PRARANCANGAN PABRIK ASETALDEHIDA DENGAN PROSES DEHIDROGENASI ETANOL MENGGUNAKAN KATALIS TEMBAGA DAN KROM KAPASITAS 22.000 TON/TAHUN
Preliminary Design of Acetaldehyde Plant by Ethanol Dehydrogenation Process Using Copper and Chromium Catalyst Capacity of 22.000 Ton/Year
TUGAS AKHIR
Oleh : DINI INDRIYANI ILMA AMALIA
NIM : 08414004 NIM : 08414015
POLBAN
PROGRAM STUDI D-IV TEKNIK KIMIA PRODUKSI BERSIH JURUSAN TEKNIK KIMIA POLITEKNIK NEGERI BANDUNG 2012
CURRICULUM VITAE
Nama
: Dini Indriyani
NIM
: 08414004
Tempat, Tanggal Lahir
: Garut, 03 Desember 1989
Alamat
: Jl. Samarang Kp. Ciroyom RT/RW 001/004 Ds. Cintarakyat
Kec. Samarang, Kab. Garut
Email
Pendidikan
:
[email protected]
:
Tahun 1996 - 2002 2002 - 2005 2005 - 2008 2008 - 2012
Sekolah SDN Mekarwangi II SMPN 2 Garut SMAN 15 Garut Politeknik Negeri Bandung
Jurusan IPA Teknik Kimia
Nama
: Ilma Amalia
NIM
: 08414015
Tempat, Tanggal Lahir
: Bandung, 8 April 1990
Alamat
: Jl. Karta Atmaja No. 69 A /118 Bandung
Email Pendidikan
:
Tahun 1996 - 2002 2002 - 2005 2005 - 2008 2008 - 2012
:
[email protected]
Sekolah SDN Cigondewah 02 SMPN 4 Cimahi SMA Pasundan 3 Bandung Politeknik Negeri Bandung
Jurusan IPA Teknik Kimia
KATA PENGANTAR
Puji Syukur kehadirat Allah SWT yang telah melimpahkan rahmat, taufik dan
hidayah-Nya sehingga penulis akhirnya dapat menyelesaikan penyusunan laporan akhir dengan judul “Prarancangan Pabrik Asetaldehida dengan Proses tugas
Dehidrogenasi Etanol Menggunakan Katalis Tembaga dan Krom Kapasitas 22.000 ton/tahun”. Laporan tugas akhir ini disusun sebagai persyaratan untuk memperoleh
gelar Sarjana Sains Terapan di Jurusan Teknik Kimia Program Studi Teknik Kimia
Produksi Bersih Politeknik Negeri Bandung.
Dalam penyusunan tugas akhir ini penulis memperoleh banyak bantuan baik
berupa dukungan moral maupun spiritual dari berbagai pihak. Oleh karena itu penulis mengucapkan terima kasih kepada : 1. Bapak Rispiandi, ST, MT., selaku pembimbing I yang telah bersedia meluangkan waktu untuk memberikan bimbingan, arahan, dan motivasi dalam penyusunan tugas akhir, 2. Ibu Dianty Rosirda D.K, ST, MT., selaku pembimbing II yang telah bersedia meluangkan waktu untuk memberikan bimbingan, arahan, dan motivasi dalam penyusunan tugas akhir, 3. Bapak Ir. Ahmad Rifandi, M.Sc selaku Koordinator Tugas Akhir Teknik Kimia Produksi Bersih 2008, 4. Ibu Ir. Ninik Lintang, M.Sc, selaku Ketua Program Studi Teknik Kimia Produksi Bersih Politeknik Negeri Bandung, 5. Bapak Ir. Dwi Nirwantoro, MT., selaku Ketua Jurusan Teknik Kimia Politeknik Negri Bandung, 6. Serta semua pihak yang tidak dapat penulis sebutkan satu persatu yang telah membantu atas terselesainya laporan tugas akhir ini. Penulis menyadari bahwa laporan tugas akhir ini masih jauh dari sempurna. Oleh karena itu penulis membuka diri terhadap segala saran dan kritik yang membangun. Semoga laporan tugas akhir ini dapat bermanfaat bagi penulis pada khususnya dan pembaca pada umumnya. Bandung, Juli 2012
Penulis i
DAFTAR ISI
Halaman HALAMAN JUDUL KATA PENGANTAR ............................................................................................. i ABSTRAK .............................................................................................................. ii ABSTRACT ............................................................................................................. iii DAFTAR ISI .......................................................................................................... iv DAFTAR TABEL ................................................................................................. vii DAFTAR GAMBAR ............................................................................................. ix DAFTAR LAMPIRAN ............................................................................................x I PENDAHULUAN BAB 1.1 Latar Belakang Pendirian Pabrik ............................................................1 1.2 Kapasitas Perancangan ............................................................................2 1.3 Pemilihan Lokasi Pabrik ........................................................................3 1.4 GPM (Gross Profit Margin) ...................................................................4 BAB II DASAR PERANCANGAN 2.1 Spesifikasi Bahan Baku dan Produk ......................................................5 2.1.1 Spesifikasi Bahan Baku................................................................5 2.1.2 Spesifikasi Produk ........................................................................5 2.1.3 Spesifikasi Katalis ........................................................................5 2.2 Konsep Proses ........................................................................................6 2.2.1 Dasar Reaksi.................................................................................6 2.2.2 Mekanisme Reaksi .......................................................................6 2.2.3 Kondisi Operasi............................................................................7 2.3 Lokasi Pabrik .........................................................................................9 2.4 Rona Lingkungan .................................................................................10 BAB III TINJAUAN PUSTAKA 3.1 Proses Produksi Asetaldehida ..............................................................11 3.2 Proses Dehidrogenasi Etanol................................................................13 3.2.1 Persiapan Bahan Baku ................................................................14 3.2.2 Reaksi Dehidrogenasi Etanol .....................................................14 3.2.3 Pemisahan dan Pemurnian Etanol Sisa ......................................15 3.3 Sifat Fisik dan Kimia Bahan Baku dan Produk ...................................16 3.3.1 Bahan Baku ................................................................................16 3.3.2 Produk ........................................................................................17 BAB IV NERACA MASSA DAN NERACA ENERGI 4.1 Neraca Massa .......................................................................................19 4.1.1 Holding Tank ..............................................................................19 4.1.2 Reaktor ........................................................................................19 4.1.3 Absorber ......................................................................................20 4.1.4 Kolom Distlasi I ..........................................................................20 4.1.4 Kolom Distilasi II........................................................................20 4.2. Neraca Panas .......................................................................................21 4.2.1 Holding Tank .............................................................................21
iv
4.2.2 Vaporizer ....................................................................................21 4.2.3 Furnace ......................................................................................21 4.2.4 Reaktor .......................................................................................21 4.2.5 Waste Heat Boiler ......................................................................22 4.2.6 Cooler-01 ...................................................................................22 4.2.7 Cooler-02 ...................................................................................22 4.2.8 Absorber .....................................................................................22 4.2.9 Kolom Distilasi I ........................................................................23 4.3.0 Kolom Distilasi II.......................................................................23 BAB V SPESIFIKASI PERALATAN 5.1 Reaktor ...............................................................................................24 5.2 Absorber ...............................................................................................25 5.3 Kolom Distilasi ....................................................................................26 5.4 Alat Penukar Panas ..............................................................................28 5.5 Furnace ................................................................................................36 5.6 Accumulator ........................................................................................37 5.7 Tangki Penyimpanan ............................................................................39 5.8 Pompa...................................................................................................41 BAB VI UTILITAS 6.1 Unit Penyediaan Listrik ......................................................................44 6.2.1 Pengolahan Secara Fisika ...........................................................48 6.2.2 Pengolahan Secara Kimia ..........................................................48 6.2.3 Pengolahan Secara Internal ........................................................49 6.3 Unit Penyediaan Bahan Bakar ............................................................50 6.4 Unit Penyediaan Steam ........................................................................50 6.5 Limbah Proses ......................................................................................51 BAB VII TATA LETAK PABRIK DAN PERALATAN 7.1 Tata Letak Pabrik ...............................................................................52 7.2 Tata Letak Peralatan Proses .................................................................53 BAB VIII STRUKTUR ORGANISASI DAN TATA KERJA 8.1 Bentuk Perusahaan ...............................................................................56 8.2 Struktur Organisasi ..............................................................................57 8.3 Tugas dan Wewenang ..........................................................................59 8.3.1 Pemegang Saham .......................................................................59 8.3.2 Dewan Komisaris .......................................................................60 8.3.3 Direktur Utama ..........................................................................60 8.3.4 Staf Ahli .....................................................................................61 8.3.5 Kepala Bagian ............................................................................61 8.4 Pembagian Jam Kerja Karyawan ........................................................66 8.4.1 Karywan Non-Shift ....................................................................66 8.4.2 Karywan Shift ............................................................................66 8.5 Status Karyawan ..................................................................................68 8.6 Penggolongan Jabatan, Jumlah Karyawan dan Gaji ............................68 8.6.1 Penggolongan Jabatan ................................................................68 8.6.2 Jumlah Karyawan dan Gaji ........................................................69 8.7 Kesejahteraan Sosial Karyawan ...........................................................70
v
8.8 Manajemen Produksi ...........................................................................71 8.8.1 Perencanaan Produksi ................................................................72 8.8.2 Pengendalian Produksi ...............................................................73 BAB IX ANALISA EKONOMI 9.1 Penafsiran Harga Alat ..........................................................................76 9.2 Dasar perhitungan ................................................................................78 9.3 Perhitungan Biaya ................................................................................78 9.3.1 Total Capital Investment ............................................................78 9.3.2 Total Production Cost ...............................................................80 9.3.3 Keuntungan (Profit) ...................................................................82 9.3.4 Analisa Kelayakan ....................................................................83 BAB X KESIMPULAN .........................................................................................88 DAFTAR PUSTAKA LAMPIRAN
vi
DAFTAR TABEL
Halaman
Tabel 1.1 Data Pabrik Penghasil Asetaldehida Di Dunia .......................................... 2 Tabel 1.2 Data Impor Asetaldehida di Indonesia ....................................................... 2 Tabel 4.1 Neraca Massa di Holding Tank ............................................................... 19 Tabel 4.2 Neraca Massa di Reaktor ........................................................................ 19 Tabel 4.3 Neraca Massa di Absorber ....................................................................... 20 4.4 Neraca Massa di Kolom Distilasi I .......................................................... 20 Tabel Tabel 4.5 Neraca Massa di Kolom Distilasi II ......................................................... 20 Tabel 4.6 Neraca Panas di Holding Tank ................................................................. 21 Tabel 4.7 Neraca Panas di Vaporizer ....................................................................... 21 Tabel 4.8 Neraca Panas di Furnace ......................................................................... 21 Tabel 4.9 Neraca Panas di Reaktor .......................................................................... 21 Tabel 4.10 Neraca Panas di WHB............................................................................ 22 Tabel 4.11 Neraca Panas di Cooler-01 .................................................................... 22 Tabel 4.12 Neraca Panas di Cooler-02 .................................................................... 22 Tabel 4.13 Neraca Panas di Absorber ...................................................................... 22 Tabel 4.14 Neraca Panas di Kolom Distilasi I ......................................................... 23 Tabel 4.15 Neraca Panas di Kolom Distilasi II ........................................................ 23 Tabel 5.1 Spesifikasi dan Skema Alat Reaktor ........................................................ 22 Tabel 5.2 Spesifikasi dan Skema Alat Absorber...................................................... 25 Tabel 5.3 Spesifikasi dan Skema Alat Kolom Distilasi I ......................................... 26 Tabel 5.4 Spesifikasi dan Skema Alat Kolom Distilasi II ....................................... 27 Tabel 5.5 Spesifikasi dan Skema Alat Vaporizer .................................................... 28 Tabel 5.6 Spesifikasi dan Skema Alat WHB ........................................................... 39 Tabel 5.7 Spesifikasi dan Skema Alat Cooler-01 .................................................... 30 Tabel 5.8 Spesifikasi dan Skema Alat Cooler-02 .................................................... 31 Tabel 5.9 Spesifikasi dan Skema Alat Kondensor ................................................... 32 Tabel 5.10 Spesifikasi dan Skema Alat Kondensor ................................................. 33 Tabel 5.11 Spesifikasi dan Skema Alat Reboiler ..................................................... 34 Tabel 5.12 Spesifikasi dan Skema Alat Reboiler ..................................................... 35 Tabel 5.13 Spesifikasi dan Skema Alat Furnace ..................................................... 36 Tabel 5.14 Spesifikasi dan Skema Alat Accumulator .............................................. 37 Tabel 5.15 Spesifikasi dan Skema Alat Accumulator .............................................. 38 Tabel 5.16 Spesifikasi dan Skema Alat Storage Tank Bahan Baku ........................ 39 Tabel 5.17 Spesifikasi dan Skema Alat Storage Tank Produk Asetaldehida ........... 39 Tabel 5.18 Spesifikasi dan Skema Alat Storage Tank Produk Hidrogen ................ 40 Tabel 5.19 Spesifikasi dan Skema Alat Holding Tank ............................................ 40 Tabel 5.20 Spesifikasi dan Skema Alat Pompa P-101 A/B ..................................... 41 Tabel 5.21 Spesifikasi dan Skema Alat Pompa P-102 A/B ..................................... 41 Tabel 5.22 Spesifikasi dan Skema Alat Pompa P-103 A/B ..................................... 42
vii
Tabel 5.23 Spesifikasi dan Skema Alat Pompa P-201 A/B ..................................... 42 Tabel 5.24 Spesifikasi dan Skema Alat Pompa P-202 A/B ..................................... 42 Tabel 5.25 Spesifikasi dan Skema Alat Pompa P-203 A/B .................................... 43 Tabel 5.26 Spesifikasi dan Skema Alat Pompa P-204 A/B ..................................... 43 Tabel 5.27 Spesifikasi dan Skema Alat Pompa P-205 A/B ..................................... 43 Tabel 6.1 Kebutuhan Listrik untuk Proses ............................................................... 44 Tabel 6.2 Kebutuhan Listrik untuk Penerangan 24 Jam .......................................... 45 Tabel 6.3 Kebutuhan Listrik untuk Penerangan 12 Jam .......................................... 45 Tabel 8.1 Jadwal Kerja Masing-masing Regu ......................................................... 67 Tabel 8.2 Perincian Jumlah Karyawan .................................................................... 69 8.3 Perincian Golongan dan Gaji ................................................................... 70 Tabel Tabel 9.1 Indeks Harga ............................................................................................ 76 9.2 Purchased Equipment Cost ...................................................................... 78 Tabel Tabel 9.3 Fixed Capital Investment ......................................................................... 79 Tabel 9.4 Biaya Bahan Baku dan katalis ................................................................. 80 Tabel 9.5 Biaya Utilitas............................................................................................ 81 Tabel 9.6 Biaya Produksi Langsung ........................................................................ 81 Tabel 9.7 Biaya Tidak Langsung ............................................................................. 81 Tabel 9.8 Fixed Manufacturing Cost ....................................................................... 81 Tabel 9.9 Total Manufacturing Cost ........................................................................ 82 Tabel 9.10 Total General Expanse .......................................................................... 82 Tabel 9.11 Perhitungan Break Event Point .............................................................. 83 Tabel 9.12 Perhitungan Net Cash Flow Diagram .................................................... 85
viii
DAFTAR GAMBAR
Gambar 2.1 Gambar 6.1 Gambar 6.2 Gambar 7.1 Gambar 7.2 Gambar 8.1 Gambar 9.1 Gambar 9.2 Gambar 9.3
Halaman Peta Lokasi Pabrik Asetaldehida ........................................................ 9 Diagram Kebutuhan Air ................................................................... 47 Diagram Kebutuhan Bahan Bakar dan Listrik ................................. 50 Layout Pabrik Asetaldehida ............................................................. 53 Layout Peralatan Proses ................................................................... 54 Struktur Organisasi Pabrik Asetaldehida ........................................ 59 Indeks Harga Perlatan ...................................................................... 77 Break Event Point ............................................................................ 84 Net Cash Flow Diagram .................................................................. 86
ix
DAFTAR LAMPIRAN
Halaman
LAMPIRAN A PERHITUNGAN NERACA MASSA 1. Kolom Distilasi I ................................................................................................ 1 2. Kolom Distilasi II ............................................................................................... 3 3. Reaktor ................................................................................................................ 4 4. Absorber ............................................................................................................. 6
LAMPIRAN B PERHITUNGAN NERACA PANAS 1. Holding Tank ..................................................................................................... 3 2. Vaporizer............................................................................................................. 4 3. Furnace ................................................................................................................ 6 4. Reaktor ................................................................................................................ 7 5. Waste Heat Boiler (WHB) .................................................................................. 9 6. Cooler-01 ......................................................................................................... 11 7. Cooler-02 .......................................................................................................... 12 8. Absorber ............................................................................................................ 13 9. Kolom Distilasi I ............................................................................................... 14 10. Kolom Distilasi II ........................................................................................... 19 LAMPIRAN C PERHITUNGAN SPESIFIKASI PERLATAN 1. Tangki Penyimpanan Etanol (T-101 A/B) .......................................................... 1 2. Tangki Penyimpanan Asetaldehida (T-102 A/B) ............................................... 3 3. Tangki Penyimpanan Hidrogen (T-103 A/B) ..................................................... 6 4. Holding Tank (T-104 A/B) ................................................................................. 9 5. Vaporizer (HE-101) .......................................................................................... 11 6. Furnace (F-101) ................................................................................................ 16 7. Reaktor (R-101) ................................................................................................ 24 8. Waste Heat Boiler (HE-102) ............................................................................. 39 9. Cooler (HE-103) ............................................................................................... 45 10. Cooler (HE-104) ............................................................................................. 50 11. Absorber (T-201) ........................................................................................... 55 12. Kolom Distilasi I (T-202) ............................................................................... 63 13. Kondensor (HE-201) ...................................................................................... 85 14. Reboiler (HE-202) .......................................................................................... 94 15. Accumulator (ACC-201) ................................................................................ 99 16. Kolom Distilasi II (T-203) ........................................................................... 102 17. Kondensor (HE-203) .................................................................................... 125 18. Reboiler (HE-204) ....................................................................................... 134 19. Accumulator (ACC-202) .............................................................................. 139 20. Pompa ........................................................................................................... 142 LAMPIRAN D FORM BIMBINGAN TUGAS AKHIR
x
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