PRARANCANGAN PABRIK PHENYL ETHYL ALCOHOL DARI BENZENE DAN ETHYLENE OXIDE KAPASITAS 5.000 TON/TAHUN.
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TUGAS AKHIR
PRARANCANGAN PABRIK PHENYL ETHYL ALCOHOL
DARI BENZENE DAN ETHYLENE OXIDE
KAPASITAS 5.000 TON/TAHUN
Disusun Oleh:
Irwan Fauzi
I 1507032
Surya Haditya
I 0508117
JURUSAN TEKNIK KIMIA FAKULTAS TEKNIK
UNIVERSITAS SEBELAS MARET
SURAKARTA
2014
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TUGAS AKHIR
PRARANCANGAN PABRIK PHENYL ETHYL ALCOHOL
DARI BENZENE DAN ETHYLENE OXIDE
KAPASITAS 5.000 TON/TAHUN
Disusun Oleh:
Irwan Fauzi
I 1507032
Surya Haditya
I 0508117
JURUSAN TEKNIK KIMIA FAKULTAS TEKNIK
UNIVERSITAS SEBELAS MARET
SURAKARTA
2014
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KATA PENGANTAR
Alhamdulillah puji syukur kepada Allah SWT karena rahmat beserta
hidayahNya, laporan tugas akhir dengan judul “Prarancangan Pabrik Phenyl Ethyl
Alcohol dari Benzene dan Ethylene Oxide kapasitas 5.000 ton/tahun” selesai.
Dalam penyusunan tugas akhir ini, bantuan baik berupa dukungan moral dan
material dari pelbagai pihak turut mendukung penyelesaiannya. Karena itu,
ucapan terima kasih ditujukan kepada kedua orang tua kami yang telah
memberikan kami banyak doa, Dr. Sunu H. Pranolo sebagai dosen pembimbing I
dan Inayati, S.T., M.T., Ph.D sebagai dosen pembimbing II, mba Purna Katamsi
dan mba Rukayah yang telah memberikan dukungan moril, teman-teman di stuba
dan stuta yang tidak bisa disebutkan semua yang telah membantu berbagi ilmu,
informasi, dan pengalaman.
Laporan tugas akhir ini masih jauh dari sempurna, jadi saran dan kritik
membangun sangat diharapkan. Semoga laporan ini dapat bermanfaat.
Surakarta, Desember 2014
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DAFTAR ISI
Halaman Judul ...................................................................................................... i
Lembar Pengesahan ............................................................................................. ii
Kata Pengantar ...................................................................................................... iii
Daftar Isi ............................................................................................................... iv
Daftar Tabel ......................................................................................................... viii
Daftar Gambar ...................................................................................................... xi
Intisari .................................................................................................................. xii
BAB I
PENDAHULUAN ............................................................................. 1
I.1. Latar Belakang Pendirian Pabrik ............................................... 1
I.2. Kapasitas Perancangan ............................................................... 2
I.3. Pemilihan Lokasi Pabrik ............................................................ 5
I.4. Tinjauan Pustaka ........................................................................ 7
I.4.1. Macam-macam Proses Pembuatan PEA ........................... 7
I.4.2. Alasan Pemilihan Proses ................................................... 10
I.4.3. Kegunaan Produk ...............................................................10
I.4.4. Sifat Fisis dan Kimia ........................................................ 10
A. Bahan Baku .................................................................. 10
B. Bahan Pembantu (Katalis) ........................................... 12
C. Produk Utama .............................................................. 13
I.4.5. Tinjauan Proses Secara Umum ..........................................14
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BAB II
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DESKRIPSI PROSES ....................................................................... 16
2.1
2.2
Spesifikasi Bahan Baku dan Produk ........................................ 16
2.1.1
Spesifikasi Bahan Baku ............................................... 16
2.1.2
Spesifikasi Katalis ......................................................... 16
2.1.3
Spesifikasi Produk ........................................................ 17
Konsep Proses .......................................................................... 17
2.2.1
Dasar Reaksi ................................................................ 17
2.2.2 Kondisi Operasi ........................................................... 17
2.2.3 Tinjauan Termodinamika ..............................................18
2.3
Diagram Alir Proses dan Tahapan Proses ............................... 20
2.3.1
Diagram Alir Kualitatif ................................................ 20
2.3.2 Diagram Alir Kuantitatif .............................................. 20
2.3.3 Diagram Alir Proses ..................................................... 20
2.3.4 Penjadwalan Proses .......................................................24
2.3.5
2.4
Langkah Proses ........................................................... 26
Neraca Massa dan Neraca Panas ............................................. 28
2.4.1
Neraca Massa ............................................................... 28
2.4.2 Neraca Panas ................................................................ 31
2.5
Layout Pabrik dan Peralatan Proses ......................................... 34
2.5.1
Layout Pabrik ............................................................... 34
2.5.2 Layout Peralatan Proses ............................................... 40
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BAB III
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SPESIFIKASI ALAT PROSES ........................................................ 41
3.1
Reaktor ..................................................................................... 41
3.2
Mixer ........................................................................................ 42
3.3
Decanter ................................................................................... 43
3.4
Evaporator ................................................................................ 43
3.5
Menara Distilasi ....................................................................... 44
3.6
Silo ........................................................................................... 44
3.7
Bucket elevator ........................................................................ 45
3.8
Belt Conveyor .......................................................................... 45
3.9
Hopper ..................................................................................... 45
3.10 Tangki .......................................................................................46
3.11 Heat Exchanger .........................................................................48
3.12 Pompa........................................................................................50
BAB IV
UNIT PENDUKUNG PROSES DAN LABORATORIUM ............. 52
4.1
Unit Pengadaan Air .................................................................. 53
4.2
Unit Pengadaan Steam dan Bahan Bakar .................................. 55
4.3
Unit Pengadaan Udara Tekan .................................................. 56
4.4
Unit Pengadaan Listrik ............................................................ 56
4.5
Unit Refrigerasi ....................................................................... 59
4.6
Unit Pengolahan Limbah .......................................................... 59
4.7
Laboratorium ........................................................................... 61
4.7.1 Laboratorium Fisik ......................................................... 63
4.7.2 Laboratorium Analitik .................................................... 63
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4.7.3 Laboratorium Penelitian dan Pengembangan ................. 63
BAB V
MANAJEMEN PERUSAHAAN ...................................................... 65
5.1
Bentuk Perusahaan .................................................................. 65
5.2
Struktur Organisasi .................................................................. 66
5.3
Tugas dan Wewenang .............................................................. 68
5.4
Pembagian Jam Kerja dan Gaji Karyawan .............................. 69
5.5
BAB VI
5.4.1
Karyawan Non Shift ..................................................... 71
5.4.2
Karyawan Shift ............................................................. 71
Health and Safety Environment ................................................ 72
5.5.1
Tinjauan Hukum .......................................................... 72
5.5.2
Identifikasi Bahaya ...................................................... 74
ANALISA EKONOMI ..................................................................... 76
6.1
Penaksiran Harga Peralatan ................................................... 76
6.2
Dasar Perhitungan ................................................................. 78
6.3
Penentuan Total Capital Investment (TCI) ........................... 79
6.4
Hasil Perhitungan .................................................................. 80
DAFTAR PUSTAKA .......................................................................................... xiii
LAMPIRAN
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DAFTAR TABEL
Tabel 1.1.
Data Impor PEA di Indonesia ......................................................... 3
Tabel 1.2.
Kapasitas Pabrik PEA di Berbagai Negara ..................................... 5
Tabel 1.3.
Kelebihan dan Kelemahan Proses Pembuatan PEA ........................ 9
Tabel 2.1.
Data Panas Pembentukan ................................................................ 18
Tabel 2.2.
Data Energi Bebas Gibbs ................................................................ 19
Tabel 2.3.
Neraca Massa Reaktor .................................................................... 29
Tabel 2.4.
Neraca Massa Mixer ....................................................................... 29
Tabel 2.5.
Neraca Massa Decanter .................................................................. 29
Tabel 2.6.
Neraca Massa Evaporator ............................................................... 30
Tabel 2.7.
Neraca Massa Menara Distilasi ....................................................... 30
Tabel 2.8.
Neraca Panas Reaktor ...................................................................... 31
Tabel 2.9.
Neraca Panas Mixer ........................................................................ 31
Tabel 2.10. Neraca Panas Decanter ................................................................... 32
Tabel 2.11. Neraca Panas Evaporator ................................................................. 32
Tabel 2.12. Neraca Panas Menara Distilasi ....................................................... 32
Tabel 2.13. Neraca Panas Total ......................................................................... 33
Tabel 3.1.
Spesifikasi Reaktor ......................................................................... 41
Tabel 3.2.
Spesifikasi Mixer ............................................................................ 42
Tabel 3.3.
Spesifikasi Decanter ....................................................................... 43
Tabel 3.4.
Spesifikasi Evaporator .................................................................... 43
Tabel 3.5.
Spesifikasi Menara Distilasi
44
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Tabel 3.6.
Spesifikasi Silo ............................................................................... 44
Tabel 3.7.
Spesifikasi Bucket Elevator ............................................................ 45
Tabel 3.8.
Spesifikasi Belt Conveyor ............................................................... 45
Tabel 3.9.
Spesifikasi Hopper .......................................................................... 45
Tabel 3.10
Spesifikasi Tangki ........................................................................... 46
Tabel 3.11
Spesifikasi Tangki Penampung ....................................................... 47
Tabel 3.12
Spesifikasi Tangki (Lanjutan) ......................................................... 48
Tabel 3.13
Spesifikasi Heat Exchanger ............................................................ 48
Tabel 3.14
Spesifikasi Heat Exchanger (Lanjutan) .......................................... 49
Tabel 3.15
Spesifikasi Heat Exchanger (Lanjutan) .......................................... 50
Tabel 3.16
Spesifikasi Pompa ........................................................................... 50
Tabel 4.1.
Kebutuhan Air Proses ..................................................................... 53
Tabel 4.2.
Kebutuhan Air Pendingin ............................................................... 53
Tabel 4.3.
Kebutuhan Air Umpan Boiler ......................................................... 54
Tabel 4.4.
Kebutuhan Air Konsumsi Umum dan Sanitasi ............................... 54
Tabel 4.5.
Kebutuhan Air Sungai .................................................................... 54
Tabel 4.6.
Spesifikasi Boiler ............................................................................ 56
Tabel 4.7.
Spesifikasi Kompresor .................................................................... 56
Tabel 4.8.
Kebutuhan Listrik Utilitas .............................................................. 57
Tabel 4.9.
Kebutuhan Listrik Proses ................................................................58
Tabel 4.10
Kebutuhan Listrik Total .................................................................. 58
Tabel 4.l1
Spesifikasi Generator ...................................................................... 59
Tabel 5.1.
Perincian Kualifikasi, Jumlah, dan Gaji Karyawan Non Shift ........ 70
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Tabel 5.2.
Perincian Kualifikasi, Jumlah, dan Gaji Karyawan Shift ................ 71
Tabel 5.3.
Jadwal Pembagian Kelompok Shift ................................................ 72
Tabel 5.4.
Material Safety Data Sheet PEA .....................................................74
Tabel 5.5.
Perlengkapan Pencegahan Bahaya ..................................................75
Tabel 6.1.
Indeks Harga Alat ........................................................................... 77
Tabel 6.2.
Fixed Capital Investment ................................................................ 80
Tabel 6.3.
Working Capital Investment ........................................................... 80
Tabel 6.4.
Direct Manufacturing Cost ............................................................. 81
Tabel 6.5.
Indirect Manufacturing Cost .......................................................... 81
Tabel 6.6.
Fixed Manufacturing Cost .............................................................. 81
Tabel 6.7.
General Expense ............................................................................. 82
Tabel 6.8.
Analisa Kelayakan .......................................................................... 86
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DAFTAR GAMBAR
Gambar I.1.
Grafik Impor PEA dari Tahun 2007-2012 .................................... 3
Gambar I.2.
Gambar Pemilihan Lokasi Pabrik ................................................. 5
Gambar 2.1. Diagram Alir Kualitatif ................................................................ 21
Gambar 2.2. Diagram Alir Kuantitatif .............................................................. 22
Gambar 2.3. Diagram Alir Proses ..................................................................... 23
Gambar 2.4. Penjadwalan Alat Pabrik PEA ...................................................... 25
Gambar 2.5. Blok Diagram Alir Proses Pabrik PEA ........................................ 28
Gambar 2.6. Layout Pabrik PEA ....................................................................... 38
Gambar 2.7. Layout Peralatan Proses ................................................................ 39
Gambar 4.1. Skema Pengolahan Air Sungai ..................................................... 55
Gambar 4.2. Diagram Alir Pengolahan Limbah Cair ........................................ 59
Gambar 5.1. Struktur Organisasi Pabrik PEA ................................................... 68
Gambar 5.2. Gambar Identifikasi Bahaya PEA ................................................ 73
Gambar 6.1. Grafik Linierisasi Indeks Harga ................................................... 77
Gambar 6.2. Grafik Analisa Kelayakan ............................................................ 88
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ABSTRACT
Irwan Fauzi, Surya Haditya, 2014, Preeliminary Design Phenyl Ethyl Alcohol
from Benzene and Ethylene Oxide Capacity 5.000 ton/year, Chemical
Engineering Major, Sebelas Maret University.
Phenyl Ethyl Alcohol (PEA) is colorless liquid, good smell, mostly used
for fragrance compund rose like odor, lily, ylang-ylang, orange. PEA compound is
also used for desinfectant, antibacterial agent, etc. PEA plant is classified as low
risk industry that will built on industrial district on 2017 at industrial district at
Tangerang City, Banten with capacity 5.000 ton/year.
PEA is made by reacting benzene liquid and ethylene oxide liquid by
Friedel Crafts methode with adding catalyst Aluminum Chloride in low
temperature 100 C and pressure is about 1,01 bar in the batch reactor with
operation conditions are irreversible isothermal non-adiabatic and exothermis.
Raw materials are benzene liquid with 99% pure by Pertamina ltd. Cilacap,
ethylene oxide liquid with 97% pure by Prima Ethycolindo ltd. Merak, catalyst
aluminum chloride with 99% pure by Lumbung Sumber Rejeki ltd. Cirebon.
Product is phenyl ethyl alcohol with 99% pure.
Process support units are water utility (cooler water, boiler feed water,
consumptions, sanitation water) necessary is from Cisadane river about 14.086
L/hour, steam utility necessary about 10,176,94 kg/hour, electricity necessary is
from PLN about 277,77 kW, fuel utility is IDO about 6,95 L/hour, and
compressed air is about 63,2 Nm3/jam, refrigerant utilty for heat exchanger and
reactor coil 261,98 kg/hour. There are three laboratoriums, physic laboratorium,
analytic, research and development.
Company type is limited company. Labors are 113 people. Economic
analysis is made which result Return of Investment (ROI) is 19,95% before tax,
14,26% after tax, Pay Out Time (POT) is 3,3 years before tax, 4 years after tax.
Break Event Point (BEP) is 58,01%, Shut Down Point (SDP) is 32,80%, and
Discounted Cash Flow (DCF) is 17,23%. From that results mean PEA plant is
considered to build.
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INTISARI
Irwan Fauzi, Surya Haditya, 2014, Prarancangan Pabrik Phenyl Ethyl
Alcohol dari Benzene dan Ethylene Oxide kapasitas 5.000 ton/tahun, Jurusan
Teknik Kimia, Universitas Sebelas Maret, Surakarta.
Phenyl Ethyl Alcohol (PEA) merupakan cairan tidak berwarna, memiliki
aroma, yang banyak digunakan sebagai salah satu bahan baku parfum untuk
aroma bunga mawar, lili, ilan-ilang, jeruk. Senyawa PEA juga digunakan untuk
bahan desinfektan, bahan pengawet, antibakteri. Pabrik PEA tergolong pabrik
resiko kecil akan didirikan di kawasan industri terpadu Kota Tangerang, Banten
yang akan dibangun pada tahun 2017 kapasitas 5.000 ton/tahun.
Pembuatan PEA dengan cara mereaksikan benzene dan ethylene oxide
melalui reaksi Friedel-Crafts dengan bantuan katalis alumunium klorida pada
suhu di bawah ruangan 100 C dan tekanan 1,01 bar di dalam reaktor batch dengan
kondisi operasi bersifat irreversibel ekotermis non-adiabatis isotermal. Bahan
baku yang dibutuhkan adalah benzene dengan kemurnian 99% b/v dari Pertamina
Cilacap, ethylene oxide dari PT.Prima Ethycolindo kemurnian 97% b/v, dan
katalis Alumunium Klorida yang berasal dari PT. Lumbung Sumber Rejeki,
Cirebon 99% berat. Produk yang dihasilkan berupa Phenyl Ethyl Alcohol dengan
kemurnian mencapai 99% berat dengan impuritas air.
Unit pendukung proses meliputi unit pengadaan air (air pendingin, air
umpan boiler , air konsumsi umum, dan air sanitasi) diperoleh dari air sungai
Cisadane dengan kebutuhan sebesar 14.086 L/jam, unit pengadaan steam dengan
kebutuhan sebesar 10.176,94 kg/jam, unit pengadaan listrik sebesar 277,77 kW
dari PLN, unit pengadaan bahan bakar IDO sebesar 6,94 L/jam, dan unit
pengadaan udara tekan sebesar 63,2 Nm3/jam, unit pengadaan refrigerant untuk
pendingin Heat Exchanger dan koil reaktor digunakan chilled water sebanyak
261,98 kg/jam. Terdapat tiga laboratorium yaitu laboratorium fisik, analitik,
penelitian dan pengembangan.
Bentuk perusahaan yang dipilih adalah Perseroan Terbatas. Jumlah
kebutuhan tenaga kerja sebanyak 113 orang. Hasil analisis ekonomi didapatkan
Return of Investment (ROI) sebesar 19,95% sebelum pajak dan 14,26% sesudah
pajak. Pay Out Time (POT) didapatkan sebesar 3,3 tahun sebelum pajak dan 4
tahun sesudah pajak. Break Event Point (BEP) sebesar 58,01%, Shut Down Point
(SDP) sebesar 32,80%, dan Discounted Cash Flow (DCF) sebesar 17,23%. Dari
hasil analisis ekonomi dapat disimpulkan pabrik PEA layak dipertimbangkan
untuk didirikan.
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TUGAS AKHIR
PRARANCANGAN PABRIK PHENYL ETHYL ALCOHOL
DARI BENZENE DAN ETHYLENE OXIDE
KAPASITAS 5.000 TON/TAHUN
Disusun Oleh:
Irwan Fauzi
I 1507032
Surya Haditya
I 0508117
JURUSAN TEKNIK KIMIA FAKULTAS TEKNIK
UNIVERSITAS SEBELAS MARET
SURAKARTA
2014
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TUGAS AKHIR
PRARANCANGAN PABRIK PHENYL ETHYL ALCOHOL
DARI BENZENE DAN ETHYLENE OXIDE
KAPASITAS 5.000 TON/TAHUN
Disusun Oleh:
Irwan Fauzi
I 1507032
Surya Haditya
I 0508117
JURUSAN TEKNIK KIMIA FAKULTAS TEKNIK
UNIVERSITAS SEBELAS MARET
SURAKARTA
2014
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KATA PENGANTAR
Alhamdulillah puji syukur kepada Allah SWT karena rahmat beserta
hidayahNya, laporan tugas akhir dengan judul “Prarancangan Pabrik Phenyl Ethyl
Alcohol dari Benzene dan Ethylene Oxide kapasitas 5.000 ton/tahun” selesai.
Dalam penyusunan tugas akhir ini, bantuan baik berupa dukungan moral dan
material dari pelbagai pihak turut mendukung penyelesaiannya. Karena itu,
ucapan terima kasih ditujukan kepada kedua orang tua kami yang telah
memberikan kami banyak doa, Dr. Sunu H. Pranolo sebagai dosen pembimbing I
dan Inayati, S.T., M.T., Ph.D sebagai dosen pembimbing II, mba Purna Katamsi
dan mba Rukayah yang telah memberikan dukungan moril, teman-teman di stuba
dan stuta yang tidak bisa disebutkan semua yang telah membantu berbagi ilmu,
informasi, dan pengalaman.
Laporan tugas akhir ini masih jauh dari sempurna, jadi saran dan kritik
membangun sangat diharapkan. Semoga laporan ini dapat bermanfaat.
Surakarta, Desember 2014
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DAFTAR ISI
Halaman Judul ...................................................................................................... i
Lembar Pengesahan ............................................................................................. ii
Kata Pengantar ...................................................................................................... iii
Daftar Isi ............................................................................................................... iv
Daftar Tabel ......................................................................................................... viii
Daftar Gambar ...................................................................................................... xi
Intisari .................................................................................................................. xii
BAB I
PENDAHULUAN ............................................................................. 1
I.1. Latar Belakang Pendirian Pabrik ............................................... 1
I.2. Kapasitas Perancangan ............................................................... 2
I.3. Pemilihan Lokasi Pabrik ............................................................ 5
I.4. Tinjauan Pustaka ........................................................................ 7
I.4.1. Macam-macam Proses Pembuatan PEA ........................... 7
I.4.2. Alasan Pemilihan Proses ................................................... 10
I.4.3. Kegunaan Produk ...............................................................10
I.4.4. Sifat Fisis dan Kimia ........................................................ 10
A. Bahan Baku .................................................................. 10
B. Bahan Pembantu (Katalis) ........................................... 12
C. Produk Utama .............................................................. 13
I.4.5. Tinjauan Proses Secara Umum ..........................................14
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BAB II
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DESKRIPSI PROSES ....................................................................... 16
2.1
2.2
Spesifikasi Bahan Baku dan Produk ........................................ 16
2.1.1
Spesifikasi Bahan Baku ............................................... 16
2.1.2
Spesifikasi Katalis ......................................................... 16
2.1.3
Spesifikasi Produk ........................................................ 17
Konsep Proses .......................................................................... 17
2.2.1
Dasar Reaksi ................................................................ 17
2.2.2 Kondisi Operasi ........................................................... 17
2.2.3 Tinjauan Termodinamika ..............................................18
2.3
Diagram Alir Proses dan Tahapan Proses ............................... 20
2.3.1
Diagram Alir Kualitatif ................................................ 20
2.3.2 Diagram Alir Kuantitatif .............................................. 20
2.3.3 Diagram Alir Proses ..................................................... 20
2.3.4 Penjadwalan Proses .......................................................24
2.3.5
2.4
Langkah Proses ........................................................... 26
Neraca Massa dan Neraca Panas ............................................. 28
2.4.1
Neraca Massa ............................................................... 28
2.4.2 Neraca Panas ................................................................ 31
2.5
Layout Pabrik dan Peralatan Proses ......................................... 34
2.5.1
Layout Pabrik ............................................................... 34
2.5.2 Layout Peralatan Proses ............................................... 40
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BAB III
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SPESIFIKASI ALAT PROSES ........................................................ 41
3.1
Reaktor ..................................................................................... 41
3.2
Mixer ........................................................................................ 42
3.3
Decanter ................................................................................... 43
3.4
Evaporator ................................................................................ 43
3.5
Menara Distilasi ....................................................................... 44
3.6
Silo ........................................................................................... 44
3.7
Bucket elevator ........................................................................ 45
3.8
Belt Conveyor .......................................................................... 45
3.9
Hopper ..................................................................................... 45
3.10 Tangki .......................................................................................46
3.11 Heat Exchanger .........................................................................48
3.12 Pompa........................................................................................50
BAB IV
UNIT PENDUKUNG PROSES DAN LABORATORIUM ............. 52
4.1
Unit Pengadaan Air .................................................................. 53
4.2
Unit Pengadaan Steam dan Bahan Bakar .................................. 55
4.3
Unit Pengadaan Udara Tekan .................................................. 56
4.4
Unit Pengadaan Listrik ............................................................ 56
4.5
Unit Refrigerasi ....................................................................... 59
4.6
Unit Pengolahan Limbah .......................................................... 59
4.7
Laboratorium ........................................................................... 61
4.7.1 Laboratorium Fisik ......................................................... 63
4.7.2 Laboratorium Analitik .................................................... 63
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4.7.3 Laboratorium Penelitian dan Pengembangan ................. 63
BAB V
MANAJEMEN PERUSAHAAN ...................................................... 65
5.1
Bentuk Perusahaan .................................................................. 65
5.2
Struktur Organisasi .................................................................. 66
5.3
Tugas dan Wewenang .............................................................. 68
5.4
Pembagian Jam Kerja dan Gaji Karyawan .............................. 69
5.5
BAB VI
5.4.1
Karyawan Non Shift ..................................................... 71
5.4.2
Karyawan Shift ............................................................. 71
Health and Safety Environment ................................................ 72
5.5.1
Tinjauan Hukum .......................................................... 72
5.5.2
Identifikasi Bahaya ...................................................... 74
ANALISA EKONOMI ..................................................................... 76
6.1
Penaksiran Harga Peralatan ................................................... 76
6.2
Dasar Perhitungan ................................................................. 78
6.3
Penentuan Total Capital Investment (TCI) ........................... 79
6.4
Hasil Perhitungan .................................................................. 80
DAFTAR PUSTAKA .......................................................................................... xiii
LAMPIRAN
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DAFTAR TABEL
Tabel 1.1.
Data Impor PEA di Indonesia ......................................................... 3
Tabel 1.2.
Kapasitas Pabrik PEA di Berbagai Negara ..................................... 5
Tabel 1.3.
Kelebihan dan Kelemahan Proses Pembuatan PEA ........................ 9
Tabel 2.1.
Data Panas Pembentukan ................................................................ 18
Tabel 2.2.
Data Energi Bebas Gibbs ................................................................ 19
Tabel 2.3.
Neraca Massa Reaktor .................................................................... 29
Tabel 2.4.
Neraca Massa Mixer ....................................................................... 29
Tabel 2.5.
Neraca Massa Decanter .................................................................. 29
Tabel 2.6.
Neraca Massa Evaporator ............................................................... 30
Tabel 2.7.
Neraca Massa Menara Distilasi ....................................................... 30
Tabel 2.8.
Neraca Panas Reaktor ...................................................................... 31
Tabel 2.9.
Neraca Panas Mixer ........................................................................ 31
Tabel 2.10. Neraca Panas Decanter ................................................................... 32
Tabel 2.11. Neraca Panas Evaporator ................................................................. 32
Tabel 2.12. Neraca Panas Menara Distilasi ....................................................... 32
Tabel 2.13. Neraca Panas Total ......................................................................... 33
Tabel 3.1.
Spesifikasi Reaktor ......................................................................... 41
Tabel 3.2.
Spesifikasi Mixer ............................................................................ 42
Tabel 3.3.
Spesifikasi Decanter ....................................................................... 43
Tabel 3.4.
Spesifikasi Evaporator .................................................................... 43
Tabel 3.5.
Spesifikasi Menara Distilasi
44
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Tabel 3.6.
Spesifikasi Silo ............................................................................... 44
Tabel 3.7.
Spesifikasi Bucket Elevator ............................................................ 45
Tabel 3.8.
Spesifikasi Belt Conveyor ............................................................... 45
Tabel 3.9.
Spesifikasi Hopper .......................................................................... 45
Tabel 3.10
Spesifikasi Tangki ........................................................................... 46
Tabel 3.11
Spesifikasi Tangki Penampung ....................................................... 47
Tabel 3.12
Spesifikasi Tangki (Lanjutan) ......................................................... 48
Tabel 3.13
Spesifikasi Heat Exchanger ............................................................ 48
Tabel 3.14
Spesifikasi Heat Exchanger (Lanjutan) .......................................... 49
Tabel 3.15
Spesifikasi Heat Exchanger (Lanjutan) .......................................... 50
Tabel 3.16
Spesifikasi Pompa ........................................................................... 50
Tabel 4.1.
Kebutuhan Air Proses ..................................................................... 53
Tabel 4.2.
Kebutuhan Air Pendingin ............................................................... 53
Tabel 4.3.
Kebutuhan Air Umpan Boiler ......................................................... 54
Tabel 4.4.
Kebutuhan Air Konsumsi Umum dan Sanitasi ............................... 54
Tabel 4.5.
Kebutuhan Air Sungai .................................................................... 54
Tabel 4.6.
Spesifikasi Boiler ............................................................................ 56
Tabel 4.7.
Spesifikasi Kompresor .................................................................... 56
Tabel 4.8.
Kebutuhan Listrik Utilitas .............................................................. 57
Tabel 4.9.
Kebutuhan Listrik Proses ................................................................58
Tabel 4.10
Kebutuhan Listrik Total .................................................................. 58
Tabel 4.l1
Spesifikasi Generator ...................................................................... 59
Tabel 5.1.
Perincian Kualifikasi, Jumlah, dan Gaji Karyawan Non Shift ........ 70
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Tabel 5.2.
Perincian Kualifikasi, Jumlah, dan Gaji Karyawan Shift ................ 71
Tabel 5.3.
Jadwal Pembagian Kelompok Shift ................................................ 72
Tabel 5.4.
Material Safety Data Sheet PEA .....................................................74
Tabel 5.5.
Perlengkapan Pencegahan Bahaya ..................................................75
Tabel 6.1.
Indeks Harga Alat ........................................................................... 77
Tabel 6.2.
Fixed Capital Investment ................................................................ 80
Tabel 6.3.
Working Capital Investment ........................................................... 80
Tabel 6.4.
Direct Manufacturing Cost ............................................................. 81
Tabel 6.5.
Indirect Manufacturing Cost .......................................................... 81
Tabel 6.6.
Fixed Manufacturing Cost .............................................................. 81
Tabel 6.7.
General Expense ............................................................................. 82
Tabel 6.8.
Analisa Kelayakan .......................................................................... 86
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DAFTAR GAMBAR
Gambar I.1.
Grafik Impor PEA dari Tahun 2007-2012 .................................... 3
Gambar I.2.
Gambar Pemilihan Lokasi Pabrik ................................................. 5
Gambar 2.1. Diagram Alir Kualitatif ................................................................ 21
Gambar 2.2. Diagram Alir Kuantitatif .............................................................. 22
Gambar 2.3. Diagram Alir Proses ..................................................................... 23
Gambar 2.4. Penjadwalan Alat Pabrik PEA ...................................................... 25
Gambar 2.5. Blok Diagram Alir Proses Pabrik PEA ........................................ 28
Gambar 2.6. Layout Pabrik PEA ....................................................................... 38
Gambar 2.7. Layout Peralatan Proses ................................................................ 39
Gambar 4.1. Skema Pengolahan Air Sungai ..................................................... 55
Gambar 4.2. Diagram Alir Pengolahan Limbah Cair ........................................ 59
Gambar 5.1. Struktur Organisasi Pabrik PEA ................................................... 68
Gambar 5.2. Gambar Identifikasi Bahaya PEA ................................................ 73
Gambar 6.1. Grafik Linierisasi Indeks Harga ................................................... 77
Gambar 6.2. Grafik Analisa Kelayakan ............................................................ 88
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ABSTRACT
Irwan Fauzi, Surya Haditya, 2014, Preeliminary Design Phenyl Ethyl Alcohol
from Benzene and Ethylene Oxide Capacity 5.000 ton/year, Chemical
Engineering Major, Sebelas Maret University.
Phenyl Ethyl Alcohol (PEA) is colorless liquid, good smell, mostly used
for fragrance compund rose like odor, lily, ylang-ylang, orange. PEA compound is
also used for desinfectant, antibacterial agent, etc. PEA plant is classified as low
risk industry that will built on industrial district on 2017 at industrial district at
Tangerang City, Banten with capacity 5.000 ton/year.
PEA is made by reacting benzene liquid and ethylene oxide liquid by
Friedel Crafts methode with adding catalyst Aluminum Chloride in low
temperature 100 C and pressure is about 1,01 bar in the batch reactor with
operation conditions are irreversible isothermal non-adiabatic and exothermis.
Raw materials are benzene liquid with 99% pure by Pertamina ltd. Cilacap,
ethylene oxide liquid with 97% pure by Prima Ethycolindo ltd. Merak, catalyst
aluminum chloride with 99% pure by Lumbung Sumber Rejeki ltd. Cirebon.
Product is phenyl ethyl alcohol with 99% pure.
Process support units are water utility (cooler water, boiler feed water,
consumptions, sanitation water) necessary is from Cisadane river about 14.086
L/hour, steam utility necessary about 10,176,94 kg/hour, electricity necessary is
from PLN about 277,77 kW, fuel utility is IDO about 6,95 L/hour, and
compressed air is about 63,2 Nm3/jam, refrigerant utilty for heat exchanger and
reactor coil 261,98 kg/hour. There are three laboratoriums, physic laboratorium,
analytic, research and development.
Company type is limited company. Labors are 113 people. Economic
analysis is made which result Return of Investment (ROI) is 19,95% before tax,
14,26% after tax, Pay Out Time (POT) is 3,3 years before tax, 4 years after tax.
Break Event Point (BEP) is 58,01%, Shut Down Point (SDP) is 32,80%, and
Discounted Cash Flow (DCF) is 17,23%. From that results mean PEA plant is
considered to build.
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INTISARI
Irwan Fauzi, Surya Haditya, 2014, Prarancangan Pabrik Phenyl Ethyl
Alcohol dari Benzene dan Ethylene Oxide kapasitas 5.000 ton/tahun, Jurusan
Teknik Kimia, Universitas Sebelas Maret, Surakarta.
Phenyl Ethyl Alcohol (PEA) merupakan cairan tidak berwarna, memiliki
aroma, yang banyak digunakan sebagai salah satu bahan baku parfum untuk
aroma bunga mawar, lili, ilan-ilang, jeruk. Senyawa PEA juga digunakan untuk
bahan desinfektan, bahan pengawet, antibakteri. Pabrik PEA tergolong pabrik
resiko kecil akan didirikan di kawasan industri terpadu Kota Tangerang, Banten
yang akan dibangun pada tahun 2017 kapasitas 5.000 ton/tahun.
Pembuatan PEA dengan cara mereaksikan benzene dan ethylene oxide
melalui reaksi Friedel-Crafts dengan bantuan katalis alumunium klorida pada
suhu di bawah ruangan 100 C dan tekanan 1,01 bar di dalam reaktor batch dengan
kondisi operasi bersifat irreversibel ekotermis non-adiabatis isotermal. Bahan
baku yang dibutuhkan adalah benzene dengan kemurnian 99% b/v dari Pertamina
Cilacap, ethylene oxide dari PT.Prima Ethycolindo kemurnian 97% b/v, dan
katalis Alumunium Klorida yang berasal dari PT. Lumbung Sumber Rejeki,
Cirebon 99% berat. Produk yang dihasilkan berupa Phenyl Ethyl Alcohol dengan
kemurnian mencapai 99% berat dengan impuritas air.
Unit pendukung proses meliputi unit pengadaan air (air pendingin, air
umpan boiler , air konsumsi umum, dan air sanitasi) diperoleh dari air sungai
Cisadane dengan kebutuhan sebesar 14.086 L/jam, unit pengadaan steam dengan
kebutuhan sebesar 10.176,94 kg/jam, unit pengadaan listrik sebesar 277,77 kW
dari PLN, unit pengadaan bahan bakar IDO sebesar 6,94 L/jam, dan unit
pengadaan udara tekan sebesar 63,2 Nm3/jam, unit pengadaan refrigerant untuk
pendingin Heat Exchanger dan koil reaktor digunakan chilled water sebanyak
261,98 kg/jam. Terdapat tiga laboratorium yaitu laboratorium fisik, analitik,
penelitian dan pengembangan.
Bentuk perusahaan yang dipilih adalah Perseroan Terbatas. Jumlah
kebutuhan tenaga kerja sebanyak 113 orang. Hasil analisis ekonomi didapatkan
Return of Investment (ROI) sebesar 19,95% sebelum pajak dan 14,26% sesudah
pajak. Pay Out Time (POT) didapatkan sebesar 3,3 tahun sebelum pajak dan 4
tahun sesudah pajak. Break Event Point (BEP) sebesar 58,01%, Shut Down Point
(SDP) sebesar 32,80%, dan Discounted Cash Flow (DCF) sebesar 17,23%. Dari
hasil analisis ekonomi dapat disimpulkan pabrik PEA layak dipertimbangkan
untuk didirikan.
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