PRA RANCANGAN UNIT PROSES PENGURANGAN ASAM NAPTENAT PADA PRODUKSI AVTUR DARI KEROSIN DI
KILANG PERTAMINA UP II DUMAI
Preliminary Design of Naphthenic Acid Reduction Process Unit
in the Production of Avtur from Kerosene at Pertamina Refinery Unit II Dumai
TUGAS AKHIR
OLEH Annisa Syafitri K
NIM. 08414001
Fristy Utami
NIM. 08414012
PROGRAM STUDI DIV TEKNIK KIMIA PRODUKSI BERSIH JURUSAN TEKNIK KIMIA POLITEKNIK NEGERI BANDUNG 2012
PRA RANCANGAN UNIT PROSES PENGURANGAN ASAM NAPTENAT PADA PRODUKSI AVTUR DARI KEROSIN DI
KILANG PERTAMINA UP II DUMAI
Preliminary Design of Naphthenic Acid Reduction Process Unit
in the Production of Avtur from Kerosene at Pertamina Refinery Unit II Dumai
TUGAS AKHIR
Diajukan untuk memenuhi salah satu persyaratan dalam menyelesaikan Program Studi Diploma IV Teknik Kimia Produksi Bersih
OLEH : Annisa Syafitri K Fristy Utami
NIM. 08414001 NIM. 08414012
PROGRAM STUDI DIV TEKNIK KIMIA PRODUKSI BERSIH JURUSAN TEKNIK KIMIA POLITEKNIK NEGERI BANDUNG 2012
KATA PENGANTAR
Tugas akhir pra rancangan pabrik atau unit proses merupakan salah satu persyaratan untuk menyelesaikan program studi D4 Teknik Kimia Produksi Bersih di Politeknik Negeri Bandung. Judul yang diambil dalam tugas akhir perancangan ini yaitu “Pra Rancangan Unit Proses Pengurangan Asam Naptenat pada Produksi Avtur dari Kerosin di Kilang Pertamina UP II Dumai”. Adapun latar belakang dari pemilihan judul tersebut yaitu merupakan tindak lanjut dari penelitian industri yang telah dilakukan pada semester VII di R&D PT.Pertamina. Penelitian industri yang telah dilakukan yaitu mengenai pemilihan proses yang terbaik untuk pengurangan asam naphthenate pada kerosin. Berdasarkan hasil penelitian tersebut diperoleh proses yang terbaik adalah ekstraksi dengan menggunakan NaOH dengan kadar 1 %wt. Hasil penelitian tersebut akan dilakukan scale up ke skala industri yang dilakukan pada tugas akhir perancangan ini. Bahan baku yang diproses pada perancangan unit ini adalah kerosin asam yang dapat diolah menjadi produk avtur (bahan bakar pesawat terbang) yang memiliki nilai komersil lebih. Apabila rancangan unit proses ini dapat diterapkan maka akan memberikan keuntungan bagi perusahaan. Penulis menyadari bahwa pra perancang unit proses ini masih terdapat banyak kekurangan untuk dapat langsung diterapkan pada skala industri. Hal ini dikarenakan untuk melakukan proses scale up dari skala laratorium ke skala industri, pada umumnya terlebih dahulu perlu dilakukan perancangan pada skala pilot. Namun tahapnnya dapat dibaik, yaitu dengan melakukan scale down dari perancagan skala industri yang telah dibuat ke skala pilot untuk mendapatkan hasil perancangan yang lebih akurat. Akhir kata Penulis berharap semoga tugas akhir pra rancangan ini dapat memberikan manfaat bagi pembaca.
Bandung, Juli 2012
Penulis
UCAPAN TERIMAKASIH
Puji dan syukur Penulis panjatkan kehadirat Allah SWT. karena atas rahmat
dan kehendak-Nya Penulis dapat menyelesaikan Tugas Akhir Pra Rancangan Unit Proses Pengurangan Asam Naptenat pada Produksi Avtur dari Kerosin di Kilang
Pertamina UP II Dumai, sesuai dengan waktu yang telah ditentukan.
Dalam
penyusunan
laporan
tugas
akhir
perancangan
ini
Penulis
mendapatkan dukungan dari berbagai pihak. Pada kesempatan ini Penulis ingin mengucapkan terima kasih, kepada : 1. Ir. Herawati Budiastuti, M.Eng.Sc, Ph.D. selaku Dosen Pembimbing I, 2. Dr.Ir. Ahmad Rifandi, M.Sc. Certificate IV in Training and Assessment selaku Koordinator Tugas Akhir Program Studi Teknik Kimia Produksi Bersih dan Pembimbing II, 3. Ir. Ninik Lintang, MT. selaku Ketua Program Studi Teknik Kimia Produksi Bersih, 4. Ir. Dwi Nirwantoro Nur, MT. selaku ketua Jurusan Teknik Kimia Politeknik Negeri Bandung, 5. Seluruh pihak yang telah membantu Penulis. Akhir kata Penulis berharap semoga laporan Tugas Akhir ini dapat bermanfaat bagi Pembaca. Bandung, Juli 2012
Penulis
ABSTRAK
Program konversi bahan bakar dari kerosin menjadi LPG telah mengakibatkan berlebihnya jumlah pasokan kerosin di dalam negeri. Untuk menindaklanjuti hal tersebut, PT.Pertamina berupaya melakukan alih fungsi kerosin dari bahan bakar rumah tangga menjadi bahan bakar pesawat (avtur) yang memiliki nilai komersial lebih tinggi dibandingkan dengan kerosin. Sebagian kerosin yang dihasilkan PT.Pertamina, khususnya yang dihasilkan di kilang UP II Dumai, memiliki kilang nilai keasaman melebihi ambang batas maksimal yang diperbolehkan pada bahan avtur (>0,015 mgKOH/g). Penyebab keasaman pada kerosin ini adalah bakar adanya kandungan senyawa asam naptenat. Asam naptenat ini dapat dihilangkan dengan cara ekstraksi menggunakan larutan NaOH. Pra rancangan ini dibuat untuk mengolah kerosin produk langsung dari unit distilasi minyak mentah di kilang UP II Pertamina Dumai menjadi avtur, dengan cara mengurangi kandungan asam naptenat melalui proses ekstraksi dengan larutan NaOH 1% wt. Unit yang dirancang berkapasitas 19,7 MBSD terdiri atas mixer untuk pembuatan larutan NaOH 1% wt, caustic treatment vessel, sand filter, tangki penampung bahan baku dan produk. Lokasi unit proses direncanakan di area kilang UP II Pertamina Dumai. Kebutuhan utilitas yang diperlukan untuk perancangan unit ini yaitu air sejumlah 5930,0041 ton/tahun dan listrik sejumlah 224,224 MWH /tahun. Berdasarkan hasil analisis kelayakan investasi secara ekonomi diperoleh harga jual avtur sebesar Rp9.500 /Liter. Dengan harga jual ini akan diperoleh nilai Break Event Point (BEP) sebesar 40,03%, Internal Rate of Return (IRR) sebesar 23,53%, Payback Period selama 0,095 tahun, dan Return On Investment (ROI) sebesar 26,13%.
Kata Kunci : Pra rancangan, kerosin, asam naptenat, ekstraksi, avtur.
ABSTRACT
Fuel convertion program from kerosene to LPG has resulted in excessive amount of kerosene in the country. Therefore, PT.Pertamina attempts to perform the conversion of kerosene from household fuel into aircraft fuel (avtur) which has more commercial value. Some of kerosene produced in PT.Pertamina refineries, especially those produced at UP II Dumai refinery, has an acidity number exceeding the maximum limit allowed on avtur fuel (> 0.015 mgKOH/g). The cause of acidity in kerosene is that it contains naphthenic acid compounds. The naphthenic acid compounds can be removed by extraction process using a dilute NaOH solution. This preliminary design was conducted to utilise kerosene derived from Crude Distillation Unit of UP II Dumai to be avtur by reducing the amount of naphthenic acid by extraction process using 1% wt NaOH solution. The unit which was designed to utilise 19.7 MBSD consisted of mixers, caustic treatment vessels, sand fiters, storage tanks of feed and product. The location of the process unit was planned to be in the area of Refinery Unit II Pertamina Dumai. Utility needs for this unit consisted of 5930,0041 ton of water /year and 224,224 MWH of electricity /year. Based on the economic feasibility analysis of investment,it was obtained a selling price of aviation fuel products of Rp9,500/ Litre. This selling price, resulted in Break Event Point (BEP) of 40.03%, Internal Rate of Return (IRR) of 23,53%, Payback Period for 0.095 year, and Return On Investment (ROI) of 26.13%.
Keywords: Preliminary Design, kerosene, naphthenic acid, extraction, avtur.
DAFTAR ISI
HALAMAN JUDUL
HALAMAN PENGESAHAN KATA PENGANTAR .......................................................................................... iii
UCAPAN TERIMAKASIH................................................................................. vi ABSTRAK ..............................................................................................................v
ABSTRACT ........................................................................................................... vi
DAFTAR ISI ........................................................................................................ vii
DAFTAR TABEL ................................................................................................ xi DAFTAR GAMBAR .......................................................................................... xiii DAFTAR LAMPIRAN ........................................................................................xv BAB I PENDAHULUAN .......................................................................................1 1.1 Latar Belakang.........................................................................................1 1.2 Tujuan Tugas Akhir .................................................................................2 1.3 Ruang Lingkup Perancangan ...................................................................2 BAB II DASAR-DASAR PERANCANGAN .......................................................3 2.1 Spesifikasi Bahan Baku dan Produk........................................................3 2.1.1 Bahan Baku.................................................................................... 4 2.1.2 Produk (Avtur) .............................................................................. .6 2.2 Kapasitas Perancangan ............................................................................7 2.3 Rona Lingkungan......................................................................................7 2.4 Standar dan Kode Perancangan Proses .....................................................9 2.4.1 Kode Diagram Perpipaan dan Instrumentasi ................................. 9 2.4.2 Standar Pengujian Spesifikasi Bilangan Asam Avtur (ASTM D 3242) ............................................................................................. 9 2.4.3 Standar Satuan (SI atau Sistem Satuan Internasional)................. 10 2.5 Deskripsi Proses Kerosene Treatment Unit ...........................................11 2.6 Teknologi Bersih ...................................................................................14 2.6.1 Pemanfaatan Sodium Naphthenate .............................................. 14
2.6.2 Pengolahan Sisa Larutan Caustic pada Caustic Treatment Vessel
..................................................................................................... 15
BAB III KAJIAN PUSTAKA .............................................................................16 3.1 Penghilangan Naphthenic Acid dari Kerosin Menggunakan Metode
Caustic Wash .........................................................................................16
3.1.1 Sistem
Napfining,
Mericati,
Aquafining
dari
Merichem
Technology. ................................................................................. 16
3.1.2 Unit Treating Jet Fuel ..................................................................18
3.2 Ekstraksi Cair-Cair ................................................................................22
3.2.1 Kesetimbangan Fasa untuk Ekstraksi Cair-Cair ...........................23 3.2.2 Faktor yang Mempengaruhi Ekstraksi Cair-Cair..........................24 3.2.3 Neraca Massa ................................................................................24 3.2.4 Ekstraksi Kesetimbangan Satu Tahap ..........................................24 3.3 Filtrasi ....................................................................................................26 3.3.1 Jenis Filter.....................................................................................27 3.3.2 Jenis Media Filter .........................................................................27 3.3.3 Media Filter dan Distribusi Pasir ..................................................27 3.3.4 Hidrolika Filtrasi...........................................................................28 3.3.5 Hidrolika Pencucian dengan Aliran ke Atas (Backwashing)........28 3.3.6 Pencucian Filter ............................................................................29 3.4 Tangki Pencampuran .............................................................................30 3.4.1 Bagian-Bagian Alat Pencampur ...................................................30 3.4.2 Daya Pengadukan .........................................................................33 3.5 Kolom Isian ...........................................................................................34 3.6 Tangki Penampung ................................................................................40 3.7 Bucket Elevator......................................................................................41 3.8 Liquid-liquid Coalescer .........................................................................42 3.8.1 Prinsip Kerja Coalescer ................................................................43 3.8.2 Jenis-jenis Media Coalescer .........................................................44 3.9 Pompa ....................................................................................................45 3.9.1 Pompa Sentrifugal ........................................................................45
3.9.2 Klasifikasi Pompa Sentrifugal ......................................................46
3.9.3 Bagian-bagian Pompa Sentrifugal ................................................47
3.9.4 Kapasitas Pompa...........................................................................49
3.9.5 Head Pompa .................................................................................49
BAB IV NERACA MASSA .................................................................................50 4.1 Neraca Massa Caustic Treatment Vessel (V-01/02/03).........................50
4.2 Neraca Massa Sand Filter (C-01/02) .....................................................51
4.3 Neraca Massa Mixer (M-01/02) ............................................................52
V PERANCANGAN ALAT DAN DIAGRAM ALIR PROSES .............53 BAB
5.1 Perancangan Alat ...................................................................................53 5.1.1 Caustic Treatment Vessel (V-01/02/03) .......................................53 5.1.2 Sand Filter (C-01/02) ...................................................................55 5.1.3 Mixer (M-01/02) ...........................................................................57 5.1.4 Tangki Bahan Baku (T-01) ...........................................................59 5.1.5 Tangki Produk (T-02 A/B) ...........................................................61 5.1.6 Perpipaan ......................................................................................63 5.1.7 Pompa Kerosin (P-01 A/B)...........................................................64 5.1.8 Pompa NaOH (P-02 A/B) .............................................................64 5.1.9 Pompa Produk (P-03 A/B) ............................................................64 5.1.10 Bucket Elevator...........................................................................65 5.1.11 Gudang NaOH ............................................................................65 5.2 Diagram Alir Proses ..............................................................................66 BAB VI UTILITAS .............................................................................................67 6.1 Kebutuhan Utilitas .................................................................................67 6.1.1 Kebutuhan Air ..............................................................................67 6.1.2 Kebutuhan Listrik .........................................................................68 6.2 Sumber Utilitas ......................................................................................69 6.2.1 Air .................................................................................................69 6.2.2 Listrik............................................................................................72 BAB VII TATA LETAK KEROSENE TREATMENT UNIT ..........................73 7.1 Lokasi Unit Proses ..................................................................................73
7.2 Tata Letak Unit Proses............................................................................74 BAB VIII STRUKTUR ORGANISASI DAN TATA KERJA ........................76
8.1 Struktur Kepegawaian Pws.Jaga Kerosene Treatment Unit ...................79
8.2 Peraturan Kerja .......................................................................................79
8.2.1 Jam Kerja Karyawan ....................................................................79
8.2.2 Jumlah Karyawan dan Penggajian ................................................80 BAB IX ANALISIS EKONOMI ........................................................................81
9.1 Biaya Investasi .......................................................................................81
9.2 Biaya Produksi .......................................................................................82
9.3 Keuntungan (Profit) ...............................................................................83 9.4 Analisa Kelayakan .................................................................................84 9.4.1 Break Event Point (BEP) ..............................................................84 9.4.2 Internal Rate of Return (IRR) .......................................................84 9.4.3 Pay Back Period ...........................................................................84 9.4.4 Return On Investment (ROI).........................................................84 DAFTAR PUSTAKA LAMPIRAN A NERACA MASSA LAMPIRAN B PERANCANGAN ALAT LAMPIRAN C ANALISIS EKONOMI LAMPIRAN D LEMBAR KEGIATAN BIMBINGAN TUGAS AKHIR LAMPIRAN E FORM PERBAIKAN SEMINAR TUGAS AKHIR
DAFTAR TABEL
2.1 Spesifikasi Kerosin Keluaran Unit CDU Kilang Dumai ........................ 4 Tabel
Tabel 2.2 Sifat Fisik Naphtenic Acid ...................................................................... 5
Tabel 2.3 Spesifikasi Kristal NaOH ........................................................................ 5 Tabel 2.4 Spesifikasi Larutan NaOH 1%wt ............................................................ 5
Tabel 2.5 Spesifikasi Produk Avtur ........................................................................ 6 Tabel 2.6 Kode Huruf untuk Simbol Instrumentasi ................................................ 9
Tabel 2.7 Jenis Produk Naphthenic Acid dan Penggunaannya ............................. 15 Tabel 3.1 Karakteristik Naphthenic Caustic / Spent Caustic ................................ 18 Tabel 3.2 Spesifikasi Umpan Jet Fuel .................................................................. 20 Tabel 3.3 Karakteristik Random Packing 1 .......................................................... 36 Tabel 3.4 Karakteristik Random Packing 2 .......................................................... 37 Tabel 3.5 Karakteristik Random Packing 3 .......................................................... 38 Tabel 3.6 Karakteristik Random Packing 4 .......................................................... 39 Tabel 3.7 Sumber Dispersi Emulsi dan Karakteristiknya ..................................... 43 Tabel 3.8 Pemilihan Jenis Media Coalescer ......................................................... 44 Tabel 3.9 Klasifikasi Pompa Sentrifugal .............................................................. 46 Tabel 3.10 Fungsi Bagian-Bagian Pompa Sentrifugal .......................................... 47 Tabel 4.1 Neraca Massa Pada Caustic Treatment Vessel ..................................... 51 Tabel 4.2 Neraca Massa Pada Sand Filter. ........................................................... 51 Tabel 4.3 Neraca Massa Pada Mixer ..................................................................... 52 Tabel 5.1 Spesifikasi Caustic Treatment Vessel (V-01/02/03) ............................. 53 Tabel 5.2 Spesifikasi Sand Filter (C-01/02) ......................................................... 55 Tabel 5.3 Spesifikasi Mixer (M-01/02) ................................................................. 57 Tabel 5.4 Spesifikasi Tangki Bahan Baku (T-01) ................................................. 59 Tabel 5.5 Spesifikasi Tangki Produk (T-02 A/B) ................................................. 61 Tabel 5.6 Spesifikasi Perpipaan ............................................................................ 63 Tabel 5.7 Spesifikasi Pompa Kerosin (P-01 A/B) ................................................ 64 Tabel 5.8 Spesifikasi Pompa NaOH (P-02 A/B) ................................................... 64
Tabel 5.9 Spesifikasi Pompa Produk (P-03A/B)................................................... 64 Tabel 5.10 Spesifikasi Bucket Elevator ................................................................ 65
Tabel 5.11 Spesifikasi Gudang NaOH .................................................................. 65 6.1 Rekapitulasi Kebutuhan Utilitas Kerosene Treatment Unit. ................. 67 Tabel
Tabel 6.2 Kebutuhan Listrik Kerosene Treatment Unit. ...................................... 68 Tabel 8.1 Jadwal Shift Kerosene Treatment Unit Selama Seminggu................... 80 Tabel 8.2 Rencana Penggaji Karyawan Kerosene Treatment Unit.. .................... 80
Tabel 9.1 Biaya Investasi.. ................................................................................... 82 9.2 Biaya Produksi.. ................................................................................... 83 Tabel
DAFTAR GAMBAR
Gambar 2.1 Struktur Kimia Naphtenic Acid ........................................................... 4
Gambar 2.2 Diagram Alir Sederhana UP II Dumai ................................................ 7
Gambar 2.3 Peta Lokasi Pertamina UP II Dumai ................................................... 8 Gambar 2.4 Diagram Alir UOP Extraction Merox Process ................................. 11 Gambar 3.1 Diagram Alir Sistem Napfining ........................................................ 16
Gambar 3.2 Vessel Fiber Film Contactor ............................................................. 17 Gambar 3.3 Diagram Alir Proses Unit Treating Jet Fuel ..................................... 19 Gambar 3.4 Kurva Antara Rasio Bilangan Asam dan Waktu Reaksi ................... 21 Gambar 3.5 Diagram Kesetimbangan untuk Sistem dengan Solvent Tidak Saling Larut Uranium nitrat- tributil-fospat-air................................................................ 23 Gambar 3.6 (a) Aliran Proses (b) Penambahan Secara Garafis dan Hukum Panjang Lengan ....................................................................................................................25 Gambar 3.7 Diagram Alir Ekstraksi Tahap Tunggal ............................................ 26 Gambar 3.8 Kondisi Filter Saat Terjadi Penyumbatan ......................................... 29 Gambar 3.9 Dimensi Tangki ................................................................................. 30 Gambar 3.10 Macam-Macam Impeller ................................................................. 32 Gambar 3.11 Pola Aliran Pengadukan .................................................................. 33 Gambar 3.12 Kurva Perbandingan Kebutuhan Daya Impeller ............................. 34 Gambar 3.13 Jenis-Jenis Random Packing ........................................................... 35 Gambar 3.14 Dome Roof Tank .............................................................................. 40 Gambar 3.15 Floating Roof Tank ......................................................................... 41 Gambar 3.16 Bucket Elevator ............................................................................... 42 Gambar 3.17 Cara Kerja Coalescer ...................................................................... 44 Gambar 3.18 Konfigurasi Coalescer pada Kolom Ekstraksi Vertikal .................. 45 Gambar 3.19 Bagian-Bagian Pompa Sentrifugal .................................................. 47 Gambar 5.1 Caustic Treatment Vessel (V-01/02/03) ............................................ 54 Gambar 5.2 Sand Filter (C-01/02) ........................................................................ 56
Gambar 5.3 Mixer (M-01/02) ............................................................................... 58 Gambar 5.4 Tangki Bahan Baku (T-01) ............................................................... 60
Gambar 5.5 Tangki Produk (T-02 A/B) ................................................................ 62 Gambar 6.1 Diagram Alir Sungai Rokan dan Water Treatment Plant ................. 70
Gambar 7.1 Letak UP II Dumai ............................................................................ 74 Gambar 7.2 Tata Letak Kerosene Treatment Unit ................................................ 75 Gambar 8.1 Struktur Organisasi UP II Dumai ...................................................... 77
Gambar 8.2 Struktur Organisasi Bagian HSC....................................................... 78 Gambar 8.3 Rencana Struktur Organisasi Bagian HSC ........................................ 78
DAFTAR LAMPIRAN
LAMPIRAN A PERHITUNGAN NERACA MASSA ................................. LA-1
A.1 Caustic Treatment Vessel (V-01/02/03) ..................................................... LA-1 A.2 Sand Filter (C-01/02) ................................................................................. LA-9 A.3 Mixer (M-01/02) ....................................................................................... LA-12 LAMPIRAN B PERHITUNGAN SPESIFIKASI PERALATAN .............. LB-1
B.1 Caustic Treatment Vessel (V-01/02/03) ..................................................... LB-1
B.2 Sand Filter (C-01/02) ............................................................................... LB-11 B.3 Mixer (M-01/02) ....................................................................................... LB-15 B.4 Tangki Bahan Baku (T-01)....................................................................... LB-20 B.5 Tangki Produk (T-02 A/B) ....................................................................... LB-24 B.6 Perpipaan .................................................................................................. LB-28 B.7 Pompa Kerosin (P-01 A/B) ...................................................................... LB-37 B.8 Pompa NaOH (P-02 A/B)......................................................................... LB-41 B.9 Pompa Produk (P-03 A/B) ....................................................................... LB-45 B.10 Bucket Elevator ...................................................................................... LB-48 B.11 Gudang NaOH ........................................................................................ LB-50 LAMPIRAN C PERHITUNGAN ANALISIS EKONOMI ......................... LC-1 C.1 Biaya Investasi ........................................................................................... LC-2 C.1.1 Fixed Capital Investment................................................................. LC -2 C.1.2 Working Capital .............................................................................. LC -7 C.2 Biaya Produksi ......................................................................................... LC-10 C.2.1 Biaya Manufaktur (Manufacturing Cost) ....................................... LC-10 C.2.2 Biaya Umum (General Expanses) .................................................. LC-13 C.3 Keuntungan (Profit) ................................................................................. LC-15 C.3.1 Keuntungan Sebelum Pajak............................................................ LC-15 C.3.2 Keuntungan Setelah Pajak .............................................................. LC-15 C.4 Analisa Kelayakan ................................................................................... LC-15 C.4.1 Break Event Point (BEP) ................................................................ LC-16
C.4.2 Internal Rate of Return (IRR) ........................................................ LC-20
C.4.3 Pay Back Period ............................................................................. LC-23
C.4.4 Return On Investment (ROI) .......................................................... LC-23
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