PRARANCANGAN PABRIK ASETALDEHIDA DENGAN PROSES DEHIDROGENASI ETANOL KAPASITAS 30.000 TON/TAHUN
Disusun oleh : Oktaviana Lupita Ainiyah D500110001
Dosen Pembimbing : 1. Ir. Herry Purnama, M.T., Ph.D. 2. Ir. Haryanto, AR., M.S.
JURUSAN TEKNIK KIMIA FAKULTAS TEKNIK UNIVERSITAS MUHAMMADIYAH SURAKARTA 2016
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MOTTO
Dan tidaklah Aku (Allah) ciptakan jin dan manusia kecuali untuk beribadah kepada-Ku (Adz-Dzariyat : 56)
Ilmu itu banyak, sementara umur kita pendek, maka ambillah ilmu yang engkau butuhkan dalam urusan agamamu, dan tinggalkan selainnya, jangan disibukkan dengannya. (Salman Al-Farisi r.a.)
Bukti akal pikiran seseorang ialah perbuatannya dan bukti ilmunya ialah ucapannya.
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ABSTRAK Pendirian pabrik asetaldehida dengan kapasitas 30.000 ton/tahun sangat penting untuk memenuhi kebutuhan asetaldehida di Indonesia. Bahan baku pembuatan asetaldehida adalah etanol dengan proses dehidrogenasi yang direaksikan menggunakan reaktor fixed bed multitube pada suhu 260-290oC dan tekanan 1,25 atm dengan katalis padat Cr2Cu2O5. Reaksi ini berlangsung secara endotermis dan irreversible. Konversi reaksi sebesar 50% dan yield sebesar 85%. Prarancangan pabrik asetaldehida akan didirikan di Gresik, Jawa Timur dengan luas area 60.000 m2. Total kebutuhan bahan baku etanol adalah 7920,9102 kg/jam, total produk yang dihasilkan adalah 3750 kg/jam, total kebutuhan air untuk semua unit adalah 105,8817 m3/jam, total kebutuhan listrik adalah 194,0699 kW dan total kebutuhan bahan bakarnya adalah 99,7345 L/jam. Didapatkan return of investment sebelum pajak 38,91%, sesudah pajak 27,24%, break even point 46,68%, shut down point 26,28%, pay out time sebelum pajak 2,04 tahun, sesudah pajak 2,69 tahun dan discounted cash flow sebesar 24,2%. Berdasarkan analisa ekonomi tersebut, maka dapat disimpulkan bahwa pabrik asetaldehida ini layak untuk didirikan. Kata kunci : asetaldehida, dehidrogenasi, etanol ABSTRACT The establishment of acetaldehyde plant with a capacity of 30.000 ton/year is very important to meet the needs of acetaldehyde in Indonesia. Raw material for making acetaldehyde is ethanol reacted dehydrogenation process using the fixed bed multitube reactor at a temperatur of 260-290oC and a pressure of 1,25 atm with solid catalyst Cr2Cu2O5. This reaction takes place in endothermic and irreversible. Conversion of reaction is 50% and yield 85%. The manufacturer of acetaldehyde plant will be established in Gresik, East Java by area 60.000 m 2. Total raw material requirement ethanol is 7920,9102 kg/hr, total product produced is 3750 kg/hr, total water needs for all units is 105,8817 m3/hr, total electricity needs is 194,0699 kW and total fuel needs is 99,7345 L/hr. That obtained return of investment before taxes of 38,91%, after taxes of 27,24%, break even point 46,68%, shut down point 26,28%, pay out time before taxes of 2,04 year, after taxes of 2,69 year, and discounted cash flow 24,2%. Based on the calculation of the economic analysis, it can be concluded that this manufacturer of acetaldehyde plant is reasonable to establish. Keywords : acetaldehyde, dehydrogenation, ethanol
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KATA PENGANTAR Assalaamu’alaikum warahmatullaahi wabarakaatuh Alhamdulillah, segala puji dan syukur Penulis panjatkan kehadirat Allah SWT yang telah melimpahkan rahmat dan karunia-Nya, sehingga penulis dapat menyelesaikan naskah tugas akhir dengan judul “Prarancangan Pabrik Asetaldehida
dengan
Proses
Dehidrogenasi
Etanol
Kapasitas
30.000
Ton/Tahun” dengan baik dan lancar. Naskah tugas akhir ini disusun dalam rangka memenuhi mata kuliah Program Strata-1 Jurusan Teknik Kimia, Fakultas Teknik, Universitas Muhammadiyah Surakarta. Dalam penyusunan naskah ini, Penulis mendapatkan bimbingan dan bantuan dari berbagai pihak baik secara langsung maupun tidak langsung. Oleh karena itu, Penulis mengucapkan terima kasih kepada: 1. Kedua orang tua, kakak dan adik yang telah memberikan dukungan baik secara moral maupun material 2. Bapak Rois Fatoni, S.T, M.Sc., Ph.D. selaku Ketua Jurusan Teknik Kimia, Fakultas Teknik, Universitas Muhammadiyah Surakarta 3. Bapak Ir. Herry Purnama, M.T., Ph.D. selaku dosen pembimbing I yang selalu membantu kami 4. Bapak Ir. Haryanto, AR., M.S. selaku dosen pembimbing II yang selalu membantu dan mengarahkan dalam penyusunan naskah 5. Siti Khomariyah Arjiani, teman seperjuangan dalam proses penyusunan tugas akhir, tanpa-mu tugas ini akan terasa sangatlah berat 6. Teman-teman Teknik Kimia 2011 di Universitas Muhammadiyah Surakarta 7. Semua pihak yang telah membantu dalam proses dan penyusunan naskah tugas akhir yang tidak mungkin Penulis sebutkan satu per satu. Penulis menyadari bahwa dalam penyusunan naskah tugas akhir ini masih jauh dari sempurna. Untuk itu Penulis mengharapkan koreksi berupa saran dan kritik yang membangun untuk kesempurnaan naskah ini. Akhir kata Penulis iv
berharap naskah tugas akhir ini dapat bermanfaat dan berguna serta menambah pengetahuan bagi yang membaca. Wassalaamu’alaikum warahmatullaahi wabarakaatuh
Surakarta, 26 April 2016
Penulis
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DAFTAR ISI
HALAMAN JUDUL .............................................................................................. i HALAMAN PENGESAHAN ............................................................................... ii INTISARI ............................................................................................................. iii KATA PENGANTAR .......................................................................................... iv DAFTAR ISI ......................................................................................................... vi DAFTAR GAMBAR ............................................................................................ ix DAFTAR TABEL ..................................................................................................x BAB I PENDAHULUAN .......................................................................................1 1.1. Latar Belakang Pendirian Pabrik ......................................................................1 1.2. Kapasitas Perancangan Pabrik ..........................................................................2 1.3. Pemilihan Lokasi Pabrik ...................................................................................4 1.4. Tinjauan Pustaka ...............................................................................................6 BAB II DESKRIPSI PROSES ............................................................................13 2.1. Spesifikasi Bahan baku dan Produk ................................................................13 2.2. Konsep Reaksi .................................................................................................14 2.3. Tinjauan Kinetika ............................................................................................15 2.4. Tinjauan Termodinamika ................................................................................15 2.5. Langkah Proses ...............................................................................................16 2.6. Diagram Alir Proses ........................................................................................19 2.7. Neraca Massa dan Neraca Panas .....................................................................21 2.8. Tata Letak Pabrik dan Peralatan .....................................................................27 BAB III SPESIFIKASI ALAT ............................................................................31 3.1. Absorber ..........................................................................................................31 3.2. Accumulator-01 ...............................................................................................31 3.3. Accumulator-02 ...............................................................................................32 3.4. Condenser-01 ..................................................................................................32 3.5. Condenser-02 ..................................................................................................33 3.6. Cooler-01 ........................................................................................................33
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3.7. Cooler-02 ........................................................................................................34 3.8. Heater-01 ........................................................................................................35 3.9. Heater-02 ........................................................................................................35 3.10.
Menara Destilasi-01 ...................................................................................36
3.11.
Menara Destilasi-02 ...................................................................................37
3.12.
Pompa-01 ...................................................................................................37
3.13.
Pompa-02 ...................................................................................................38
3.14.
Pompa-03 ...................................................................................................39
3.15.
Pompa-04 ...................................................................................................39
3.16.
Pompa-05 ...................................................................................................40
3.17.
Pompa-06 ...................................................................................................41
3.18.
Pompa-07 ...................................................................................................41
3.19.
Pompa-08 ...................................................................................................42
3.20.
Pompa-09 ...................................................................................................43
3.21.
Reaktor .......................................................................................................43
3.22.
Reboiler-01 .................................................................................................44
3.23.
Reboiler-02 .................................................................................................45
3.24.
Separator ....................................................................................................45
3.25.
Tangki Asetaldehida...................................................................................46
3.26.
Tangki Etanol .............................................................................................47
3.27.
Vaporizer ....................................................................................................47
BAB IV UNIT PENDUKUNG PROSES DAN LABORATORIUM ...............49 4.1.Unit Pendukung Proses ....................................................................................49 4.2.Laboratorium ....................................................................................................66 BAB V MANAJEMEN PERUSAHAAN ...........................................................70 5.1.Bentuk Perusahaan ...........................................................................................70 5.2.Struktur Organisasi ..........................................................................................71 5.3.Tugas dan Wewenang ......................................................................................72 5.4.Status Karyawan dan Sistem Penggajian .........................................................77 5.5.Pembagian Jam Kerja Karyawan .....................................................................78 5.6.Penggolongan Jabatan, Jumlah Karyawan, dan Gaji .......................................79
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5.7.Kesejahteraan Karyawan ..................................................................................81 5.8.Manajemen Produksi ........................................................................................82 5.9.Perencanaan Produksi ......................................................................................83 5.10.
Pengendalian Produksi ..................................................................................... 84
BAB VI ANALISIS EKONOMI .........................................................................87 6.1.Investasi Modal (Capital Investment) ..............................................................87 6.2.Biaya Produksi (Manufacturing Cost) .............................................................87 6.3.Pengeluaran Umum (General Expenses) .........................................................88 6.4.Analisis Kelayakan...........................................................................................88 BAB VII KESIMPULAN ....................................................................................99 DAFTAR PUSTAKA ........................................................................................... xi LAMPIRAN
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DAFTAR GAMBAR
Gambar 1.1. Data Impor Asetaldehida di Indonesia ................................................3 Gambar 2.1. Diagram Alir Kualitatif .....................................................................19 Gambar 2.2. Diagram Alir Kuantitatif ..................................................................20 Gambar 2.3. Tata Letak Pabrik ..............................................................................29 Gambar 2.4. Layout Pabrik Asetaldehida ..............................................................30 Gambar 4.1. Skema Pengolahan Air .....................................................................69 Gambar 5.1. Struktur Organisasi ...........................................................................86 Gambar 6.1. Cost Index Chemical Plant tiap tahun .............................................92 Gambar 6.2. Analisis Ekonomi .............................................................................98
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DAFTAR TABEL
Tabel 1.1. Data statistik impor asetaldehida di Indonesia ........................................2 Tabel 1.2. Kapasitas produksi asetaldehida di Amerika Serikat .............................4 Tabel 2.1. Neraca massa vaporizer ........................................................................21 Tabel 2.2. Neraca massa separator .........................................................................21 Tabel 2.3. Neraca massa reaktor ............................................................................21 Tabel 2.4. Neraca massa absorber .........................................................................22 Tabel 2.4. Neraca massa menara destilasi-01 ........................................................22 Tabel 2.4. Neraca massa menara destilasi-02 ........................................................22 Tabel 2.7. Neraca massa total ................................................................................23 Tabel 2.8. Neraca panas di sekitar vaporizer .........................................................24 Tabel 2.9. Neraca panas di sekitar heater-01 .........................................................24 Tabel 2.10. Neraca panas di sekitar reaktor ..........................................................24 Tabel 2.11. Neraca panas di sekitar cooler-01 .......................................................24 Tabel 2.12. Neraca panas di sekitar absorber ........................................................25 Tabel 2.13. Neraca panas di sekitar heater-02 .......................................................25 Tabel 2.14. Neraca panas di sekitar menara destilasi-01 .......................................25 Tabel 2.15. Neraca panas di sekitar cooler-02 .......................................................25 Tabel 2.14. Neraca panas di sekitar menara destilasi-02 .......................................26 Tabel 2.17. Perincian luas tanah bangunan pabrik .................................................28 Tabel 5.1. Jabatan dan prasyarat karyawan ..................................................................... 80 Tabel 5.2. Jumlah karyawan dan gaji ................................................................................ 81
Tabel 6.1. Cost index chemical plant .....................................................................91 Tabel 6.2. Fixed capital investment .......................................................................93 Tabel 6.3. Manufacturing cost ...............................................................................94 Tabel 6.4. Working capital .....................................................................................94 Tabel 6.5. General expenses ..................................................................................95 Tabel 6.6. Fixed cost ..............................................................................................96 Tabel 6.7. Variable Cost ........................................................................................96 Tabel 6.8. Regulated Cost ......................................................................................97 x
