively. Pay out Time (POT) before
tax and after tax is about 1.28 years and 1.74 years, respectively. Break Even Point
(BEP) is 46% and shut down point is 35%. Discounted cash flow (DCF) is 56%.
Based on the economic feasibility, it can be concluded that the titanium dioxide
plant is considered feasible to be built.

Keyword: Titanium dioxide, Ilmenite, Fluidized Bed Reactor

1. INTRODUCTION
1.1. Background
In the industrial and free trade era, it is necessary to set up an industry
that can provide great benefit to the development of industry in Indonesia.
One type of these industries include industrial of titanium dioxide (TiO2).
Based on statistical data, Indonesia is still importing titanium dioxide from
China, Australia, Japan, USA, etc (BPS, 2015).

2
 It is the brightest white pigment with the highest opacity of any
commercial product, and is used to impart whiteness and opacity to paints,
plastics, paper and in many other smaller applications. TiO₂ can also
improve the durability of coatings, paper laminate and plastic items.
Because of its clean tone and opacifying properties, TiO₂ is widely used in
pastel and colored finishes as well as whites. Around 60% is used in paints
or coatings, 20% in plastics, 12% in paper and 8% in a wide range of
smaller applications (Cristal, 2016).
1.2. Design Capacity
Titanium dioxide import developments in Indonesia can be seen in
Table 1.2 below.
Table 1.2 Data of Titanium Dioxide Import in 2011-2014 (BPS, 2015)
Years Consumption (tons)
2011 46,706.1100
2012 51,581.2400
2013 50,381.6330
2014 53,456.7600

From the results of data processing and review of titanium dioxide

production capacity of the plant that has been operating and market
absorption capability, so it will be built the titanium dioxide plant using
the chloride process with a capacity of 55,000 tons/ year and the plant will
start operating in 2020.

2. METHODOLOGY
2.1. PROCESS SELECTION
There are two processes of titanium dioxide manufacturer, namely:
a. Chloride Process
The chloride process begins with the conversion of high-grade
ilmenite into titanium tetrachloride. This step occurs in a fluidized bed
chlorinator in the presence of chlorine gas at a temperature of
approximately 900°C. Coke also is added as a reductant. The gaseous
product stream is purified to separate the titanium tetrachloride from other

3
 metal chloride impurities using condensation. The purified TiCl4 is then
oxidized to TiO2.
b. Sulfate Process
The sulfate process starts with dried and milled slag TiO2 being
dissolved in sulfuric acid and water in a digester. This produces a titanyl
sulfate liquor. The titanium liquor then is concentrated and hydrolyzed to
titanium dioxide hydrate.
Based on the above process, titanium dioxide plant will use the
chloride process for titanium dioxide which would be produced in the form
of rutile. The considerations of the chloride process selection are:
1. Titanium dioxide is main product.
2. No form waste in large quantities
3. Produce titanium dioxide high quality of rutile. Rutile is the most
stable oxide titania.

2.2. THE USE OF THE PRODUCT

Titanium dioxide is used as a white pigment (in paints, plastics,
rubber, and paper), industrial ceramics, fiber, cosmetics, and also used as
catalysts and photocatalysts.

2.3. PLANT LOCATION

The plant will be built in East Belitung Area, Bangka Belitung. The
factors that influence in considerations of plant location in Belitung Island
are directly affect the main production which is near the raw materials and
easy of the distribution of the products.

2.4. THE STEPS OF THE PROCESS

Production process of titanium dioxide through three process units,
raw materials preparation and storage unit, product formation unit, and
finishing unit.
a. Raw Materials Preparation and Storage Unit
Raw material of chlorine (Cl2) is stored in cylindrical tank (F-112)
with operating condition at temperature 30˚C and pressure 9 atm in liquid

4
 phase with the aims to minimize volume of tank used. Chlorine gas used
is high purity of chlorine as much as 99.99%. The aims of using chlorine
with high purity to maintain the high purity of titanium dioxide product.
Then, chlorine gas is passed into valve and change into gas phase then
pressed until the pressure 1.2 atm as feed of Reactor (R-100).
Raw material of ilmenite obtained from residue of tin mining of PT.
Timah Tbk., ilmenite is stored in storehouse at operating condition with
temperature 30˚C and pressure 1 atm, then messed using Ball Mill (C-114)
until the size is 149 μm, then ilmenite by Screw Conveyor (J-115)
distributed as Reactor feed (R-100).
Air is taken from surrounding environment with the operating
condition at temperature 30˚C and pressure 1 atm the pressed until 1.2 atm
using Blower (G-118) then is fed to the Reactor (R-100).
b. Product Formation Unit
Titanium dioxide is produced from reaction between titanium
dioxide ore in ilmenite with chlorine gas in reactor of TiCl4 formation with
type of Fluidized Bed Reactor (R-100) at temperature around 900˚C and
pressure 1 atm by adding the coke as reductant.
FeCl3 formed from Fe2O3 contained in ilmenite. Chloride non-
volatile, residual coke, and the unreacted impurities of ilmenite ore are
removed from the gas stream and from the bottom of the Chlorinator (R-
100) into Grate Cooler (E-121) to be cooled until ambient temperature and
input to the waste management unit. Gas main stream products exit from
reactor (R-100) then cooled in cooler (E-122) - (E-124) using dowtherm
until temperature 420˚C. Gas stream products have been cooled then
purified to separate TiCl4 from other gas through condensation, so that
product input to the partial condenser (E-216) cooled until temperature
reach 170˚C where FeCl3 will be condensed then cooled back until
temperature reach 40˚C, then input to the partial condenser (E-315) the
cooled until temperature 53.54˚C, and TiCl4 will be condensed. Exhaust
gas in the form of CO, N2, and Cl2 taken to the Absorber (D-300), where

5
 Cl2 reacted with NaOH produced NaCl, NaOCl, and H2O. Then NaCl,
NaOCl, and H2O sent to the waste management unit. Besides, CO, N2, TiCl4
and FeCl3 is separated then input to the waste management to be burned in
the stack.
The purified TiCl4 that have been condensed input to the Vaporizer
(V-313) to be vaporized, then fed into oxidation reactor with type
Fluidized Bed Reactor (R-200). In the reactor, gas phase of TiCl4 then
through oxidation reactions with oxygen at temperature 1000˚C and
atmospheric pressure to form the titanium dioxide and chlorine gas.
The stream that contain chlorine gas, little bit of TiCl4 and other gas
are recycled joining with chlorine gas as feed of R-100. The pure TiO2 is
slurred and sent to finishing process.
c. Finishing Unit
Titanium dioxide exit from Reactor (R-200) then cooled in Grate
Cooler (E-223) until temperature 40˚C, then is stored in Silo (F-224).

6
7
2.5. THE CONCEPT OF THE PROCESS
a. Basic of Reaction
Titanium dioxide is formed from mineral of ilmenite and chloride
gas follows the reaction:
TiO2 + 2Cl2 + 2CO TiCl4 + 2CO2 (2-1)
TiCl4 + O2 TiO2 + 2Cl2 (2-2)
b. Kinetic Review
Formation reaction of titanium dioxide from ilmenite goes through
several steps of reactions:
1. Combustion reaction of coke using air. The reaction equation as follows:
C + ½O2 CO (2-3)
Reaction constant k that influenced by an Arrhenius equation as
follows (Hughes, 1971):
1.914 𝑥 108 −156200
𝑘= 𝑒𝑥𝑝 ( ) (2-4)
0.5 𝑅𝑇
Where k is the rate coefficient (s-1), R is gas constant (8.314 J/mol.K) and
T is temperature (K).
2. Reaction of ilmenite with Cl2 and outlet gas of coke combustion. The
equation reaction as follows:
TiO2 + 2Cl2 + 2CO TiCl4 + 2CO2 (2-5)
Fe2O3 + 3Cl2 + 3CO 2FeCl3 + 3CO2 (2-6)
The chlorination rate and time (Li-Ping, 2013):
2 1
𝑅 𝑟𝑜 2 1 𝑏𝑐
+ + [ 1 − (1 − 𝑅)3 − 3 𝑅] + 𝑘 [1 − (1 − 𝑅)3 ] = 𝑡
3𝑘𝑔 2𝐷𝑒 𝑟 𝑟𝑜 𝜌𝑠

(2-7)
Where:
R = Reaction rate;
kg = Gas film mass transfer coefficient;
kr = Rate constant of interfacial reaction;
ro = Radius of particles;
De = Effective diffusivity of Cl2 in TiO2 particle;
ρs = Density of fluidized particle;

8
 t = Time
b = 538
c = 11873
3. The formation of TiO2 takes place by the overall reaction of TiCl4 with O2
TiCl4 + O2 TiO2 + 2Cl2 (2-8)
The depletion of TiCl4 rate can be calculated by the equation 2-9
(Spicer, 2002):
−10,681
𝑘 = 8.26 𝑥 104 exp ( ) (2-9)
𝑇

Where T (K) is the process temperature and k is the overall oxidation

rate constant of TiCl4, s-1).
c. Thermodynamic Review
The goal of thermodynamics review is to know the reaction
characteristic (endothermic/ exothermic) and directions of the reaction
(reversible/ irreversible).
Reaction in Chlorinator:
ΔHreaction 298 K = Σ ΔHf product - Σ ΔHf reactant
= (1.ΔH˚fTiCl4 + 2.ΔH˚fCO2) – (1.ΔH˚fTiO2 + 2.ΔH˚fCl2 +
2.ΔH˚fCO)
= -384.46 kJ/ mol (exothermic)
Reaction in Burner:
ΔHreaction 298 K = Σ ΔHf product - Σ ΔHf reactant
= (1.ΔH˚fTiO2 + 2.ΔH˚fCl2) – (1.ΔH˚fTiCl4 + 1.ΔH˚fO2)
= -181.5 kJ/ mol (exothermic)
Reaction in Chlorinator:
ΔGreaction 298 K = Σ ΔGproduct - Σ ΔGreactant
= -351.96 kJ/ mol
Reaction in Burner:
ΔGreaction 298 K = Σ ΔGproduct - Σ ΔGreactant
= -162.5 kJ/ mol
Equilibrium constant at temperature 25˚C (298 K)
Reaction in Chlorinator:

9
 ΔG298 K = -R.T ln K (2-10)
Where:
R = 8.314 J/ mol.K
T = Temperature (K)
K = equilibrium constant
ln K = 197.4191
K = 5.4704 x 1085
Equilibrium constant at temperature 900˚C (1173 K)
𝑙𝑛 𝐾1173 ∆𝐻 1 1
= − (𝑇 − ) (2-11)
𝑙𝑛 𝐾298 𝑅 2 𝑇1

ln K1173 = 632.5497
K = 5.1621 x 10274
Reaction in Burner:
ΔG298 K = -R.T ln K (2-12)
ln K = 65.5884
K = 3.0527 x 1028
Equilibrium constant at temperature 1000˚C (1273 K)
ln 𝐾1273 ∆𝐻 1 1
= − (𝑇 − ) (2-13)
ln 𝐾298 𝑅 2 𝑇1

ln K1273 = 210.1515
K = 1.8521 x 1091
The value of K is very high so that the reaction is irreversible.

3. RESULT AND DISCUSSION

3.1. Reactor – 01
Code : R-100
Function : The place for reacting of coke with hot air to
form CO gas that reacts with ilmenite to form
TiCl4 gas
Amount :1
Type : Fluidized Bed Chlorinator
Material : Carbon Steel 212 Grade C + Firebrick
Cost : 997,536.95 USD

10
 Operating Conditions
Temperature, ℃ : 900
Pressure, atm :1
Diameter of Reactor, m : 7.4748
Total Height of Reactor, m : 33.2037
Distribution Plate : 567
3.2. Reactor – 02
Code : R-200
Function : The place for the reaction TiCl4 with hot air
to produced TiO2
Amount :1
Type : Fluidized Bed Chlorinator
Material : Carbon Steel 212 Grade C + Firebrick
Cost : 775,862.07 USD
Operating Conditions
Temperature, ℃ : 1000
Pressure, atm :1
Diameter of Reactor, m : 3.7583
Total Height of Reactor, m : 25.4120
Distribution Plate : 1127

3.3. Utility
Process supporting unit is often called the utility unit that is an
important part to support the production process in the plant. Process
supporting unit contained within the plant of titanium dioxide are:
1. Water Supply Unit
Water supply unit aims to provide water to be used as process water,
cooling water, water consumption and sanitation.
2. Dowtherm Supply Unit
Dowtherm supply unit aims to provide coolant to be used as cooling
process.

11
 3. Electricity Supply Unit
This unit to fulfill the electricity needs for titanium dioxide plant.
4. Fuel Supply Unit
This unit is used to supply the fuel of generator.
5. Compressed Air Supply Unit
Compressed air is used to operate the instrumentation system.
6. Waste Treatment Unit
Waste generated from titanium dioxide plant to be processed prior to waste
treatment unit before being discharged into the environment.
7. Laboratory
Laboratory is a very important part in supporting a smooth production
process and maintain product quality.

3.4. Plant Management

Form : Limited Liability Company (PT)
Business Field : Titanium Dioxide Industry
Location : East Belitung
Consideration of the selection of companies based on several factors, are:
1. Regulated law and easy to get capitals by selling shares of the company.
2. The responsibility of shareholder is limited, so that the fluency
production is only held by the company.
3. The owners and executives of companies apart from one another, the
owner of the company is the shareholder and management of the
company is the directors and its staffs are supervised by commissioners.
4. Continuity of the company is more secure because it does not affect the
cessation of shareholder, directors or employees of the company and its
staff and the efficiency of management and business field broader.
3.5. Economic Anaysis
Economic analysis is useful to determine whether the plant to be
established can be profitable or not and feasible or not. The most important
of design plant is estimation of equipment cost because equipment cost is
used as basic for capital investment feasibility in production of a plant by

12
 review needs of Rate of Investment (ROI), profit, and Pay Out Time
(POT), and Break Even Point (BEP).
3600
Cost (billion Rupiah) per Year

3200
2800 Ra
2400
2000 V
a
1600
Sa
1200
800
400
0
SDP BEP Fa
0 10 20 30 40 50 60 70 80 90 100 110
Capacity of Production Per Year (%)

Figure 1 Economic Analysis

4. CONCLUSION
The result of the economic analysis feasibility as a follows:
1. Profit before tax is 400,433,669,735.39IDR per year.
Profit after tax is 280,303,568,814 IDR per year.
2. ROI (Return on Investment) before tax is 68%.
ROI after tax is 47%.
3. POT (Pay Out Time) before tax is 1.28 years.
POT after tax 1.74 years.
4. BEP (Break Even Point) is 46% and SDP (Shut Down Point) is 35%.
BEP for common chemical plant is around 40 – 60%.
5. IRR (Internal Rate Return) is 56%.
Titanium dioxide plant with chloride process is designed with a capacity
of 55,000 tons/ year. The plant is classified as high risk plant operates at
temperature 900–1000˚C and pressure 1 atm. Based on the economic
feasibility, it can be concluded that the titanium dioxide plant is considered
feasible to be built.

13
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