Prarancangan Pabrik Hexamine dengan Proses Leonard Kapasitas 25.000 Ton/Tahun TUGAS AKHIR PRARANCANGAN PABRIK HEXAMINE DARI AMONIA DAN FORMALIN DENGAN PROSES LEONARD KAPASITAS 25.000 TON/TAHUN Oleh : Devinta Rachmawati Anggraeni I 0505024 Lydia Eka Fitri I 0505040 JURUSAN TEKNIK KIMIA FAKULTAS TEKNIK UNIVERSITAS SEBELAS MARET SURAKARTA 2010 Bab I Pendahuluan 1 Prarancangan Pabrik Hexamine dengan Proses Leonard Kapasitas 25.000 Ton/Tahun Halaman Pengesahan TUGAS AKHIR PRARANCANGAN PABRIK HEXAMINE DARI AMONIA DAN FORMALIN DENGAN PROSES LEONARD KAPASITAS 25.000 TON / TAHUN Oleh : Devinta Rachmawati Anggraeni NIM. I 0505024 Lydia Eka Fitri NIM. I 0505040 Dosen pembimbing Endang Kwartiningsih,S.T.,M.T NIP. 19730306 199802 2 001 Dipertahankan di depan Tim Penguji : 1. Ir. Endah Retno D., M.T 1. ...................................... NIP. 19690719 200003 2 001 2. Ir. Nunik Sri W., M.Si 2. ...................................... NIP. 19560811 198601 2 001 Disahkan Ketua Jurusan Teknik Kimia Ir. Arif Jumari, M.Sc. NIP. 19650315 199702 1 001 Bab I Pendahuluan 2 Prarancangan Pabrik Hexamine dengan Proses Leonard Kapasitas 25.000 Ton/Tahun KATA PENGANTAR Segala puji hanya bagi Allah SWT, hanya karena Rahmat dan Hidayah- Nya, penulis akhirnya dapat menyelesaikan penyusunan laporan tugas akhir dengan judul “ Prarancangan Pabrik Hexamine dari Amonia dan Formalin dengan Proses Leonard Kapasitas 25.000 ton/tahun”. 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. Ir. Arif Jumari M.Sc., selaku Ketua Jurusan Teknik Kimia FT UNS. 2. Endang Kwartiningsih S.T., M.T., selaku Dosen Pembimbing atas bimbingan dan bantuannya dalam penulisan tugas akhir. 3. Ir. Rusdiansjah dan Ir. Arif Jumari M.Sc., selaku Pembimbing Akademis. 4. Segenap Civitas Akademika, atas segala bantuannya. 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 dan pembaca sekalian. Surakarta, April 2010 Penyusun Bab I Pendahuluan 3 Prarancangan Pabrik Hexamine dengan Proses Leonard Kapasitas 25.000 Ton/Tahun DAFTAR ISI Halaman Judul ................................................................................................... i Lembar Pengesahan........................................................................................... ii Kata Pengantar................................................................................................... iii Daftar Isi ......................................................................................................... iv Daftar Tabel ...................................................................................................... xi Daftar Gambar ................................................................................................. xiii Intisari.............................................................................................................. xiv BAB I PENDAHULUAN............................................................................. 1 1.1 Latar Belakang Pendirian Pabrik.............................................. 1 1.2 Penentuan Kapasitas Perancangan .......................................... 2 1.2.1 Data Impor Produk.................................................... 3 1.2.2 Ketersediaan Bahan Baku......................................... 4 1.2.3 Kapasitas Minimum Pabrik Hexamine..................... 5 1.3 Pemilihan Lokasi Pabrik ......................................................... 6 1.3.1 Faktor Primer............................................................ 7 1.3.2 Faktor Sekunder........................................................ 9 1.4 Tinjauan Pustaka ..................................................................... 11 1.4.1 Macam-macam Proses ................................................. 11 1.4.2 Kegunaan Produk ........................................................ 14 1.4.3 Sifat Fisis dan Kimia Bahan Baku dan Produk............ 15 1.4.4 Tinjauan Proses Secara Umum .................................... 19 Bab I Pendahuluan 4 Prarancangan Pabrik Hexamine dengan Proses Leonard Kapasitas 25.000 Ton/Tahun BAB II DESKRIPSI PROSES........................................................................ 21 2.1 Spesifikasi Bahan Baku dan Produk ....................................... 21 2.1.1 Spesifikasi Bahan Baku ............................................... 21 2.1.2 Spesifikasi Produk........................................................ 22 2.2 Konsep Proses ......................................................................... 23 2.2.1 Dasar Reaksi ................................................................ 23 2.2.2 Mekanisme Reaksi ....................................................... 23 2.2.3 Kondisi Operasi ........................................................... 24 2.2.4 Tinjauan Termodinamika ............................................ 25 2.2.5 Tinjauan Kinetika......................................................... 27 2.3 Diagram Alir Proses dan Tahapan Proses ............................... 28 2.3.1 Diagram Alir Proses..................................................... 28 2.3.2 Tahapan Proses............................................................. 32 2.3.2.1 Tahap Persiapan Bahan Baku………………… 32 2.3.2.2 Tahap Pembentukan Hexamine……………… 32 2.3.2.3 Tahap Pemurnian dan Penyimpanan Produk... 33 2.4 Neraca Massa dan Neraca Panas ............................................. 34 2.4.1 Neraca Massa ............................................................... 34 2.4.2 Neraca Panas ................................................................ 42 2.5 Lay Out Pabrik dan Peralatan................................................... 46 2.5.1 Lay Out Pabrik.............................................................. 46 2.5.2 Lay Out Peralatan......................................................... 49 Bab I Pendahuluan 5 Prarancangan Pabrik Hexamine dengan Proses Leonard Kapasitas 25.000 Ton/Tahun BAB III SPESIFIKASI PERALATAN PROSES ........................................... 52 3.1 Tangki Penyimpan Amonia ....................................................... 52 3.2 Tangki Penyimpan Formalin....................................................... 53 3.3 Silo Penyimpanan Hexamine...................................................... 54 3.4 Reaktor-01................................................................................... 54 3.5 Reaktor-02................................................................................... 56 3.6 Evaporator-01............................................................................. 58 3.7 Evaporator-02............................................................................. 60 3.8 Centrifuge.................................................................................... 61 3.9 Dryer........................................................................................... 61 3.10 Ejector-01.................................................................................... 62 3.11 Ejector-02.................................................................................... 63 3.12 Barometric Condenser-01........................................................... 64 3.13 Barometric Condenser-02........................................................... 64 3.14 Expander .................................................................................... 65 3.15 Screw Conveyor.......................................................................... 65 3.16 Belt Conveyor.............................................................................. 65 3.17 Bucket Elevator........................................................................... 66 3.18 Pompa-01.................................................................................... 67 3.19 Pompa-02.................................................................................... 67 3.20 Pompa-03.................................................................................... 68 3.21 Pompa-04.................................................................................... 69 Bab I Pendahuluan 6 Prarancangan Pabrik Hexamine dengan Proses Leonard Kapasitas 25.000 Ton/Tahun 3.22 Pompa-05.................................................................................... 70 3.23 Pompa-06.................................................................................... 71 3.24 Preheater-01(HE-01).................................................................. 71 3.25 Cooler(HE-02)............................................................................ 72 3.26 Preheater-02(HE-03).................................................................. 74 BAB IV UNIT PENDUKUNG PROSES DAN LABORATORIUM............ 76 4.1 Unit Pendukung Proses ........................................................... 76 4.1.1 Unit Pengadaan Air ..................................................... 77 4.1.1.1 Air Pendingin ................................................ 79 4.1.1.2 Air Umpan Boiler........................................... 81 4.1.1.3 Air Konsumsi umum dan Sanitasi ................. 85 4.1.2 Unit Pengadaan Steam.................................................. 86 4.1.3 Unit Pengadaan Udara Tekan....................................... 88 4.1.4 Unit Pengadaan Listrik ................................................ 89 4.1.5 Unit Pengadaan Bahan Bakar ...................................... 95 4.1.6 Unit Refrigerasi............................................................ 96 4.2 Laboratorium ........................................................................... 99 4.2.1 Laboratorium Fisik .................................................... 101 4.2.2 Laboratorium Analitik ............................................... 101 4.2.3 Laboratorium Penelitian dan Pengembangan ............ 101 4.2.4 Prosedur Analisa Bahan Baku.................................... 101 4.2.5 Prosedur Analisa Produk............................................ 102 4.2.6 Analisa Air.................................................................. 103 Bab I Pendahuluan 7 Prarancangan Pabrik Hexamine dengan Proses Leonard Kapasitas 25.000 Ton/Tahun 4.3 Unit Pengolahan Limbah ......................................................... 104 BAB V MANAJEMEN PERUSAHAAN........................................................ 106 5.1 Bentuk Perusahaan .................................................................. 106 5.2 Struktur Organisasi .................................................................. 107 5.3 Tugas dan Wewenang ............................................................. 110 5.3.1 Pemegang Saham ........................................................ 110 5.3.2 Dewan Komisaris ........................................................ 111 5.3.3 Dewan Direksi ............................................................. 111 5.3.4 Staf Ahli ....................................................................... 113 5.3.5 Penelitian dan Pengembangan (Litbang) ..................... 113 5.3.6 Kepala Bagian .............................................................. 114 5.3.7 Kepala Seksi ................................................................ 118 5.4 Pembagian Jam Kerja Karyawan ............................................ 118 5.4.1 Karyawan Non Shift..................................................... 118 5.4.2 Karyawan Shift............................................................. 119 5.5 Status Karyawan dan Sistem Upah ......................................... 121 5.4.1 Karyawan Tetap........................................................... 121 5.4.2 Karyawan Harian......................................................... 121 5.4.3 Karyawan Borongan.................................................... 121 5.6 Penggolongan Jabatan, Jumlah Karyawan dan Gaji ............... 121 5.6.1 Penggolongan Jabatan ................................................. 121 5.6.2 Jumlah Karyawan dan Gaji .......................................... 122 5.7 Kesejahteraan Sosial Karyawan .............................................. 125 Bab I Pendahuluan 8 Prarancangan Pabrik Hexamine dengan Proses Leonard Kapasitas 25.000 Ton/Tahun BAB VI ANALISIS EKONOMI..................................................................... 127 6.1 Penaksiran Harga Peralatan ..................................................... 127 6.2 Dasar Perhitungan ................................................................... 130 6.3 Penentuan Total Capital Investment (TCI) ............................ 130 6.4 Hasil Perhitungan ................................................................... 132 6.4.1 Fixed Capital Investment (FCI) .................................... 132 6.4.2 Working Capital Investment (WCI) .............................. 133 6.4.3 Total Capital Investment (TCI) .................................... 133 6.4.4 Direct Manufacturing Cost (DMC) .............................. 133 6.4.5 Indirect Manufacturing Cost (IMC) ............................. 134 6.4.6 Fixed Manufacturing Cost (FMC) ................................ 134 6.4.7 Total Manufacturing Cost (TMC) ................................ 135 6.4.8 General Expense ........................................................... 135 6.4.9 Total Production Cost (TPC) ....................................... 135 6.4.10 Perhitungan Keuntungan............................................... 135 6.5 Analisis Kelayakan.................................................................. 136 5.4.1 Persent Return On Investment (ROI)........................... ......................................................................................136 5.4.2 Pay Out Time............................................................... 137 5.4.3 Break Even Point (BEP).............................................. 138 5.4.4 Shutdown Point (SDP)................................................. 139 5.4.5 Discounted Cash Flow (DCF)...................................... 140 Bab I Pendahuluan 9 Prarancangan Pabrik Hexamine dengan Proses Leonard Kapasitas 25.000 Ton/Tahun 6.1 Pembahasan.............................................................................. 143 6.2 Kesimpulan.............................................................................. 143 Daftar Pustaka ................................................................................................. xv Lampiran Bab I Pendahuluan 10