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library.uns.ac.id digilib.uns.ac.id
TUGAS AKHIR
PRARANCANGAN PABRIK ETIL ASETAT DARI ETANOL
DAN ASAM ASETAT DENGAN REACTIVE DISTILLATION
KAPASITAS 60.000 TON/TAHUN
Disusun Oleh:
Nanda Suhartono Suryadi Putra I 0514041
PROGAM STUDI SARJANA TEKNIK KIMIA
FAKULTAS TEKNIK
UNIVERSITAS SEBELAS MARET
SURAKARTA
2018
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KATA PENGANTAR
Syukur Alhamdulillah, segala puji hanya bagi Allah SWT, karena
limpahan rahmat dan hidayah-Nya, penulis akhirnya dapat menyelesaikan
penyusunan Laporan Tugas Akhir dengan judul “Prarancangan Pabrik Etil Asetat
dari Etanol dan Asam Asetat dengan Reactive Distillation Kapasitas 60.000
Ton/Tahun”.
Dalam penyusunan tugas akhir ini penulis memperoleh banyak bantuan
dari berbagai pihak. Oleh karena itu, penulis ingin mengucapkan terimakasih
kepada:
1. Orang tua dan keluarga tercinta atas doa, dukungan moril dan materiil.
2. Dr. Margono, S.T., M.T. selaku Kepala Program Studi S1 Teknik Kimia atas
bimbingannya.
3. Dr. Ari Diana Susanti, S.T., M.T. dan Dr. Sunu Herwi Pranolo, S.T., M.Sc.
selaku dosen pembimbing atas bimbingan dan arahannya dalam penyelesaian
tugas akhir ini.
4. Teman-teman Teknik Kimia UNS angkatan 2014, khususnya, Aman, Fio,
Mamat, Aje, Andhika, Arum, Annisa Puji, Cua, Asih, Deni, Damar, Edwin, Esa,
Jon, Faiz, Mitha, Fera, Hesa, Ihang, Farid, Jeihan, Karina, Kresna, Nurin,
Maudy, Tarmiul, Iqbal, Fadil, Reza, Fardan, Rara, Ratri, Rina, Rita, Siti, Stella,
Uci, Susor, Ghina, dan Topal atas bantuan, semangat dan dukungannya dalam
penyelesaian 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
dan pembaca sekalian.
Surakarta, November 2018
Penulis
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DAFTAR ISI
LEMBAR PENGESAHAN ................................................................................................ ii
LEMBAR KONSULTASI ................................................................................................. iii
KATA PENGANTAR ....................................................................................................... vi
DAFTAR ISI ..................................................................................................................... vii
DAFTAR TABEL .............................................................................................................. ix
DAFTAR GAMBAR .......................................................................................................... x
INTISARI .......................................................................................................................... xi
ABSTRACT ........................................................................................................................ xii
BAB I PENDAHULUAN ................................................................................................... 1
I.1. Latar Belakang Pendirian Pabrik .......................................................................... 1
I.2. Kapasitas Perancangan Pabrik .............................................................................. 2
I.3. Pemilihan Lokasi Pabrik ....................................................................................... 5
I.4. Tinjauan Pustaka ................................................................................................... 6
BAB II DESKRIPSI PROSES ......................................................................................... 14
II.1. Spesifikasi Bahan Baku, Bahan Pembantu, dan Produk ..................................... 14
II.2. Konsep Dasar Proses ........................................................................................... 15
II.3. Diagram Alir Proses ............................................................................................ 19
II.4. Neraca Massa dan Neraca Panas ......................................................................... 24
II.5. Tata Letak Pabrik dan Peralatan Proses .............................................................. 27
BAB III SPESIFIKASI PERALATAN PROSES ............................................................. 32
III.1. Tangki ................................................................................................................. 32
III.2. Reactive Distillation Column .............................................................................. 34
III.3 Dekanter .............................................................................................................. 35
III.4. Stripping Column ................................................................................................ 36
III.5. Pompa ................................................................................................................. 36
III.6. Heat Exchanger .................................................................................................. 41
III.7. Reboiler ............................................................................................................... 42
III.8. Kondesnsor ......................................................................................................... 43
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BAB IV UNIT PENDUKUNG PROSES DAN LABORATORIUM .............................. 45
IV.I. Unit Pendukung Proses ....................................................................................... 45
IV.2. Laboratorium ....................................................................................................... 55
IV.3. Keselamatan dan Kesehatan Kerja ...................................................................... 57
BAB V MANAJEMEN PERUSAHAAN ......................................................................... 58
V.1. Bentuk Perusahaan .............................................................................................. 58
V.2. Struktur Organisasi ............................................................................................. 58
V.3. Tugas dan Wewenang ......................................................................................... 61
V.4. Pembagian Jam Kerja Karyawan ........................................................................ 64
V.5. Status Karyawan dan Sistem Upah ..................................................................... 65
V.6. Penggolongan Jabatan, Jumlah Karyawan, dan Gaji .......................................... 66
V.7. Keselamatan Kerja (Safety) ................................................................................. 68
V.8. Jaminan Sosial Tenaga Kerja .............................................................................. 69
BAB VI ANALISA EKONOMI ....................................................................................... 71
VI.1. Penaksiran Harga Peralatan ................................................................................ 73
VI.2. Dasar Perhitungan ............................................................................................... 74
VI.3. Penentuan Total Capital Investment (TCI) ......................................................... 74
DAFTAR PUSTAKA ....................................................................................................... 79
LAMPIRAN ...................................................................................................................... 82
Lampiran A. Sifat-Sifat Fisis Bahan ................................................................................. 83
Lampiran B. Neraca Massa ............................................................................................... 88
Lampiran C. Neraca Panas ................................................................................................ 97
Lampiran D. Reactive Distillation Column ..................................................................... 108
Lampiran E. Stripping Column ....................................................................................... 182
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DAFTAR TABEL
Tabel I.1. Data Impor Etil Asetat di Indonesia (BPS, 2009-2016) ..................................... 2
Tabel I.2. Data Kapasitas Produksi Etil Asetat di Berbagai Negara (Dutia, 2004)............. 4
Tabel I.3. Perbandingan Proses Produksi Etil Asetat .......................................................... 8
Tabel II.1. Neraca Massa di Reactive Distillation ............................................................ 25
Tabel II.2. Neraca Massa di Dekanter ............................................................................... 25
Tabel II.3. Neraca Massa di Tee ....................................................................................... 25
Tabel II.4. Neraca Massa di Stripping Column ................................................................. 25
Tabel II.5. Neraca Massa Total ......................................................................................... 26
Tabel II.6. Neraca Panas Reactive Distillation dan Dekanter ........................................... 26
Tabel II.7. Neraca Panas Stripping Column ...................................................................... 26
Tabel II.8. Neraca Panas Total .......................................................................................... 27
Tabel III.1. Spesifikasi HE-01 .......................................................................................... 41
Tabel III.2. Spesifikasi RB-01 .......................................................................................... 42
Tabel III.3. Spesifikasi CD-01 .......................................................................................... 43
Tabel III.4. Spesifikasi CD-02 .......................................................................................... 44
Tabel IV.1. Kebutuhan air pendingin................................................................................ 50
Tabel IV.2. Kebutuhan air untuk steam ............................................................................ 50
Tabel IV.3. Kebutuhan air konsumsi umum dan sanitasi ................................................. 51
Tabel IV.4. Kebutuhan air total ....................................................................................... 51
Tabel V.1. Jadwal Pembagian Kelompok Shift ................................................................. 65
Tabel V.2. Jumlah dan Gaji Karyawan Sesuai Jabatan ..................................................... 67
Tabel VI.1. Indeks Harga Alat .......................................................................................... 73
Tabel VI.2. Fixed Capital Investment (FCI) ..................................................................... 75
Tabel VI.3. Working Capital Invesment (WCI) ................................................................ 75
Tabel VI.4. Direct Manufacturing Cost (DMC) ............................................................... 76
Tabel VI.5. Indirect Manufacturing Cost (IMC) .............................................................. 76
Tabel VI.6. Fixed Manufacturing Cost (FMC) ................................................................. 76
Tabel VI.7. General Expense (GE) ................................................................................... 77
Tabel VI.8. Profit .............................................................................................................. 77
Tabel VI.9. Analisis Kelayakan ........................................................................................ 77
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DAFTAR GAMBAR
Gambar I.1. Grafik Impor Etil Asetat di Indonesia ............................................................. 3
Gambar I.2 Lokasi Pendirian Pabrik Etil Asetat ................................................................. 5
Gambar II.1. Blok Diagram Kualitatif Pabrik Etil Asetat ................................................. 20
Gambar II.2. Blok Diagram Kuantitatif Pabrik Etil Asetat ............................................... 21
Gambar II.3. Diagram Alir Proses Pabrik Etil Asetat ....................................................... 22
Gambar II.4. Tata Letak Pabrik Etil Asetat ...................................................................... 29
Gambar II.5. Tata Letak Peralatan Proses ......................................................................... 31
Gambar IV.1. Skema Pengolahan Air Sungai ................................................................... 49
Gambar IV.2. Skema Instalasi Pengolahan Air Limbah ................................................... 54
Gambar V.1. Struktur Organisasi Pabrik Etil Asetat ........................................................ 60
Gambar VI.1. Chemical Engineering Cost Index ............................................................. 74
Gambar VI.2. Grafik Analisis Kelayakan ......................................................................... 78
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INTISARI
Nanda Suhartono Suryadi Putra, 2018, Prarancangan Pabrik Etil Asetat dari
Etanol dan Asam Asetat dengan Reactive Distillation Kapasitas 60.000
Ton/Tahun, Program Studi S1 Teknik Kimia, Fakultas Teknik, Universitas
Sebelas Maret, Surakarta.
Prarancangan pabrik etil asetat dengan kapasitas 60.000 ton/tahun
beroperasi secara kontinyu selama 330 hari/tahun dan 24 jam/hari. Satu kg produk
etil asetat membutuhkan bahan baku asam asetat 0,70 kg dan etanol 0,57 kg serta
menghasilkan limbah cair 0,27 kg. Pabrik etil asetat akan didirikan di Kawasan
Industri Kabupaten Gresik, Jawa Timur.
Reaksi pembentukan etil asetat dengan cara esterifikasi dari asam asetat
dan etanol melalui proses reaksi fase cair-cair dengan katalis resin penukar ion yaitu
amberlyst 30 wet. Reaksi berlangsung dalam reactive distillation column dengan
tujuan membuat konversi mencapai 100% terhadap asam asetat. Kondisi operasi
berjalan secara non-adiabatic non-isothermal pada temperatur 81–122°C dan
tekanan 1,5 bar dengan pemanas steam jenuh pada suhu 150°C dan tekanan 4,76
bar. Tahapan pemurnian produk dilakukan dalam dekanter dan stripping column
hingga kemurnian 99,96% berat.
Unit Pendukung pabrik etil asetat terdiri dari unit utilitas untuk pengadaan
air sebesar 13,95 L/kg produk yang diperoleh dari sungai Bengawan Solo, tenaga
listrik sebesar 0,05 kWh/kg produk, penyediaan udara tekan sebesar 0,02 Nm3/kg
produk, penyediaan steam jenuh sebesar 3,43 kg/kg produk, penyediaan bahan
bakar HSD sebesar 0,01 L/kg produk untuk generator, dan natural gas sebesar
1,35×10-4 MMBtu/kg produk untuk boiler. Pabrik didukung oleh tiga laboratorium,
yaitu laboratorium fisik, laboratorium analitik, serta laboratorium penelitian dan
pengembangan. Pabrik didirikan di area dengan luas tanah 2,46 ha pada tahun 2019
dan akan beroperasi pada tahun 2020. Jumlah karyawan sebanyak 146 orang yang
terdiri dari karyawan shift dan non shift dengan 0,02 man hour/kg produk.
Hasil analisis ekonomi prarancangan pabrik etil asetat diperoleh total
production cost sebesar Rp16.316,93 /kg produk dengan harga jual produk
Rp18.626,00 /kg produk, POS (Profit on Sales) sebelum dan sesudah pajak
sebesar 12,40% dan 9,92%, ROI (Return on Investment) sebelum dan sesudah
pajak sebesar 39,96% dan 31,97%, POT (Pay Out Time) sebelum dan sesudah pajak
selama 2,04 dan 2,44 tahun, BEP (Break Event Point) 40,46%, SDP (Shut Down
Point) 22,28%, DCF (Discounted Cash Flow) sebesar 25,99%, BCR (Benefit Cost
Ratio) sebesar 11,32%, NPV (Net Present Value) US$3.616.394, dan IRR (Internal
Rate of Return) sebesar 12,01%. Jadi, dari segi ekonomi pabrik tersebut layak
didirikan.
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ABSTRACT
Ethyl acetate plant designed to 60,000 tons/year of capacity and operate
continuously 330 days/year. In order to produce 1 kg methyl chloride product, 0.70
kg acetic acid and 0.57 kg ethanol are required as raw materials. This process
produces 0.27 kg of liquid waste. Ethyl acetate plant will be constructed in Gresik,
East Java.
Acetic acid is reacted with ethanol to form ethyl acetate through liquid
reaction using amberlyst 30 wet ion exchange as catalyst. The reaction is running
in a reactive distillation column to bring the conversion to 100% of the acetic
acid. Operating conditions running with non-adiabatic non-isothermal process at
temperature of 81–122°C and pressure of 1.5 bar using saturated steam as heater
at temperature of 150°C and pressure of 4.76 bar. The product purification is
carried out in the decanter and stripping column to get a product with a purity of
99.96% weight.
The utility requires 13.95 L/kg product of water, 0.05 kWh/kg product of
electricity, 0.02 Nm3/kg product of air instrument, 3.43 kg/kg product of saturated
steam, 0.01 L/kg product of HSD for generator, and 1.35×10-4 MMBtu/kg product
of natural gas for boiler. This plant is supported by three laboratories, those are
physical laboratory, analytical laboratory, and research & development
laboratory. Ethyl acetate plant will be constructed in an area with 2.46 hectares of
land area and this plant will be operated in 2020. This plant requires
146 employees, consist of shift employees and non shift employees with
0.02 man hour/kg product.
Based on the economical feasibility study, Rp16,316.93/kg product of total
production cost, Rp18,626.00/kg product of price of ethyl acetate, 12.40% (before
taxes) and 9.92% (after taxes) of POS, 39.96% (before taxes) and 31.97% (after
taxes) of ROI, 2.04 years (before taxes) and 2.44 years (after taxes) of POT,
40.46% of BEP, 22.28% of SDP, 25.99% of DCF, 11.32% of BCR, US$3,616,394
of NPV, and 12.01% of IRR. So, from those points, the plant is worthy of being
established.