commit to user TUGAS AKHIR
PRARANCANGAN PABRIK ETILEN GLIKOL
DARI ETILEN OKSIDA DAN AIR
MELALUI PROSES HIDRASI KATALITIK
KAPASITAS 160.000 TON/TAHUN
Oleh :
Erfan Setiyo Nugroho ( I 0508087 ) Denny Sugiantoro ( I 0509009 )
JURUSAN TEKNIK KIMIA FAKULTAS TEKNIK UNIVERSITAS SEBELAS MARET
SURAKARTA
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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
1.1 Latar Belakang Pendirian Pabrik ... 1
1.2 Kapasitas Perancangan ... 2
1.3 Pemilihan Lokasi Pabrik ... 4
1.4 Tinjauan Pustaka ... 8
1.4.1 Macam-macam Proses ... 8
1.4.2 Kegunaan Produk ... 10
1.4.3 Sifat Fisis dan Kimia ... 10
A. Bahan Baku ... 10
B. Bahan Pembantu (Katalis) ... 12
C. Produk ... 13
1.4.4 Tinjauan Proses Secara Umum ... 14
BAB II DESKRIPSI PROSES ... 16
2.1 Spesifikasi Bahan Baku dan Produk ... 16 iv
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2.1.1 Spesifikasi Bahan Baku ... 16
2.1.2 Spesifikasi Produk ... 17
2.2 Konsep Dasar Proses ... 18
2.2.1 Dasar Reaksi ... 18 2.2.2 Tinjauan Kinetika ... 20 2.2.3 Tinjauan Termodinamika... 21 2.2.4 Fase Reaksi ... 26 2.2.5 Kondisi Operasi ... 26 2.2.6 Katalis ... 27
2.3 Diagram Alir Proses dan Tahapan Proses ... 28
2.3.1 Diagram Alir Kualitatif ... 29
2.3.2 Diagram Alir Kuantitatif... 30
2.3.3 Diagram Alir Proses ... 31
2.3.4 Tahapan Proses ... 32
2.3.4.1. Tahap Penyiapan Bahan Baku ... 32
2.3.4.2. Tahap Reaksi Hidrasi ... 32
2.3.4.3. Tahap Pemurnian Produk ... 32
2.4 Neraca Massa dan Neraca Panas ... 34
2.4.1 Neraca Massa ... 34
2.4.2 Neraca Panas ... 37
2.5 Lay Out Pabrik dan Peralatan Proses ... 39
2.5.1 Lay Out Pabrik ... 39
2.5.2 Lay Out Peralatan Proses ... 41
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BAB III SPESIFIKASI ALAT PROSES ... 43
BAB IV UNIT PENDUKUNG PROSES DAN LABORATORIUM... 55
4.1 Unit Pendukung Proses ... 56
4.1.1 Unit Pengadaan Air ... 61
4.1.2 Unit Pengadaan Steam ... 64
4.1.3 Unit Pengadaan Udara Tekan ... 66
4.1.4 Unit Pengadaan Listrik ... 67
4.1.5 Unit Pengadaan Bahan Bakar ... 72
4.2 Laboratorium ... 73
4.2.1 Laboratorium Fisik ... 75
4.2.2 Laboratorium Analitik ... 75
4.2.3 Laboratorium Penelitian dan Pengembangan ... 76
4.3 Unit Pengolahan Limbah ... 79
4.4 Keselamatan dan Kesehatan Kerja ... 81
BAB V MANAJEMEN PERUSAHAAN ... 83
5.1 Bentuk Perusahaan ... 83
5.2 Struktur Organisasi ... 84
5.3 Tugas dan Wewenang ... 86
5.4 Pembagian Jam Kerja dan Gaji Karyawan ... 86
5.4.1 Karyawan Non Shift ... 88
5.4.2 Karyawan Shift ... 88
BAB VI ANALISIS EKONOMI ... 90
6.1 Penaksiran Harga Peralatan ... 91
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6.2 Dasar Perhitungan ... 92
6.3 Penentuan Total Capital Investment (TCI) ... 93
6.4 Hasil Perhitungan ... 93
DAFTAR PUSTAKA ... xiii LAMPIRAN
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DAFTAR GAMBAR
Gambar I.1. Impor Etilen Glikol di Indonesia ... 2
Gambar I.2. Lokasi Pabrik Etilen Glikol ... 8
Gambar II.1. Diagram Alir Kualitatif ... 29
Gambar II.2. Diagram Alir Kuantitatif ... 30
Gambar II.3. Diagram Alir Proses ... 31
Gambar II.4. Layout Pabrik Etilen Glikol ... 40
Gambar II.5. Layout Pabrik Peralatan Proses ... 42
Gambar IV.1. Diagram Alir Pengolahan Air ... 57
Gambar V.1. Struktur Organisasi Pabrik Etilen Glikol ... 85
Gambar VI.1. Grafik Linierisasi Indeks Harga ... 91
Gambar VI.2. Grafik Analisa Kelayakan ... 101
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DAFTAR TABEL
Tabel I.1 Kenaikan Import Etilen Glikol di Indonesia ... 2
Tabel I.2 Pabrik Penghasil Etilen Glikol di Dunia ... 4
Tabel I.3 Produsen Industri PSF/PFY Indonesia ... 5
Tabel I.4 Produsen Industri PET Resin di Indonesia ... 6
Tabel I.5. Produsen NFY di Indonesia ... 6
Tabel I.6. Macam- Macam Proses Pembuatan Etilen Glikol ... 9
Tabel II.1. Harga ΔH°f masing- masing komponen. ... 22
Tabel II.2. Harga ΔG°f masing- masing komponen ... 23
Tabel II.3. Neraca Massa di Tee-01 ... 34
Tabel II.4. Neraca Massa di Tee-02 ... 34
Tabel II.5. Neraca Massa di Tee-03 ... 34
Tabel II.6. Neraca Massa di Mixer M-01 ... 34
Tabel II.7. Neraca Massa Reaktor R-01... 35
Tabel II.8. Neraca Massa Evaporator E-01 ... 35
Tabel II.9. Neraca Massa Evaporator E-02 ... 35
Tabel II.10. Neraca Massa Menara Distilasi 1 MD-01 ... 36
Tabel II.11. Neraca Massa Menara Distilasi 2 MD-02 ... 36
Tabel II.12. Neraca Massa Total ... 36
Tabel II.13. Neraca Panas Reaktor R-01 ... 37
Tabel II.14. Neraca Panas Reaktor Evaporator 1 E-01 ... 37
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Tabel II.15. Neraca Panas Evaporator 2 E-02... 38
Tabel II.16. Neraca Panas Menara Distilasi 1 MD-01 ... 38
Tabel II.17. Neraca Panas Menara Distilasi 2 MD-02 ... 38
Tabel II.18. Neraca Panas Mixer M-01 ... 39
Tabel III.1. Spesifikasi Mixer ... 44
Tabel III.2. Spesifikasi Reaktor ... 44
Tabel III.3. Spesifikasi Double Effect Evaporator ... 45
Tabel III.4. Spesifikasi Menara Destilasi ... 46
Tabel III.5. Spesifikasi Tangki ... 46
Tabel III.6. Spesifikasi Accumulator ... 47
Tabel III.7. Spesifikasi Pompa ... 48
Tabel III.8. Spesifikasi Heat Exchanger ... 50
Tabel IV.1. Kebutuhan Air Proses ... 58
Tabel IV.2. Kebutuhan Air Pendingin ... 59
Tabel IV.3. Kebutuhan Air untuk Steam ... 60
Tabel IV.4. Jumlah Kebutuhan Air ... 64
Tabel IV.5. Kebutuhan Listrik untuk Keperluan Proses dan Utilitas ... 68
Tabel IV.6. Jumlah Lumen Berdasarkan Luas Bangunan ... 70
Tabel IV.7. Total Kebutuhan Listrik Pabrik dari PLN ... 71
Tabel V.1. Perincian kualifikasi, jumlah, dan gaji karyawan non shift ... 87
Tabel V.2. Perincian kualifikasi, jumlah, dan gaji karyawan shift ... 88
Tabel V.3. Jadwal Pembagian Kelompok Shift ... 89
Tabel VI.1. Indeks Harga Alat ... 91 ix
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Tabel VI.2. Fixed Capital Investment ... 94
Tabel VI.3. Working Capital Investment ... 94
Tabel VI.4. Direct Manufacturing Cost ... 95
Tabel VI.5. Indirect Manufacturing Cost ... 95
Tabel VI.6. Fixed Manufacturing Cost ... 95
Tabel VI.7. General Expense ... 96
Tabel VI.8. Analisis Kelayakan ... 100
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Erfan Setiyo Nugroho, Denny Sugiantoro, 2014, Preliminary Design of Ethylene Glycol Plant from Ethylene Oxide and Water by Catalytic Hydration, Capacity 160,000 tons/year, Chemical Engineering, Sebelas Maret University, Surakarta.
Ethylene Glycol (C2H4(OH)2) is an organic compound founded by Wurtz on 1859 by treating 1,2-Dibromoethane with silver acetate to produce ethylene glycol diacetateand with further hydrolysis to produce ethylene glycol. Commercially in Indonesia, 97.34% of Ethylene Glycol is used as feedstock to polyester industry (textile) and 2.66% is used as additional feedstock in dye, brake fluid, solvent, alkyd resin, thinner, ink, foam stabilizer, cosmetic product, and anti-freeze agent. Ethylene Glycol Plant (from Ethylene Oxide and water by using catalytic hydration) will be built on Cilegon industrial area, Banten on 2017 with 160,000 tons/year capacity.
Ethylene Glycol is produced by treating Ethylene Oxide with water at 46oC – 99.85oC and 17 atm in a fixed bed single tube reactor at adiabatic condition. The molar ratio of Ethylene Oxide and water is 1 : 20. The reaction operates in exothermic reaction and liquid phase. The feeds used are Ethylene Oxide with purity of 99.9 wt percent (119,662.15 tons/year), water (47,507.29 tons/year) and amberlyst 15 as catalyst (82.67 tons/year). The main products are Ethylene Glycol with purity of 99.5 wt percent, water impurity and Diethylene Glycol. The by products are Diethylene Glycol with purity of 96 wt percent and Triethylene Glycol.
The utilities including water (process water, cooler water, boiler feed water, drinking water, and sanitized water) and steam from PT Krakatau Tirta Industri (PT. KTI) which located in Cilegon industrial area. The water consumption rate is 298,686,411 kg/hour and steam consumption rate is 105,689.416 kg/hour. The electricity usage is 511.75 kW from
Perusahaan Listrik Negara (PLN). The fuel consumption rate from IDO (Industrial Diesel
Oil) is 4,249.27 litre/month. And the pressurized air consumption rate is 99 m3/hour. There are 3 laboratories, physical, analytical and research and development laboratory. The liquid waste is from the sanitation equipment and oiled water from the main equipment.
The type of company is chosen as Private Limited with line and staff structure. The company employs 169 people.
Economic analysis shows that the Return of Investment (ROI) is 38.78% before tax and 25.21% after tax. Pay Out Time (POT) is 2.1 year before tax and 3.0 year after tax. Break Even Point (BEP) is 44.04%, Shut Down Point (SDP) is 29.61% and Discounted Cash Flow (DCF) is 14.50%. These data show that Ethylene Glycol Plant can be established.
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Erfan SetiyoNugroho, Denny Sugiantoro, 2014, Preliminary Design of Ethylene Glycol Plant from Ethylene Oxide and Water by Catalytic Hydration, Capacity 160,000 tons/year, Chemical Engineering, Sebelas Maret University, Surakarta.
Ethylene Glycol (C2H4(OH)2) is an organic compound founded by Wurtz on 1859 by treating 1,2-Dibromoethane with silver acetate to produce ethylene glycol diacetateand with further hydrolysis to produce ethylene glycol. Commercially in Indonesia, 97.34% of Ethylene Glycol is used as feedstock to polyester industry (textile) and 2.66% is used as additional feedstock in dye, brake fluid, solvent, alkyd resin, thinner, ink, foam stabilizer, cosmetic product, and anti-freeze agent. Ethylene Glycol Plant (from Ethylene Oxide and water by using catalytic hydration) will be built on Cilegon industrial area, Banten on 2017 with 160,000 tons/year capacity.
Ethylene Glycol is produced by treating Ethylene Oxide with water at 46oC – 99.85oC and 17 atm in a fixed bed single tube reactor at adiabatic condition. The molar ratio of Ethylene Oxide and water is 1 : 20. The reaction operates in exothermic reaction and liquid phase. The feeds used are Ethylene Oxide with purity of 99.9 wt percent (119,662.15 tons/year), water (47,507.29 tons/year) and amberlyst 15 as catalyst (82.67 tons/year). The main products are Ethylene Glycol with purity of 99.5 wt percent, water impurity and Diethylene Glycol. The by products are Diethylene Glycol with purity of 96 wt percent and Triethylene Glycol.
The utilities including water (process water, cooler water, boiler feed water, drinking water, and sanitized water) and steam from PT Krakatau Tirta Industri (PT. KTI) which located in Cilegon industrial area. The water consumption rate is 298,686,411 kg/hour and steam consumption rate is 105,689.416 kg/hour. The electricity usage is 511.75 kW from
Perusahaan Listrik Negara (PLN). The fuel consumption rate from IDO (Industrial Diesel
Oil) is 4,249.27 litre/month. And the pressurized air consumption rate is 99 m3/hour. There are 3 laboratories, physical, analytical and research and development laboratory. The liquid waste is from the sanitation equipment and oiled water from the main equipment.
The type of company is chosen as Private Limited with line and staff structure. The company employs 169 people.
Economic analysis shows that the Return of Investment (ROI) is 38.78% before tax and 25.21% after tax. Pay Out Time (POT) is 2.1 year before tax and 3.0 year after tax. Break Even Point (BEP) is 44.04%, Shut Down Point (SDP) is 29.61% and Discounted Cash Flow (DCF) is 14.50%. These data show that Ethylene Glycol Plant can be established.
