DAFTAR ISI

HALAMAN PERSETUJUAN ..................................................................................i

HALAMAN PENGESAHAN .......................................................................... .......ii

HALAMAN KEASLIAN NASKAH..................................................................... iii

HALAMAN PERSEMBAHAN............................................................................. iv

HALAMAN MOTTO ...........................................................................................viii

KATA PENGANTAR .............................................................................................x

DAFTAR ISI .........................................................................................................xii

DAFTAR TABEL ................................................................................................xvii

DAFTAR GAMBAR ...........................................................................................xix

DAFTAR LAMBANG ..........................................................................................xx

INTISARI........................................................................................................... xxiv

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

1.1. Latar Belakang........................................................................................1

1.2. Tinjauan Pustaka.................................................................................... 2

1.3. Kegunaan Produk ............................................................................ .......4

1.4. Penentuan Kapasitas Pabrik....................................................................4

1.5. Pemilihan Lokasi................................................................................... .8

1.6. Spesifikasi Bahan Baku dan Produk.................................................... .13

1.7. Tinjauan Termodinamika..................................................................... 18

1.8. Tinjauan Kinetika................................................................................ .21

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BAB II URAIAN PROSES....................................................................................24

2.1. Uraian Proses.......................................................................................24

2.2. Diagram Kualitatif...............................................................................27

2.3. Diagram Kuantitatif.............................................................................28

BAB III SPESIFIKASI BAHAN BAKU DAN PRODUK.................................. 29

3.1. Spesifikasi Bahan Baku ..................................................................... .29

3.2. Spesifikasi Bahan Pembantu ............................................................. .31

3.3. Spesifikasi Produk.............................................................................. .32

BAB IV NERACA MASSA.................................................................................. 34

4.1. Neraca Massa Tiap Alat...................................................................... 34

4.2. Neraca Massa Total ........................................................................... .37

BAB V NERACA PANAS.................................................................................... 38

5.1. Neraca Panas di Heat Exchanger (HE-01)......................................... .38

5.2. Neraca Panas di Heat Exchanger (HE-02)......................................... .38

5.3. Neraca Panas di Reaktor (R-01)......................................................... .39

5.4. Neraca Panas di Cooler (CL-01)........................................................ .39

5.5. Neraca Panas Menara Distilasi (MD-01)........................................... .40

5.6. Neraca Panas di Heat Exchanger (HE-03)......................................... .40

5.7. Neraca Panas Menara Distilasi (MD-02)........................................... .41

5.8. Neraca Panas di Cooler (CL-02)........................................................ .41

5.9. Neraca Panas Menara Distilasi (MD-03)........................................... .42

5.10. Neraca Panas di Cooler (CL-03)....................................................... ..42

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 5.11. Neraca Panas di Cooler (CL-04)........................................................ .43

5.12. Neraca Panas Total Prarancangan Pabrik Metil Laktat...................... .44

BAB VI SPESIFIKASI ALAT.............................................................................. 46

6.1. Tangki Metanol (T-01)....................................................................... .46

6.2. Tangki Asam Laktat (T-02).................................................................46

6.3. Tangki Metil Laktat (T-03)................................................................ .47

6.4. Heat Exchanger 01 (HE-01).............................................................. .48

6.5. Heat Exchanger 02 (HE-02) .............................................................. 48

6.6. Heat Exchanger 03 (HE-03)............................................................... 49

6.7. Reaktor 01 (R-01)................................................................................50

6.8. Cooler 01 (CL-01)...............................................................................51

6.9. Cooler 02 (Cl-02)............................................................................... .52

6.10. Cooler 03 (CL-03)...............................................................................52

6.11. Cooler 04 (CL-04)...............................................................................53

6.12. Menara Destilasi-01 (MD-01)........................................................... .54

6.13. Menara Destilasi-02 (MD-02)........................................................... .55

6.14. Menara Destilasi-03 (MD-03)........................................................... .56

6.15. Reboiler-01 (RB-01).......................................................................... 57

6.16. Reboiler-02 (RB-02).......................................................................... 57

6.17. Reboiler-03 (RB-03).......................................................................... 58

6.18. Condenser 01 (CD-01)...................................................................... .59

6.19. Condenser 02 (CD-02)...................................................................... .59

6.20. Condenser 03 (CD-03)...................................................................... .60

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 6.21. Accumulator 01 (ACC-01)................................................................ .61

6.22. Accumulator 02 (ACC-02)................................................................ .61

6.23. Accumulator 03 (ACC-03)................................................................ .62

6.24. Pompa 01 (P-01).................................................................................62

6.25. Pompa 02 (P-02).................................................................................63

6.26. Pompa 03 (P-03).................................................................................64

6.27. Pompa 04 (P-04).................................................................................64

6.28. Pompa 05 (P-05).................................................................................65

6.29. Pompa 06 (P-06).................................................................................65

6.30. Pompa 07 (P-07).................................................................................66

6.31. Pompa 08 (P-08).................................................................................67

6.32. Pompa 09 (P-09).................................................................................67

6.33. Pompa 10 (P-10).................................................................................68

6.34. Pompa 11 (P-11).................................................................................68

BAB VII UTILITAS............................................................................................. .70

7.1. Unit Penyediaan dan Pengolahan Air.................................................70

7.2. Unit Pembangkit Steam......................................................................77

7.3. Unit Pembangkit Listrik................................................................... 108

7.4. Unit Penyedia Bahan Bakar............................................................. 108

7.5. Pengolahan Limbah......................................................................... 108

BAB VIII LAY OUT PABRIK DAN PERALATAN PROSES........................ .119

8.1. Lokasi Pabrik................................................................................... 119

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 8.2. Tata Letak Pabrik............................................................................. 122

8.3. Tata Letak Proses............................................................................. 128

BAB IX STRUKTUR ORGANISASI PERUSAHAAN....................................130

9.1. Organisasi Perusahaan..................................................................... 130

9.2. Struktur Organisasi..........................................................................131

9.3. Tugas dan Wewenang..................................................................... .131

9.4. Pembagian Jam Kerja...................................................................... 141

9.5. Perincian Tugas dan Keahlian......................................................... 142

9.6. Sistem Kepegawaian dan Sistem Gaji............................................. 144

9.7. Kesejahteraan Sosial Karyawan...................................................... .147

9.8. Manajemen Perusahaan.................................................................. .148

BAB X EVALUASI EKONOMI........................................................................ 150

10.1. Penafsiran Harga Alat.................................................................... .150

10.2. Dasar Perhitungan........................................................................... 154

10.3. Perhitungan Biaya........................................................................... 155

10.4. Analisa Kelayakan.......................................................................... 156

BAB XI KESIMPULAN.................................................................................... 166

DAFTAR PUSTAKA......................................................................................... 168

LAMPIRAN........................................................................................................ 171

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 DAFTAR TABEL

Tabel 1.1. Kelebihan dan Kekurangan Proses Pembuatan Metil Laktat................. .3

Tabel 1.2. Data Impor Metil Laktat di Indonesia................................................... ..5

Tabel 1.3. Perhitungan Kapasitas............................................................................ .6

Tabel 1.4. Pabrik Metil Laktat di Luar Negeri........................................................ .8

Tabel 1.5. Harga Bahan Baku dan Produk Per Kg................................................ .10

Tabel 1.6. Harga ∆Hfo masing-masing komponen (Yaws, 1999) ..........................18

Tabel 1.7. Harga ∆Gfo masing-masing komponen (Yaws, 1999)...........................19

Tabel 4.1. Neraca Massa Reaktor (R-01).............................................................. .34

Tabel 4.2. Neraca Massa Menara Distilasi (MD-01)............................................. 35

Tabel 4.3. Neraca Massa Menara Distilasi (MD-02)............................................. 35

Tabel 4.4. Neraca Massa Menara Distilasi (MD-03)............................................. 36

Tabel 4.5. Neraca Massa Total Prarancangan Pabrik Metil Laktat........................ 36

Tabel 5.1. Neraca Panas di Heat Exchanger (HE-01)........................................... 37

Tabel 5.2. Neraca Panas di Heat Exchanger (HE-02)........................................... 37

Tabel 5.3. Neraca Panas di Reaktor (R-01)............................................................38

Tabel 5.4. Neraca Panas di Cooler (CL-01).......................................................... .38

Tabel 5.5. Neraca Panas di Menara Distilasi (MD-01)......................................... .39

Tabel 5.6. Neraca Panas di Heat Exchanger (HE-03)........................................... 39

Tabel 5.7. Neraca Panas di Menara Distilasi (MD-02).......................................... 40

Tabel 5.8. Neraca Panas di Cooler (CL-02).......................................................... .40

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Tabel 5.9. Neraca Panas di Menara Distilasi (MD-03)......................................... .41

Tabel 5.10. Neraca Panas di Cooler (CL-03)........................................................ .41

Tabel 5.11. Neraca Panas di Cooler (CL-04)........................................................ .42

Tabel 5.12. Neraca Panas Total Prarancangan Pabrik Metil Laktat...................... 43

Tabel 8.1. Harga Bahan Baku dan Produk Per Kg.............................................. .120

Tabel 8.2. Distribusi Pabrik dan Luasnya............................................................ 125

Tabel 9.1. Jadwal Hari dan Jam Kerja Karyawan Shift....................................... 142

Tabel 9.2. Komposisi dan Sistem Gaji Karyawan............................................... 146

Tabel 10.1. Index dari Chemical Engineering Plant Cost Inside......................... 151

Tabel 10.2. Daftar Harga Alat Proses.................................................................. 153

Tabel 10.3. Fixed Capital Investment.................................................................. 159

Tabel 10.4. Harga Bahan Baku............................................................................ 159

Tabel 10.5. Manufacturing Cost...........................................................................160

Tabel 10.6. Working Capital................................................................................ 160

Tabel 10.7. General Expense............................................................................... 161

Tabel 10.8. Hasil trial nilai interest (i) menggunakan Ms. Excel........................ 164

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 DAFTAR GAMBAR

Gambar 1.1. Grafik Kebutuhan Metil Laktat di Indonesia..................................... .7

Gambar 1.2. Peta Lokasi Pendirian Pabrik Metil Laktat......................................... 9

Gambar 2.1. Digaram alir kualitatif prarancangan pabrik Metil Laktat................ 27

Gambar 2.2. Digaram alir kuantitatif prarancangan pabrik Metil Laktat.............. 28

Gambar 7.1. Digram alir unit proses utilitas........................................................ 107

Gambar 7.2. Diagram Alir Sistem Pengolahan Limbah...................................... 113

Gambar 8.1. Tata Letak Bangunan Pabrik........................................................... 126

Gambar 8.2. Tata Letak Alat Proses.................................................................... 129

Gambar 9.1. Struktur Organisasi Perusahaan...................................................... 140

Gambar 10.1. Grafik Ekstrapolasi Indeks Harga................................................. 152

Gambar 10.2. Grafik Hubungan Kapasitas Produksi dan Biaya.......................... 165

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 DAFTAR LAMBANG

A = Luas perpindahan panas, ft2, in2, m2

ACC = Akumulator

AR = Luas permukaan dinding reaktor, m2

a = Jari-jari dalam reaktor, m

BEP = Break Event Point

BHP = Brake Horse Power, Hp

BM = Berat Molekul, Kg/kmol

b = Sumbu tegak head, m

C = Faktor korosi, in

CA = Konsentrasi zat A, Kmol/L

CAo = Konsentrasi zat A mula-mula, Kmol/L

CB = Konsentrasi zat B, Kmol/L

CBo = Konsentrasi zat B mula-mula, Kmol/L

CD = Condensor

CL = Cooler

Cp = Kapasitas panas, Btu/lb oF, Kkal/Kg oC

DMC = Direct Manufactoring Cost

DPC = Direct Plant Cost

E = Effisiensi pengelasan

Ea = Harga alat dengan kapasitas diketahui

Eb = Harga alat dengan kapasitas dicari

Ex = Harga alat untuk tahun x

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Ey = Harga alat untuk tahun y

FV = Kecepatan volumetrik,m3/j, L/j

FCI = Fixed Capital Investment

Fa = Fixed Expence

f = Allowable strees

f = Faktor friksi

GE = General Expence

gc = Gravitasi, m2/s

gpm = Gallon per menit

HE = Heat Excehanger

hi = Koefisien perpindahan panas pada diameter dalam, Btu/j.ft.oF

hio = Koeisien perpindahan panas, Btu/j.ft.oF

ID = Diameter dalam, in, m, ft

IMC = Indirect Manufacturing Cost

J = Lebar baffle, m, in, ft

L = Tinggi, m, in, ft

LC = Level control

Le = Panjang elbow, ft

MD = Menara Destilasi

m = massa, Kg/j

NRe = Reynold Number

Nt = Jumlah tube

Nx = Nilai index tahun x

xxiii
Ny = Nilai index tahun y

OD = Diameter luar, m,in,ft

P = Tekanan, atm

P = Power motor, Hp

PEC = Purchased Equipment Cost

POT = Pay Out Time

Q = Panas, Btu/j, Kkal/j, KJ/j

r = Jari-jari, m

R = Reaktor

RB = Reboiler

ROI = Returrn Of Investment

Ra = Regulated Expence

SDP = Shut Down Point

Sa = Sales Expence

Sch = Shcedule

T = Suhu

T – n = Tangki

t = Waktu, detik, menit, jam

th = Tebal dinding head, in

ts = Tebal dinding shell, in

WC = Working Capital

X = Konversi

Zl = Tinggi cairan, in, m, ft

xxiv
μ = Viscositas, Cp

η = Effisiensi pompa

π = Jari-jari, in, m, ft

∑ = Jumlah

ρ = Densitas, Kg/m3

ΔP = Pressure drop, psi

ΔT = Beda suhu

xxv