TUGAS AKHIR HALAMAN JUDUL Prarancangan Pabrik Maleic Anhydride Dari LPG Dan Udara Kapasitas 25.000 Ton/Tahun.
TUGAS AKHIR
HALAMAN JUDUL
PRARANCANGAN PABRIK MALEIC ANHYDRIDE
DARI LPG DAN UDARA
KAPASITAS 25.000 TON/TAHUN
Diajukan untuk
Memenuhi Persyaratan Meraih Gelar Sarjana Teknik Strata-1
pada Program Studi Teknik Kimia Fakultas Teknik
Universitas Muhammadiyah Surakarta
Oleh :
Aulia Firda Alfiana
D 500 100 040
Dosen Pembimbing :
Ir.Herry Purnama, M.T., Ph.D.
Rois Fatoni, S.T., M.Sc., Ph.D.
PROGRAM STUDI TEKNIK KIMIA FAKULTAS TEKNIK
UNIVERSITAS MUHAMMADIYAH SURAKARTA
2014
i
ii
UNIYERSITAS MUHAMMADIYAH SURAKARTA
FAKULTAS TEKNIK
Jl. A. Yani Tromol Pos I Pabelan Kartasura Telp (0271) 717417
Surakarta-57102
PtrRNYATAAN KEASLIAN TUGAS AKI{IR
Saya yang bertanda tangan
di bawah ini
:
Nama
Aulia Firda Alfiana
NTM
D500 r00040
Program Studi
Teknik Kimia
Judul Tugas Akhir
Prarancangan Pabrik Maleic Anhydride dari LPG dan Udara
Kapasitas 25.000 ton/ tahun
Menyatakan dengan sebenarnya bahwa Tugas Akhir yang saya buat dan serahkan ini
merupakan hasil karya saya sendiri, kecuali kutipan-kutipan dan ringkasan-ringkasan yang
semuanya telah saya jelaskan sumbernya. Apabila dikemudian hari terbukti dan atau dapat
dibuktikan bahwa Tugas Akhir hasiljiplakan, maka saya bersedia menerima sanksi apapun
dari Fakultas Teknik atau gelar dan ijazah yang diberikan oleh Universitas Muhammadiyah
Surakarta batal saya terima.
Surakarta, l5 Oktober 2014
Yang membuat pernyataan,
su"$
(Aulia Firda Alfiana)
INTISARI
Maleic anhydride dibuat dengan cara mereaksikan LPG dan udara pada
suhu 400oC dan tekanan diatas atmosferis (2 atm) di dalam reaktor fixed bed
multitube yang berisi katalis vanadium phosphorus oxide (VPO), reaksi yang
terjadi merupakan reaksi eksotermis dan non adiabatis. Kondisi operasi produk
keluaran reaktor 396,99 oC dan tekanan 1,76 atm. Hasil samping dari reaksi
tersebut adalah karbonmonoksida dan karbondioksiada.
Pabrik maleic anhydride dengan bahan baku n-butana dan udara dengan
kapasitas 25.000 ton per tahun direncanakan beroperasi selama 24 jam per hari
dan 330 hari per tahun. Kebutuhan LPG untuk pabrik ini sebanyak 2.825,7339
kg/jam. Produk yang dihasilkan berupa maleic anhydride sebanyak 3.156,5657
kg/jam. Utilitas pendukung proses meliputi penyediaan air sebesar 10.647,9570
kg/jam yang diperoleh dari air sungai Mahakam, penyediaan saturated steam
sebesar 14.016,9072 kg/jam yang diperoleh dari boiler. Kebutuhan bahan bakar
solar baik untuk generator, boiler dan furnace sebesar 1.244,2761 kg/jam,
kebutuhan udara tekan sebesar 2.884 kg/jam, kebutuhan listrik diperoleh dari PLN
dan generator sebesar 1.444,8834 kW. Pabrik ini direncanakan berdiri di kawasan
Bontang, Kalimantan Timur dengan luas tanah 13.956 m2 dan jumlah karyawan
sebanyak 116 orang.
Pabrik maleic anhydride direncanakan mulai dikonstruksi pada tahun
2020. Pabrik ini menggunakan modal tetap sebesar Rp 258.928.743.648 dan
modal kerja sebesar Rp. 158.950.398.667. Dari analisis ekonomi terhadap pabrik
ini menunjukkan keuntungan sebelum pajak Rp 114.312.503.805 per tahun
setelah dipotong pajak 25 % keuntungan mencapai Rp 85.734.377.853. Percent
Return On Investment (ROI) sebelum pajak 44,12% dan setelah pajak 33,09%.
Pay Out Time (POT) sebelum pajak 1,85 tahun dan setelah pajak 2,32 tahun.
Break Even Point (BEP) sebesar 41,56%, dan Shut Down Point (SDP) sebesar
21,86 % dan Discounted Cash Flow (DCF) terhitung sebesar 42,80%. Dari data
analisis kelayakan di atas disimpulkan, bahwa pabrik maleic anhydride dari nbutana dan udara dengan kapasitas 25.000 ton/tahun ini menguntungkan dan
layak untuk didirikan.
iii
KATA PENGANTAR
Assalamu’alaikum Wr. Wb.
Puji syukur penulis panjatkan kepada Allah SWT atas limpahan rahmat,
taufik dan hidayah-Nya sehingga penulis dapat menyelesaikan Tugas Akhir
dengan judul “Prarancangan Pabrik Maleic Anhydride dari LPG dan Udara
Kapasitas 25.000 Ton/Tahun”.
Tugas Prarancangan Pabrik merupakan salah satu syarat yang wajib
ditempuh untuk menyelesaikan program strata 1 di Jurusan Teknik Kimia,
Fakultas Teknik, Universitas Muhammadiyah Surakarta.
Pada kesempatan ini, penulis ingin mengucapkan terima kasih kepada
pihak-pihak yang telah memberikan dukungan, bimbingan, dan bantuan hingga
terselesaikannya laporan tugas akhir ini. Melalui laporan ini penyusun ingin
mengucapkan terima kasih yang tiada terhingga, terutama kepada:
1.
Rois Fatoni, S.T., M.Sc., Ph.D., selaku Ketua Program Studi Teknik Kimia,
Universitas Muhammadiyah Surakarta.
2.
Eni Budiyati, S.T., M.Eng., selaku koordinator tugas akhir.
3.
Ir. Herry Purnama, M.T., Ph.D., sebagai dosen pembimbing utama yang
telah memberikan bimbingan dan arahan dalam penulisan tugas akhir ini.
4.
Rois Fatoni, S.T., M.Sc., Ph.D., sebagai dosen pembimbing kedua yang turut
serta memberikan bimbingan dan arahan dalam penulisan tugas akhir ini
5.
Seluruh dosen dan staf Teknik Kimia Universitas Muhammadiyah Surakarta.
6.
Semua pihak yang telah membantu dan menyelesaikan tugas akhir ini.
Penulis menyadari bahwa dalam penulisan tugas akhir ini masih jauh
dari kata sempurna dan tidak menutup kemungkinan membutuhkan saran dan
kritik yang bersifat membangun. Penulis berharap semoga tugas akhir ini dapat
memberikan manfaat yang berarti bagi pembaca dan semua pihak yang
membutuhkan.
Wassalamu’alaikum Wr. Wb.
Surakarta,
September 2014
Penulis
iv
Daftar Isi
Halaman Judul ......................................................................................................... i
Halaman Pengesahan ............................................................................................. ii
Intisari ................................................................................................................... iii
Kata Pengantar ...................................................................................................... iv
Daftar Isi.................................................................................................................. v
Daftar Tabel .......................................................................................................... xi
Daftar Gambar .................................................................................................... xiii
BAB I ..................................................................................................................... 1
PENDAHULUAN .................................................................................................. 1
1.1. Latar Belakang............................................................................................. 1
1.2. Kapasitas Pabrik ......................................................................................... 2
1.2.1. Prediksi Kebutuhan Maleic Anhydride di Indonesia ........................ 2
1.2.2. Ketersedian Bahan Baku................................................................... 3
1.2.3. Kapasitas Minimum Pabrik .............................................................. 3
1.3. Penentuan Lokasi Pabrik ............................................................................ 4
1.4. Tinjauan Pustaka ........................................................................................ 6
1.4.1. Macam-macam Proses ..................................................................... 6
1.4.2. Kegunaan produk ............................................................................. 7
1.4.3. Sifat Fisik dan Kimia ....................................................................... 8
1.4.4. Tinjauan Pustaka............................................................................. 12
BAB II .................................................................................................................. 14
DESKRIPSI PROSES ......................................................................................... 14
2.1 Spesifikasi Bahan Baku dan Produk........................................................... 14
2.1.1 Spesifikasi Bahan ............................................................................ 14
2.1.2 Spesifikasi Produk ........................................................................... 14
2.2 Konsep Reaksi ........................................................................................... 15
2.2.1 Dasar Reaksi.................................................................................... 15
2.2.2 Mekanisme Reaksi .......................................................................... 15
2.2.3 Kondisi Operasi ............................................................................... 16
2.4.4 Langkah Proses ............................................................................... 16
v
2.3 Sifat Reaksi ................................................................................................ 18
2.3.1 Tinjauan Termodinamika Reaksi .................................................... 18
2.3.2 Tinjauan Kinetika Reaksi ................................................................ 20
2.4 Diagram Alir Proses .................................................................................. 21
2.5 Neraca Massa dan Neraca Panas ............................................................... 24
2.5.1 Neraca Massa .................................................................................. 24
2.5.2 Neraca Panas ................................................................................... 33
2.6 Tata Letak Pabrik dan Peralatan ........................................................ 43
2.6.1 Tata Letak Pabrik ............................................................................ 43
2.6.2 Tata Letak Peralatan ........................................................................ 47
BAB III ................................................................................................................. 50
SPESIFIKASI ALAT ........................................................................................... 50
3.1 Absorber-01 ............................................................................................... 50
3.2 Absorber-02 ............................................................................................... 50
3.3 Akumulator ................................................................................................ 51
3.4 Chiller-01 .................................................................................................. 51
3.5 Chiller-02 .................................................................................................. 52
3.6 Condenser-01 ............................................................................................ 53
3.7 Condenser-02 ............................................................................................ 54
3.8 Cooler-01 ................................................................................................... 55
3.9 Cooler-02 ................................................................................................... 55
3.10 Cooler-03 ................................................................................................. 56
3.11 Expander-01 ............................................................................................ 57
3.12 Expander-02 ............................................................................................ 58
3.13 Furnace ................................................................................................... 58
3.14 Kompresor-01 ......................................................................................... 59
3.15 Kompresor-02 ......................................................................................... 59
3.16 Pompa-01 ................................................................................................ 60
3.17 Pompa-02 ................................................................................................ 60
3.18 Pompa-03 ................................................................................................ 61
3.19 Pompa-04 ................................................................................................ 61
vi
3.20 Pompa-05 ................................................................................................. 62
3.21 Pompa-06 ................................................................................................. 62
3.22 Pompa-07 ................................................................................................. 63
3.23 Reaktor .................................................................................................... 63
3.24 Reboiler-01 .............................................................................................. 64
3.25 Reboiler-02 .............................................................................................. 65
3.26 Separator-01 ............................................................................................ 65
3.27 Separator-02 ............................................................................................ 66
3.28 Stripper-01 ............................................................................................... 67
3.29 Stripper-02 ............................................................................................... 67
3.30 Tangki Penyimpanan Bahan Baku LPG .................................................. 68
3.31 Tangki Penyimpanan Dibutyl Phthalate ................................................. 68
3.32 Tangki Penyimpanan Produk Maleic Anhydride .................................... 69
BAB IV ................................................................................................................ 71
UNIT PENDUKUNG PROSES DAN LABORATORIUM ................................ 71
4.1 Unit Pendukung Proses ............................................................................. 71
4.1.1 Unit penyedia dan pengolahan air ................................................... 71
4.1.2 Unit pengadaan steam ..................................................................... 78
4.1.3 Unit pengadaan tenaga listrik .......................................................... 78
4.1.4 Unit pengadaan bahan bakar ........................................................... 81
4.1.5 Unit pengadaan udara tekan ............................................................ 81
4.1.6 Unit pengolahan limbah .................................................................. 81
4.1.7 Unit pengadaan pendingin dowtherm A .......................................... 82
4.2 Laboratoium .............................................................................................. 82
4.2.1 Program kerja laboratorium ............................................................ 83
4.2.2 Alat-alat utama laboratorium .......................................................... 84
4.3 Spesifikasi Alat-alat Utilitas ...................................................................... 84
4.3.1 Screen .............................................................................................. 84
4.3.2 Bak Pengendapan Awal .................................................................. 85
4.3.3 Bak Penggumpalan........................................................................... 85
4.3.4 Clarifier ........................................................................................... 86
vii
4.3.5 Bak Saringan Pasir .......................................................................... 86
4.3.6 Carbon Filter ................................................................................... 86
4.3.7 Tangki Penampung Sementara ........................................................ 87
4.3.8 Bak Penampung Air Pendingin ....................................................... 87
4.3.9 Tangki Penampung Air Bersih ........................................................ 87
4.3.10 Tangki Penampung Umpan Boiler ................................................ 88
4.3.11 Tangki Klorin ................................................................................ 88
4.3.12 Tangki NaCl .................................................................................. 88
4.3.13 Tangki NaOH ................................................................................ 89
4.3.14 Tangki Na2SO4 ............................................................................. 89
4.3.15 Kation Exchanger........................................................................... 89
4.3.16 Anion Exchanger ........................................................................... 90
4.3.17 Deaerator ...................................................................................... 90
4.3.18 Boiler ............................................................................................. 90
4.3.19 Pompa (PU-01) .............................................................................. 90
4.3.20 Pompa (PU-02) .............................................................................. 91
4.3.21 Pompa (PU-03) .............................................................................. 91
4.3.22 Pompa (PU-04) .............................................................................. 91
4.3.23 Pompa (PU-05) .............................................................................. 92
4.3.24 Pompa (PU-06) .............................................................................. 92
4.3.25 Pompa (PU-07) .............................................................................. 92
4.3.26 Pompa (PU-08) .............................................................................. 92
4.3.27 Pompa (PU-09) .............................................................................. 93
4.3.28 Pompa (PU-10) .............................................................................. 93
4.3.29 Pompa (PU-11) .............................................................................. 93
4.3.30 Pompa (PU-12) .............................................................................. 94
4.3.31 Pompa (PU-13) .............................................................................. 94
4.3.32 Pompa (PU-14) .............................................................................. 94
4.3.33 Cooling Tower ............................................................................... 95
4.3.34 Generator ....................................................................................... 95
BAB V .................................................................................................................. 97
viii
MANAJEMEN PERUSAHAAN ......................................................................... 97
5.1 Bentuk Perusahaan .................................................................................... 97
5.2 Struktur Organisasi .................................................................................... 98
5.3 Tugas dan Wewenang .............................................................................. 100
5.3.1 Pemegang Saham .......................................................................... 100
5.3.2 Dewan Komisaris .......................................................................... 100
5.3.3 Direktur Utama.............................................................................. 100
5.3.4 Staf Ahli ........................................................................................ 101
5.3.5 Kepala Bagian ............................................................................... 101
5.3.6 Kepala Seksi .................................................................................. 104
5.4 Pembagian Jam Kerja Karyawan.............................................................. 104
5.4.1 Karyawan non-shift ....................................................................... 104
5.4.2 Karyawan shift .............................................................................. 104
5.5 Penggolongan Jabatan, Jumlah Karyawan dan Gaji ................................ 105
5.5.1 Penggolongan Jabatan ................................................................... 105
5.5.2 Jumlah Karyawan dan Gaji ........................................................... 106
5.6 Kesejahteraan Karyawan ......................................................................... 107
5.6.1 Tunjangan ...................................................................................... 107
5.6.2 Cuti ................................................................................................ 108
5.6.3 Pakaian Kerja ................................................................................ 108
5.6.4 Pengobatan .................................................................................... 108
5.6.5 Badan Penyelenggara Jaminan Sosial (BPJS) Kesehatan ............ 108
5.7 Keselamatan dan Kesehatan Kerja .......................................................... 108
5.8 Manajemen Produksi ............................................................................... 108
5.8.1 Perencanaan Produksi ................................................................... 109
5.8.2 Pengendalian Produksi .................................................................. 110
BAB VI .............................................................................................................. 112
ANALISIS EKONOMI ...................................................................................... 112
6.1 Modal (Capital Investment) ..................................................................... 113
6.2 Biaya Produksi (Manufacturing Cost) .................................................... 113
6.3 Pengeluaran Umum (General Expense) .................................................. 113
ix
6.4 Analisa kelayakan .................................................................................... 114
6.5 Dasar Perhitungan ................................................................................... 116
6.6 Perhitungan Ekonomi Teknik .................................................................. 119
BAB VII ............................................................................................................. 124
KESIMPULAN .................................................................................................. 124
DAFTAR PUSTAKA ........................................................................................ 125
Lampiran Perhitungan Alat ................................................................................ 127
x
Daftar Tabel
Tabel 1.1 Data ekspor dan impor maleic anhydride di Indonesia........................... 2
Tabel 1.2 Pabrik maleic anhydride dengan bahan baku n-butana ......................... 4
Tabel 1.3 Sifat fisis udara........................................................................................ 9
Tabel 2.1 Neraca massa disekitar arus recycle...................................................... 25
Tabel 2.2 Neraca massa disekitar arus pertemuan umpan ................................... 25
Tabel 2.3 Neraca massa di reaktor ....................................................................... 26
Tabel 2.4 Neraca massa di arus recycle absorben ................................................ 26
Tabel 2.5 Neraca massa di absorber ..................................................................... 27
Tabel 2.6 Neraca massa di separator 01 ............................................................... 28
Tabel 2.7 Neraca massa di separator 02 ............................................................... 29
Tabel 2.8 Neraca massa di absorber-02 ............................................................... 29
Tabel 2.9 Neraca massa di arus pertemuan umpan stripper 01 ........................... 30
Tabel 2.10 Neraca massa di stripper 01 ............................................................... 30
Tabel 2.11 Neraca massa di stripper 02 ............................................................... 31
Tabel 2.12 Neraca massa total ............................................................................. 32
Tabel 2.13 Neraca panas umpan LPG .................................................................. 33
Tabel 2.14 Neraca panas di expander 01 ............................................................. 34
Tabel 2.15 Neraca panas di kompresor 01 ........................................................... 34
Tabel 2.16 Neraca panas di arus pertemuan umpan LPG dan udara ................... 34
Tabel 2.17 Neraca panas di furnace ..................................................................... 35
Tabel 2.18 Neraca panas di reaktor ...................................................................... 35
Tabel 2.19 Neraca panas di expander 02 ............................................................. 36
Tabel 2.20 Neraca panas di cooler 01 .................................................................. 37
Tabel 2.21 Neraca panas di cooler 02 .................................................................. 37
Tabel 2.22 Neraca panas di absorber ................................................................... 38
Tabel 2.23 Neraca panas di arus pertemuan absorbent ........................................ 38
Tabel 2.24 Neraca panas di chiller 01 .................................................................. 39
Tabel 2.25 Neraca panas di chiller 02 .................................................................. 40
Tabel 2.26 Neraca panas di separator 01 ............................................................. 41
Tabel 2.27 Neraca panas di separator 02 ............................................................. 41
xi
Tabel 2.28 Neraca panas di kompresor 02 ........................................................... 42
Tabel 2.29 Neraca panas di cooler 03 .................................................................. 42
Tabel 2.30 Neraca panas di arus pertemuan umpan stripper ............................... 42
Tabel 2.31 Neraca panas di stripper 01 ............................................................... 43
Tabel 2.32 Neraca panas di stripper 02 ............................................................... 43
Tabel 2.33 Perincian luas tanah dan bangunan pabrik ......................................... 46
Tabel 4.1 Kebutuhan air pendingin ...................................................................... 77
Tabel 4.2 Kebutuhan air sanitasi .......................................................................... 77
Tabel 4.3 Kebutuhan air umpan boiler ................................................................ 78
Tabel 4.4 Kebutuhan listrik pada alat proses ....................................................... 79
Tabel 4.5 Kebutuhan listrik untuk alat utilitas ..................................................... 80
Tabel 5.1 Pembagian kerja tiap-tiap shift .......................................................... 105
Tabel 5.2 Jumlah karyawan dan gaji .................................................................. 107
Tabel 6.1 Index harga ......................................................................................... 116
Tabel 6.2 Fixed Capital Investment ................................................................... 119
Tabel 6.3 Working Capital Investment................................................................ 119
Tabel 6.4 Manufacturing Cost ........................................................................... 120
Tabel 6.5 General Expense ................................................................................ 121
Tabel 6.6 Fixed Cost .......................................................................................... 121
Tabel 6.7 Variable cost ...................................................................................... 121
Tabel 6.8 Regulated cost .................................................................................... 122
xii
Daftar Gambar
Gambar 1.1 Grafik kebutuhan ekspor dan impor maleic anhydride di Indonesia . 3
Gambar 2.1 Diagram alir kuantitatif .................................................................... 22
Gambar 2.2 Diagram alir kualitatif ...................................................................... 23
Gambar 2.3 Diagram alir neraca massa ............................................................... 24
Gambar 2.4 Diagram alir neraca panas ................................................................ 33
Gambar 2.5 Tata letak pabrik ............................................................................... 47
Gambar 2.6 Tata letak peralatam proses .............................................................. 49
Gambar 4.1 Diagram alir pengolahan air ............................................................. 96
Gambar 5.1 Struktur oganisasi perusahaan ........................................................ 111
Gambar 6.1 Index harga ..................................................................................... 117
Gambar 6.2 Analisis ekonomi ............................................................................ 123
xiii
HALAMAN JUDUL
PRARANCANGAN PABRIK MALEIC ANHYDRIDE
DARI LPG DAN UDARA
KAPASITAS 25.000 TON/TAHUN
Diajukan untuk
Memenuhi Persyaratan Meraih Gelar Sarjana Teknik Strata-1
pada Program Studi Teknik Kimia Fakultas Teknik
Universitas Muhammadiyah Surakarta
Oleh :
Aulia Firda Alfiana
D 500 100 040
Dosen Pembimbing :
Ir.Herry Purnama, M.T., Ph.D.
Rois Fatoni, S.T., M.Sc., Ph.D.
PROGRAM STUDI TEKNIK KIMIA FAKULTAS TEKNIK
UNIVERSITAS MUHAMMADIYAH SURAKARTA
2014
i
ii
UNIYERSITAS MUHAMMADIYAH SURAKARTA
FAKULTAS TEKNIK
Jl. A. Yani Tromol Pos I Pabelan Kartasura Telp (0271) 717417
Surakarta-57102
PtrRNYATAAN KEASLIAN TUGAS AKI{IR
Saya yang bertanda tangan
di bawah ini
:
Nama
Aulia Firda Alfiana
NTM
D500 r00040
Program Studi
Teknik Kimia
Judul Tugas Akhir
Prarancangan Pabrik Maleic Anhydride dari LPG dan Udara
Kapasitas 25.000 ton/ tahun
Menyatakan dengan sebenarnya bahwa Tugas Akhir yang saya buat dan serahkan ini
merupakan hasil karya saya sendiri, kecuali kutipan-kutipan dan ringkasan-ringkasan yang
semuanya telah saya jelaskan sumbernya. Apabila dikemudian hari terbukti dan atau dapat
dibuktikan bahwa Tugas Akhir hasiljiplakan, maka saya bersedia menerima sanksi apapun
dari Fakultas Teknik atau gelar dan ijazah yang diberikan oleh Universitas Muhammadiyah
Surakarta batal saya terima.
Surakarta, l5 Oktober 2014
Yang membuat pernyataan,
su"$
(Aulia Firda Alfiana)
INTISARI
Maleic anhydride dibuat dengan cara mereaksikan LPG dan udara pada
suhu 400oC dan tekanan diatas atmosferis (2 atm) di dalam reaktor fixed bed
multitube yang berisi katalis vanadium phosphorus oxide (VPO), reaksi yang
terjadi merupakan reaksi eksotermis dan non adiabatis. Kondisi operasi produk
keluaran reaktor 396,99 oC dan tekanan 1,76 atm. Hasil samping dari reaksi
tersebut adalah karbonmonoksida dan karbondioksiada.
Pabrik maleic anhydride dengan bahan baku n-butana dan udara dengan
kapasitas 25.000 ton per tahun direncanakan beroperasi selama 24 jam per hari
dan 330 hari per tahun. Kebutuhan LPG untuk pabrik ini sebanyak 2.825,7339
kg/jam. Produk yang dihasilkan berupa maleic anhydride sebanyak 3.156,5657
kg/jam. Utilitas pendukung proses meliputi penyediaan air sebesar 10.647,9570
kg/jam yang diperoleh dari air sungai Mahakam, penyediaan saturated steam
sebesar 14.016,9072 kg/jam yang diperoleh dari boiler. Kebutuhan bahan bakar
solar baik untuk generator, boiler dan furnace sebesar 1.244,2761 kg/jam,
kebutuhan udara tekan sebesar 2.884 kg/jam, kebutuhan listrik diperoleh dari PLN
dan generator sebesar 1.444,8834 kW. Pabrik ini direncanakan berdiri di kawasan
Bontang, Kalimantan Timur dengan luas tanah 13.956 m2 dan jumlah karyawan
sebanyak 116 orang.
Pabrik maleic anhydride direncanakan mulai dikonstruksi pada tahun
2020. Pabrik ini menggunakan modal tetap sebesar Rp 258.928.743.648 dan
modal kerja sebesar Rp. 158.950.398.667. Dari analisis ekonomi terhadap pabrik
ini menunjukkan keuntungan sebelum pajak Rp 114.312.503.805 per tahun
setelah dipotong pajak 25 % keuntungan mencapai Rp 85.734.377.853. Percent
Return On Investment (ROI) sebelum pajak 44,12% dan setelah pajak 33,09%.
Pay Out Time (POT) sebelum pajak 1,85 tahun dan setelah pajak 2,32 tahun.
Break Even Point (BEP) sebesar 41,56%, dan Shut Down Point (SDP) sebesar
21,86 % dan Discounted Cash Flow (DCF) terhitung sebesar 42,80%. Dari data
analisis kelayakan di atas disimpulkan, bahwa pabrik maleic anhydride dari nbutana dan udara dengan kapasitas 25.000 ton/tahun ini menguntungkan dan
layak untuk didirikan.
iii
KATA PENGANTAR
Assalamu’alaikum Wr. Wb.
Puji syukur penulis panjatkan kepada Allah SWT atas limpahan rahmat,
taufik dan hidayah-Nya sehingga penulis dapat menyelesaikan Tugas Akhir
dengan judul “Prarancangan Pabrik Maleic Anhydride dari LPG dan Udara
Kapasitas 25.000 Ton/Tahun”.
Tugas Prarancangan Pabrik merupakan salah satu syarat yang wajib
ditempuh untuk menyelesaikan program strata 1 di Jurusan Teknik Kimia,
Fakultas Teknik, Universitas Muhammadiyah Surakarta.
Pada kesempatan ini, penulis ingin mengucapkan terima kasih kepada
pihak-pihak yang telah memberikan dukungan, bimbingan, dan bantuan hingga
terselesaikannya laporan tugas akhir ini. Melalui laporan ini penyusun ingin
mengucapkan terima kasih yang tiada terhingga, terutama kepada:
1.
Rois Fatoni, S.T., M.Sc., Ph.D., selaku Ketua Program Studi Teknik Kimia,
Universitas Muhammadiyah Surakarta.
2.
Eni Budiyati, S.T., M.Eng., selaku koordinator tugas akhir.
3.
Ir. Herry Purnama, M.T., Ph.D., sebagai dosen pembimbing utama yang
telah memberikan bimbingan dan arahan dalam penulisan tugas akhir ini.
4.
Rois Fatoni, S.T., M.Sc., Ph.D., sebagai dosen pembimbing kedua yang turut
serta memberikan bimbingan dan arahan dalam penulisan tugas akhir ini
5.
Seluruh dosen dan staf Teknik Kimia Universitas Muhammadiyah Surakarta.
6.
Semua pihak yang telah membantu dan menyelesaikan tugas akhir ini.
Penulis menyadari bahwa dalam penulisan tugas akhir ini masih jauh
dari kata sempurna dan tidak menutup kemungkinan membutuhkan saran dan
kritik yang bersifat membangun. Penulis berharap semoga tugas akhir ini dapat
memberikan manfaat yang berarti bagi pembaca dan semua pihak yang
membutuhkan.
Wassalamu’alaikum Wr. Wb.
Surakarta,
September 2014
Penulis
iv
Daftar Isi
Halaman Judul ......................................................................................................... i
Halaman Pengesahan ............................................................................................. ii
Intisari ................................................................................................................... iii
Kata Pengantar ...................................................................................................... iv
Daftar Isi.................................................................................................................. v
Daftar Tabel .......................................................................................................... xi
Daftar Gambar .................................................................................................... xiii
BAB I ..................................................................................................................... 1
PENDAHULUAN .................................................................................................. 1
1.1. Latar Belakang............................................................................................. 1
1.2. Kapasitas Pabrik ......................................................................................... 2
1.2.1. Prediksi Kebutuhan Maleic Anhydride di Indonesia ........................ 2
1.2.2. Ketersedian Bahan Baku................................................................... 3
1.2.3. Kapasitas Minimum Pabrik .............................................................. 3
1.3. Penentuan Lokasi Pabrik ............................................................................ 4
1.4. Tinjauan Pustaka ........................................................................................ 6
1.4.1. Macam-macam Proses ..................................................................... 6
1.4.2. Kegunaan produk ............................................................................. 7
1.4.3. Sifat Fisik dan Kimia ....................................................................... 8
1.4.4. Tinjauan Pustaka............................................................................. 12
BAB II .................................................................................................................. 14
DESKRIPSI PROSES ......................................................................................... 14
2.1 Spesifikasi Bahan Baku dan Produk........................................................... 14
2.1.1 Spesifikasi Bahan ............................................................................ 14
2.1.2 Spesifikasi Produk ........................................................................... 14
2.2 Konsep Reaksi ........................................................................................... 15
2.2.1 Dasar Reaksi.................................................................................... 15
2.2.2 Mekanisme Reaksi .......................................................................... 15
2.2.3 Kondisi Operasi ............................................................................... 16
2.4.4 Langkah Proses ............................................................................... 16
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2.3 Sifat Reaksi ................................................................................................ 18
2.3.1 Tinjauan Termodinamika Reaksi .................................................... 18
2.3.2 Tinjauan Kinetika Reaksi ................................................................ 20
2.4 Diagram Alir Proses .................................................................................. 21
2.5 Neraca Massa dan Neraca Panas ............................................................... 24
2.5.1 Neraca Massa .................................................................................. 24
2.5.2 Neraca Panas ................................................................................... 33
2.6 Tata Letak Pabrik dan Peralatan ........................................................ 43
2.6.1 Tata Letak Pabrik ............................................................................ 43
2.6.2 Tata Letak Peralatan ........................................................................ 47
BAB III ................................................................................................................. 50
SPESIFIKASI ALAT ........................................................................................... 50
3.1 Absorber-01 ............................................................................................... 50
3.2 Absorber-02 ............................................................................................... 50
3.3 Akumulator ................................................................................................ 51
3.4 Chiller-01 .................................................................................................. 51
3.5 Chiller-02 .................................................................................................. 52
3.6 Condenser-01 ............................................................................................ 53
3.7 Condenser-02 ............................................................................................ 54
3.8 Cooler-01 ................................................................................................... 55
3.9 Cooler-02 ................................................................................................... 55
3.10 Cooler-03 ................................................................................................. 56
3.11 Expander-01 ............................................................................................ 57
3.12 Expander-02 ............................................................................................ 58
3.13 Furnace ................................................................................................... 58
3.14 Kompresor-01 ......................................................................................... 59
3.15 Kompresor-02 ......................................................................................... 59
3.16 Pompa-01 ................................................................................................ 60
3.17 Pompa-02 ................................................................................................ 60
3.18 Pompa-03 ................................................................................................ 61
3.19 Pompa-04 ................................................................................................ 61
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3.20 Pompa-05 ................................................................................................. 62
3.21 Pompa-06 ................................................................................................. 62
3.22 Pompa-07 ................................................................................................. 63
3.23 Reaktor .................................................................................................... 63
3.24 Reboiler-01 .............................................................................................. 64
3.25 Reboiler-02 .............................................................................................. 65
3.26 Separator-01 ............................................................................................ 65
3.27 Separator-02 ............................................................................................ 66
3.28 Stripper-01 ............................................................................................... 67
3.29 Stripper-02 ............................................................................................... 67
3.30 Tangki Penyimpanan Bahan Baku LPG .................................................. 68
3.31 Tangki Penyimpanan Dibutyl Phthalate ................................................. 68
3.32 Tangki Penyimpanan Produk Maleic Anhydride .................................... 69
BAB IV ................................................................................................................ 71
UNIT PENDUKUNG PROSES DAN LABORATORIUM ................................ 71
4.1 Unit Pendukung Proses ............................................................................. 71
4.1.1 Unit penyedia dan pengolahan air ................................................... 71
4.1.2 Unit pengadaan steam ..................................................................... 78
4.1.3 Unit pengadaan tenaga listrik .......................................................... 78
4.1.4 Unit pengadaan bahan bakar ........................................................... 81
4.1.5 Unit pengadaan udara tekan ............................................................ 81
4.1.6 Unit pengolahan limbah .................................................................. 81
4.1.7 Unit pengadaan pendingin dowtherm A .......................................... 82
4.2 Laboratoium .............................................................................................. 82
4.2.1 Program kerja laboratorium ............................................................ 83
4.2.2 Alat-alat utama laboratorium .......................................................... 84
4.3 Spesifikasi Alat-alat Utilitas ...................................................................... 84
4.3.1 Screen .............................................................................................. 84
4.3.2 Bak Pengendapan Awal .................................................................. 85
4.3.3 Bak Penggumpalan........................................................................... 85
4.3.4 Clarifier ........................................................................................... 86
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4.3.5 Bak Saringan Pasir .......................................................................... 86
4.3.6 Carbon Filter ................................................................................... 86
4.3.7 Tangki Penampung Sementara ........................................................ 87
4.3.8 Bak Penampung Air Pendingin ....................................................... 87
4.3.9 Tangki Penampung Air Bersih ........................................................ 87
4.3.10 Tangki Penampung Umpan Boiler ................................................ 88
4.3.11 Tangki Klorin ................................................................................ 88
4.3.12 Tangki NaCl .................................................................................. 88
4.3.13 Tangki NaOH ................................................................................ 89
4.3.14 Tangki Na2SO4 ............................................................................. 89
4.3.15 Kation Exchanger........................................................................... 89
4.3.16 Anion Exchanger ........................................................................... 90
4.3.17 Deaerator ...................................................................................... 90
4.3.18 Boiler ............................................................................................. 90
4.3.19 Pompa (PU-01) .............................................................................. 90
4.3.20 Pompa (PU-02) .............................................................................. 91
4.3.21 Pompa (PU-03) .............................................................................. 91
4.3.22 Pompa (PU-04) .............................................................................. 91
4.3.23 Pompa (PU-05) .............................................................................. 92
4.3.24 Pompa (PU-06) .............................................................................. 92
4.3.25 Pompa (PU-07) .............................................................................. 92
4.3.26 Pompa (PU-08) .............................................................................. 92
4.3.27 Pompa (PU-09) .............................................................................. 93
4.3.28 Pompa (PU-10) .............................................................................. 93
4.3.29 Pompa (PU-11) .............................................................................. 93
4.3.30 Pompa (PU-12) .............................................................................. 94
4.3.31 Pompa (PU-13) .............................................................................. 94
4.3.32 Pompa (PU-14) .............................................................................. 94
4.3.33 Cooling Tower ............................................................................... 95
4.3.34 Generator ....................................................................................... 95
BAB V .................................................................................................................. 97
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MANAJEMEN PERUSAHAAN ......................................................................... 97
5.1 Bentuk Perusahaan .................................................................................... 97
5.2 Struktur Organisasi .................................................................................... 98
5.3 Tugas dan Wewenang .............................................................................. 100
5.3.1 Pemegang Saham .......................................................................... 100
5.3.2 Dewan Komisaris .......................................................................... 100
5.3.3 Direktur Utama.............................................................................. 100
5.3.4 Staf Ahli ........................................................................................ 101
5.3.5 Kepala Bagian ............................................................................... 101
5.3.6 Kepala Seksi .................................................................................. 104
5.4 Pembagian Jam Kerja Karyawan.............................................................. 104
5.4.1 Karyawan non-shift ....................................................................... 104
5.4.2 Karyawan shift .............................................................................. 104
5.5 Penggolongan Jabatan, Jumlah Karyawan dan Gaji ................................ 105
5.5.1 Penggolongan Jabatan ................................................................... 105
5.5.2 Jumlah Karyawan dan Gaji ........................................................... 106
5.6 Kesejahteraan Karyawan ......................................................................... 107
5.6.1 Tunjangan ...................................................................................... 107
5.6.2 Cuti ................................................................................................ 108
5.6.3 Pakaian Kerja ................................................................................ 108
5.6.4 Pengobatan .................................................................................... 108
5.6.5 Badan Penyelenggara Jaminan Sosial (BPJS) Kesehatan ............ 108
5.7 Keselamatan dan Kesehatan Kerja .......................................................... 108
5.8 Manajemen Produksi ............................................................................... 108
5.8.1 Perencanaan Produksi ................................................................... 109
5.8.2 Pengendalian Produksi .................................................................. 110
BAB VI .............................................................................................................. 112
ANALISIS EKONOMI ...................................................................................... 112
6.1 Modal (Capital Investment) ..................................................................... 113
6.2 Biaya Produksi (Manufacturing Cost) .................................................... 113
6.3 Pengeluaran Umum (General Expense) .................................................. 113
ix
6.4 Analisa kelayakan .................................................................................... 114
6.5 Dasar Perhitungan ................................................................................... 116
6.6 Perhitungan Ekonomi Teknik .................................................................. 119
BAB VII ............................................................................................................. 124
KESIMPULAN .................................................................................................. 124
DAFTAR PUSTAKA ........................................................................................ 125
Lampiran Perhitungan Alat ................................................................................ 127
x
Daftar Tabel
Tabel 1.1 Data ekspor dan impor maleic anhydride di Indonesia........................... 2
Tabel 1.2 Pabrik maleic anhydride dengan bahan baku n-butana ......................... 4
Tabel 1.3 Sifat fisis udara........................................................................................ 9
Tabel 2.1 Neraca massa disekitar arus recycle...................................................... 25
Tabel 2.2 Neraca massa disekitar arus pertemuan umpan ................................... 25
Tabel 2.3 Neraca massa di reaktor ....................................................................... 26
Tabel 2.4 Neraca massa di arus recycle absorben ................................................ 26
Tabel 2.5 Neraca massa di absorber ..................................................................... 27
Tabel 2.6 Neraca massa di separator 01 ............................................................... 28
Tabel 2.7 Neraca massa di separator 02 ............................................................... 29
Tabel 2.8 Neraca massa di absorber-02 ............................................................... 29
Tabel 2.9 Neraca massa di arus pertemuan umpan stripper 01 ........................... 30
Tabel 2.10 Neraca massa di stripper 01 ............................................................... 30
Tabel 2.11 Neraca massa di stripper 02 ............................................................... 31
Tabel 2.12 Neraca massa total ............................................................................. 32
Tabel 2.13 Neraca panas umpan LPG .................................................................. 33
Tabel 2.14 Neraca panas di expander 01 ............................................................. 34
Tabel 2.15 Neraca panas di kompresor 01 ........................................................... 34
Tabel 2.16 Neraca panas di arus pertemuan umpan LPG dan udara ................... 34
Tabel 2.17 Neraca panas di furnace ..................................................................... 35
Tabel 2.18 Neraca panas di reaktor ...................................................................... 35
Tabel 2.19 Neraca panas di expander 02 ............................................................. 36
Tabel 2.20 Neraca panas di cooler 01 .................................................................. 37
Tabel 2.21 Neraca panas di cooler 02 .................................................................. 37
Tabel 2.22 Neraca panas di absorber ................................................................... 38
Tabel 2.23 Neraca panas di arus pertemuan absorbent ........................................ 38
Tabel 2.24 Neraca panas di chiller 01 .................................................................. 39
Tabel 2.25 Neraca panas di chiller 02 .................................................................. 40
Tabel 2.26 Neraca panas di separator 01 ............................................................. 41
Tabel 2.27 Neraca panas di separator 02 ............................................................. 41
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Tabel 2.28 Neraca panas di kompresor 02 ........................................................... 42
Tabel 2.29 Neraca panas di cooler 03 .................................................................. 42
Tabel 2.30 Neraca panas di arus pertemuan umpan stripper ............................... 42
Tabel 2.31 Neraca panas di stripper 01 ............................................................... 43
Tabel 2.32 Neraca panas di stripper 02 ............................................................... 43
Tabel 2.33 Perincian luas tanah dan bangunan pabrik ......................................... 46
Tabel 4.1 Kebutuhan air pendingin ...................................................................... 77
Tabel 4.2 Kebutuhan air sanitasi .......................................................................... 77
Tabel 4.3 Kebutuhan air umpan boiler ................................................................ 78
Tabel 4.4 Kebutuhan listrik pada alat proses ....................................................... 79
Tabel 4.5 Kebutuhan listrik untuk alat utilitas ..................................................... 80
Tabel 5.1 Pembagian kerja tiap-tiap shift .......................................................... 105
Tabel 5.2 Jumlah karyawan dan gaji .................................................................. 107
Tabel 6.1 Index harga ......................................................................................... 116
Tabel 6.2 Fixed Capital Investment ................................................................... 119
Tabel 6.3 Working Capital Investment................................................................ 119
Tabel 6.4 Manufacturing Cost ........................................................................... 120
Tabel 6.5 General Expense ................................................................................ 121
Tabel 6.6 Fixed Cost .......................................................................................... 121
Tabel 6.7 Variable cost ...................................................................................... 121
Tabel 6.8 Regulated cost .................................................................................... 122
xii
Daftar Gambar
Gambar 1.1 Grafik kebutuhan ekspor dan impor maleic anhydride di Indonesia . 3
Gambar 2.1 Diagram alir kuantitatif .................................................................... 22
Gambar 2.2 Diagram alir kualitatif ...................................................................... 23
Gambar 2.3 Diagram alir neraca massa ............................................................... 24
Gambar 2.4 Diagram alir neraca panas ................................................................ 33
Gambar 2.5 Tata letak pabrik ............................................................................... 47
Gambar 2.6 Tata letak peralatam proses .............................................................. 49
Gambar 4.1 Diagram alir pengolahan air ............................................................. 96
Gambar 5.1 Struktur oganisasi perusahaan ........................................................ 111
Gambar 6.1 Index harga ..................................................................................... 117
Gambar 6.2 Analisis ekonomi ............................................................................ 123
xiii