PRARANCANGAN PABRIK UREA FORMALDEHYDE CONCENTRATE (UFC-85) DENGAN PROSES OKSIDASI METANOL HALDOR TOPSOE KAPASITAS 41.250 TON/TAHUN.
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TUGAS AKHIR
PRARANCANGAN PABRIK
UREA FORMALDEHYDE CONCENTRATE (UFC-85)
DENGAN PROSES OKSIDASI METANOL
HALDOR TOPSOE KAPASITAS 41.250 TON/TAHUN
HALAMAN JUDUL
Oleh :
EVI ZAHROTUN NISA
I 0510014
RISKA AGUSTINA WULANDARI
I 0510033
JURUSAN TEKNIK KIMIA FAKULTAS TEKNIK
UNIVERSITAS SEBELAS MARET
SURAKARTA
2014
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KATA PENGANTAR
Segala puji syukur kepada Allah SWT, karena rahmat dan ridho-Nya, penulis
dapat menyelesaikan penyusunan laporan ini. Dalam penyusunan laporan penulis
ingin mengucapkan terimakasih kepada:
1. Kedua orang tua dan keluarga atas dukungan, doa, materi dan semangat yang
senantiasa diberikan tanpa kenal lelah.
2. Bapak Dr. Sunu Herwi Pranolo selaku Ketua Jurusan Teknik Kimia FT UNS.
3. Bapak Dr. Eng. Agus Purwanto, S.T., M.T. dan Bapak Mujtahid Kaavessina,
S.T.,M.T, P.hD selaku Dosen Pembimbing I dan II atas bimbingan dan bantuan
beliau.
4. Bapak Dr. Margono, S.T., M.T. dan Bapak Dr. Sunu H. Pranolo selaku
pembimbing akademik.
5. Segenap Civitas Akademika atas semua bantuan yang diberikan.
6. Teman-teman mahasiswa Teknik Kimia FT UNS khususnya angkatan 2010.
Penulis menyadari kemungkinan laporan ini belum sempurna. Oleh karena
itu, diharapkan saran dan kritik yang membangun. Semoga laporan ini dapat
bermanfaat bagi penulis dan pembaca.
Surakarta, Juli 2014
Penulis
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DAFTAR ISI
HALAMAN JUDUL...................................................................................................... i
LEMBAR PENGESAHAN ........................................ Error! Bookmark not defined.
KATA PENGANTAR .................................................................................................. ii
DAFTAR ISI ................................................................................................................. v
DAFTAR TABEL ........................................................................................................ ix
DAFTAR GAMBAR ................................................................................................... xi
INTISARI..................................................................................................................... xi
BAB I ............................................................................................................................ 1
PENDAHULUAN......................................................................................................... 1
1.1
Latar Belakang................................................................................................ 1
1.2
Kapasitas Perencanaan ................................................................................... 2
1.2.1 Kebutuhan UFC .............................................................................................. 2
1.2.2 Ketersediaan Bahan Baku ............................................................................... 4
1.2.3 Kapasitas Maksimum dan Minimum Pabrik di Luar Negeri ......................... 4
1.3
Pemilihan Lokasi Pabrik................................................................................. 5
1.3.1 Faktor Primer .................................................................................................. 6
1.3.2 Faktor Sekunder .............................................................................................. 7
1.4
Tinjauan Pustaka ............................................................................................ 9
1.4.1 Proses Pembuatan UFC................................................................................... 9
1.4.2 Alasan Pemilihan Proses ............................................................................... 12
1.4.3 Kegunaan Produk ..........................................................................................13
1.4.4 Sifat Fisis dan Kimia Produk dan Bahan Baku ............................................. 13
1.4.5 Tinjauan Proses Secara Umum .....................................................................21
BAB II ......................................................................................................................... 23
DESKRIPSI PROSES ................................................................................................. 23
2.1
Spesifikasi Bahan Baku dan Produk............................................................. 23
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2.1.1 Spesifikasi Bahan Baku ................................................................................ 23
2.1.2 Spesifikasi Produk ........................................................................................ 25
2.1.3 Spesifikasi Bahan Pembantu (Katalis) .......................................................... 25
2.2
Konsep Proses .............................................................................................. 26
2.2.1 Dasar Reaksi ................................................................................................. 26
2.2.2 Tinjauan Kinetika.......................................................................................... 27
2.2.3 Tinjauan Termodinamika .............................................................................. 28
2.2.4 Kondisi Proses .............................................................................................. 30
2.2.5 Katalis ...........................................................................................................30
2.3
Diagram Alir Proses dan Tahapan Proses .................................................... 31
2.3.1 Diagram Alir Proses ...................................................................................... 31
2.3.2 Langkah Proses ............................................................................................. 35
2.4
Neraca Massa dan Neraca Panas .................................................................. 38
2.4.1 Neraca Massa ................................................................................................ 38
2.4.2 Neraca Panas ................................................................................................. 42
2.5
Lay Out Pabrik dan Peralatan Proses............................................................ 45
2.5.1 Lay Out Pabrik .............................................................................................. 45
2.5.2 Lay Out Peralatan.......................................................................................... 49
BAB III........................................................................................................................ 52
SPESIFIKASI PERALATAN PROSES ..................................................................... 52
3.1
Reaktor ......................................................................................................... 52
3.2
Absorber ....................................................................................................... 53
3.3
Mixer ............................................................................................................ 54
3.4
Vaporizer ...................................................................................................... 55
3.5
Tangki Penyimpan ........................................................................................ 56
3.6
Silo................................................................................................................ 57
3.7
Separator ....................................................................................................... 57
3.8
Alat Penukar Panas .......................................................................................58
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3.9
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Pompa ...........................................................................................................62
3.10 Blower ...........................................................................................................63
3.11 Belt Conveyor ...............................................................................................63
3.12 Hopper...........................................................................................................64
BAB IV ....................................................................................................................... 65
UNIT PENDUKUNG PROSES DAN LABORATORIUM ....................................... 65
4.1
Unit Pendukung Proses................................................................................. 65
4.1.1 Unit Pengadaan Air ....................................................................................... 66
4.1.2 Unit Pengadaan Pendingin Reaktor .............................................................. 73
4.1.3 Unit Pengadaan Udara Tekan ....................................................................... 73
4.1.4 Unit Pengadaan Listrik ................................................................................. 74
4.1.5 Unit Pengadaan Bahan Bakar ....................................................................... 79
4.1.6 Unit pengolahan limbah ................................................................................ 80
4.2
Laboratorium ................................................................................................ 80
4.2.1 Laboratorium Analisis Bahan Baku dan Produk .......................................... 82
4.2.2 Laboratorium Penguji Kualitas Air ............................................................... 83
4.2.3 Laboratorium Penelitian dan Pengembangan ............................................... 83
BAB V ......................................................................................................................... 85
MANAJEMEN PERUSAHAAN ................................................................................ 85
5.1
Bentuk Perusahaan ....................................................................................... 85
5.2
Struktur Organisasi....................................................................................... 86
5.3
Pembagian Jam Kerja Karyawan.................................................................. 90
5.3.1 Karyawan non shift ....................................................................................... 91
5.3.2 Karyawan Shift .............................................................................................. 91
5.4
Status Karyawan dan Sistem Upah............................................................... 93
5.4.1 Karyawan Tetap ............................................................................................ 93
5.4.2 Karyawan Harian .......................................................................................... 93
5.4.3 Karyawan Borongan ..................................................................................... 93
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5.5
Penggolongan Jabatan, Jumlah Karyawan, dan Gaji.................................... 93
5.6
Kesejahteraan Sosial Karyawan ................................................................... 95
BAB VI ....................................................................................................................... 97
ANALISIS EKONOMI............................................................................................... 97
6.1
Penafsiran Harga Peralatan........................................................................... 98
6.2
Dasar Perhitungan ...................................................................................... 100
6.3
Hasil Perhitungan ....................................................................................... 101
6.3.1 Capital Investment ...................................................................................... 101
6.3.2 Manufacturing Cost .................................................................................... 104
6.3.3 General Expense ......................................................................................... 105
6.3.4 Total Production Cost ................................................................................. 106
6.4
Analisa Kelayakan ...................................................................................... 106
DAFTAR PUSTAKA ............................................................................................... 113
LAMPIRAN .............................................................................................................. 116
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DAFTAR TABEL
Tabel I-1 Data Impor UFC di Indonesia Tahun 2008-2012 .......................................... 2
Tabel I-2 Daftar Pabrik Produsen UFC di Luar Negeri ................................................ 4
Tabel II-1 Neraca massa di tee 1 ................................................................................. 38
Tabel II-2 Neraca massa di reaktor ............................................................................. 39
Tabel II-3 Neraca massa di absorber ........................................................................... 39
Tabel II-4 Neraca massa di tee 2 ................................................................................. 40
Tabel II-5 Neraca massa di mixer ............................................................................... 40
Tabel II-6 Neraca massa keseluruhan ......................................................................... 41
Tabel II-7 Neraca panas pada vaporizer...................................................................... 42
Tabel II-8 Neraca panas pada tee 1 ............................................................................. 42
Tabel II-9 Neraca panas pada reaktor ......................................................................... 43
Tabel II-10 Neraca panas pada mixer ......................................................................... 43
Tabel II-11 Neraca panas pada absorber ..................................................................... 44
Tabel II-12 Neraca panas pada tee 2 ........................................................................... 44
Tabel II-13 Neraca panas keseluruhan ........................................................................ 45
Tabel III-1 Spesifikasi reaktor .................................................................................... 52
Tabel III-2 Spesifikasi absorber .................................................................................. 53
Tabel III-3 Spesifikasi mixer ...................................................................................... 53
Tabel III-4 Spesifikasi vaporizer ................................................................................. 55
Tabel III-5 Spesifikasi tangki penyimpan ................................................................... 56
Tabel III-6 Spesifikasi silo .......................................................................................... 57
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Tabel III-7 Spesifikasi separator ................................................................................. 57
Tabel III-8 Spesifikasi alat penukar panas .................................................................. 58
Tabel III-9 Spesifikasi pompa proses.......................................................................... 62
Tabel III-10 Spesifikasi blower................................................................................... 63
Tabel III-11 Spesifikasi belt conveyor ........................................................................63
Tabel III-12 Spesifikasi hopper...................................................................................64
Tabel IV-1 Penggunaan air laut sebagai media pendingin.......................................... 67
Tabel IV-2 Jumlah kebutuhan air konsumsi dan sanitasi............................................ 72
Tabel IV-3 Kebutuhan air PT. Kaltim Industrial Estate ............................................. 72
Tabel IV-4 Kebutuhan listrik untuk keperluan proses dan utilitas ............................. 75
Tabel IV-5 Penentuan jumlah lumen pabrik ............................................................... 76
Tabel IV-6 Total kebutuhan listrik pabrik .................................................................. 78
Tabel V-1 Jadwal Pembagian Kelompok Shift ........................................................... 92
Tabel V-2 Perincian Jumlah Karyawan dan Gaji dalam Rupiah ................................ 94
Tabel VI-1 Indeks harga alat (Chemical Engineering Plan Cost Index) ..................... 99
Tabel VI-2 Fixed Capital Investment........................................................................ 102
Tabel VI-3 Working Capital Investment................................................................... 103
Tabel VI-4 Direct Manufacturing Cost..................................................................... 104
Tabel VI-5 Indirect Manufacturing Cost .................................................................. 104
Tabel VI-6 Fixed Manufacturing Cost ...................................................................... 105
Tabel VI-7 General Expense ..................................................................................... 105
Tabel VI-8 Total Production Cost .......................................................................... .106
Tabel VI-9 Analisis Kelayakan ................................................................................. 112
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DAFTAR GAMBAR
Gambar I-1 Grafik Impor UFC-85 di Indonesia Tahun 2008-2012.............................. 3
Gambar I-2 Peta Lokasi Pendirian Pabrik .................................................................... 9
Gambar II-1 Diagram Alir Kualitatif .......................................................................... 32
Gambar II-2 Diagram Alir Kuantitatif ........................................................................ 33
Gambar II-3 Diagram Alir Proses ............................................................................... 34
Gambar II-4 Tata Letak Pabrik ................................................................................... 48
Gambar II-5 Tata Letak Peralatan Proses ................................................................... 51
Gambar IV-1 Pengolahan Air Laut ............................................................................. 69
Gambar IV-2 Pengolahan Air Proses dan Sanitasi ..................................................... 71
Gambar V-1 Struktur Organisasi Pabrik ..................................................................... 90
Gambar VI-1 Grafik Indeks Harga ........................................................................... 100
Gambar VI-2 Grafik Hasil Analisis Ekonomi ........................................................... 111
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TUGAS AKHIR
PRARANCANGAN PABRIK
UREA FORMALDEHYDE CONCENTRATE (UFC-85)
DENGAN PROSES OKSIDASI METANOL
HALDOR TOPSOE KAPASITAS 41.250 TON/TAHUN
HALAMAN JUDUL
Oleh :
EVI ZAHROTUN NISA
I 0510014
RISKA AGUSTINA WULANDARI
I 0510033
JURUSAN TEKNIK KIMIA FAKULTAS TEKNIK
UNIVERSITAS SEBELAS MARET
SURAKARTA
2014
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KATA PENGANTAR
Segala puji syukur kepada Allah SWT, karena rahmat dan ridho-Nya, penulis
dapat menyelesaikan penyusunan laporan ini. Dalam penyusunan laporan penulis
ingin mengucapkan terimakasih kepada:
1. Kedua orang tua dan keluarga atas dukungan, doa, materi dan semangat yang
senantiasa diberikan tanpa kenal lelah.
2. Bapak Dr. Sunu Herwi Pranolo selaku Ketua Jurusan Teknik Kimia FT UNS.
3. Bapak Dr. Eng. Agus Purwanto, S.T., M.T. dan Bapak Mujtahid Kaavessina,
S.T.,M.T, P.hD selaku Dosen Pembimbing I dan II atas bimbingan dan bantuan
beliau.
4. Bapak Dr. Margono, S.T., M.T. dan Bapak Dr. Sunu H. Pranolo selaku
pembimbing akademik.
5. Segenap Civitas Akademika atas semua bantuan yang diberikan.
6. Teman-teman mahasiswa Teknik Kimia FT UNS khususnya angkatan 2010.
Penulis menyadari kemungkinan laporan ini belum sempurna. Oleh karena
itu, diharapkan saran dan kritik yang membangun. Semoga laporan ini dapat
bermanfaat bagi penulis dan pembaca.
Surakarta, Juli 2014
Penulis
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DAFTAR ISI
HALAMAN JUDUL...................................................................................................... i
LEMBAR PENGESAHAN ........................................ Error! Bookmark not defined.
KATA PENGANTAR .................................................................................................. ii
DAFTAR ISI ................................................................................................................. v
DAFTAR TABEL ........................................................................................................ ix
DAFTAR GAMBAR ................................................................................................... xi
INTISARI..................................................................................................................... xi
BAB I ............................................................................................................................ 1
PENDAHULUAN......................................................................................................... 1
1.1
Latar Belakang................................................................................................ 1
1.2
Kapasitas Perencanaan ................................................................................... 2
1.2.1 Kebutuhan UFC .............................................................................................. 2
1.2.2 Ketersediaan Bahan Baku ............................................................................... 4
1.2.3 Kapasitas Maksimum dan Minimum Pabrik di Luar Negeri ......................... 4
1.3
Pemilihan Lokasi Pabrik................................................................................. 5
1.3.1 Faktor Primer .................................................................................................. 6
1.3.2 Faktor Sekunder .............................................................................................. 7
1.4
Tinjauan Pustaka ............................................................................................ 9
1.4.1 Proses Pembuatan UFC................................................................................... 9
1.4.2 Alasan Pemilihan Proses ............................................................................... 12
1.4.3 Kegunaan Produk ..........................................................................................13
1.4.4 Sifat Fisis dan Kimia Produk dan Bahan Baku ............................................. 13
1.4.5 Tinjauan Proses Secara Umum .....................................................................21
BAB II ......................................................................................................................... 23
DESKRIPSI PROSES ................................................................................................. 23
2.1
Spesifikasi Bahan Baku dan Produk............................................................. 23
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2.1.1 Spesifikasi Bahan Baku ................................................................................ 23
2.1.2 Spesifikasi Produk ........................................................................................ 25
2.1.3 Spesifikasi Bahan Pembantu (Katalis) .......................................................... 25
2.2
Konsep Proses .............................................................................................. 26
2.2.1 Dasar Reaksi ................................................................................................. 26
2.2.2 Tinjauan Kinetika.......................................................................................... 27
2.2.3 Tinjauan Termodinamika .............................................................................. 28
2.2.4 Kondisi Proses .............................................................................................. 30
2.2.5 Katalis ...........................................................................................................30
2.3
Diagram Alir Proses dan Tahapan Proses .................................................... 31
2.3.1 Diagram Alir Proses ...................................................................................... 31
2.3.2 Langkah Proses ............................................................................................. 35
2.4
Neraca Massa dan Neraca Panas .................................................................. 38
2.4.1 Neraca Massa ................................................................................................ 38
2.4.2 Neraca Panas ................................................................................................. 42
2.5
Lay Out Pabrik dan Peralatan Proses............................................................ 45
2.5.1 Lay Out Pabrik .............................................................................................. 45
2.5.2 Lay Out Peralatan.......................................................................................... 49
BAB III........................................................................................................................ 52
SPESIFIKASI PERALATAN PROSES ..................................................................... 52
3.1
Reaktor ......................................................................................................... 52
3.2
Absorber ....................................................................................................... 53
3.3
Mixer ............................................................................................................ 54
3.4
Vaporizer ...................................................................................................... 55
3.5
Tangki Penyimpan ........................................................................................ 56
3.6
Silo................................................................................................................ 57
3.7
Separator ....................................................................................................... 57
3.8
Alat Penukar Panas .......................................................................................58
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3.9
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Pompa ...........................................................................................................62
3.10 Blower ...........................................................................................................63
3.11 Belt Conveyor ...............................................................................................63
3.12 Hopper...........................................................................................................64
BAB IV ....................................................................................................................... 65
UNIT PENDUKUNG PROSES DAN LABORATORIUM ....................................... 65
4.1
Unit Pendukung Proses................................................................................. 65
4.1.1 Unit Pengadaan Air ....................................................................................... 66
4.1.2 Unit Pengadaan Pendingin Reaktor .............................................................. 73
4.1.3 Unit Pengadaan Udara Tekan ....................................................................... 73
4.1.4 Unit Pengadaan Listrik ................................................................................. 74
4.1.5 Unit Pengadaan Bahan Bakar ....................................................................... 79
4.1.6 Unit pengolahan limbah ................................................................................ 80
4.2
Laboratorium ................................................................................................ 80
4.2.1 Laboratorium Analisis Bahan Baku dan Produk .......................................... 82
4.2.2 Laboratorium Penguji Kualitas Air ............................................................... 83
4.2.3 Laboratorium Penelitian dan Pengembangan ............................................... 83
BAB V ......................................................................................................................... 85
MANAJEMEN PERUSAHAAN ................................................................................ 85
5.1
Bentuk Perusahaan ....................................................................................... 85
5.2
Struktur Organisasi....................................................................................... 86
5.3
Pembagian Jam Kerja Karyawan.................................................................. 90
5.3.1 Karyawan non shift ....................................................................................... 91
5.3.2 Karyawan Shift .............................................................................................. 91
5.4
Status Karyawan dan Sistem Upah............................................................... 93
5.4.1 Karyawan Tetap ............................................................................................ 93
5.4.2 Karyawan Harian .......................................................................................... 93
5.4.3 Karyawan Borongan ..................................................................................... 93
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5.5
Penggolongan Jabatan, Jumlah Karyawan, dan Gaji.................................... 93
5.6
Kesejahteraan Sosial Karyawan ................................................................... 95
BAB VI ....................................................................................................................... 97
ANALISIS EKONOMI............................................................................................... 97
6.1
Penafsiran Harga Peralatan........................................................................... 98
6.2
Dasar Perhitungan ...................................................................................... 100
6.3
Hasil Perhitungan ....................................................................................... 101
6.3.1 Capital Investment ...................................................................................... 101
6.3.2 Manufacturing Cost .................................................................................... 104
6.3.3 General Expense ......................................................................................... 105
6.3.4 Total Production Cost ................................................................................. 106
6.4
Analisa Kelayakan ...................................................................................... 106
DAFTAR PUSTAKA ............................................................................................... 113
LAMPIRAN .............................................................................................................. 116
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DAFTAR TABEL
Tabel I-1 Data Impor UFC di Indonesia Tahun 2008-2012 .......................................... 2
Tabel I-2 Daftar Pabrik Produsen UFC di Luar Negeri ................................................ 4
Tabel II-1 Neraca massa di tee 1 ................................................................................. 38
Tabel II-2 Neraca massa di reaktor ............................................................................. 39
Tabel II-3 Neraca massa di absorber ........................................................................... 39
Tabel II-4 Neraca massa di tee 2 ................................................................................. 40
Tabel II-5 Neraca massa di mixer ............................................................................... 40
Tabel II-6 Neraca massa keseluruhan ......................................................................... 41
Tabel II-7 Neraca panas pada vaporizer...................................................................... 42
Tabel II-8 Neraca panas pada tee 1 ............................................................................. 42
Tabel II-9 Neraca panas pada reaktor ......................................................................... 43
Tabel II-10 Neraca panas pada mixer ......................................................................... 43
Tabel II-11 Neraca panas pada absorber ..................................................................... 44
Tabel II-12 Neraca panas pada tee 2 ........................................................................... 44
Tabel II-13 Neraca panas keseluruhan ........................................................................ 45
Tabel III-1 Spesifikasi reaktor .................................................................................... 52
Tabel III-2 Spesifikasi absorber .................................................................................. 53
Tabel III-3 Spesifikasi mixer ...................................................................................... 53
Tabel III-4 Spesifikasi vaporizer ................................................................................. 55
Tabel III-5 Spesifikasi tangki penyimpan ................................................................... 56
Tabel III-6 Spesifikasi silo .......................................................................................... 57
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Tabel III-7 Spesifikasi separator ................................................................................. 57
Tabel III-8 Spesifikasi alat penukar panas .................................................................. 58
Tabel III-9 Spesifikasi pompa proses.......................................................................... 62
Tabel III-10 Spesifikasi blower................................................................................... 63
Tabel III-11 Spesifikasi belt conveyor ........................................................................63
Tabel III-12 Spesifikasi hopper...................................................................................64
Tabel IV-1 Penggunaan air laut sebagai media pendingin.......................................... 67
Tabel IV-2 Jumlah kebutuhan air konsumsi dan sanitasi............................................ 72
Tabel IV-3 Kebutuhan air PT. Kaltim Industrial Estate ............................................. 72
Tabel IV-4 Kebutuhan listrik untuk keperluan proses dan utilitas ............................. 75
Tabel IV-5 Penentuan jumlah lumen pabrik ............................................................... 76
Tabel IV-6 Total kebutuhan listrik pabrik .................................................................. 78
Tabel V-1 Jadwal Pembagian Kelompok Shift ........................................................... 92
Tabel V-2 Perincian Jumlah Karyawan dan Gaji dalam Rupiah ................................ 94
Tabel VI-1 Indeks harga alat (Chemical Engineering Plan Cost Index) ..................... 99
Tabel VI-2 Fixed Capital Investment........................................................................ 102
Tabel VI-3 Working Capital Investment................................................................... 103
Tabel VI-4 Direct Manufacturing Cost..................................................................... 104
Tabel VI-5 Indirect Manufacturing Cost .................................................................. 104
Tabel VI-6 Fixed Manufacturing Cost ...................................................................... 105
Tabel VI-7 General Expense ..................................................................................... 105
Tabel VI-8 Total Production Cost .......................................................................... .106
Tabel VI-9 Analisis Kelayakan ................................................................................. 112
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DAFTAR GAMBAR
Gambar I-1 Grafik Impor UFC-85 di Indonesia Tahun 2008-2012.............................. 3
Gambar I-2 Peta Lokasi Pendirian Pabrik .................................................................... 9
Gambar II-1 Diagram Alir Kualitatif .......................................................................... 32
Gambar II-2 Diagram Alir Kuantitatif ........................................................................ 33
Gambar II-3 Diagram Alir Proses ............................................................................... 34
Gambar II-4 Tata Letak Pabrik ................................................................................... 48
Gambar II-5 Tata Letak Peralatan Proses ................................................................... 51
Gambar IV-1 Pengolahan Air Laut ............................................................................. 69
Gambar IV-2 Pengolahan Air Proses dan Sanitasi ..................................................... 71
Gambar V-1 Struktur Organisasi Pabrik ..................................................................... 90
Gambar VI-1 Grafik Indeks Harga ........................................................................... 100
Gambar VI-2 Grafik Hasil Analisis Ekonomi ........................................................... 111
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