SKRIPSI

PRARANCANGAN PABRIK BENZENE

DENGAN PROSES HIDRODEALKILASI TERMAL
KAPASITAS 150.000 TON/TAHUN

Oleh:
ARIF THOHA BARIKLANA 21030114120067
THUFAIL IKHSAN SHIDDIQI 21030114140199

DEPARTEMEN TEKNIK KIMIA FAKULTAS TEKNIK

UNIVERSITAS DIPONEGORO

2018
 HALAMAN PERNYATAAN ORISINILITAS

Skripsi ini adalah hasil karya kami sendiri dan semua sumber, baik yang
dikutip maupun dirujuk telah kami nyatakan benar

Nama/NIM : 1. Arif Thoha Bariklana/21030114120067

2. Thufail Ikhsan Shiddiqi/21030114140190

Tanda Tangan : 1. ............................

2. ............................

Tanggal : 20 Desember 2018

ii
 HALAMAN PENGESAHAN

Nama/NIM : 1. Arif Thoha Bariklana/21030114120067

2. Thufail Ikhsan Shiddiqi/21030114140190

Judul : Prarancangan Pabrik Benzene dengan Proses

Hidrodealkilasi Termal Kapasitas 150.000 Ton/Tahun

Semarang, 20 Desember 2018

Telah Menyetujui,
Dosen Pembimbing

Prof. Dr.Widayat, S.T, M.T.

NIP. 197202906 199803 1 001

iii
 HALAMAN PERNYATAAN PERSETUJUAN PUBLLIKASI
TUGAS AKHIR UNTUK KEPENTINGAN AKADEMIS

Sebagai civitas akademika Universitas Diponegoro, kami yang bertanda tangan di

bawah ini:

Nama/NIM : 1. Arif Thoha Bariklana/21030114120067

2. Thufail Ikhsan Shiddiqi/21030114140190

Departemen : Teknik Kimia

Fakultas : Teknik
Jenis Karya : Skripsi
Demi pengembangan ilmu pengetahun, menyetujui untuk memberikan kepada
Universitas Diponegoro Hak Bebas Royalti Noneksklusif (Non-exclusive Royalty
Free Right) atas karya ilmiah yang berjudul:
Prarancangan Pabrik Benzene dengan Proses Hidrodealkilasi Termal
Kapasitas 150.000 Ton/Tahun
Beserta perangkat yang ada (jika diperlukan). Dengan Hak Bebas Royalti
Noneksklusif ini, Universitas Diponegoro berhak menyimpan, mengalih
media/formatkan, mengelola dalam bentuk pangkalan data (database), merawat
dan mempublikasikan tugas akhir kami selama tetap mencantumkan nama kami
sebagai peneliti/pencipta dan sebagai pemilik Hak Cipta.

Demikian pernyataan ini kami buat dengan sebenarnya.

Semarang,

Yang menyatakan

Penulis 1 Penulis 2

(Arif Thoha Bariklana) (Thufail Ikhsan Shiddiqi)

iv
 LEMBAR CATATAN UJIAN TUGAS AKHIR

Prarancangan Pabrik Benzene dengan Proses Hidrodealkilasi Termal

Kapasitas 150.000 Ton/Tahun

Hari :

Tanggal :

v
 PRAKATA

Puji syukur kami panjatkan ke hadirat Allah SWT, karena atas berkat
rahmat dan hidayah-Nya, skripsi dengan judul “Prarancangan Pabrik Benzene
dengan Proses Hidrodealkilasi Termal Kapasitas 150.000 Ton/Tahun” dapat
terselesaikan dengan baik
Dengan adanya tugas akhir prarancangan ini, mahasiswa diharapkan
mampu menerapkan semua teori dan kemahiran teknik kimia kedalam bentuk
prarancangan pabrik secara komprehensif sesuai dengan bekal penalaran dan
improvisasinya, sehingga mampu membuat rancangan pabrik sampai tahap rancang
bangun yang dibukukan.
Pada kesempatan ini kami mengucapkan terima kasih kepada:
 Prof. Dr. Widayat,S.T, M.T. selaku Dosen Pembimbing Skripsi Prarancangan
Pabrik Kimia
 Dr. Siswo Sumardiono, S.T., M.T. selaku Ketua DepartemenTeknik Kimia
 Pihak-pihak lain yang telah membantu secara moril maupun materiil sehingga
skripsi ini dapat diselesaikan.
Kami menyadari bahwa laporan ini masih terdapat kekurangan, karenanya kritik
dan saran dari berbagai pihak sangat kami harapkan. Semoga laporan ini dapat
memberikan manfaat.

Semarang, Desember 2018

Penulis

vi
 DAFTAR ISI

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

HALAMAN PERNYATAAN ORISINALITAS .................................................. ii
HALAMAN PENGESAHAN ............................................................................... iii
HALAMAN PERNYATAAN PERSETUJUAN PUBLIKASI ............................ iv
LEMBAR CATATAN PENGUJI SKRIPSI ......................................................... v
PRAKATA ............................................................................................................ vi
DAFTAR ISI ......................................................................................................... vii
DAFTAR TABEL ................................................................................................. xi
DAFTAR GAMBAR ............................................................................................ xiv
DAFTAR LAMPIRAN ......................................................................................... xv
RINGKASAN ....................................................................................................... xvi
SUMMARY .......................................................................................................... xvii
BAB I PENDAHULUAN ..................................................................................... 1
1.1 Latar Belakang Pendirian Pabrik .................................................................... 1
1.2 Kapasitas Rancangan ...................................................................................... 2
1.2.1 Prediksi Kebutuhan Benzene di Indonesia............................................ 3
1.2.2 Ketersediaan Bahan Baku ..................................................................... 7
1.3 Pemilihan Lokasi Pabrik ................................................................................. 8
1.3.1 Faktor Utama.………………………………………………………….8
1.3.2 Faktor Penunjang………………………………………………………11
1.4 Tinjauan Proses ............................................................................................... 12
1.4.1 Macam-macam Proses ........................................................................... 12
1.5 Kegunaan Produk ............................................................................................ 17
BAB II DESKRIPSI PROSES .............................................................................. 18
2.1 Spesifikasi Bahan Baku dan Produk ............................................................... 18
2.1.1 Spesifikasi Bahan Baku.......................................................................... 18
2.1.2 Spesifikasi Produk Utama dan Produk samping .................................... 18
2.2 Sifat Fisik dan Kimia Bahan baku dan Produk ............................................... 19
2.2.1 Sifat Fisik Bahan Baku dan Produk ...................................................... 19
2.2.2 Sifat Kimia Bahan Baku dan Produk .................................................... 20
2.3 Konsep Proses ................................................................................................. 21

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 2.3.1 Mekanisme Reaksi ................................................................................. 21
2.3.2 Kondisi Operasi ...................................................................................... 21
2.3.3 Tinjauan Kinetika ................................................................................... 22
2.3.4 Tinjauan Termodinamika ....................................................................... 23
2.4 Diagram Alir Proses ........................................................................................ 27
2.4.1 Langkah Proses ...................................................................................... 27
2.5 Diagram Alir Neraca Massa dan Neraca Panas .............................................. 29
2.5.1 Neraca Massa ......................................................................................... 29
2.5.2 Neraca Panas .......................................................................................... 34
2.6 Tata Letak Pabrik dan Peralatan ..................................................................... 41
2.6.1 Tata Letak Pabrik ................................................................................... 41
2.6.2 Tata Letak Peralatan Proses ................................................................... 45
BAB III SPESIFIKASI ALAT ............................................................................ 41
3.1 Unit Penyimpanan Toluene (T-01) ................................................................. 48
3.2 Unit Transportasi Fluida ................................................................................. 49
3.3 Unit Penukar Panas ......................................................................................... 50
3.4 Unit Reaksi Kimia ........................................................................................... 52
3.5 Unit Pemisah ................................................................................................... 53
BAB IV UNIT PENDUKUNG PROSES ............................................................ 55
4.1 Unit Pendukung Proses ................................................................................... 55
4.1.1 Unit Penyediaan Air ............................................................................... 56
4.1.1.1 Penyediaan Air ........................................................................ 56
4.1.1.2 Pengolahan Air ........................................................................ 59
4.1.2 Kebutuhan Air ........................................................................................ 65
4.1.2.1 Kebutuhan Air Pendingin........................................................ 65
4.1.2.2 Kebutuhan Air Sanitasi ........................................................... 68
4.1.2.3 Kebutuhan Air Hydrant ........................................................... 68
4.1.3 Unit Penyediaan Steam .......................................................................... 70
4.1.4 Unit Penyediaan Tenaga Listrik ............................................................. 72
4.1.4.1 Kebutuhan Listrik.................................................................... 72
4.1.4.2 Generator ................................................................................. 75
4.1.5 Unit Penyediaan Bahan Bakar ............................................................... 75

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 4.1.6 Unit Penyediaan Udara Tekan ............................................................... 77
4.1.7 Unit Pengolahan Limbah........................................................................ 78
4.2 Laboratorium ................................................................................................... 83
4.2.1 Alat-alat utama Laboratorium ................................................................ 84
BAB V MANAJEMEN PERUSAHAAN............................................................. 86
5.1 Bentuk Perusahaan .......................................................................................... 86
5.2 Struktur Organisasi dan Deskripsi Tugas ........................................................ 87
5.2.1 Struktur Organisasi ................................................................................ 87
5.2.2 Deskripsi Tugas ...................................................................................... 89
5.2.2.1 Pemegang Saham .................................................................... 89
5.2.2.2 Dewan Komisaris .................................................................... 89
5.2.2.3 Dewan Direksi ......................................................................... 89
5.2.2.4 Staff Ahli ................................................................................. 90
5.2.2.5 Kepala Bagian ......................................................................... 90
5.3 Kebutuhan Karyawan dan Sistem Pengupahan............................................... 92
5.3.1 Pembagian Jam Kerja Karyawan ........................................................... 93
5.3.2 Jumlah Karyawan dan Gaji .................................................................... 95
5.4 Kesejahteraan Karyawan ................................................................................. 98
5.5 CSR (Corporate Social Responsibility) .......................................................... 100
BAB VI ANALISA EKONOMI ........................................................................... 101
6.1 Penaksiran Harga Peralatan............................................................................. 101
6.2 Dasar Perhitungan ........................................................................................... 103
6.3 Perhitungan Biaya ........................................................................................... 104
6.3.1 Capital Investment ................................................................................. 104
6.3.2 Manufacturing Cost................................................................................ 106
6.3.3 General Expense..................................................................................... 108
6.4 Analisa Kelayakan .......................................................................................... 108
6.5 Hasil Perhitungan .......................................................................................... 110
DAFTAR PUSTAKA ........................................................................................... 111
LAMPIRAN

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 DAFTAR TABEL

Tabel 1.1 Data Impor dan Ekspor Benzene di Indonesia .....................................2

Tabel 1.2 Kebutuhan Benzene di Indonesia .......................................................3

Tabel 1.3 Prediksi Kebutuhan Benzene di Indonesia............................................4

Tabel 1.4 Kontribusi Pabrik terhadap Kebutuhan Benzene di Indonesia..............6
Tabel 1.5 Data Pabrik Penghasil Benzene di Indonesia........................................6
Tabel 1.6 Data Pabrik Penghasil Benzene di Dunia..............................................7
Tabel 1.7 Data Kebutuhan Benzene di Dunia tahun 2014-2016...........................7
Tabel 1.8 Kapasitas Produksi Pabrik Pemenuh Kebutuhan Bahan Baku..............8
Tabel 1.9 Produksi Toluene di Dunia....................................................................9
Tabel 1.10 Perbandingan Alternatif Lokasi Pendirian Pabrik...............................10
Tabel 1.11 Macam-macam Proses Sintesis............................................................12
Tabel 2.1 Sifat Fisika Bahan Baku dan Produk .................................................... 19
Tabel 2.2 Harga panas pembentukan standar dan energi Gibbs ........................... 23
Tabel 2.3 Neraca massa di sekitar Mixing Valve 1 .............................................. 29
Tabel 2.4 Neraca massa di sekitar Mixing Valve 2 .............................................. 29
Tabel 2.5 Neraca massa di sekitar Reaktor ........................................................... 30
Tabel 2.6 Neraca massa di sekitar Flash Drum .................................................... 30
Tabel 2.7 Neraca massa di sekitar Kolom Distilasi 1 ........................................... 31
Tabel 2.8 Neraca massa di sekitar Kolom Distilasi 2 ........................................... 31
Tabel 2.9 Neraca massa pada Purging .................................................................. 32
Tabel 2.10 Panas pada arus campuran Hydrogen (M-01) .................................... 34
Tabel 2.11 Beban kerja Kompresor (K-01) .......................................................... 34
Tabel 2.12 Panas pada arus campuran Toluene (M-02) ....................................... 35
Tabel 2.13 Beban panas feed Hidrogen (F-01) ..................................................... 35
Tabel 2.14 Harga panas sensibel feed Toluene (F-01) ......................................... 35
Tabel 2.15 Harga panas laten feed Toluene (F-01) .............................................. 36
Tabel 2.16 Beban panas feed Toluene (F-01) ....................................................... 36
Tabel 2.17 Panas reaktan Hydrogen (R-01) ......................................................... 36
Tabel 2.18 Panas reaktan Toluene (R-01) ............................................................ 37
Tabel 2.19 Panas pada produk (R-01) .................................................................. 37

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Tabel 2.20 Panas yang dilepas di WHB (WHB-01) ............................................. 38
Tabel 2.21 Panas yang dilepas Cooler (C-01) ...................................................... 38
Tabel 2.22 Panas pada Flash Drum (FD-01) ........................................................ 39
Tabel 2.23 Panas yang diserap Heater (H-01) ...................................................... 39
Tabel 2.24 Panas pada Kolom Distilasi 1 (D-01) ................................................. 39
Tabel 2.25 Panas yang dilepas Cooler (C-02) ........................................................... 40
Tabel 2.26 Panas pada Kolom Distilasi 2 (D-02) ...................................................... 40
Tabel 2.27 Panas yang dilepas Cooler (C-03) ...................................................... 40
Tabel 2.28 Perincian luas tanah dan bangunan ..................................................... 44
Tabel 4.1 Syarat mutu air pendingin ..................................................................... 56
Tabel 4.2 Persyaratan air umpan boiler ................................................................ 57
Tabel 4.3 Syarat Mutu Air Sanitasi ...................................................................... 58
Tabel 4.4 Kebutuhan air pendingin ...................................................................... 59
Tabel 4.5 Kebutuhan air untuk steam ................................................................... 61
Tabel 4.6 Daya pada peralatan proses .................................................................. 66
Tabel 4.7 Daya pada peralatan proses .................................................................. 67
Tabel 4.8 Kebutuhan lumen .................................................................................. 68
Tabel 4.9 Baku Mutu Air Limbah B3 ................................................................... 75
Tabel 5.1 Pembagian shift karyawan................................................................... 80
Tabel 5.2 Rincian jumlah karyawan proses..........................................................80
Tabel 5.3 Rincian jumlah karyawan utilitas.........................................................81
Tabel 5.4 Rincian Jumlah Karyawan HSE Lingkungan, Lab Analisa, dan
Maintenance........................................................................................81
Tabel 5.5 Rincian Jumlah Karyawan....................................................................82
Tabel 5.6 Rincian Gaji Berdasar Jabatan..............................................................83
Tabel 6.1 Indeks CEP dari Tahun 2001 hingga 2016...........................................88
Tabel 6.2 Total Biaya Physical Plant Cost...........................................................96
Tabel 6.3 Total Biaya Direct Plant Cost...............................................................96
Tabel 6.4 Total Fixed Capital Investment.............................................................96
Tabel 6.5 Total Working Capital Investment .......................................................97
Tabel 6.6 Total Capital Investment (TCI).............................................................97
Tabel 6.7 Direct Manufacturing Cost...................................................................97

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Tabel 6.8 Indirect Manufacturing Cost................................................................98
Tabel 6.9 Total Fixed Manufacturing Cost .........................................................98
Tabel 6.10 Total Manufacturing Cost..................................................................98
Tabel 6.11 Total General Expense.......................................................................98
Tabel 6.12 Total Biaya Produksi..........................................................................99
Tabel 6.13 Evaluasi Kelayakan Pabrik...............................................................100

xii
 DAFTAR GAMBAR

Gambar 1.1 Kebutuhan Benzene di Indonesia Tahun 2013-2017..........................4

Gambar 1.2 Prediksi kebutuhan Benzene di Indonesia..........................................5
Gambar 1.3 Peta Kawasan Krakatau Industrial Estate Cilegon (KIEC)...............11
Gambar 1.4 Process Flow Diagram Platforming..................................................14
Gambar 1.5 Process Flow Diagram Hidrodealkilasi Thermal..............................14
Gambar 1.6 Process Process Flow Diagram Hidrodealkilasi Katalitik.................15
Gambar 1.7 Process Flow Diagram Disproporsionasi Toluene.............................16
Gambar 2.1 Tata letak pabrik ............................................................................... 44
Gambar 2.2 Tata letak peralatan ........................................................................... 46
Gambar 4.1 Skema pengolahan air ....................................................................... 54
Gambar 4.2 Proses reverse osmosis...................................................................... 57
Gambar 4.3 Rangkaian proses unit desalinasi dengan sistem Reverse Osmosis .. 57
Gambar 4.4 Blok Diagram Kebutuhan Air ........................................................... 60
Gambar 4.5 Diagram alir proses pengolahan udara tekan .................................... 72
Gambar 4.6 Diagram Alir Pengolahan Limbah Cair ............................................ 74
Gambar 5.1 Struktur Organisasi Perusahaan.........................................................73
Gambar 6.1 Grafik Hubungan Tahun dengan Plant Cost Index…………….........88
Gambar 6.2 Grafik Analisa BEP dan SDP ........................................................... 100

xiii
 DAFTAR LAMPIRAN

LAMPIRAN A NERACA MASSA ...................................................................... A-1

LAMPIRAN B NERACA PANAS ....................................................................... B-1
LAMPIRAN C PERANCANGAN ALAT ........................................................... C-1
LAMPIRAN D PERHITUNGAN EKONOMI..................................................... D-1

xiv
 RINGKASAN

Benzene banyak digunakan sebagai bahan pelarut dalam ekstraksi maupun distilasi, juga
digunakan sebagai bahan baku pembuatan senyawa lain seperti styrene, phenol, aniline, dan
chlorobenzene. Untuk memenuhi kebutuhan dalam negeri, maka dirancang pabrik benzene dengan
kapasitas 150.000 ton/tahun dengan bahan baku toluene 18.2633,8412 ton/tahun dan gas hydrogen
8.631,9368 ton/tahun pada 30 oC dan tekanan 32 atm. Dengan memperhatikan beberapa faktor,
seperti aspek penyediaan bahan baku, transportasi, tenaga kerja, pemasaran, serta utilitas, maka
lokasi pabrik yang cukup strategis adalah di Kawasan Industri Cilegon, Jawa Barat.
Proses yang dipilih dalam pembuatan Benzene adalah proses Hidrodelakilasi Thermal.
Peralatan proses yang ada antara lain kompresor, furnace, reaktor, Waste Heat Boiler, flash drum,
menara distilasi, dan pompa. Benzen dihasilkan dari reaksi toluene dan hidrogen dalam Reaktor
Alir Pipa (RAP) Multitube pada kondisi non isotermal non adiabatik pada suhu 621 – 665 oC dan
tekanan 34 atm. Produk gas dari reaktor masuk Waste Heat Boiler untuk mengubah fase kemudian
Flash Drum untuk memisahkan gas metana dari campuran tersebut. Gas metana yang terpisah
dijadikan fuel gas pada Furnace. Produk cair yang mengandung benzene, sisa toluene dan diphenyl
dipisahkan dalam Menara Distilasi untuk mendapatkan benzene dengan kemurnian 99,92 %berat.
Sisa toluene dan diphenyl dipisahkan lagi dengan Menara Distilasi untuk mendapatkan produk
samping diphenyl dengan kemurnian 99,28 % berat. Sedangkan toluene sisa di-recycle untuk
bereaksi lagi membentuk benzene.
Utilitas terdiri dari unit penyediaan air pendingin, pendingin reaktor (molten salt), tenaga
listrik, penyediaan bahan bakar, dan unit pengolahan limbah. Terdapat tiga laboratorium, yaitu
laboratorium fisik, laboratorium analitik, dan laboratorium penelitian dan pengembangan, untuk
menjaga kualitas bahan baku dan produk. Perusahaan berbentuk Perseroan Terbatas (PT) dengan
struktur organisasi line and staff. Sistem kerja karyawan berdasarkan pembagian jam kerja yang
terdiri dari karyawan shift dan non shift .
Hasil analisis ekonomi terhadap prarancangan pabrik benzene diperoleh total investasi
sebesar US$ 276.545.698,20 dan total biaya produksi US$ 213.050.373,14. Hasil analisis
kelayakan menunjukkan ROI sebelum pajak 54,45 %dan setelah pajak 40,84 %, POT pada tahun ke
14, BEP 35,26 %, SDP 28,089 % dan IRR sebesar 14,72 %. Berdasar analisis ekonomi dapat
disimpulkan bahwa pendirian pabrik benzene dengan kapasitas 150.000 ton/tahun layak
dipertimbangkan untuk direalisasikan pembangunannya.

Kata kunci :Benzene, Hidrodealkilasi Thermal

xv
 SUMMARY

Benzene is widely used as a solvent in extraction and distillation, is also used as

a raw material for the manufacture of other compounds such as styrene, phenol, aniline,
and chlorobenzene. To meet domestic demand, the benzene plant was designed with a
capacity of 150,000 tons / year with toluene raw materials 182,633.8412 tons / year and
hydrogen gas 8,631.9368 tons/ year at 30 oC and 32 atm pressure. By taking into account
several factors, such as aspects of raw material supply, transportation, labor, marketing,
and utilities, the strategic location of the factory is in Cilegon Industrial Estate, West Java.
The process chosen in the manufacture of phthalic anhydride is the Thermal
Hydrodealcylation process. Existing process equipment include compressors, furnaces,
reactors, flash drums, Waste Heat Boiler,distillation towers and pumps. Benzene is
produced from the toluene and hydrogen reactions in the Multitube Pipe Flow Reactor
(RAP) in non-adiabatic non-isothermal conditions at a temperature of 621 - 665 oC and a
pressure of 34 atm. The gas product from the reactor enters to Waste Heat Boiler to change
phase And then the Flash Drum to separate methane from the mixture. Separate methane
gas is used as fuel gas in Furnace. Liquid products containing benzene, remaining toluene
and diphenyl are separated in Distillation Tower to get benzene with a purity of 99.92%
by weight. The toluene and diphenyl residues are separated again by Distillation Tower to
obtain diphenyl by-products with a purity of 99.28% by weight. Whereas the remaining
toluene is recycled to react again to form benzene.
Utilities consist of a cooling water supply unit, reactor coolant (molten salt),
electricity, fuel supply, and a waste treatment unit. There are three laboratories, namely
physical laboratories, analytical laboratories, and research and development laboratories,
to maintain the quality of raw materials and products. Company in the form of Limited
Liability Company (PT) with line and staff organizational structure. The employee work
system is based on the distribution of working hours consisting of shift and non-shift
employees.
The results of the economic analysis of the benzene factory design obtained a
total investment of US $ US$ 276,545,698.20 and a total production cost of US $
213,050,373.14.. The results of the feasibility analysis showed 54.45% pre-tax ROI and
40.84% after tax, POT in the 14th year, 35.26% BEP, 18.089% SDP and 14.72% IRR.
Based on economic analysis, it can be concluded that the establishment of a Benzene plant
with a capacity of 150,000 tons / year is worth considering to be realized.

Keywords :Benzene, Hidrodealkilasi Thermal

xvi