PRA RANCANGAN PABRIK POLIMETIL METAKRILAT

DENGAN KAPASITAS PRODUKSI

20.000 TON/TAHUN
LAPORAN PRA RANCANGAN PABRIK

Disusun oleh :
Eka Irawan
(3335090994)
Faulina Popy Puspita
(3335091327)
Reni Mutiara Sari
(3335090155)

Cilegon-Banten

JURUSAN TEKNIK KIMIA FAKULTAS TEKNIK

UNIVERSITAS SULTAN AGENG TIRTAYASA
CILEGON BANTEN
2013

PRA RANCANGAN PABRIK POLIMETIL METAKRILAT

DENGAN KAPASITAS PRODUKSI
20.000 TON/TAHUN
Laporan pra rancangan pabrik ini disusun sebagai syarat
Kelulusan mata kuliah rancangan pabrik dan salah
Satu syarat menempuh sarjana strata I
Teknik Kimia Universitas Sultan Ageng Tirtayasa

Disusun oleh :
Eka Irawan
Faulina Popy Puspita
Reni Mutiara Sari

(3335090994)
(3335091327)
(3335090155)

Cilegon-Banten

JURUSAN TEKNIK KIMIA FAKULTAS TEKNIK

UNIVERSITAS SULTAN AGENG TIRTAYASA
CILEGON BANTEN
2013

ii

LEMBAR PENGESAHAN
PRA RANCANGAN PABRIK POLIMETIL METAKRILAT

DENGAN KAPASITAS PRODUKSI

20.000 TON/TAHUN

Catatan :

Cilegon, Juli 2013

Mengetahui,
Pembimbing

DHENA RIA BARLEANY . ST.,M.Eng

NIP:198203152005012002
iii

DAFTAR ISI

HALAMAN DEPAN ........................................................................................ i

LEMBAR PENGESAHAN.............................................................................. ii
ABSTRAK......................................................................................................... iii
KATA PENGANTAR....................................................................................... iv
DAFTAR ISI..................................................................................................... vi
DAFTAR TABEL.............................................................................................. xii
DAFTAR GAMBAR......................................................................................... xiv
BAB I PENDAHULUAN
1.1 Latar Belakang............................................................................................ 1
1.2 Analisa Pasar................................................................................................ 2
1.3 Jenis Teknologi............................................................................................ 2
1.4 Pemilihan Proses.......................................................................................... 13
1.5 Deskripsi Proses.......................................................................................... 15
1.6 Pemilihan Lokasi Pabrik.............................................................................. 20
1.7 Kegunaan Produk............................................................................. 23
1.2 Spesifikasi Bahan Baku dan Produk............................................................ 24

BAB II NERACA MASSA DAN ENERGI

2.1 Neraca Massa ............................................................................................. 28
2.1.1 Neraca Massa di Feed Mix Drum (V-101)...................................... 19
2.1.2 Neraca Massa di Reaktor (R-101)................................................... 20
2.1.3 Neraca Massa di Evaporator (V-102).............................................. 21
2.1.4 Neraca Massa di Kristalizer (V-104)............................................... 22
2.1.5 Neraca Massa di Press Filter (F-101).............................................. 23
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2.1.6 Neraca Massa di Rotary Dryer (M-101).......................................... 24

2.1.7 Neraca Massa di Mother Liquor Drum (V-105).............................. 25
2.1.8 Neraca Massa di Evaporator (V-106).............................................. 26
2.1.9 Neraca Massa di Evaporator (V-103).............................................. 27
2.1.10 Neraca Massa di Absorber (T-101).................................................. 28
2.2 Neraca Energi ............................................................................................. 29
2.2.1 Neraca Energi di Heater (E-101)..................................................... 29
2.2.2 Neraca Energi di Heater (E-102)..................................................... 30
2.2.3 Neraca Energi di Reaktor (R-101)................................................... 30
2.2.4 Neraca Energi di Evaporator (V-102).............................................. 31
2.2.5 Neraca Energi di Condenser (E-103)............................................... 32
2.2.6 Neraca Energi di Condenser (E-104)............................................... 32
2.2.7 Neraca Energi di Cooler (E-105)..................................................... 33
2.2.8 Neraca Energi di Kristalizer (V-104)............................................... 34
2.2.9 Neraca Energi di Rotary Dryer (M-101)......................................... 34
2.2.10 Neraca Energi Heater (E-106)......................................................... 35
2.2.11 Neraca Energi di Evaporator (V-103).............................................. 35
2.2.12 Neraca Energi di Evaporator (V-106).............................................. 36
2.2.13 Neraca Energi di Condenser (T-107)............................................... 37
2.2.14 Neraca Energi di Cooler (T-108)..................................................... 38

BAB III SPESIFIKASI PERALATAN PROSES

3.1 Sistem Proses ............................................................................................... 39
3.1.1 Feed Mix Drum (V-101).................................................................... 39
3.1.2 Reaktor Oksidasi (R-101).................................................................. 40
3.1.3 Kristalizer (V-104)............................................................................. 41
3.1.4 Mother Liquor Drum (V-105)............................................................ 43
3.2 Alat Pemisah ................................................................................................ 44
3.2.1 Evaporator (V-102) .......................................................................... 44
3.2.2 Evaporator (V-103)............................................................................ 45
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3.2.3 Evaporator (V-106)............................................................................ 46

3.2.4 Press Filter (F-101)............................................................................ 47
3.2.5 Rotary Dryer (M-102)........................................................................ 48
3.2.6 Absorber (T-101)............................................................................... 48
3.2.7 Ball Mill (BM-101)............................................................................ 49
3.2.8 Screener (SC-101).............................................................................. 49
3.2.9 Filter Udara (F-102)........................................................................... 49
3.3 Alat Penukar Panas....................................................................................... 50
3.3.1 Heater Etilen Glikol (E-101).............................................................. 50
3.3.2 Heater Asam Nitrat (E-102)............................................................... 50
3.3.3 Condenser (E-103)............................................................................. 51
3.3.4 Condenser (E-104)............................................................................. 51
3.3.5 Cooler (E-105)................................................................................... 52
3.3.6 Heater (E-106).................................................................................... 53
3.3.7 Condenser (E-107)............................................................................. 53
3.3.8 Cooler (E-108)................................................................................... 54
3.4 Alat Penyimpanan ........................................................................................ 55
3.4.1 Tangki Penampung HNO3 (TK-101) ................................................. 55
3.4.2 Tangki Penampung Etilen Glikol (TK-102) ...................................... 55
3.4.3 Gudang Penyimpanan Vanadium (SH-101)....................................... 56
3.4.4 Gudang Penyimpanan Asam Oksalat (SH-102)................................. 57
3.4.5 Bak Kondensat (D-101)..................................................................... 57
3.4.6 Bak Kondensat (D-102)..................................................................... 57
3.4.7 Bak Kondensat (D-103)..................................................................... 58
3.4.8 Bak Kondensat (D-104)..................................................................... 58
3.4.9 Bak Kondensat (D-105)..................................................................... 59
3.4.10Bin (B-101)....................................................................................... 59
3.4.11Bin (B-102)....................................................................................... 59
3.5 Alat Transportasi .......................................................................................... 60
3.5.1 Pompa (P-101) ................................................................................... 60
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3.5.2 Pompa (P-102) ................................................................................... 60

3.5.3 Pompa (P-103) ................................................................................... 61
3.5.4 Pompa (P-104) ................................................................................... 61
3.5.5 Pompa (P-105) ................................................................................... 62
3.5.6 Pompa (P-106) ................................................................................... 62
3.5.7 Pompa (P-107) ................................................................................... 63
3.5.8 Pompa (P-108) ................................................................................... 63
3.5.9 Pompa (P-109) ................................................................................... 64
3.5.10 Pompa (P-110) .................................................................................. 64
3.5.11 Belt Conveyor (BC-101) .................................................................. 64
3.5.12 Belt Conveyor (BC-102) .................................................................. 65
3.5.13 Screw Conveyor (S-101) .................................................................. 66
3.5.14 Screw Conveyor (S-102) .................................................................. 66
3.6 Sistem Utilitas dan Pengolahan Limbah....................................................... 67
3.6.1 Unit Utilitas........................................................................................ 67
3.6.2 Unit Penyediaan Air ........................................................................... 67
3.6.3 Penyediaan Air Pendingin.................................................................. 67
3.6.4 Perhitungan Jumlah Kebutuhan Air.................................................... 70
3.6.5 Unit Pengadaan Tenaga Listrik........................................................... 72
3.6.6 Unit Pengadaan Bahan Bakar............................................................. 74
3.6.7 Unit Pengolahan Limbah.................................................................... 77

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3.6.8 Pengolahan Bahan Buangan Gas........................................................ 78

3.6. 9 Pengolahan Bahan Buangan Padat..................................................... 78
3.6.10 Laboratorium...................................................................................... 79
3.6.11 Program Kerja Laboratorium............................................................. 79

BAB IV SISTEM INSTRUMENTASI DAN PERPIPAAN

4.1 Sistem Perpipaan ......................................................................................... 82
4.2 Instrumentasi ............................................................................................... 82
4.2.1 Instrumentasi Pengukuran ................................................................. 83
4.2.1.1 Tekanan ................................................................................. 83
4.2.1.2 Temperatur ........................................................................... 83
4.2.1.3 Laju Alir ............................................................................... 84
4.2.1.4 Tinggi Permukaaan Cairan .................................................. 84
4.2.1.5 Konsentrasi Cairan ............................................................... 84
4.2.2 Prinsip Kerja Instrumentasi dan Alarm Proses ................................. 84
4.3 Sistem Pengendalian Proses ........................................................................ 86
4.3.1 Variabel Proses .................................................................................. 87
4.3.2 Desain Elemen Pengendalian Proses................................................. 88
4.3.3 Pendefinisian Tujuan Pengendali ...................................................... 89
4.3.4 Pemilihan Variabel yang Terukur ...................................................... 89
4.3.5 Pemilihan Variabel yang Dimanipulasi ............................................. 90
4.3.6 Pemilihan Konfigurasi Pengendalian................................................. 90
4.3.7 Perancangan Sistem Pengendali ........................................................ 93
4.3.8 Penggunaan Komputer Digital Pada Pengendalian Proses ............... 94
4.3.9 Perangkat Keras Sistem Pengendalian Proses .................................. 98
4.4 Hasil Perancangan Sistem pengendalian ..................................................... 99
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4.4.1 Reaktor .............................................................................................. 100

4.4.2 Penukar Panas ................................................................................... 101
4.4.3 Evaporator.......................................................................................... 102
4.4.4 Kristalizer........................................................................................... 102
4.4.5 Absorber ............................................................................................ 103
4.4.6 Mother Liquor ................................................................................... 105
4.4.7 Pompa ................................................................................................ 106
4.5 Lay Out Pabrik dan Lay Out Peralatan Proses ............................................ 107
4.5.1 Lay Out Pabrik .................................................................................. 107
4.5.2 Lay Out Peralatan Proses................................................................... 112

BAB V EKONOMI TEKNIK DAN ANALISA KELAYAKAN

5.1 Analisa Ekonomi ......................................................................................... 114
5.2 Penaksiran Harga Peralatan ......................................................................... 115
5.3 Dasar Perhitungan ........................................................................................ 117
5.3.1 Perhitungan Biaya ........................................................................... 118
5.3.1.1 Total Investasi Pabrik ......................................................... 118
5.3.1.2 Manufacturing Cost ........................................................... 118
5.3.1.3 General Expense ................................................................ 118
5.3.2 Analisa Kelayakan Ekonomi........................................................... 118
5.3.3 Hasil Perhitungan ............................................................................ 121
BAB VI KESIMPULAN
DAFTAR PUSTAKA
LAMPIRAN

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DAFTAR TABEL
Tabel 1.1 Distribusi Penggunaan PMMA dalam Industri di tahun 2007........... 2
Tabel 1.2 Data Impor dan ekspor PMMA di Indonesia....................................... 3
Tabel 1.3 Neraca Massa di Feed Mix Drum (V-101)........................................ 19
Tabel 2.1 Neraca Massa di Reaktor (R-101)...................................................... 20
Tabel 2.2 Neraca Massa di Evaporator (V-102)................................................. 22
Tabel 2.3 Neraca Massa di Kristalizer (V-104).................................................. 23
Tabel 2.4 Neraca Massa di Press Filter (F-101)................................................. 24
Tabel 2.5 Neraca Massa di Rotary Dryer (M-101)............................................. 25
Tabel 2.6 Neraca Massa di Mother Liquor Drum (V-105)................................. 26
Tabel 2.7 Neraca Massa di Evaporator (V-106)................................................. 27
Tabel 2.8 Neraca Massa di Evaporator (V-103)................................................. 28
Tabel 2.9 Neraca Massa di Absorber (T-101)..................................................... 29
Tabel 2.7 Neraca Energi di Heater (E-101)........................................................ 29
Tabel 2.8 Neraca Energi di Heater (E-102)........................................................ 30
Tabel 2.9 Neraca Energi di Reaktor (R-101)...................................................... 31
Tabel 2.10 Neraca Energi di Evaporator (V-102)............................................... 31
Tabel 2.11 Neraca Energi di Condenser (E-103)................................................ 32
Tabel 2.12 Neraca Energi di Condenser (E-104)................................................ 33
Tabel 2.13 Neraca Energi di Cooler (E-105)...................................................... 33
Tabel 2.14 Neraca Energi di Kristalizer (V-104)................................................ 34
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Tabel 2.15 Neraca Energi di Rotary Dryer (M-101).......................................... 35

Tabel 2.16 Neraca Energi di Heater (E-106)...................................................... 35
Tabel 2.17 Neraca Energi di Evaporator (V-103)............................................... 36
Tabel 2.18 Neraca Energi di Evaporator (V-106)............................................... 37
Tabel 2.19 Neraca Energi di Condenser (E-107)................................................ 37
Tabel 2.20 Neraca Energi di Cooler (E-108)...................................................... 38
Tabel 3.1 Daftar Kebutuhan Air Pendingin
.......................................................................................................
70
Tabel 3.2 Daftar Kebutuhan Air Umpan Boiler
.......................................................................................................
71
Tabel 3.3 Rincian Kebutuhan Air........................................................................ 72

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DAFTAR GAMBAR
Gambar 1.1 Rumus Struktur Monomer Metil Metakrilat................................... 3
Gambar 1.2 Prediksi data impor dan ekspor PMMA hingga tahun 2020........... 19
Gambar 1.3 Polimerisasi Bulk............................................................................ 20
Gambar 1.4 Polimerisasi Suspensi..................................................................... 21
Gambar 1.5 Polimerisasi Kontinyu.................................................................... 22
Gambar 1.6 Polimerisasi Emulsi........................................................................ 23
Gambar 1.7 Polimerisasi Larutan....................................................................... 24
Gambar 1.9 Lokasi Pabrik PMMA.................................................................... 25
Gambar 2.1 Skema Neraca Massa...................................................................... 26
Gambar 2.2 Persamaan Neraca Massa Umum................................................... 27
Gambar 2.3 Persamaan Mencari Massa yang Terakumulasi.............................. 27
Gambar 2.4 Sistem Tidak Terjadi Akumulasi..................................................... 28
Gambar 2.5 Sistem Tertutup............................................................................... 28
Gambar 2.6 NM Vessel Berpengaduk............................................................... 32
Gambar 2.7 NM Reaktor................................................................................... 32
Gambar 2.8 NM Vessel pendingin..................................................................... 33
Gambar 2.9 NM Centrifuge filter...................................................................... 34
Gambar 2.10 NM Rotary dryer.......................................................................... 34
Gambar 2.11 NE Reaktor................................................................................... 36
xii

Gambar 2.12 NE Vessel pendingin..................................................................... 37

Gambar 2.13 NM Centrifuge filter)................................................................... 38
Gambar 2.14 NE Rotary dryer........................................................................... 39
Gambar 2.15 NE Heat Exchanger Air................................................................ 39
Gambar 2.16 NE Heat Exchanger recycle.......................................................... 40

xiii