TAHUN

       

PERANCANGAN PABRIK METHYL TERTIARY BUTYL ETHER (MTBE) DARI METANOL DAN ISOBUTENA   DENGAN KAPASITAS 60.000 TON/TAHUN  

   

Design Plant Methyl Tertiary Butyl Ether (MTBE) from Methanol and Isobutylene with Capacity 60.000 Ton/Year    

TUGAS AKHIR

 

Oleh : INTANIA ANNISA NABILLA RAFAINI PUTRI

NIM : 08414016 NIM : 08414021

POLBAN

PROGRAM STUDI D-IV TEKNIK KIMIA PRODUKSI BERSIH JURUSAN TEKNIK KIMIA POLITEKNIK NEGERI BANDUNG 2012

 

       

PERANCANGAN PABRIK METHYL TERTIARY BUTYL ETHER (MTBE) DARI METANOL DAN ISOBUTENA   DENGAN KAPASITAS 60.000 TON/TAHUN  

   

Design Plant Methyl Tertiary Butyl Ether (MTBE) from Methanol and Isobutylene with Capacity 60.000 Ton/Year    

TUGAS AKHIR

 

Diajukan untuk memenuhi salah satu persyaratan dalam menyelesaikan pendidikan program Diploma IV Teknik Kimia Produksi Bersih

Oleh : INTANIA ANNISA NABILLA RAFAINI PUTRI

NIM : 08414016 NIM : 08414021

PROGRAM STUDI D-IV TEKNIK KIMIA PRODUKSI BERSIH JURUSAN TEKNIK KIMIA POLITEKNIK NEGERI BANDUNG 2012

 

                     

 

     

ABSTRAK

   

   

 

  Methyl Tertiary Butyl Ether (MTBE) digunakan sebagai aditif bahan bakar dalam motor bensin guna meningkatkan bilangan oktan. Penggunaan MTBE sebagai pengganti TEL (Tetra Ethyl Lead) merupakan upaya untuk mengurangi pencemaran lingkungan, namun bahan tersebut harus diimpor. Tujuan perancangan ini ialah untuk merancang pabrik MTBE dari metanol & isobutena dengan kapasitas 60.000 ton/tahun. MTBE diproduksi dengan mereaksikan   metanol dan isobutena. Konversi isobutena sebesar 94%. Reaksi ini bersifat   eksotermik dan berlangsung pada suhu 100°C. Katalis yang digunakan ialah resin acidic cation exchange. Reaksi kimia yang terjadi : CH 3OH  (CH 3 ) 2 C  CH 2  (CH 3 ) 3 C  O  CH 3  Produk MTBE yang dihasilkan memiliki kemurnian 95%-berat. Bahan baku metanol yang digunakan memiliki kemurnian 100%-berat dan bahan baku mixed butenes yang digunakan terdiri atas 23%-mol isobutena, 20%-mol 1-butena dan 57%-mol cis-2-butena. Peralatan yang terlibat dalam proses ini meliputi reaktor, kolom distilasi, absorber, mixer, heat exchanger dan pompa. Besarnya investasi yang dibutuhkan untuk membangun pabrik ini adalah Rp 500 miliar, dimana harga jual produk diasumsikan sebesar US$ 763,07/ton. Analisis kelayakan ekonomi mendapatkan nilai : Break Event Point (BEP) sebesar 40%, Return On Investment (ROI) sebesar 15,9%, Internal Rate of Return (IRR) sebesar 46% dan Payback Period selama 2,028 tahun. Faktor yang paling sensitif yang dapat mempengaruhi kelayakan proyek ini adalah harga jual produk. Berdasarkan analisa yang dilakukan, pabrik layak untuk dibangun.

Kata Kunci : Bilangan oktan, pabrik MTBE, konversi isobutena, analisa ekonomi

 

     

ABSTRACT

   

   

 

  Methyl Tertiary Butyl Ether (MTBE) is used as a fuel additive in motor gasoline to increase octane number. The use of MTBE as a replacement for TEL (Tetra Ethyl Lead) is an attempt to reduce environmental pollution, but currently this chemical must be imported. The goal of this preliminary design is to design a plant MTBE using methanol and isobutylene as raw materials with a capacity of 60,000 tons/year. MTBE is produced by reacting methanol and isobutylene, with   isobutylene conversion of 94%. This reaction is exothermic and takes place at a   temperature of 100°C. The catalyst used is acidic cation exchange resin. Chemical reaction that occur is : CH 3OH  (CH 3 ) 2 C  CH 2  (CH 3 ) 3 C  O  CH 3  Product MTBE has purity of 95%wt. Methanol feed used has a purity of 100%wt and mixed butenes feed used consists of 23%-mol isobutylene, 20%-mol of 1butene and 57%-mol of cis-2-butene. Equipment employed in this process are reactor, distillation columns, absorber, mixer, heat exchangers and pumps. Total investment required to construct this plant is about Rp 500 billion, which is assumed product price of US$ 763,07/ton. Economic feasibility analysis yielded values : Break Event Point (BEP) of 40%, Return On Investment (ROI) of 15.9%, Internal Rate of Return (IRR) of 46% and the Pay back Period of 2.028 operatingyears. The most significant factor influencing the feasibility is product price. Based on the analysis that has been done, the plant is feasible to be built.

Key Words : octane number, MTBE plant, isobutylene conversion, economic analysis

 

     

KATA PENGANTAR

     

Dengan segala kerendahan hati, puji dan syukur penyusun panjatkan kehadirat

 

Allah SWT, karena atas ridho dan limpahan rahmat-Nya penyusun dapat

 

menyelesaikan kegiatan Tugas Akhir yang berjudul “Perancangan Pabrik Methyl Tertiary Butyl Ether (MTBE) dari Metanol dan Isobutena dengan Kapasitas   60.000 Ton/Tahun”.  

 

Dalam penulisan laporan ini, penyusun mengucapkan terima kasih dan penghargaan yang setinggi-tingginya kepada kedua orang tua dan seluruh keluarga penyusun atas doa dan dukungan baik moril maupun materil, serta semua pihak yang telah membantu, terutama kepada : 1) Ir. Heriyanto, MT selaku pembimbing I. 2) Ir. Unung Leoanggraini, MT, selaku dosen pembimbing II. 3) Ir. Dwi Nirwantoro Nur, M.Sc. selaku Ketua Jurusan Teknik Kimia Politeknik Negeri Bandung, 4) Ir. Ninik Lintang, MT. selaku Ketua Program Studi Teknik Kimia Produksi Bersih Politeknik Negeri Bandung. 5) Ir. Ahmad Rifandi, M.Sc, selaku Koordinator Tugas Akhir Program Studi Teknik Kimia Produksi Bersih angkatan 2008 Jurusan Teknik Kimia Politeknik Negeri Bandung. Penyusun menyadari bahwa laporan Tugas Akhir ini masih jauh dari kesempurnaan, baik dalam penulisan maupun penyajiannya, untuk itu penyusun sangat mengharapkan kritik dan saran yang membangun. Semoga laporan ini dapat bermanfaat bagi semua pihak yang membutuhkan. Bandung, Juli 2012

Penyusun

 

     

DAFTAR ISI

     

HALAMAN DEPAN  

HALAMAN JUDUL

 

LEMBAR PENGESAHAN ................................................................................... i CURRICULUM VITAE ......................................................................................... ii   KATA PENGANTAR ......................................................................................... iii  

ABSTRAK ........................................................................................................... iv  

ABSTRACT ........................................................................................................... v DAFTAR ISI......................................................................................................... vi DAFTAR TABEL ................................................................................................ ix DAFTAR GAMBAR ............................................................................................ xi DAFTAR LAMPIRAN ...................................................................................... xii BAB I

PENDAHULUAN ................................................................................I-1

1.1

Latar Belakang Perancangan ................................................................. 1-1

1.2 Tujuan Perancangan ................................................................................. 1-4 1.3 Ruang Lingkup Perancangan ................................................................... 1-4 1.4 Kapasitas Perancangan .............................................................................. I-5 BAB II BASIS DESAIN................................................................................... II-1 2.1

Bahan Baku .......................................................................................... II-1 2.1.1 Metanol ...................................................................................... II-1 2.1.2 Isobutena .................................................................................... II-1

2.2 Bahan Pendukung ................................................................................. II-2 2.3 Produk .................................................................................................. II-3 2.4 Kondisi Ambien .................................................................................... II-3 2.5 Filosofi Operasi ..................................................................................... II-4 2.6 Kode dan Standar ................................................................................. II-4 2.7 GPM (Grosir Profit Margin) ................................................................ II-4 BAB III TINJAUAN UMUM PROSES ........................................................ III-1 3.1 Proses Produksi .................................................................................... III-1

 

       

   

 

3.2 Deskripsi Alur Proses .......................................................................... III-3 3.3 Peralatan Proses .................................................................................. III-5  

3.3.1 Peralatan Utama ......................................................................... III-5

 

3.3.2 Peralatan Penunjang ................................................................... III-5

3.4 Diagram Blok Alur Proses ................................................................... III-6 BAB IV NERACA MASSA DAN NERACA ENERGI ................................ IV-1 4.1 Neraca Massa ....................................................................................... IV-1

 

4.1.1 Mixer (M – 201) ......................................................................... IV-2

 

4.1.2 Reaktor (R – 101)....................................................................... IV-3 4.1.3 Distilasi MTBE (T – 101) .......................................................... IV-4 4.1.4 Absorpsi (T – 102) ..................................................................... IV-6 4.1.5 Distilasi Metanol (T – 103) ........................................................ IV-7

4.2 Neraca Energi ...................................................................................... IV-9 4.2.1 Mixer (M – 201) ......................................................................... IV-9 4.2.2 Heater (E – 101) ...................................................................... IV-10 4.2.3 Reaktor (R – 101)..................................................................... IV-10 4.2.4 Reduce Valve I ......................................................................... IV-11 4.2.5 Distilasi MTBE (T – 101) ........................................................ IV-11 4.2.6 Reduve Valve II ........................................................................ IV-12 4.2.7Absorpsi (T – 102) .................................................................... IV-12 4.2.8 Distilasi Metanol (T – 103) ...................................................... IV-12 4.2.9 Cooler (E – 201) ...................................................................... IV-13 BAB V PERANCANGAN ALAT .................................................................... V-1 5.1 Reaktor ................................................................................................. V-1 5.2 Kolom Distilasi ................................................................................... V-2 5.3 Absorber ............................................................................................... V-4 5.4 Heat Exchanger .................................................................................... V-5 5.5 Mixer ................................................................................................... V-11 5.6 Pompa ................................................................................................ V-12 5.7 Tangki Penyimpanan Bahan Baku dan Produk .................................. V-13 5.8 Perpipaan ............................................................................................. V-15

 

       

BAB VI UTILITAS .......................................................................................... VI-1 6.1 Kebutuhan Uap .................................................................................... VI-1  

6.2 Kebutuhan Air .................................................................................... VI-1

 6.3 Penyediaan Air ..................................................................................... VI-3    

6.4 Kebutuhan Listrik ................................................................................ VI-6 6.5 Unit Pengolahan Limbah ..................................................................... VI-8 BAB VII LOKASI DAN TATA LETAK PABRIK .................................... VII-1  

7.1 Lokasi Pabrik ......................................................................................VII-1

 7.2 Lay Out Pabrik ....................................................................................VII-3  

7.3 Lay Out Peralatan ................................................................................VII-4 BAB VIII ORGANISASI DAN MANAJEMEN PERUSAHAAN ............VIII-1 8.1 Organisasi Perusahaan ...................................................................... VIII-1 8.2 Sistem Ketenagakerjaan .................................................................... VIII-3 8.3 Keselamatan dan Kesehatan Kerja .................................................... VIII-4 8.4 Tata Tertib Perusahaan ..................................................................... VIII-6 BAB IX ANALISA EKONOMI ...................................................................... IX-1 9.1 Dasar Analisa Ekonomi ....................................................................... IX-1 9.2 Perhitungan Harga Alat (Purchased Equipment Cost) ........................ IX-2 9.3 Perhitungan Fixed Capital Investment (FCI) ....................................... IX-3 9.4 Perhitungan Total Production Costs (TPC) ......................................... IX-4 9.4.1Manufacturing Costs .................................................................... IX-4 9.5 Keuntungan (Profit) ............................................................................. IX-7 9.6 Analisa Kelayakan .............................................................................. IX-7 BAB X KESIMPULAN .................................................................................... X-1 DAFTAR PUSTAKA

 

     

DAFTAR TABEL

     

Tabel 1.1

Produsen Metanol dan Kapasitas Produksi ...................................... I-2

 

Tabel 1.2

Perbandingan Harga Bahan Baku dan Produk ................................. I-3

 

Tabel 1.3

Data Impor MTBE di Indonesia ..................................................... I-5

Tabel   4.1

Neraca Massa Mixer ...................................................................... IV-3

Tabel 4.2  

Neraca Massa Reaktor ................................................................... IV-4

Tabel 4.3

Neraca Massa Distilasi MTBE ...................................................... IV-5

Tabel 4.4

Neraca Massa Absorpsi ................................................................. IV-7

Tabel 4.5

Neraca Massa Distilasi Metanol .................................................... IV-9

Tabel 4.6

Neraca Energi Mixer ...................................................................... IV-9

 

Tabel 4.6a Neraca Energi Heater ................................................................... IV-10 Tabel 4.7

Neraca Energi Reaktor ................................................................. IV-10

Tabel 4.7a Neraca Energi Reduce Valve I...................................................... IV-11 Tabel 4.8

Neraca Energi Distilasi MTBE .................................................... IV-11

Tabel 4.8a Neraca Energi Reduce Valve II .................................................... IV-12 Tabel 4.9

Neraca Energi Absorpsi ............................................................... IV-12

Tabel 4.10 Neraca Energi Distilasi Metanol .................................................. IV-13 Tabel 4.10a Neraca Energi Cooler ................................................................... IV-13

 

Tabel 6.1

Kebutuhan Uap Sebagai Media Pemanas ...................................... VI-1

Tabel 6.2

Kebutuhan Air Pendingin .............................................................. VI-2

Tabel 6.3

Kebutuhan listrik............................................................................ VI-6

Tabel 8.1

Tenaga Kerja Berdasarkan Jenis Kelamin .................................. VIII-3

Tabel 8.2

Tenaga Kerja Berdasarkan Tingkatan Umur .............................. VIII-3

Tabel 8.3

Tenaga Kerja Berdasarkan Tingkat Pendidikan ......................... VIII-3

Tabel 9.1

Harga Alat ...................................................................................... IX-3

Tabel 9.2

Total Fixed Capital Investment ...................................................... IX-3

Tabel 9.3

Biaya Bahan Baku dan Katalis pada Tahun 2014 .......................... IX-4

Tabel 9.4

Total Operating Labour Cost ........................................................ IX-5

       

Tabel 9.5

Biaya Utilitas ................................................................................. IX-6

Tabel 9.6

Perhitungan Biaya Produksi ........................................................... IX-6

 

Tabel 9.7

Break Event Point .......................................................................... IX-8

  9.8 Tabel

Net Cash Flow ............................................................................. IX-10

         

 

     

DAFTAR GAMBAR

     

Gambar 1.1 Kenaikan Kebutuhan MTBE di Indonesia ....................................... I-5  

Gambar 3.1 Mekanisme Proses Pembentukan MTBE ...................................... III-4

 

Gambar 3.2 Diagram Blok Alur Proses ............................................................ III-6 Gambar 4.1 Aliran Proses Start-up ................................................................... IV-2   Gambar 4.2 Aliran Proses Continue ................................................................. IV-2  

 

Gambar 4.3 Aliran Proses di Reaktor ............................................................... IV-3 Gambar 4.4 Aliran Proses Distilasi MTBE ....................................................... IV-4 Gambar 4.5 Aliran Proses Absorpsi .................................................................. IV-6 Gambar 4.6 Aliran Proses Distilasi Metanol .................................................... IV-8 Gambar 4.7 Diagram Alir Proses (PFD) ......................................................... IV-14 Gambar 5.1 Diagram Perpipaan dan Instrumentasi (P&ID) ............................ V-16 Gambar 6.1 Alur Proses Unit Pengolahan Air .................................................. VI-4 Gambar 6.2 One-line Diagram Kebutuhan Air ................................................. VI-5 Gambar 6.3 One-line Diagram Kebutuhan Listrik............................................ VI-7 Gambar 7.1 Denah Perencanaan Lokasi Pabrik ...............................................VII-2

Gambar 7.2 Lay Out Pabrik MTBE (Bagian Perkantoran dan Penunjang) ....VII-4 Gambar 7.3 Tata Letak Peralatan di Plant MTBE ...........................................VII-5 Gambar 8.1 Stuktur Organisasi ...................................................................... VIII-7 Gambar 9.1 Indeks Harga Peralatan ................................................................. IX-2 Gambar 9.2 Break Event Point ......................................................................... IX-9 Gambar 9.3 Net Cash Flow Diagram ............................................................. IX-11

 

     

DAFTAR LAMPIRAN

     

Lampiran A

Perhitungan Neraca Massa

 

Lampiran B

Perhitungan Neraca Energi

 

Lampiran C

Spesifikasi Alat

Lampiran D  

Lembar Kegiatan Bimbingan

Lampiran E  

Lembar Perbaikan Seminar

 

 

     

CURRICULUM VITAE

   

Nama

 

Tempat, Tanggal Lahir : Bandung, 17 Desember 1990

 

Alamat

 

 

: Intania Annisa : Cipaku No. 98 RT/RW 04/02 Desa Tarajusari Kec. Banjaran Kab. Bandung 40377

 

No. HP

: 081214625610

 

Email

: [email protected]

Pendidikan : Tahun 1996 – 2002 2002 – 2005 2005 – 2008 2008 – 2012

Sekolah SDN Banjaran VII MTs No.3 Pameungpeuk SMAN 1 Baleendah Politeknik Negeri Bandung

Nama

Jurusan

-

IPA Teknik Kimia

: Nabilla Rafaini Putri

Tempat, Tanggal Lahir : Bandung, 1 Juni 1990 Alamat

: Jl. Bunut Kertayasa No. 56 RT/RW 01/04 Karawang – Jawa Barat

No. HP

: 081310761822

Email

: [email protected]

Pendidikan : Tahun 1996 – 1997 1997 – 2002 2002 – 2005 2005 – 2008 2008 – 2012

 

Sekolah SDN Pelita Bandung SDN Taruma Negara 1 Karawang SLTPN 1 Karawang SMAN 1 Karawang Politeknik Negeri Bandung

Jurusan

-

IPA Teknik Kimia