PRARANCANGAN PABRIK ASETALDEHIDA DENGAN PROSES DEHIDROGENASI ETANOL Prarancangan Pabrik Asetaldehida dengan Proses Dehidrogenasi Etanol Kapasitas 30.000 Ton/Tahun.

PRARANCANGAN PABRIK ASETALDEHIDA
DENGAN PROSES DEHIDROGENASI ETANOL
KAPASITAS 30.000 TON/TAHUN

Disusun oleh :
Oktaviana Lupita Ainiyah
D500110001

Dosen Pembimbing :
1. Ir. Herry Purnama, M.T., Ph.D.
2. Ir. Haryanto, AR., M.S.

JURUSAN TEKNIK KIMIA FAKULTAS TEKNIK
UNIVERSITAS MUHAMMADIYAH SURAKARTA
2016

i

MOTTO

Dan tidaklah Aku (Allah) ciptakan jin dan manusia kecuali untuk beribadah

kepada-Ku
(Adz-Dzariyat : 56)

Ilmu itu banyak, sementara umur kita pendek, maka ambillah ilmu yang
engkau butuhkan dalam urusan agamamu, dan tinggalkan selainnya,
jangan disibukkan dengannya.
(Salman Al-Farisi r.a.)

Bukti akal pikiran seseorang ialah perbuatannya dan bukti ilmunya ialah
ucapannya.

ii

ABSTRAK
Pendirian pabrik asetaldehida dengan kapasitas 30.000 ton/tahun sangat
penting untuk memenuhi kebutuhan asetaldehida di Indonesia. Bahan baku
pembuatan asetaldehida adalah etanol dengan proses dehidrogenasi yang
direaksikan menggunakan reaktor fixed bed multitube pada suhu 260-290oC dan
tekanan 1,25 atm dengan katalis padat Cr2Cu2O5. Reaksi ini berlangsung secara
endotermis dan irreversible. Konversi reaksi sebesar 50% dan yield sebesar 85%.

Prarancangan pabrik asetaldehida akan didirikan di Gresik, Jawa Timur dengan
luas area 60.000 m2. Total kebutuhan bahan baku etanol adalah 7920,9102
kg/jam, total produk yang dihasilkan adalah 3750 kg/jam, total kebutuhan air
untuk semua unit adalah 105,8817 m3/jam, total kebutuhan listrik adalah 194,0699
kW dan total kebutuhan bahan bakarnya adalah 99,7345 L/jam. Didapatkan return
of investment sebelum pajak 38,91%, sesudah pajak 27,24%, break even point
46,68%, shut down point 26,28%, pay out time sebelum pajak 2,04 tahun, sesudah
pajak 2,69 tahun dan discounted cash flow sebesar 24,2%. Berdasarkan analisa
ekonomi tersebut, maka dapat disimpulkan bahwa pabrik asetaldehida ini layak
untuk didirikan.
Kata kunci : asetaldehida, dehidrogenasi, etanol
ABSTRACT
The establishment of acetaldehyde plant with a capacity of 30.000 ton/year
is very important to meet the needs of acetaldehyde in Indonesia. Raw material for
making acetaldehyde is ethanol reacted dehydrogenation process using the fixed
bed multitube reactor at a temperatur of 260-290oC and a pressure of 1,25 atm
with solid catalyst Cr2Cu2O5. This reaction takes place in endothermic and
irreversible. Conversion of reaction is 50% and yield 85%. The manufacturer of
acetaldehyde plant will be established in Gresik, East Java by area 60.000 m 2.
Total raw material requirement ethanol is 7920,9102 kg/hr, total product produced

is 3750 kg/hr, total water needs for all units is 105,8817 m3/hr, total electricity
needs is 194,0699 kW and total fuel needs is 99,7345 L/hr. That obtained return
of investment before taxes of 38,91%, after taxes of 27,24%, break even point
46,68%, shut down point 26,28%, pay out time before taxes of 2,04 year, after
taxes of 2,69 year, and discounted cash flow 24,2%. Based on the calculation of
the economic analysis, it can be concluded that this manufacturer of acetaldehyde
plant is reasonable to establish.
Keywords : acetaldehyde, dehydrogenation, ethanol

iii

KATA PENGANTAR
Assalaa mu’alaikum warahmatullaahi wabarakaatuh

Alhamdulillah, segala puji dan syukur Penulis panjatkan kehadirat Allah
SWT yang telah melimpahkan rahmat dan karunia-Nya, sehingga penulis dapat
menyelesaikan naskah tugas akhir dengan judul “Prarancangan Pabrik
Asetaldehida

dengan


Proses

Dehidrogenasi

Etanol

Kapasitas

30.000

Ton/Tahun ” dengan baik dan lancar.

Naskah tugas akhir ini disusun dalam rangka memenuhi mata kuliah
Program Strata-1 Jurusan Teknik Kimia, Fakultas Teknik, Universitas
Muhammadiyah Surakarta.
Dalam penyusunan naskah ini, Penulis mendapatkan bimbingan dan
bantuan dari berbagai pihak baik secara langsung maupun tidak langsung. Oleh
karena itu, Penulis mengucapkan terima kasih kepada:
1. Kedua orang tua, kakak dan adik yang telah memberikan dukungan baik

secara moral maupun material
2. Bapak Rois Fatoni, S.T, M.Sc., Ph.D. selaku Ketua Jurusan Teknik Kimia,
Fakultas Teknik, Universitas Muhammadiyah Surakarta
3. Bapak Ir. Herry Purnama, M.T., Ph.D. selaku dosen pembimbing I yang
selalu membantu kami
4. Bapak Ir. Haryanto, AR., M.S. selaku dosen pembimbing II yang selalu
membantu dan mengarahkan dalam penyusunan naskah
5. Siti Khomariyah Arjiani, teman seperjuangan dalam proses penyusunan
tugas akhir, tanpa-mu tugas ini akan terasa sangatlah berat
6. Teman-teman Teknik Kimia 2011 di Universitas Muhammadiyah
Surakarta
7. Semua pihak yang telah membantu dalam proses dan penyusunan naskah
tugas akhir yang tidak mungkin Penulis sebutkan satu per satu.
Penulis menyadari bahwa dalam penyusunan naskah tugas akhir ini masih
jauh dari sempurna. Untuk itu Penulis mengharapkan koreksi berupa saran dan
kritik yang membangun untuk kesempurnaan naskah ini. Akhir kata Penulis
iv

berharap naskah tugas akhir ini dapat bermanfaat dan berguna serta menambah
pengetahuan bagi yang membaca.

Wassalaa mu’alaikum warahmatullaahi wabarakaatuh

Surakarta, 26 April 2016

Penulis

v

DAFTAR ISI

HALAMAN JUDUL .............................................................................................. i
HALAMAN PENGESAHAN ............................................................................... ii
INTISARI ............................................................................................................. iii
KATA PENGANTAR .......................................................................................... iv
DAFTAR ISI ......................................................................................................... vi
DAFTAR GAMBAR ............................................................................................ ix
DAFTAR TABEL ..................................................................................................x
BAB I PENDAHULUAN .......................................................................................1
1.1. Latar Belakang Pendirian Pabrik ......................................................................1
1.2. Kapasitas Perancangan Pabrik ..........................................................................2

1.3. Pemilihan Lokasi Pabrik ...................................................................................4
1.4. Tinjauan Pustaka ...............................................................................................6
BAB II DESKRIPSI PROSES ............................................................................13
2.1. Spesifikasi Bahan baku dan Produk ................................................................13
2.2. Konsep Reaksi .................................................................................................14
2.3. Tinjauan Kinetika ............................................................................................15
2.4. Tinjauan Termodinamika ................................................................................15
2.5. Langkah Proses ...............................................................................................16
2.6. Diagram Alir Proses ........................................................................................19
2.7. Neraca Massa dan Neraca Panas .....................................................................21
2.8. Tata Letak Pabrik dan Peralatan .....................................................................27
BAB III SPESIFIKASI ALAT ............................................................................31
3.1. Absorber ..........................................................................................................31
3.2. Accumulator -01 ...............................................................................................31
3.3. Accumulator -02 ...............................................................................................32
3.4. Condenser -01 ..................................................................................................32
3.5. Condenser -02 ..................................................................................................33
3.6. Cooler -01 ........................................................................................................33

vi


3.7. Cooler -02 ........................................................................................................34
3.8. Heater -01 ........................................................................................................35
3.9. Heater -02 ........................................................................................................35
3.10.

Menara Destilasi-01 ...................................................................................36

3.11.

Menara Destilasi-02 ...................................................................................37

3.12.

Pompa-01 ...................................................................................................37

3.13.

Pompa-02 ...................................................................................................38


3.14.

Pompa-03 ...................................................................................................39

3.15.

Pompa-04 ...................................................................................................39

3.16.

Pompa-05 ...................................................................................................40

3.17.

Pompa-06 ...................................................................................................41

3.18.

Pompa-07 ...................................................................................................41


3.19.

Pompa-08 ...................................................................................................42

3.20.

Pompa-09 ...................................................................................................43

3.21.

Reaktor .......................................................................................................43

3.22.

Reboiler -01 .................................................................................................44

3.23.

Reboiler -02 .................................................................................................45


3.24.

Separator ....................................................................................................45

3.25.

Tangki Asetaldehida...................................................................................46

3.26.

Tangki Etanol .............................................................................................47

3.27.

Vaporizer ....................................................................................................47

BAB IV UNIT PENDUKUNG PROSES DAN LABORATORIUM ...............49
4.1.Unit Pendukung Proses ....................................................................................49
4.2.Laboratorium ....................................................................................................66
BAB V MANAJEMEN PERUSAHAAN ...........................................................70
5.1.Bentuk Perusahaan ...........................................................................................70
5.2.Struktur Organisasi ..........................................................................................71
5.3.Tugas dan Wewenang ......................................................................................72
5.4.Status Karyawan dan Sistem Penggajian .........................................................77
5.5.Pembagian Jam Kerja Karyawan .....................................................................78
5.6.Penggolongan Jabatan, Jumlah Karyawan, dan Gaji .......................................79

vii

5.7.Kesejahteraan Karyawan ..................................................................................81
5.8.Manajemen Produksi ........................................................................................82
5.9.Perencanaan Produksi ......................................................................................83
5.10.

Pengendalian Produksi ..................................................................................... 84

BAB VI ANALISIS EKONOMI .........................................................................87
6.1.Investasi Modal (Capital Investment) ..............................................................87
6.2.Biaya Produksi (Manufacturing Cost) .............................................................87
6.3.Pengeluaran Umum (General Expenses) .........................................................88
6.4.Analisis Kelayakan...........................................................................................88
BAB VII KESIMPULAN ....................................................................................99
DAFTAR PUSTAKA ........................................................................................... xi
LAMPIRAN

viii

DAFTAR GAMBAR

Gambar 1.1. Data Impor Asetaldehida di Indonesia ................................................3
Gambar 2.1. Diagram Alir Kualitatif .....................................................................19
Gambar 2.2. Diagram Alir Kuantitatif ..................................................................20
Gambar 2.3. Tata Letak Pabrik ..............................................................................29
Gambar 2.4. Layout Pabrik Asetaldehida ..............................................................30
Gambar 4.1. Skema Pengolahan Air .....................................................................69
Gambar 5.1. Struktur Organisasi ...........................................................................86
Gambar 6.1. Cost Index Chemical Plant tiap tahun .............................................92
Gambar 6.2. Analisis Ekonomi .............................................................................98

ix

DAFTAR TABEL

Tabel 1.1. Data statistik impor asetaldehida di Indonesia ........................................2
Tabel 1.2. Kapasitas produksi asetaldehida di Amerika Serikat .............................4
Tabel 2.1. Neraca massa vaporizer ........................................................................21
Tabel 2.2. Neraca massa separator .........................................................................21
Tabel 2.3. Neraca massa reaktor ............................................................................21
Tabel 2.4. Neraca massa absorber .........................................................................22
Tabel 2.4. Neraca massa menara destilasi-01 ........................................................22
Tabel 2.4. Neraca massa menara destilasi-02 ........................................................22
Tabel 2.7. Neraca massa total ................................................................................23
Tabel 2.8. Neraca panas di sekitar vaporizer .........................................................24
Tabel 2.9. Neraca panas di sekitar heater -01 .........................................................24
Tabel 2.10. Neraca panas di sekitar reaktor ..........................................................24
Tabel 2.11. Neraca panas di sekitar cooler -01 .......................................................24
Tabel 2.12. Neraca panas di sekitar absorber ........................................................25
Tabel 2.13. Neraca panas di sekitar heater -02 .......................................................25
Tabel 2.14. Neraca panas di sekitar menara destilasi-01 .......................................25
Tabel 2.15. Neraca panas di sekitar cooler -02 .......................................................25
Tabel 2.14. Neraca panas di sekitar menara destilasi-02 .......................................26
Tabel 2.17. Perincian luas tanah bangunan pabrik .................................................28
Tabel 5.1. Jabatan dan prasyarat karyawan ..................................................................... 80
Tabel 5.2. Jumlah karyawan dan gaji ................................................................................ 81

Tabel 6.1. Cost index chemical plant .....................................................................91
Tabel 6.2. Fixed capital investment .......................................................................93
Tabel 6.3. Manufacturing cost ...............................................................................94
Tabel 6.4. Working capital .....................................................................................94
Tabel 6.5. General expenses ..................................................................................95
Tabel 6.6. Fixed cost ..............................................................................................96
Tabel 6.7. Variable Cost ........................................................................................96
Tabel 6.8. Regulated Cost ......................................................................................97
x