TUGAS AKHIR

PRARANCANGAN PABRIK ASAM FORMAT

DENGAN PROSES HIDROLISIS METIL FORMAT
KAPASITAS 20.000 TON/TAHUN

Disusun oleh:
Angga Listya Saputra D500100014

Dosen Pembimbing :
Ir. Haryanto A.R ., M.S.
Rois Fatoni S.T., M.Sc., Ph.D.

PROGRAM STUDI TEKNIK KIMIA

FAKULTAS TEKNIK
UNIVERSITAS MUHAMMADIYAH SURAKARTA
SURAKARTA
2016
 INTISARI
Angga Listya Saputra, 2016, Prarancangan Pabrik Asam Format dengan
Proses Hidrolisis Metil Format Kapasitas 20.000 Ton/Tahun. Jurusan
Teknik Kimia, Fakultas Teknik, Universitas Muhammadiyah Surakarta.
Asam format banyak digunakan sebagai kougulan pada karet alam,
pengawet latex, pengatur pH pada industri tekstil, digunakan pada proses tanning
pada industri kulit, dan sebagai bahan aditif anti bakteri pada industri makanan
ternak. Prarancangan pabrik asam format dengan proses hidrolisis metil format
20.000 ton/tahun didirikan untuk memenuhi kebutuhan dalam negeri dan
selebihnya diekspor.
Pembentukan asam format merupakan reaksi hidrolisis yang dilakukan
dengan cara mereaksikan metil format dengan air. Reaksi yang terjadi adalah
reaksi endotermis dan dilakukan dalam reaktor alir tangki berpengaduk (RATB).
Reaksi ini berlangsung pada kondisi 80oC dan tekanan 3 atm. Kebutuhan bahan
baku metil format pada pabrik ini sebanyak 2.914,719 kg/jam dan air sebanyak
1.276,747 kg/jam. Produk yang dihasilkan adalah asam format sebanyak
2.216,566 kg/jam sebagai produk utama dan metanol sebanyak 1.618,065 kg/jam
sebagai produk samping. Tahapan proses meliputi persiapan bahan baku metil
format dan air, pembentukan asam format di reaktor, dan pemurnian hasil di
menara distilasi.
Untuk menunjang proses produksi, maka didirikan unit pendukung yaitu
unit utilitas yang meliputi pengadaan dan pengolahan air sebanyak 23.213,69
kg/jam, pengadaan listrik sebesar 324,415 kW, pengadaan steam sebanyak 202,77
kg/jam, pengadaan bahan bakar sebanyak 354,246 liter/jam, dan pengadaan udara
tekan sebesar 97,459 m3/jam. Bentuk perusahaan yang dipilih adalah Perseroan
Terbatas (PT), dimana jumlah semua karyawan yaitu 118 orang dengan struktur
organisasi line and staff. Pabrik ini direncanakan didirikan di Palembang,
Sumatera Selatan pada tahun 2018.
Dari hasil analisis ekonomi diperoleh data yaitu pengeluaran keselurahan
tiap tahun sebesar Rp 261.499.554.956,751 sedangkan total penjualan produk
sebesar Rp 288.198.045.654,761. Sehingga keuntungan sebelum pajak sebesar Rp
26.698.490.698,01 dan keuntungan sesudah pajak sebesar Rp 18.688.943.488,607.
Maka diperoleh nilai Return on Investment (ROI) sesudah pajak sebesar 21,72%,
Pay Out Time (POT) sesudah pajak selama 3,15 tahun, Break Even Point (BEP)
47,66%, dan Shutdown Point (SDP) 33,93%. Sedangkan Discounted Cash Flow
(DCF) sebesar 35,09%. Jadi dari segi ekonomi pabrik tersebut layak untuk
didirikan.
 ABSTRACT

Angga Listya Saputra, Pre-draft of Formic Acid Factory with Hydrolysis

Process of Methyl Format with capacity for about 20,000 tons / year.
Department of Chemical Engineering, Faculty of Engineering,
Muhammadiyah Surakarta University.
Formic acid is commonly use as kougulan on natural rubber, latex
preservatives, pH controling on the textile industry, it use in the tanning process
on the leather industry, and as an anti-bacterial additives on animal food industry.
Pre-draft of Formic Acid Factory with Hydrolysis Process of Methyl Format with
capacity for about 20,000 tons / year.
The formation of formic acid is a hydrolysis reaction which is conducted
by reacting methyl formate with water. The reaction that happen is an
endothermic reaction and done in a flow stirred tank reactor (RATB) . This
reaction was conducted on the condition of 80C and a pressure of 3 atm. Raw
material for methyl formate that needed at this plant is for about 2,914.719 kg /
hour and water as much as 1,276.747 kg / hour. The resulting product is formic
acid as 2,216.566 kg / hour as the main product and methanol for about 1,618.065
kg / hour as a byproduct. The steps include the preparation of raw materials of
methyl formate and water, formic acid formation in the reactor, and the
purification results in the distillation tower.
To support the production process, some supporting units are needed like
units of utilities that includes procurement and processing water as much as
23,213.69 kg / hour, amounting to 324,415 kW of electricity procurement,
procurement of steam as 202.77 kg / hour, the procurement of fuel such as diesel
as 354.246 L / hour and provision of compressed air as much as 97,459 m3 / hour.
The company that selected is a Limited Liability company (PT), where the
number of employees is 118 people with line and staff organizational structure.
This factory is will be built in Palembang, South Sumatra in 2018.

From economic analysis we get the data like overall expenditure each year
is 263.194.047.339,132 rupiah while the total sales of the product is
288.198.045.654,761 rupiah. So the profit before the tax is 26.622.021.276,141
rupiah and the profit after the tax is 18.635.414.893,299 rupiah. The obtained
value of Return on Investment (ROI) before the tax amounted to 31.02% and
after the tax is for about 21.72%, Pay Out Time (POT) before tax for about 2.4
years after the tax for about 3.1 years, Break Even Point (BEP) 47.66%, and
Shutdown Point (SDP) 34.93%. While the Discounted Cash Flow (DCF) is
35.09%. So from economic point of view, the factory is proper to built.
 KATA PENGANTAR
Segala puji hanya bagi Allah SWT, yang telah memberikan Rahmat dan
Hidayah-Nya, sehingga penulis dapat menyelesaikan penyusunan laporan tugas
akhir dengan judul Prarancangan Pabrik Asam Format dengan Proses
Hidrolisis Metil Format Kapasitas 20.000 Ton/Tahun.
Tugas akhir Prarancangan Pabrik Kimia ini merupakan salah satu syarat
yang wajib diselesaikan oleh setiap mahasiswa untuk menyelesaikan jenjang studi
sarjana di Jurusan Teknik Kimia, Fakultas Teknik, Universitas Muhammadiyah
Surakarta.
Dalam penyusunan tugas akhir ini penulis memperoleh banyak bantuan
baik berupa dukungan moral maupun spiritual dari berbagai pihak. Oleh karena
itu penulis mengucapkan terima kasih kepada :
1. Bapak Rois Fatoni S.T., M.Sc., Ph.D selaku Ketua Jurusan Teknik Kimia
Fakultas Teknik UMS dan juga selaku Dosen Pembimbing II.
2. Bapak Ir. Haryanto A.R., MS selaku Dosen Pembimbing I.
3. Ibu Eny Budiyati S.T., M.Eng selaku Koordinator Tugas Prarancangan
Pabrik Kimia.
4. Seluruh staf dosen Jurusan Teknik Kimia.
5. Bapak dan Ibu tercinta.
6. Teman-teman mahasiswa Jurusan Teknik Kimia.
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, Oktober 2016

Penulis
 DAFTAR ISI

Halaman Judul ................................................................................................... i

Lembar Pengesahan ........................................................................................... ii
Intisari ................................................................................................................ iii
Abstract............................................................................................................... iv
Kata Pengantar ................................................................................................... v
Daftar Isi .......................................................................................................... vi
Daftar Tabel ...................................................................................................... xi
Daftar Gambar ................................................................................................. xii
BAB I PENDAHULUAN ............................................................................. 1
1.1 Latar Belakang Pendirian Pabrik .............................................. 1
1.2 Penentuan Kapasitas Perancangan .......................................... 2
1.3 Pemilihan Lokasi Pabrik .......................................................... 4
1.3.1 Faktor Primer ............................................................ 5
1.3.2 Faktor Sekunder ........................................................ 7
1.4 Tinjauan Pustaka ..................................................................... 9
1.4.1 Macam-macam Proses ................................................. 9
1.4.2 Kegunaan Produk ......................................................... 12
1.4.3 Sifat Fisis dan Kimia ................................................... 12
1.4.4 Tinjauan Proses Secara Umum .................................... 14
BAB II DESKRIPSI PROSES ........................................................................ 16
2.1 Spesifikasi Bahan Baku dan Produk ........................................ 16
2.1.1 Spesifikasi Bahan Baku ............................................... 16
2.1.2 Spesifikasi Produk ........................................................ 16
2.2 Konsep Proses ......................................................................... 17
2.2.1 Dasar Reaksi ................................................................ 17
2.2.2 Mekanisme Reaksi ....................................................... 17
2.2.3 Fase Reaksi .................................................................. 18
2.2.4 Kondisi Operasi ........................................................... 18
2.2.5 Tinjauan Termodinamika.............................................. 18
 2.2.6 Tinjauan Kinetika . ....................................................... 20
2.3 Diagram Alir Proses dan Tahapan Proses ............................... 23
2.3.1 Diagram Alir Kualitatif................................................. 23
2.3.2 Diagram Alir Kuantitatif............................................... 24
2.3.3 Daigram Alir Proses Lengkap ...................................... 25
2.4 Langkah Proses ........................................................................ 26
2.5 Neraca Massa dan Neraca Panas ............................................. 28
2.5.1 Neraca Massa ............................................................... 28
2.5.2 Neraca Panas ................................................................ 30
2.6 Lay Out Pabrik dan Peralatan ................................................... 31
2.6.1 Lay Out Pabrik .............................................................. 31
2.6.2 Lay Out Peralatan ......................................................... 32
BAB III SPESIFIKASI PERALATAN PROSES ........................................... 36
3.1 Tangki Penyimpan Metil Format ............................................... 36
3.2 Tangki Penyimpan Metanol ........................................................ 36
3.3 Tangki Penyimpan Asam Formiat ............................................. 37
3.4 Reaktor-01 ................................................................................... 38
3.5 Menara Distilasi-01 ..................................................................... 39
3.6 Menara Distilasi-02 ..................................................................... 39
3.7 Menara Distilasi-03 ..................................................................... 40
3.8 Kondensor-01 .............................................................................. 41
3.9 Kondensor-02 .............................................................................. 41
3.10 Kondensor-03 .............................................................................. 42
3.11 Reboiler-01 .................................................................................. 43
3.12 Reboiler-02 .................................................................................. 44
3.13 Reboiler-03 .................................................................................. 45
3.14 Accumulator-01 .......................................................................... 46
3.15 Accumulator-02 .......................................................................... 47
3.16 Accumulator-03 .......................................................................... 48
3.17 Pompa-01 ................................................................................... 48
3.18 Pompa-02 ................................................................................... 49
 3.19 Pompa-03 ................................................................................... 50
3.20 Pompa-04 ................................................................................... 50
3.21 Pompa-05 ................................................................................... 51
3.22 Pompa-06 ................................................................................... 52
3.23 Cooler-01 ................................................................................... 52
3.24 Cooler-02 ................................................................................... 53
3.25 Heater-01 .................................................................................... 54
3.26 Heater-02 .................................................................................... 55
3.27 Heater-03 .................................................................................... 56
BAB IV UNIT UTILITAS .............................................................................. 57
4.1 Unit Pendukung Proses ............................................................ 57
4.1.1 Unit Pengadaan Air ...................................................... 57
4.1.1.1 Air Pendingin ................................................. 59
4.1.1.2 Air Proses ....................................................... 60
4.1.1.3 Air Umpan Boiler ........................................... 61
4.1.1.4 Air Konsumsi umum dan Sanitasi ................. 66
4.1.2 Unit Pengadaan Steam .................................................. 67
4.1.3 Unit Pengadaan Udara Tekan ....................................... 68
4.1.4 Unit Pengadaan Listrik ................................................ 69
4.1.5 Unit Pengadaan Bahan Bakar ...................................... 71
4.1.6 Unit Pengolahan Limbah.............................................. 72
4.2 Laboratorium ........................................................................... 73
4.2.1 Laboratorium Fisik .................................................... 75
4.2.2 Laboratorium Analitik ............................................... 75
4.2.3 Laboratorium Penelitian dan Pengembangan ............ 75
4.2.4 Prosedur Analisa Bahan Baku.................................... 75
4.2.5 Prosedur Analisa Produk ........................................... 76
4.2.6 Analisa Air ............................................................... 77
BAB V MANAJEMEN PERUSAHAAN........................................................ 78
5.1 Bentuk Perusahaan ................................................................... 78
5.2 Struktur Organisasi ................................................................... 79
 5.3 Tugas dan Wewenang .............................................................. 82
5.3.1 Pemegang Saham ........................................................ 82
5.3.2 Dewan Komisaris ......................................................... 82
5.3.3 Dewan Direksi ............................................................. 82
5.3.4 Staf Ahli ....................................................................... 83
5.3.5 Kepala Bagian .............................................................. 84
5.3.6 Kepala Seksi ................................................................ 87
5.3 Pembagian Jam Kerja Karyawan ............................................. 87
5.4.1 Karyawan Non Shift ..................................................... 87
5.4.2 Karyawan Shift ............................................................. 88
5.4 Status Karyawan dan Sistem Upah .......................................... 89
5.5.1 Karyawan Tetap ........................................................... 90
5.5.2 Karyawan Harian ......................................................... 90
5.5.3 Karyawan Borongan..................................................... 90
5.5 Penggolongan Jabatan, Jumlah Karyawan dan Gaji ................ 90
5.6.1 Penggolongan Jabatan ................................................. 90
5.6.2 Jumlah Karyawan dan Gaji .......................................... 91
5.7 Kesejahteraan Sosial Karyawan .............................................. 93
BAB VI ANALISIS EKONOMI ..................................................................... 94
6.1 Penaksiran Harga Peralatan ..................................................... 94
6.2 Dasar Perhitungan ................................................................... 96
6.3 Penentuan Total Capital Investment (TCI) ............................. 96
6.4 Hasil Perhitungan ................................................................... 97
6.4.1 Fixed Capital Investment (FCI) .................................... 97
6.4.2 Working Capital (WC) ................................................. 98
6.4.3 Direct Manufacturing Cost (DMC) .............................. 98
6.4.4 Indirect Manufacturing Cost (IMC) ............................. 98
6.4.5 Fixed Manufacturing Cost (FMC) ................................. 99
6.4.6 Total Manufacturing Cost (MC) .................................... 99
6.4.7 General Expense (GE) .................................................. 99
6.4.8 Total Cost (TC) ............................................................... 99
 6.4.9 Perhitungan Keuntungan ............................................... 99
6.5 Analisis Kelayakan................................................................... 100
6.5.1 Persent Return On Investment (ROI) ........................... 100
6.5.2 Pay Out Time ............................................................... 101
6.5.3 Break Even Point (BEP)............................................... 102
6.5.4 Shutdown Point (SDP) ................................................. 103
6.5.5 Discounted Cash Flow (DCF)...................................... 103
6.6 Pembahasan .............................................................................. 107
KESIMPULAN ................................................................................................ 108
DAFTAR PUSTAKA ..................................................................................... xii
LAMPIRAN
 DAFTAR TABEL

Tabel 1.1 Data Kebutuhan Asam Formiat dari 2002-2010 ............................. 2

Tabel 1.2 Perkiraan Kebutuhan Asam Formiat di Indonesia .......................... 4
Tabel 1.3 Perbandingan Berbagai Macam Pembuatan Asam Format ............. 11
Tabel 2.1 Neraca Massa Reaktor-01 ........................ 28
Tabel 2.2 Neraca Massa Menara Destilasi-01 ................................................ 28
Tabel 2.3 Neraca Massa Menara Destilasi-02 ................................................ 29
Tabel 2.4 Neraca Massa Menara Destilasi-03 ................................................ 29
Tabel 2.5 Neraca Massa Total ......................................................................... 29
Tabel 2.6 Neraca Panas di Reaktor .................................................................. 30
Tabel 2.7 Neraca Panas di Menara Destilasi-01 .............................................. 30
Tabel 2.8 Neraca Panas di Menara Destilasi-02 ............................................. 30
Tabel 2.9 Neraca Panas di Menara Destilasi-03 ............................................. 30
Tabel 4.1 Kebutuhan Air Pendingin ............................................................... 60
Tabel 4.2 Spesifikasi Air Proses ...................................................................... 61
Tabel 4.3 Kebutuhan Air untuk Steam ............................................................ 62
Tabel 4.4 Kebutuhan Listrik untuk Keperluan Proses dan Utilitas ................ 69
Tabel 5.1 Jadwal Pembagian Kelompok Shift .... 88
Tabel 5.2 Jumlah Karyawan Menurut Jabatannya ...... 91
Tabel 5.3 Perincian Golongan dan Gaji Karyawan ................ 92
Tabel 6.1 Indeks Harga Alat ............ 94
Tabel 6.2 Fixed Capital Invesment ................. 97
Tabel 6.3 Working Capital Investment ........ 98
Tabel 6.4 Direct Manufacturing Cost .......... 98
Tabel 6.5 Indirect Manufacturing Cost ....... 98
Tabel 6.6 Fixed Manufacturing Cost ... 99
Tabel 6.7 General Expense .............. 99
Tabel 6.8 Analisis Kelayakan ......................................................................... 104
 DAFTAR GAMBAR

Gambar 1.1 Hubungan Kebutuhan Asam Formiat dengan Tahun ............. 3

Gambar 1.2 Peta Provinsi Sumatera Selatan ........ 8
Gambar 1.3 Peta Satelit Provinsi Sumatera Selatan .............. 8
Gambar 1.4 Peta Lahan Pendirian Pabrik Asam Formiat ............. 9
Gambar 2.1 Pengaruh Rasio Terhadap Kecepatan Reaksi ........................... 22
Gambar 2.2 Diagram Alir Kualitatif ............................................................ 23
Gambar 2.3 Diagram Alir Kuantitatif 24
Gambar 2.4 Tata Letak Pabrik ....................................................................... 35
Gambar 2.5 Tata Letak Alat .......................................... 36
Gambar 4.1 Diagram Alir Pengolahan Air Sungai ....... 58
Gambar 5.1 Struktur Organisasi Pabrik Asam Formiat ........ 81
Gambar 6.1 Chemical Engineering Cost Index ............................................ 95
Gambar 6.2 Analisa Kelayakan .................................................................... 105
Gambar 6.3 Aliran Model Tahunan ............................................................... 106