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DAFTAR ISI

Halaman
KATA PENGANTAR ...................................................................................... i
DAFTAR ISI ................................................................................................. iii
DAFTAR TABEL .......................................................................................... vi
DAFTAR GAMBAR .................................................................................... vii
DAFTAR LAMPIRAN.................................................................................. ix

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


1.1 Sejarah dan Perkembangan Pabrik ....................................................... 1
1.2 Lokasi dan Tata Letak Pabrik ............................................................... 5
1.3 Struktur Organisasi dan Manajemen Pabrik ........................................ 7
1.4 Pemasaran............................................................................................17

BAB II URAIAN PROSES .......................................................................... 20


2.1 Bahan Baku .........................................................................................20
2.1.1 Bahan Baku Pabrik Ammonia ................................................... 20
2.1.2 Bahan Baku Pabrik Urea ........................................................... 24
2.2 Proses Produksi .................................................................................. 26
2.2.1 Proses Pembuatan Ammonia...................................................... 26
2.2.2 Proses Pembuatan Urea ............................................................. 43
2.3 Produk ................................................................................................ 52
2.3.1 Produk Pabrik Ammonia ........................................................... 52
2.3.2 Produk Pabrik Urea ................................................................... 54
2.3.3 Produk Samping ........................................................................ 55
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2.4 Utilitas ................................................................................................ 56


2.5 Pengolahan Lingkungan ........................................................................... 64
2.5.1 Pengolahan Limbah Cair ........................................................... 65
2.5.2 Pengolahan Limbah Gas dan Debu ........................................... 67
2.5.3 Pengolahan Limbah Padat ......................................................... 68

BAB III TUGAS KHUSUS ......................................................................... 69


3.1 Judul ................................................................................................... 69
3.2 Latar Belakang ................................................................................... 69
3.3 Tujuan ................................................................................................ 70
3.4 Manfaat .............................................................................................. 70
3.5 Rumusan Masalah .............................................................................. 70
3.6 Tinjauan Pustaka ................................................................................ 70
3.6.1 Reaktor ...................................................................................... 70
3.6.2 Reaktor Berkatalis ......................................................................71
3.6.3 Unit Metanator .......................................................................... 73
3.6.3.1 Metanasi .............................................................................. 73
3.6.3.2 Proses Metanasi .................................................................. 74
3.6.4 Katalis ....................................................................................... 75
3.7 Pemecahan Masalah ........................................................................... 77
3.7.1 Waktu dan Tempat Pengambilan Data ...................................... 77
3.7.2 Metode Pengambilan Data ........................................................ 77
3.7.3 Menghitung Kinerja Alat Metanator ......................................... 77

3.8 Hasil konversi reaksi CO dan CO2 ..................................................... 79


3.8.1 Hasil perhitungan konversi ....................................................... 79
3.9 Pembahasan ........................................................................................ 79
3.10 Kesimpulan ...................................................................................... 81
3.11 Saran ................................................................................................. 81

BAB IV .......................................................................................................... 82
DAFTAR PUSTAKA ................................................................................... 83
LAMPIRAN

DAFTAR TABEL
Halaman
Tabel 1. Data perkembangan pabrik PT. PUSRI ........................................... 4
Tabel 2. Komposisi Gas alam...................................................................... 20
Tabel 3. Sifat-sifat fisik Gas alam................................................................ 21
Tabel 4. Sifat-sifat fisik Air.......................................................................... 22
Tabel 5. Sifat-sifat fisik Udara..................................................................... 23
Tabel 6. Sifat-sifat fisik Ammonia............................................................... 24
Tabel 7. Sifat-sifat fisik CO2........................................................................ 25
Tabel 8. Komposisi gas outlet...................................................................... 36
Tabel 9. Spesifikasi ammonia produk PT. PUSRI....................................... 53
Tabel 10. Spesifikasi CO2 produk ammonia PT. PUSRI............................. 53
Tabel 11. Sifat-sifat fisik urea...................................................................... 54
Tabel 12. Spesifikasi urea produk PT. PUSRI............................................. 55
Tabel 13. Pengolahan air di demin plant...................................................... 58
Tabel 14. Spesifikasi katalis nikel oksida.................................................... 76
Tabel 15. Syn gas feed flow FR-40 Metanator............................................ 77
Tabel 16. Fraksi mol inlet Metanator........................................................... 77
Tabel 17. Flow aliran outlet Metanator........................................................ 84
Tabel 18. Data input Metanator................................................................... 86
Tabel 19. Hasil perhitungan kmol inlet Metanator...................................... 87
Tabel 20. Neraca atom komposisi input....................................................... 88
Tabel 21. Neraca massa Metanator.............................................................. 92

DAFTAR GAMBAR

Halaman
Gambar 1. Lokasi dan tata letak PT. PUSRI.................................................. 6
Gambar 2. Struktur organisasi PT. PUSRI................................................... 16
Gambar 3. Metanator................................................................................... 74
Gambar 4. Blok diagram Metanator............................................................ 86
Gambar 5. Blok diagram hasil kmol inlet.................................................... 87
Gambar 6. Blok diagram hasil perhitungan outlet metanator..................... 91
Gambar 7. Blok diagram keseluruhan hasil perhitungan metanator............ 94
Gambar 8. Gas Mathering Station (GMS) pada unit utilitas....................... 97
Gambar 9. Water treatment pada unit utilitas ............................................. 98
Gambar 10. Demineralized water plant pada unit utilitas............................ 99
Gambar 11. Cooling water system pada unit utilitas................................ 100
Gambar 12. Plant air dan Instrument air pada unit utilitas........................ 101
Gambar 13. Gas turbine generator pada unit utilitas................................. 102
Gambar 14. Steam system pada unit utilitas.............................................. 103
Gambar 15. Waste heat boiler system pada unit utilitas............................ 104
Gambar 16. Packege boiler system pada unit utilitas................................ 105
Gambar 17. Pusri effluent treatment.......................................................... 106
Gambar 18. Instalasi pengolahan air limbah (IPAL) pada utilitas............. 107
Gambar 19. Flowsheet Feed Treating pada proses pembuatan ammonia.. 108
Gambar 20. Flowsheet proses Reforming pada pembuatan ammonia....... 109
Gambar 21. Flowsheet proses Purifikasi (Shift Converter)........................110

Gambar 22. Flowsheet proses Purifikasi (CO2 Removal).......................... 111


Gambar 23. Flowsheet proses Purifikasi (Metanator)............................... 112
Gambar 24. Flowsheet proses Sintesa Loop pada pembuatan ammonia... 113
Gambar 25. Flowsheet proses Refrigerant Loop....................................... 114
Gambar 26. Flowsheet Pembuatan Urea.................................................... 115

DAFTAR LAMPIRAN

Halaman
Lampiran Perhitungan............................................................................. 84
Lampiran Blok Diagram...........................................................................97
Lampiran Data-data .............................................................................. 116
Lampiran Surat-surat............................................................................. 118