TAHUN

perpustakaan.uns.ac.id

digilib.uns.ac.id

TUGAS AKHIR

PRARANCANGAN PABRIK PHENYL ETHYL ALCOHOL DARI BENZENE DAN ETHYLENE OXIDE KAPASITAS 5.000 TON/TAHUN

Disusun Oleh:

Irwan Fauzi

I 1507032

Surya Haditya

I 0508117

JURUSAN TEKNIK KIMIA FAKULTAS TEKNIK UNIVERSITAS SEBELAS MARET SURAKARTA 2014 commit to user

i


digilib.uns.ac.id

TUGAS AKHIR

PRARANCANGAN PABRIK PHENYL ETHYL ALCOHOL DARI BENZENE DAN ETHYLENE OXIDE KAPASITAS 5.000 TON/TAHUN

Disusun Oleh:

Irwan Fauzi

I 1507032

Surya Haditya

I 0508117

JURUSAN TEKNIK KIMIA FAKULTAS TEKNIK UNIVERSITAS SEBELAS MARET SURAKARTA 2014 commit to user

i


digilib.uns.ac.id

commit to user

iii


digilib.uns.ac.id

KATA PENGANTAR

Alhamdulillah puji syukur kepada Allah SWT karena rahmat beserta hidayahNya, laporan tugas akhir dengan judul “Prarancangan Pabrik Phenyl Ethyl Alcohol dari Benzene dan Ethylene Oxide kapasitas 5.000 ton/tahun” selesai. Dalam penyusunan tugas akhir ini, bantuan baik berupa dukungan moral dan material dari pelbagai pihak turut mendukung penyelesaiannya. Karena itu, ucapan terima kasih ditujukan kepada kedua orang tua kami yang telah memberikan kami banyak doa, Dr. Sunu H. Pranolo sebagai dosen pembimbing I dan Inayati, S.T., M.T., Ph.D sebagai dosen pembimbing II, mba Purna Katamsi dan mba Rukayah yang telah memberikan dukungan moril, teman-teman di stuba dan stuta yang tidak bisa disebutkan semua yang telah membantu berbagi ilmu, informasi, dan pengalaman. Laporan tugas akhir ini masih jauh dari sempurna, jadi saran dan kritik membangun sangat diharapkan. Semoga laporan ini dapat bermanfaat.

Surakarta, Desember 2014

commit to user

Penulis


digilib.uns.ac.id

DAFTAR ISI

Halaman Judul ...................................................................................................... i Lembar Pengesahan ............................................................................................. ii Kata Pengantar ...................................................................................................... iii Daftar Isi ............................................................................................................... iv Daftar Tabel ......................................................................................................... viii Daftar Gambar ...................................................................................................... xi Intisari .................................................................................................................. xii BAB I

PENDAHULUAN ............................................................................. 1 I.1. Latar Belakang Pendirian Pabrik ............................................... 1 I.2. Kapasitas Perancangan ............................................................... 2 I.3. Pemilihan Lokasi Pabrik ............................................................ 5 I.4. Tinjauan Pustaka ........................................................................ 7 I.4.1. Macam-macam Proses Pembuatan PEA ........................... 7 I.4.2. Alasan Pemilihan Proses ................................................... 10 I.4.3. Kegunaan Produk ...............................................................10 I.4.4. Sifat Fisis dan Kimia ........................................................ 10 A. Bahan Baku .................................................................. 10 B. Bahan Pembantu (Katalis) ........................................... 12 C. Produk Utama .............................................................. 13 I.4.5. Tinjauan Proses Secara Umum ..........................................14 commit to user

iv


BAB II

digilib.uns.ac.id

DESKRIPSI PROSES ....................................................................... 16 2.1

Spesifikasi Bahan Baku dan Produk ........................................ 16 2.1.1 Spesifikasi Bahan Baku ............................................... 16

2.2

2.1.2

Spesifikasi Katalis ......................................................... 16

2.1.3

Spesifikasi Produk ........................................................ 17

Konsep Proses .......................................................................... 17 2.2.1 Dasar Reaksi ................................................................ 17 2.2.2 Kondisi Operasi ........................................................... 17 2.2.3 Tinjauan Termodinamika ..............................................18

2.3

Diagram Alir Proses dan Tahapan Proses ............................... 20 2.3.1 Diagram Alir Kualitatif ................................................ 20 2.3.2 Diagram Alir Kuantitatif .............................................. 20 2.3.3 Diagram Alir Proses ..................................................... 20 2.3.4 Penjadwalan Proses .......................................................24 2.3.5

2.4

Langkah Proses ........................................................... 26

Neraca Massa dan Neraca Panas ............................................. 28 2.4.1 Neraca Massa ............................................................... 28 2.4.2 Neraca Panas ................................................................ 31

2.5

Layout Pabrik dan Peralatan Proses ......................................... 34 2.5.1 Layout Pabrik ............................................................... 34 2.5.2 Layout Peralatan Proses ............................................... 40

commit to user

v


BAB III

digilib.uns.ac.id

SPESIFIKASI ALAT PROSES ........................................................ 41 3.1

Reaktor ..................................................................................... 41

3.2

Mixer ........................................................................................ 42

3.3

Decanter ................................................................................... 43

3.4

Evaporator ................................................................................ 43

3.5

Menara Distilasi ....................................................................... 44

3.6

Silo ........................................................................................... 44

3.7

Bucket elevator ........................................................................ 45

3.8

Belt Conveyor .......................................................................... 45

3.9

Hopper ..................................................................................... 45

3.10 Tangki .......................................................................................46 3.11 Heat Exchanger.........................................................................48 3.12 Pompa........................................................................................50 BAB IV

UNIT PENDUKUNG PROSES DAN LABORATORIUM ............. 52 4.1

Unit Pengadaan Air .................................................................. 53

4.2

Unit Pengadaan Steam dan Bahan Bakar .................................. 55

4.3

Unit Pengadaan Udara Tekan .................................................. 56

4.4

Unit Pengadaan Listrik ............................................................ 56

4.5

Unit Refrigerasi ....................................................................... 59

4.6

Unit Pengolahan Limbah .......................................................... 59

4.7

Laboratorium ........................................................................... 61 4.7.1 Laboratorium Fisik ......................................................... 63 4.7.2 Laboratorium Analitik .................................................... 63 commit to user

vi


digilib.uns.ac.id

4.7.3 Laboratorium Penelitian dan Pengembangan ................. 63 BAB V

MANAJEMEN PERUSAHAAN ...................................................... 65 5.1

Bentuk Perusahaan .................................................................. 65

5.2

Struktur Organisasi .................................................................. 66

5.3

Tugas dan Wewenang .............................................................. 68

5.4

Pembagian Jam Kerja dan Gaji Karyawan .............................. 69 5.4.1 Karyawan Non Shift ..................................................... 71 5.4.2 Karyawan Shift ............................................................. 71

5.5

BAB VI

Health and Safety Environment ................................................ 72 5.5.1

Tinjauan Hukum .......................................................... 72

5.5.2

Identifikasi Bahaya ...................................................... 74

ANALISA EKONOMI ..................................................................... 76 6.1

Penaksiran Harga Peralatan ................................................... 76

6.2

Dasar Perhitungan ................................................................. 78

6.3

Penentuan Total Capital Investment (TCI) ........................... 79

6.4

Hasil Perhitungan .................................................................. 80

DAFTAR PUSTAKA .......................................................................................... xiii LAMPIRAN

commit to user

vii


digilib.uns.ac.id

DAFTAR TABEL

Tabel 1.1.

Data Impor PEA di Indonesia ......................................................... 3

Tabel 1.2.

Kapasitas Pabrik PEA di Berbagai Negara ..................................... 5

Tabel 1.3.

Kelebihan dan Kelemahan Proses Pembuatan PEA ........................ 9

Tabel 2.1.

Data Panas Pembentukan ................................................................ 18

Tabel 2.2.

Data Energi Bebas Gibbs ................................................................ 19

Tabel 2.3.

Neraca Massa Reaktor .................................................................... 29

Tabel 2.4.

Neraca Massa Mixer ....................................................................... 29

Tabel 2.5.

Neraca Massa Decanter .................................................................. 29

Tabel 2.6.

Neraca Massa Evaporator ............................................................... 30

Tabel 2.7.

Neraca Massa Menara Distilasi ....................................................... 30

Tabel 2.8.

Neraca Panas Reaktor ...................................................................... 31

Tabel 2.9.

Neraca Panas Mixer ........................................................................ 31

Tabel 2.10. Neraca Panas Decanter ................................................................... 32 Tabel 2.11. Neraca Panas Evaporator ................................................................. 32 Tabel 2.12. Neraca Panas Menara Distilasi ....................................................... 32 Tabel 2.13. Neraca Panas Total ......................................................................... 33 Tabel 3.1.

Spesifikasi Reaktor ......................................................................... 41

Tabel 3.2.

Spesifikasi Mixer ............................................................................ 42

Tabel 3.3.

Spesifikasi Decanter ....................................................................... 43

Tabel 3.4.

Spesifikasi Evaporator .................................................................... 43

Tabel 3.5.

Spesifikasi Menara Distilasi 44 commit to........................................................... user

viii


digilib.uns.ac.id

Tabel 3.6.

Spesifikasi Silo ............................................................................... 44

Tabel 3.7.

Spesifikasi Bucket Elevator ............................................................ 45

Tabel 3.8.

Spesifikasi Belt Conveyor ............................................................... 45

Tabel 3.9.

Spesifikasi Hopper .......................................................................... 45

Tabel 3.10

Spesifikasi Tangki ........................................................................... 46

Tabel 3.11

Spesifikasi Tangki Penampung ....................................................... 47

Tabel 3.12

Spesifikasi Tangki (Lanjutan) ......................................................... 48

Tabel 3.13

Spesifikasi Heat Exchanger ............................................................ 48

Tabel 3.14

Spesifikasi Heat Exchanger (Lanjutan) .......................................... 49

Tabel 3.15

Spesifikasi Heat Exchanger (Lanjutan) .......................................... 50

Tabel 3.16

Spesifikasi Pompa ........................................................................... 50

Tabel 4.1.

Kebutuhan Air Proses ..................................................................... 53

Tabel 4.2.

Kebutuhan Air Pendingin ............................................................... 53

Tabel 4.3.

Kebutuhan Air Umpan Boiler ......................................................... 54

Tabel 4.4.

Kebutuhan Air Konsumsi Umum dan Sanitasi ............................... 54

Tabel 4.5.

Kebutuhan Air Sungai .................................................................... 54

Tabel 4.6.

Spesifikasi Boiler ............................................................................ 56

Tabel 4.7.

Spesifikasi Kompresor .................................................................... 56

Tabel 4.8.

Kebutuhan Listrik Utilitas .............................................................. 57

Tabel 4.9.

Kebutuhan Listrik Proses ................................................................58

Tabel 4.10

Kebutuhan Listrik Total .................................................................. 58

Tabel 4.l1

Spesifikasi Generator ...................................................................... 59

Tabel 5.1.

Perincian Kualifikasi, Jumlah, dan Gaji Karyawan Non Shift ........ 70 commit to user

ix


digilib.uns.ac.id

Tabel 5.2.

Perincian Kualifikasi, Jumlah, dan Gaji Karyawan Shift ................ 71

Tabel 5.3.

Jadwal Pembagian Kelompok Shift ................................................ 72

Tabel 5.4.

Material Safety Data Sheet PEA .....................................................74

Tabel 5.5.

Perlengkapan Pencegahan Bahaya ..................................................75

Tabel 6.1.

Indeks Harga Alat ........................................................................... 77

Tabel 6.2.

Fixed Capital Investment ................................................................ 80

Tabel 6.3.

Working Capital Investment ........................................................... 80

Tabel 6.4.

Direct Manufacturing Cost ............................................................. 81

Tabel 6.5.

Indirect Manufacturing Cost .......................................................... 81

Tabel 6.6.

Fixed Manufacturing Cost .............................................................. 81

Tabel 6.7.

General Expense ............................................................................. 82

Tabel 6.8.

Analisa Kelayakan .......................................................................... 86

commit to user

x


digilib.uns.ac.id

DAFTAR GAMBAR

Gambar I.1.

Grafik Impor PEA dari Tahun 2007-2012 .................................... 3

Gambar I.2.

Gambar Pemilihan Lokasi Pabrik ................................................. 5

Gambar 2.1. Diagram Alir Kualitatif ................................................................ 21 Gambar 2.2. Diagram Alir Kuantitatif .............................................................. 22 Gambar 2.3. Diagram Alir Proses ..................................................................... 23 Gambar 2.4. Penjadwalan Alat Pabrik PEA ...................................................... 25 Gambar 2.5. Blok Diagram Alir Proses Pabrik PEA ........................................ 28 Gambar 2.6. Layout Pabrik PEA ....................................................................... 38 Gambar 2.7. Layout Peralatan Proses ................................................................ 39 Gambar 4.1. Skema Pengolahan Air Sungai ..................................................... 55 Gambar 4.2. Diagram Alir Pengolahan Limbah Cair ........................................ 59 Gambar 5.1. Struktur Organisasi Pabrik PEA ................................................... 68 Gambar 5.2. Gambar Identifikasi Bahaya PEA ................................................ 73 Gambar 6.1. Grafik Linierisasi Indeks Harga ................................................... 77 Gambar 6.2. Grafik Analisa Kelayakan ............................................................ 88

commit to user

xi


digilib.uns.ac.id

ABSTRACT

Irwan Fauzi, Surya Haditya, 2014, Preeliminary Design Phenyl Ethyl Alcohol from Benzene and Ethylene Oxide Capacity 5.000 ton/year, Chemical Engineering Major, Sebelas Maret University. Phenyl Ethyl Alcohol (PEA) is colorless liquid, good smell, mostly used for fragrance compund rose like odor, lily, ylang-ylang, orange. PEA compound is also used for desinfectant, antibacterial agent, etc. PEA plant is classified as low risk industry that will built on industrial district on 2017 at industrial district at Tangerang City, Banten with capacity 5.000 ton/year. PEA is made by reacting benzene liquid and ethylene oxide liquid by Friedel Crafts methode with adding catalyst Aluminum Chloride in low temperature 100 C and pressure is about 1,01 bar in the batch reactor with operation conditions are irreversible isothermal non-adiabatic and exothermis. Raw materials are benzene liquid with 99% pure by Pertamina ltd. Cilacap, ethylene oxide liquid with 97% pure by Prima Ethycolindo ltd. Merak, catalyst aluminum chloride with 99% pure by Lumbung Sumber Rejeki ltd. Cirebon. Product is phenyl ethyl alcohol with 99% pure. Process support units are water utility (cooler water, boiler feed water, consumptions, sanitation water) necessary is from Cisadane river about 14.086 L/hour, steam utility necessary about 10,176,94 kg/hour, electricity necessary is from PLN about 277,77 kW, fuel utility is IDO about 6,95 L/hour, and compressed air is about 63,2 Nm3/jam, refrigerant utilty for heat exchanger and reactor coil 261,98 kg/hour. There are three laboratoriums, physic laboratorium, analytic, research and development. Company type is limited company. Labors are 113 people. Economic analysis is made which result Return of Investment (ROI) is 19,95% before tax, 14,26% after tax, Pay Out Time (POT) is 3,3 years before tax, 4 years after tax. Break Event Point (BEP) is 58,01%, Shut Down Point (SDP) is 32,80%, and Discounted Cash Flow (DCF) is 17,23%. From that results mean PEA plant is considered to build.

commit to user

xii


digilib.uns.ac.id

INTISARI

Irwan Fauzi, Surya Haditya, 2014, Prarancangan Pabrik Phenyl Ethyl Alcohol dari Benzene dan Ethylene Oxide kapasitas 5.000 ton/tahun, Jurusan Teknik Kimia, Universitas Sebelas Maret, Surakarta. Phenyl Ethyl Alcohol (PEA) merupakan cairan tidak berwarna, memiliki aroma, yang banyak digunakan sebagai salah satu bahan baku parfum untuk aroma bunga mawar, lili, ilan-ilang, jeruk. Senyawa PEA juga digunakan untuk bahan desinfektan, bahan pengawet, antibakteri. Pabrik PEA tergolong pabrik resiko kecil akan didirikan di kawasan industri terpadu Kota Tangerang, Banten yang akan dibangun pada tahun 2017 kapasitas 5.000 ton/tahun. Pembuatan PEA dengan cara mereaksikan benzene dan ethylene oxide melalui reaksi Friedel-Crafts dengan bantuan katalis alumunium klorida pada suhu di bawah ruangan 100 C dan tekanan 1,01 bar di dalam reaktor batch dengan kondisi operasi bersifat irreversibel ekotermis non-adiabatis isotermal. Bahan baku yang dibutuhkan adalah benzene dengan kemurnian 99% b/v dari Pertamina Cilacap, ethylene oxide dari PT.Prima Ethycolindo kemurnian 97% b/v, dan katalis Alumunium Klorida yang berasal dari PT. Lumbung Sumber Rejeki, Cirebon 99% berat. Produk yang dihasilkan berupa Phenyl Ethyl Alcohol dengan kemurnian mencapai 99% berat dengan impuritas air. Unit pendukung proses meliputi unit pengadaan air (air pendingin, air umpan boiler, air konsumsi umum, dan air sanitasi) diperoleh dari air sungai Cisadane dengan kebutuhan sebesar 14.086 L/jam, unit pengadaan steam dengan kebutuhan sebesar 10.176,94 kg/jam, unit pengadaan listrik sebesar 277,77 kW dari PLN, unit pengadaan bahan bakar IDO sebesar 6,94 L/jam, dan unit pengadaan udara tekan sebesar 63,2 Nm3/jam, unit pengadaan refrigerant untuk pendingin Heat Exchanger dan koil reaktor digunakan chilled water sebanyak 261,98 kg/jam. Terdapat tiga laboratorium yaitu laboratorium fisik, analitik, penelitian dan pengembangan. Bentuk perusahaan yang dipilih adalah Perseroan Terbatas. Jumlah kebutuhan tenaga kerja sebanyak 113 orang. Hasil analisis ekonomi didapatkan Return of Investment (ROI) sebesar 19,95% sebelum pajak dan 14,26% sesudah pajak. Pay Out Time (POT) didapatkan sebesar 3,3 tahun sebelum pajak dan 4 tahun sesudah pajak. Break Event Point (BEP) sebesar 58,01%, Shut Down Point (SDP) sebesar 32,80%, dan Discounted Cash Flow (DCF) sebesar 17,23%. Dari hasil analisis ekonomi dapat disimpulkan pabrik PEA layak dipertimbangkan untuk didirikan.

commit to user

xiii

TAHUN

Recommend Documents