PRA RANCANGAN PABRIK

PEMBUATAN PUPUK UREA DENGAN BAHAN BAKU GAS

SINTETIS

DENGAN KAPASITAS 120.000 TON / TAHUN

TUGAS AKHIR

Diajukan Untuk Memenuhi Persyaratan

Ujian Sarjana Teknik Kimia

OLEH :

NIM: 050405065 ERIKA MONA P.SIRAIT

DEPARTEMEN TEKNIK KIMIA

FAKULTAS TEKNIK

UNIVERSITAS SUMATERA UTARA

MEDAN

2010

Universitas Sumatera Utara

INTISARI

Gas sintesis merupakan gas yang diperoleh dari suatu proses, misalnya dari

proses penyulingan minyak bumi atau dari proses gasifikasi batubara. Gas sintesis ini

biasanya diekspor secara utuh dan dapat ditingkatkan nilai tambahnya dengan

mengubahnya menjadi produk turunan misalnya produk-produk petrokimia seperti

pupuk. Gas sintesis sebagai bahan baku pada pra-rancangan pabrik ini diperoleh dari

produk samping pengilangan minyak bumi. Pra-Rancangan pabrik pembuatan Pupuk

urea dari gas sintesis ini memiliki kapasitas 120.000 ton/tahun dengan 330 hari

kerja. Pabrik pembuatan Pupuk Urea ini membutuhkan nitrogen, hidrogen dan

karbon dioksida sabagai bahan baku dengan volume bahan baku total 40.742,4518

ton/tahun. Lokasi pabrik pembuatan pupuk urea ini direncanakan didirikan di Dumai,

Riau dengan luas areal 14.920 m2, tenaga kerja yang dibutuhkan 169 orang dengan

bentuk badan usaha Perseroan Terbatas (PT) yang dipimpin oleh seorang direktur

utama dengan struktur organisasi sistem garis dan staf.

Hasil analisa ekonomi Pabrik Pupuk Urea adalah sebagai berikut:

Total Modal Investasi : Rp 871.308.635.435 ,-

Biaya Produksi : Rp 609.185.838.889 ,-

Hasil Penjualan : Rp 893.452.764.917 ,-

Laba Bersih : Rp 198.009.413.978 ,-

Profit Margin : 31,66 %

Break Even Point : 50,53 %

Return on Investment : 22,73 %

Pay Out Time : 4,4 tahun

Return on Network : 37,88 %

Internal Rate of Return : 35,23 %

Dari hasil analisa aspek ekonomi dapat disimpulkan bahwa Pabrik Pembuatan

Pupuk Urea Dari Gas Sintesis ini layak untuk didirikan.

Universitas Sumatera Utara

DAFTAR ISI Hal

KATA PENGANTAR ............................................................................................i

INTISARI ............................................................................................................ iii

DAFTAR ISI ........................................................................................................ iv

DAFTAR TABEL ................................................................................................ vi

DAFTAR GAMBAR ............................................................................................. x

DAFTAR LAMPIRAN ........................................................................................ xi

BAB I PENDAHULUAN ............................................................................ I-1

1.1 Latar Belakang ............................................................................ I-1

1.2 Perumusan Masalah .................................................................... I-2

1.3 Tujuan Perancangan ..................................................................... I-3

1.4 Manfaat Perancangan .................................................................... I-3

BAB II TINJAUAN PUSTAKA ..................................................................... II-1

2.1 Urea ............................................................................................. II-1

2.2 Macam-Macam Proses Sintesis Urea .............................................. II-2

2.3 Faktor-Faktor yang Mempengaruhi Sintesis Urea ......................... II-2

2.4 Gambaran Umum Gas Sintesis ..................................................... II-3

2.5 Proses Produksi Amonia Secara Umum ...................................... II-4

2.6 Proses Produksi Urea Secara Umum .......................................... II-9

2.7 Deskripsi Proses ...................................................................... II-11

2.8 Sifat Fisika dan Kimia Urea ..................................................... II-14

2.9 Sifat-sifat Reaktan dan Bahan Pembantu .................................. II-15

BAB III NERACA MASSA ............................................................................III-1

BAB IV NERACA ENERGI ......................................................................... IV-1

BAB V SPESIFIKASI PERALATAN ........................................................... V-1

BAB VI INSTRUMENTASI DAN KESELAMATAN KERJA ................... VI-1

6.1 Instrumentasi ............................................................................ VI-1

6.2 Keselamatan Kerja Pabrik ......................................................... VI-8

6.3 Keselamatan Kerja Pada Pra Rancangan

Pabrik Pembuatan Urea ............................................................ VI-9

Universitas Sumatera Utara

BAB VII UTILITAS...................................................................................... V11-1

7.1 Kebutuhan Steam (Uap) ........................................................... VII-1

7.2 Kebutuhan Air ......................................................................... VII-2

7.3 Kebutuhan Bahan Kimia ........................................................ VII-13

7.4 Kebutuhan Listrik .................................................................. VII-13

7.5 Kebutuhan Bahan Bakar ........................................................ VII-14

7.6 Unit Pengolahan Limbah ........................................................ VII-15

7.7 Spesifikasi Peralatan Utilitas .................................................. VII-19

BAB VIII LOKASI DAN TATA LETAK PABRIK ...................................... VIII-1

8.1 Lokasi Pabrik .......................................................................... VIII-1

8.2 Tata Letak Pabrik .................................................................... VIII-6

8.3 Perincian Luas Areal Pabrik .................................................... VIII-7

BAB IX ORGANISASI DAN MANAJEMEN PERUSAHAAN .................. IX-1

9.1 Organisasi Perusahaan .............................................................. IX-1

9.2 Manajemen Perusahaan ............................................................. IX-3

9.3 Bentuk Hukum Badan Usaha .................................................... IX-5

9.4 Uraian Tugas, Wewenang dan Tanggung Jawab ........................ IX-7

9.5 Sistem Kerja ............................................................................. IX-9

9.6 Jumlah Karyawan dan Tingkat Pendidikan .............................. IX-10

9.7 Sistem Penggajian ................................................................... IX-13

9.8 Fasilitas Tenaga Kerja ............................................................. IX-14

BAB X ANALISA EKONOMI ...................................................................... X-1

10.1 Modal Investasi ........................................................................... X-1

10.2 Biaya Produksi Total (BPT)/ Total Cost (TC) .............................. X-4

10.3 Perkiraan Rugi/labaUsaha ........................................................... X-5 10.4 Anal

BAB XI KESIMPULAN ................................................................................ XI-1

DAFTAR PUSTAKA ........................................................................................... xiv

LAMPIRAN A PERHITUNGAN NERACA MASSA

LAMPIRAN B PERHITUNGAN NERACA PANAS

LAMPIRAN C PERHITUNGAN SPESIFIKASI PERALATAN

LAMPIRAN D PERHITUNGAN SPESIFIKASI PERALATAN UTILITAS

LAMPIRAN E PERHITUNGAN ASPEK EKONOMI

Universitas Sumatera Utara

DAFTAR TABEL

Tabel 1.1 Data kebutuhan Urea di Indonesia ......................................................... I-2

Tabel 2.1 Kualitas Urea yang dihasilkan............................................................... II-3

Tabel 3.1 Neraca massa Reaktor Amonia (R-101) .............................................. III-2

Tabel 3.2 Neraca massa Flash Drum (F-101) ..................................................... III-2

Tabel 3.3 Neraca massa Reaktor Urea (R-201) ................................................... III-2

Tabel 3.4 Neraca massa Knock Out Drum (F-201) ...............................................

III-3

Tabel 3.5 Neraca massa Low Pressure Decomposer (S-201) ............................. III-3

Tabel 3.6 Neraca massa Knock Out Drum (F-202) ............................................. III-4

Tabel 3.7 Neraca massa Evaporator I (FE-301) ................................................. III-4

Tabel 3.8 Neraca massa Evaporator II (FE-302) ................................................ III-5

Tabel 3.9 Neraca massa Prilling Tank (TK-402)................................................ III-5

Tabel 3.10 Neraca massa Neraca massa Screening (C-403) ................................ III-6

Tabel 4.1 Neraca Panas Reaktor (R-101) ............................................................ IV-2

Tabel 4.2 Neraca Panas Total Neraca Panas Flash Drum (F-101) ....................... IV-2

Tabel 4.3 Neraca Panas Neraca Panas Reaktor (R-201) ...................................... IV-2

Tabel 4.4 Neraca Panas Knock Out Drum (F-201) ............................................. IV-3

Tabel 4.5 Neraca Panas Low Pressure Decomposer (S-201) ............................... IV-3

Tabel 4.6 Neraca Panas Knock Out Drum (F-202) ............................................. IV-3

Tabel 4.7 Neraca Panas Evaporator I (FE-301) ................................................... IV-4

Tabel 4.8 Neraca Panas Evaporator II (FE-302).................................................. IV-4

Tabel 4.9 Neraca Panas Mealting Tank (TK-401) ............................................... IV-4

Tabel 4.10 Neraca Panas Total Prilling Tower (TK-402) ...................................... IV-5

Tabel 4.11 Neraca Panas Heater (E-101) .............................................................. IV-5

Tabel 4.12 Neraca Panas Heater (E-102) .............................................................. IV-5

Tabel 4.13 Neraca Panas Refrigrator (E-103) ....................................................... IV-6

Tabel 4.14 Neraca Panas Heater (E-104) .............................................................. IV-6

Tabel 4.15 Neraca Panas Heater (E-201) .............................................................. IV-6

Tabel 4.16 Neraca Panas Heater (E-202) .............................................................. IV-7

Tabel 4.17 Neraca Panas Water Condenser (E-301) ............................................. IV-7

Universitas Sumatera Utara

Tabel 4.18 Neraca Panas cooler (E-302) .......................................................... IV-7

Tabel 6.1 Daftar Instrumentasi pada Pra Rancangan Pabrik Pembuatan Urea . VI-4

Tabel 7.1 Kebutuhan Uap ............................................................................. VII-1

Tabel 7.2 Kebutuhan Air Pendingin .............................................................. VII-2

Tabel 7.3 Pemakaian air untuk berbagai kebutuhan ...................................... VII-4

Tabel 7.4 Kualitas Air Sungai Rokan, Riau .................................................. VII-4

Tabel 7.5 Perincian Kebutuhan Listrik ........................................................ VII-12

Tabel 8.1 Perincian Luas Areal Pabrik ......................................................... VIII-7

Tabel 9.1 Jadwal Kerja Karyawan Shift ....................................................... IX-10

Tabel 9.2 Jumlah Karyawan dan Kualifikasinya ............................................ IX-11

Tabel 9.3 Gaji Karyawan ............................................................................... IX-13

Tabel LA-1 Neraca Massa Reaktor (R-101) ....................................................... LA-3

Tabel LA-2 Hasil Perhitungan Pbuble dan Pdew ..................................................... LA-4

Tabel LA-3 Hasil Iterasi Flash Drum (F-101) .................................................... LA-5

Tabel LA-4 Hasil Perhitungan Flash Drum (F-101) ........................................... LA-5

Tabel LA-5 Neraca Massa Flash Drum (F-101) ................................................. LA-6

Tabel LA-6 Neraca Massa Reaktor (R-201) .................................................... LA-12

Tabel LA-7 Neraca Massa Knock Out Drum (F-201) ....................................... LA-13

Tabel LA-8 Neraca Massa Low Pressure Decomposer (S-201) ........................ LA-15

Tabel LA-9 Neraca Massa Knock Out Drum (F-202) ....................................... LA-16

Tabel LA-10 Neraca Massa Evaporator I (FE-301) ............................................ LA-18

Tabel LA-11 Neraca Massa Evaporator 2 (FE-302)............................................ LA-20

Tabel LA-12 Neraca Massa Prilling Tower (TK-402) ........................................ LA-21

Tabel LA-13 Neraca Massa Screening (C-403) .................................................. LA-23

Tabel LB-1 Data Kapasitas Panas Komponen Gas ............................................. LB-1

Tabel LB-2 Data Panas Perubahan Fasa Komponen ........................................... LB-1

Tabel LB-3 Data Panas Reaksi Komponen......................................................... LB-1

Tabel LB-4 Kapasitas panas liquid amonia ........................................................ LB-2

Tabel LB-5 Estimasi kapasitas panas liquid karbamat ........................................ LB-2

Tabel LB-6 Estimasi Kapasitas panas solid karbamat ......................................... LB-2

Tabel LB-7 Kapasitas panas liquid urea ............................................................. LB-2

Tabel LB-8 Kapasitas panas solid urea............................................................... LB-3

Universitas Sumatera Utara

Tabel LB-9 Panas Pembentukan ................................................................... LB-3

Tabel LB-10 Sifat fisika bahan baku ............................................................... LB-3

Tabel LB-11 Data steam dan air pendingin yang digunakan ............................ LB-4

Tabel LB-12 Data kapasitas panas refrigrant yang digunakan ......................... LB-4

Tabel LB-13 Panas masuk alur 8 .................................................................... LB-5

Tabel LB-14 Panas masuk alur 10................................................................... LB-5

Tabel LB-15 Panas Keluar alur 11 .................................................................. LB-6

Tabel LB-16 Neraca panas Reaktor (R-101) ................................................... LB-7

Tabel LB-17 Panas keluar alur 12 fasa cair ..................................................... LB-7

Tabel LB-18 Panas keluar alur 14 fasa cair ..................................................... LB-8

Tabel LB-19 Panas keluar alur 13 fasa gas ...................................................... LB-8

Tabel LB-20 Neraca panas Flash Drum (F-101) .............................................. LB-9

Tabel LB-21 Panas masuk alur 16..................................................................LB-10

Tabel LB-22 Panas masuk alur 18..................................................................LB-10

Tabel LB-23 Panas masuk alur 21..................................................................LB-10

Tabel LB-24 Panas keluar alur 19 fasa gas .....................................................LB-11

Tabel LB-25 Panas keluar alur 19 fasa cair ....................................................LB-11

Tabel LB-26 Neraca panas Reaktor (R-201) ..................................................LB-13

Tabel LB-27 Panas masuk alur 19 fasa gas ....................................................LB-14

Tabel LB-28 Panas masuk alur 19 fasa cair ....................................................LB-14

Tabel LB-29 Panas keluar alur 22 ..................................................................LB-15

Tabel LB-30 Panas keluar alur 24 ..................................................................LB-15

Tabel LB-31 Neraca panas Knock Out Drum (F-201) ....................................LB-16

Tabel LB-32 Panas masuk alur 25..................................................................LB-17

Tabel LB-33 Panas keluar alur 26 ..................................................................LB-17

Tabel LB-34 Neraca panas Low Pressure Decomposer (S-201) .....................LB-18

Tabel LB-35 Panas keluar alur 25 ..................................................................LB-19

Tabel LB-36 Panas keluar alur 27 ..................................................................LB-20

Tabel LB-37 Panas keluar alur 26 ..................................................................LB-20

Tabel LB-38 Neraca panas Knock Out Drum (F-202) ....................................LB-20

Tabel LB-39 Panas keluar alur 28 ..................................................................LB-21

Tabel LB-40 Panas keluar alur 30 ..................................................................LB-22

Universitas Sumatera Utara

Tabel LB-41 Panas keluar alur 29 ..................................................................LB-22

Tabel LB-42 Neraca panas Evaporator I (FE-301) .........................................LB-24

Tabel LB-43 Panas masuk alur 31..................................................................LB-24

Tabel LB-44 Panas keluar alur 34 ..................................................................LB-25

Tabel LB-45 Panas keluar alur 33 ..................................................................LB-26

Tabel LB-46 Neraca panas Evaporator II (FE-302) ........................................LB-27

Tabel LB-47 Panas masuk alur 36..................................................................LB-28

Tabel LB-48 Panas masuk alur 42..................................................................LB-28

Tabel LB-49 Panas keluar alur 38 ..................................................................LB-29

Tabel LB-50 Neraca panas Melting Tank (TK-401) .......................................LB-30

Tabel LB-51 Panas masuk alur 37..................................................................LB-30

Tabel LB-52 Panas masuk udara Prilling Tower (TK-402) ............................LB-31

Tabel LB-53 Panas keluar alur 40 ..................................................................LB-32

Tabel LB-54 Panas keluar udara Prilling Tower (TK-402) .............................LB-32

Tabel LB-55 Neraca panas Prilling Tower (TK-302) .....................................LB-32

Tabel LB-56 Panas keluar alur 8 ....................................................................LB-33

Tabel LB-57 Neraca panas Heater (E-101) ....................................................LB-34

Tabel LB-58 Panas keluar alur 10 ..................................................................LB-35

Tabel LB-59 Neraca panas Heater (E-102) ....................................................LB-36

Tabel LB-60 Panas keluar alur 12 ..................................................................LB-37

Tabel LB-61 Panas keluar alur 12 ..................................................................LB-37

Tabel LB-62 Neraca panas Refrigrator (E-103) .............................................LB-38

Tabel LB-63 Panas keluar alur 15 ..................................................................LB-39

Tabel LB-64 Neraca panas Heater (E-104) ....................................................LB-40

Tabel LB-65 Panas keluar alur 18 ..................................................................LB-41

Tabel LB-66 Neraca panas Heater (E-201) ....................................................LB-42

Tabel LB-67 Panas keluar alur 21 ..................................................................LB-43

Tabel LB-68 Neraca panas Heater (E-202) ....................................................LB-44

Tabel LB-69 Panas keluar alur 36 ..................................................................LB-45

Tabel LB-70 Neraca panas Water Condenser (E-301) ....................................LB-46

Tabel LB-71 Panas keluar alur 40 ..................................................................LB-47

Tabel LB-72 Neraca panas Cooler (E-302) ....................................................LB-48

Universitas Sumatera Utara

Tabel LC-1 Komposisi umpan reaktor .........................................................LC-25

Tabel LD-1 Perhitungan Entalpi Tinggi Menara Pendingin ......................... LD-17

Tabel LE-1 Perincian Harga Bangunan dan Sarana Lainnya .......................... LE-1

Tabel LE-2 Harga Indeks Marshall dan Swift ................................................ LE-3

Tabel LE-3 Estimasi Harga Peralatan Proses ................................................. LE-6

Tabel LE-4 Estimasi Harga Peralatan Utilitas dan Pengolahan Limbah .......... LE-8

Tabel LE-5 Biaya Sarana Transportasi ..................................................... ....LE-11

Tabel LE-6 Perincian Gaji Pegawai ............................................................. LE-15

Tabel LE-7 Perician Biaya Kas .................................................................... LE-17

Tabel LE-8 Perincian Modal Kerja .............................................................. LE-19

Tabel LE-9 Aturan Depresiasi sesuai UU RI No.17 tahun 2000 ................... LE-20

Tabel LE-10 Perkiraan Biaya Depresiasi sesuai UU RI No.17 tahun 2000 ..... LE-21

Tabel LE-11 Data perhitungan IRR ............................................................... LE-29

Universitas Sumatera Utara

DAFTAR GAMBAR

Gambar 8.1 Perincian Luas Areal Pabrik ...................................................... VIII-9

Gambar 9.1 Bagan struktur organisasi perusahaan pabrik

Pembuatan Urea ........................................................................ IX-15

Gambar LD-1 Spesifikasi screening ................................................................. LD-1

Gambar LD-2 Grafik Entalpi dan Temperatur Cairan pada Cooling Tower (CT).LD-17

Gambar LD-3 Kurva Hy terhadap 1/(Hyi – Hy) .............................................. LD-18

Gambar LE-1 Grafik BEP (Break Even Point)................................................. LE-29

Universitas Sumatera Utara

DAFTAR LAMPIRAN

LAMPIRAN A PERHITUNGAN NERACA MASSA ..................................... LA-1

LAMPIRAN B PERHITUNGAN NERACA PANAS ...................................... LB-1

LAMPIRAN C PERHITUNGAN SPESIFIKASI PERALATAN ..................... LC-1

LAMPIRAN D PERHITUNGAN SPESIFIKASI PERALATAN UTILITAS... LD-1

LAMPIRAN E PERHITUNGAN ASPEK EKONOMI ..................................... LE-1

Universitas Sumatera Utara