PT.

Pupuk Sriwidjaja Palembang Universitas Jambi

DAFTAR ISI

Isi Halaman

HALAMAN JUDUL ..................................................................................................... i

HALAMAN PENGESAHAN ...................................................................................... ii
KATA PENGANTAR .................................................................................................. iii
DAFTAR ISI ................................................................................................................ iv
DAFTAR TABEL ........................................................................................................ xi
DAFTAR GAMBAR .................................................................................................... xiii

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

1.1. Latar Belakang Pendirian PT PUSRI Palembang ................... 1
1.2. Sejarah PT PUSRI Palembang ........................................................ 2
1.3. Lokasi dan Daerah Operasi PT PUSRI Palembang ................ 5
1.4. Tata Letak PT Pupuk Sriwidjaja Palembang .......................... 6
1.5. Distribusi dan Pemasaran Produk ............................................. 9
1.6. Penelitian dan Pengembangan PT Pupuk Sriwidjaja
Palembang ............................................................................................ 11
1.7. Sarana dan Fasilitas PT Pupuk Sriwidjaja ................................ 13
1.8. Kepedulian Lingkungan dari PT Pupuk Sriwidjaja
Palembang ............................................................................................ 13

BAB II STRUKTUR ORGANISASI ................................................................... 14

2.1. Struktur Organisasi PT Pupuk Sriwidjaja Palembang ........ 14
2.2. Manajemen Produksi P-1B PT Pupuk Sriwidjaja
Palembang .......................................................................................... 17
2.3. Visi dan Misi PT Pupuk Sriwidjaja Palembang ...................... 18
2.3.1. Visi ............................................................................................ 18
2.3.2. Misi ........................................................................................... 18
2.3.3. Makna Perusahaan ............................................................. 18
2.3.4. Tata Nilai ............................................................................... 18
2.3.5. Makna Logo dan Sejarah Nama Sriwidjaja

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PT. Pupuk Sriwidjaja Palembang Universitas Jambi

pada Perusahaan ................................................................. 19

2.3.1.1. Kerajaan Maritim Sriwidjaja ............................ 21
2.3.1.2. Nama Perusahaan ................................................ 22
2.3.1.3. Detail Elemen Visual Logo Perusahaan ....... 23
2.4. Sumber Daya Manusa (SDM) PT Pupuk Sriwidjaja
Palembang ...................................................................................... 24
2.5. Divisi PT Pupuk Sriwidjaja Palembang ............................... 25
2.5.1. Divisi Operasi .................................................................. 25
2.5.2. Divisi Teknologi .............................................................. 26
2.5.2.1 Departemen Perencanaan dan Pengendalian
Produksi ............................................................................ 27
2.5.3. Departemen Laboratorium ........................................ 28
2.5.4. Departemen K3 dan LH ............................................... 29
2.5.5. Divisi Pemeliharaan ...................................................... 29
2.5.6. Peraturan-Peraturan Kerja ........................................ 29
BAB III ORIENTASI LAPANGAN ................................................................ 32
3.1. Unit Utilitas .................................................................................... 33
3.1.1. Stasiun Pengisian Gas (Gas Metring Station)....... 33
3.1.2. Unit Pengolahan Air (Water Treatment Plant) ... 36
3.1.2.1. Penyaringan Zat Padat yang Terapung .. 38
3.1.2.2. Clarifier............................................................... 39
3.1.2.3. Clearwell............................................................. 41
3.1.2.4. Sand Filter ......................................................... 41
3.1.2.5. Filtered water Storage Tank ....................... 42
3.1.3. Demineralized Water Plant (Demin Plant) ........... 43
3.1.3.1. Carbon Filter ..................................................... 44
3.1.3.2. Cation Exchanger ............................................ 45
3.1.3.3. Anion Exchanger ............................................. 46
3.1.3.4. Mixed Bed Exchanger..................................... 47
3.1.3.5. Demineralized Storage Tank....................... 48
3.1.4. Cooling Tower .................................................................. 48
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3.1.5. Plant Air and Instrument Air System ....................... 50

3.1.6. Gas Turbin Generator (GTG) ...................................... 53
3.1.7. Steam System (Pembangkit Steam/Boiler)........... 54
3.1.7.1. Air Umpan Boiler ............................................ 54
3.1.7.2. Steam Generation System ............................. 56
a. Waste Heat Boiler ........................................ 56
b. Package Boiler .............................................. 57
3.1.8. Pengolahan Limbah ...................................................... 59
3.1.8.1. Pengolahan Limbah Padat .......................... 59
3.1.8.2. Pengolahan Limbah Cair.............................. 59
A. PUSRI Effluent Treatment (PET) .......... 60
B. Instalasi Pengolahan Air Limbah ......... 61
3.1.8.3. Pengolahan Limbah Gas............................... 61
3.2. Unit Amoniak ................................................................................. 61
3.2.1. Bahan Baku Proses Pembuatan Ammonia ........... 62
3.2.2. Proses Pembuatan Ammonia .................................... 63
3.2.2.1. Feed Treating Unit .......................................... 64
1) Pemisahan Sulfur Anorganik ................. 65
2) Pemisahan CO2 ............................................ 66
3) Pemisahan Sulfur Organik ...................... 68
3.2.2.2. Reforming Unit ................................................ 69
1) Primary Reformer ....................................... 70
2) Secondary Reformer ................................... 72
3.2.2.3. Purification Unit .............................................. 75
1) High Temperatur Shift Converter
(HTSC).............................................................. 76
2) Low Temperatur Shift Converter
(LTSC) .............................................................. 76
3) Pemisahan CO2 ............................................ 77
4) Metanasi......................................................... 78
3.2.2.4. Sintesa Ammonia ............................................ 79
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1) Compression..................................................... 79
2) Synthesis Reaction/ Synthesis Loop......... 81
3.2.2.5. Pemurnian Produk (Refrigeration) ....... 83
1) Ammonia Let Down Drum ........................... 83
2) Refrigerant Receiver ..................................... 84
3) Refrigerant Compresor ................................ 84
4) Refrigerant Flash Drum TK4
(1-120-CF4)..................................................... 84
5) Refrigerant Flash Drum TK3
(1-120-CF3)..................................................... 85
6) Refrigerant Flash Drum TK2
(1-120-CF2)..................................................... 85
7) Refrigerant Flash Drum TK1
(1-120-CF1)..................................................... 85
3.2.3. Penampungan Produksi Ammonia ......................... 86
3.2.4. Deaerator ......................................................................... 87
3.2.5. Purge Gas Recovery Unit .............................................. 88
3.2.5.1. Ammonia Recovery Unit ............................... 89
3.2.5.2. Hydrogen Recovery Unit ............................... 89
3.3. Unit Urea ......................................................................................... 90
3.3.1. Bahan Baku dan Bahan Pembantu Proses
Pembuatan Urea ................................................................... 91
3.3.1.1 Bahan Baku ........................................................ 91
3.3.1.2 Bahan Pembantu .............................................. 92
3.3.2. Produk ................................................................................ 94
3.3.3. Proses Pembuatan Urea .............................................. 96
3.3.3.1. Seksi Sintesa.................................................... 96
3.3.3.2. Seksi Purifikasi (Dekomposisi)................ 102
3.3.3.3. Seksi Kristalisasi............................................ 105
3.3.3.4. Seksi Pembutiran (Prilling)....................... 107
3.3.3.5. Seksi Recovery ................................................ 109
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3.3.3.6. Seksi Proses Pengolahan Condensate .... 111

BAB IV TUGAS KHUSUS I ............................................................................ 113
4.1. Latar Belakang ...........................................................................113
4.2. Permasalahan ..............................................................................114
4.3. Tujuan Tugas Khusus ...............................................................114
4.4. Ruang Lingkup ............................................................................115
4.5. Tinjauan Pustaka ........................................................................115
4.5.1. Perpindahan Panas......................................................115
4.5.2. Alat Penukar Panas .....................................................116
4.5.3. Kegunaan Alat Penukar Panas ................................118
4.5.4. Arah Aliran Fluida Pada Alat Penukar Panas ....119
4.5.5. Tipe Heat Exchanger ..................................................... 120
4.5.6. Permasalahan pada Heat Exchanger ..................... 126
4.5.7. Fouling ................................................................................. 126
4.6. Metodologi Penelitian ..............................................................133
4.6.1. Langkah Kerja ..............................................................133
4.6.2. Variabel Tetap ...............................................................133
4.6.3. Variabel Berubah .........................................................133
4.6.4. Variabel Terhitung .....................................................134
4.7. Perhitungan ..................................................................................134
4.7.1. Data Spesifikasi Heat Exchanger 115-C2 ............134
4.7.2. Data Aktual .....................................................................135
4.7.3. Perhitungan ....................................................................136
4.8. Pembahasan .................................................................................137
4.9. Kesimpulan ...................................................................................140
4.10. Saran ...............................................................................................140
BAB IV TUGAS KHUSUS II ........................................................................... 113
4.1. Latar Belakang ........................................................................... 141
4.2. Permasalahan ............................................................................. 142
4.3. Tujuan Tugas Khusus .............................................................. 142
4.4. Ruang Lingkup ........................................................................... 142
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4.5. Tinjauan Pustaka ....................................................................... 142

4.5.1. Perpindahan Panas..................................................... 142
4.5.2. Alat Penukar Panas .................................................... 143
4.5.3. Kegunaan Alat Penukar Panas ............................... 145
4.5.4. Arah Aliran Fluida Pada Alat Penukar Panas ... 146
4.5.5. Tipe Heat Exchanger .................................................. 147
4.5.6. Permasalahan pada Heat Exchanger ................... 152
4.5.7. Fouling ............................................................................. 152
4.5.7.1. Fouling Factor atau Dirt Factor (Rd) .... 153
4.5.7.2. Mekanisme Pembentukan Fouling........ 154
4.5.7.3. Penyebab dan Pencegahan Terjadinya
Fouling .............................................................. 155
4.5.7.4 Akibat Terjadinya Fouling......................... 155
4.5.7.5 Cara Mengatasi Fouling........................ 156
4.5.7.6 Analisa Performance Heat
Exchanger ................................................... 157
4.6 Metodologi ................................................................................... 159
4.6.1 Urutan Kerja .................................................................. 159
4.6.2 Variabel Tetap .............................................................. 160
4.6.3 Variabel Berubah ........................................................ 160
4.6.4 Variabel Terhitung ..................................................... 160
4.7 Perhitungan ................................................................................. 160
4.7.1 Data Desain.................................................................... 160
4.7.2 Data aktual ..................................................................... 160
4.8 Pembahasan ................................................................................ 163
4.9 Kesimpulan .................................................................................. 167
4.10 Saran .............................................................................................. 167
BAB V PENUTUP .......................................................................................... 168
5.1 Kesimpulan .................................................................................. 168
DAFTAR PUSTAKA ............................................................................................. 169
LAMPIRAN