PRARANCANGAN PABRIK ASETALDEHIDA
  DENGAN PROSES DEHIDROGENASI ETANOL
MENGGUNAKAN
 
KATALIS TEMBAGA DAN KROM
KAPASITAS 22.000 TON/TAHUN
 

 
Preliminary Design of Acetaldehyde Plant by Ethanol Dehydrogenation
  Process Using Copper and Chromium Catalyst
Capacity of 22.000 Ton/Year
 

TUGAS AKHIR

Oleh :
DINI INDRIYANI NIM : 08414004
ILMA AMALIA NIM : 08414015

POLBAN

PROGRAM STUDI D-IV TEKNIK KIMIA PRODUKSI BERSIH

JURUSAN TEKNIK KIMIA
POLITEKNIK NEGERI BANDUNG
2012

 
 

 
 

  CURRICULUM VITAE
 

  Nama : Dini Indriyani

NIM : 08414004
 
Tempat, Tanggal Lahir : Garut, 03 Desember 1989
  Alamat : Jl. Samarang Kp. Ciroyom
  RT/RW 001/004 Ds. Cintarakyat
Kec. Samarang, Kab. Garut
 
Email : indriyani.dini@gmail.com
 
Pendidikan :
Tahun Sekolah Jurusan
1996 - 2002 SDN Mekarwangi II -
2002 - 2005 SMPN 2 Garut -
2005 - 2008 SMAN 15 Garut IPA
2008 - 2012 Politeknik Negeri Bandung Teknik Kimia

Nama : Ilma Amalia

NIM : 08414015
Tempat, Tanggal Lahir : Bandung, 8 April 1990
Alamat : Jl. Karta Atmaja No. 69 A /118
Bandung
Email : ilma.tkpb08.polban@gmail.com

Pendidikan :
Tahun Sekolah Jurusan
1996 - 2002 SDN Cigondewah 02 -
2002 - 2005 SMPN 4 Cimahi -
2005 - 2008 SMA Pasundan 3 Bandung IPA
2008 - 2012 Politeknik Negeri Bandung Teknik Kimia

 
 

 
KATA PENGANTAR
 

 
Puji Syukur kehadirat Allah SWT yang telah melimpahkan rahmat, taufik dan
 
hidayah-Nya sehingga penulis akhirnya dapat menyelesaikan penyusunan laporan
  akhir dengan judul “Prarancangan Pabrik Asetaldehida dengan Proses
tugas

  Dehidrogenasi Etanol Menggunakan Katalis Tembaga dan Krom Kapasitas 22.000

ton/tahun”. Laporan tugas akhir ini disusun sebagai persyaratan untuk memperoleh
 
gelar Sarjana Sains Terapan di Jurusan Teknik Kimia Program Studi Teknik Kimia
 
Produksi Bersih Politeknik Negeri Bandung.
  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 Rispiandi, ST, MT., selaku pembimbing I yang telah bersedia meluangkan
waktu untuk memberikan bimbingan, arahan, dan motivasi dalam penyusunan
tugas akhir,
2. Ibu Dianty Rosirda D.K, ST, MT., selaku pembimbing II yang telah bersedia
meluangkan waktu untuk memberikan bimbingan, arahan, dan motivasi dalam
penyusunan tugas akhir,
3. Bapak Ir. Ahmad Rifandi, M.Sc selaku Koordinator Tugas Akhir Teknik Kimia
Produksi Bersih 2008,
4. Ibu Ir. Ninik Lintang, M.Sc, selaku Ketua Program Studi Teknik Kimia Produksi
Bersih Politeknik Negeri Bandung,
5. Bapak Ir. Dwi Nirwantoro, MT., selaku Ketua Jurusan Teknik Kimia Politeknik
Negri Bandung,
6. Serta semua pihak yang tidak dapat penulis sebutkan satu persatu yang telah
membantu atas terselesainya laporan tugas akhir ini.
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 pada
khususnya dan pembaca pada umumnya.
Bandung, Juli 2012

Penulis

i
 
 

 
DAFTAR ISI

 
Halaman
HALAMAN
  JUDUL
KATA PENGANTAR ............................................................................................. i
  ABSTRAK .............................................................................................................. ii
ABSTRACT ............................................................................................................. iii
  DAFTAR ISI .......................................................................................................... iv
DAFTAR TABEL ................................................................................................. vii
 
DAFTAR GAMBAR ............................................................................................. ix
DAFTAR LAMPIRAN ............................................................................................x
  I PENDAHULUAN
BAB
1.1 Latar Belakang Pendirian Pabrik ............................................................1
 
1.2 Kapasitas Perancangan ............................................................................2
1.3 Pemilihan Lokasi Pabrik ........................................................................3
1.4 GPM (Gross Profit Margin) ...................................................................4
BAB II DASAR PERANCANGAN
2.1 Spesifikasi Bahan Baku dan Produk ......................................................5
2.1.1 Spesifikasi Bahan Baku................................................................5
2.1.2 Spesifikasi Produk ........................................................................5
2.1.3 Spesifikasi Katalis ........................................................................5
2.2 Konsep Proses ........................................................................................6
2.2.1 Dasar Reaksi.................................................................................6
2.2.2 Mekanisme Reaksi .......................................................................6
2.2.3 Kondisi Operasi............................................................................7
2.3 Lokasi Pabrik .........................................................................................9
2.4 Rona Lingkungan .................................................................................10
BAB III TINJAUAN PUSTAKA
3.1 Proses Produksi Asetaldehida ..............................................................11
3.2 Proses Dehidrogenasi Etanol................................................................13
3.2.1 Persiapan Bahan Baku ................................................................14
3.2.2 Reaksi Dehidrogenasi Etanol .....................................................14
3.2.3 Pemisahan dan Pemurnian Etanol Sisa ......................................15
3.3 Sifat Fisik dan Kimia Bahan Baku dan Produk ...................................16
3.3.1 Bahan Baku ................................................................................16
3.3.2 Produk ........................................................................................17
BAB IV NERACA MASSA DAN NERACA ENERGI
4.1 Neraca Massa .......................................................................................19
4.1.1 Holding Tank ..............................................................................19
4.1.2 Reaktor ........................................................................................19
4.1.3 Absorber ......................................................................................20
4.1.4 Kolom Distlasi I ..........................................................................20
4.1.4 Kolom Distilasi II........................................................................20
4.2. Neraca Panas .......................................................................................21
4.2.1 Holding Tank .............................................................................21

iv
 
 

 
4.2.2 Vaporizer ....................................................................................21
  4.2.3 Furnace ......................................................................................21
4.2.4 Reaktor .......................................................................................21
 
4.2.5 Waste Heat Boiler ......................................................................22
  4.2.6 Cooler-01 ...................................................................................22
4.2.7 Cooler-02 ...................................................................................22
  4.2.8 Absorber .....................................................................................22
4.2.9 Kolom Distilasi I ........................................................................23
  4.3.0 Kolom Distilasi II.......................................................................23
BAB V SPESIFIKASI PERALATAN
  5.1 Reaktor ...............................................................................................24
5.2 Absorber ...............................................................................................25
  5.3 Kolom Distilasi ....................................................................................26
5.4 Alat Penukar Panas ..............................................................................28
 
5.5 Furnace ................................................................................................36
5.6 Accumulator ........................................................................................37
5.7 Tangki Penyimpanan ............................................................................39
5.8 Pompa...................................................................................................41
BAB VI UTILITAS
6.1 Unit Penyediaan Listrik ......................................................................44
6.2.1 Pengolahan Secara Fisika ...........................................................48
6.2.2 Pengolahan Secara Kimia ..........................................................48
6.2.3 Pengolahan Secara Internal ........................................................49
6.3 Unit Penyediaan Bahan Bakar ............................................................50
6.4 Unit Penyediaan Steam ........................................................................50
6.5 Limbah Proses ......................................................................................51
BAB VII TATA LETAK PABRIK DAN PERALATAN
7.1 Tata Letak Pabrik ...............................................................................52
7.2 Tata Letak Peralatan Proses .................................................................53
BAB VIII STRUKTUR ORGANISASI DAN TATA KERJA
8.1 Bentuk Perusahaan ...............................................................................56
8.2 Struktur Organisasi ..............................................................................57
8.3 Tugas dan Wewenang ..........................................................................59
8.3.1 Pemegang Saham .......................................................................59
8.3.2 Dewan Komisaris .......................................................................60
8.3.3 Direktur Utama ..........................................................................60
8.3.4 Staf Ahli .....................................................................................61
8.3.5 Kepala Bagian ............................................................................61
8.4 Pembagian Jam Kerja Karyawan ........................................................66
8.4.1 Karywan Non-Shift ....................................................................66
8.4.2 Karywan Shift ............................................................................66
8.5 Status Karyawan ..................................................................................68
8.6 Penggolongan Jabatan, Jumlah Karyawan dan Gaji ............................68
8.6.1 Penggolongan Jabatan ................................................................68
8.6.2 Jumlah Karyawan dan Gaji ........................................................69
8.7 Kesejahteraan Sosial Karyawan ...........................................................70

v
 
 

 
8.8 Manajemen Produksi ...........................................................................71
  8.8.1 Perencanaan Produksi ................................................................72
8.8.2 Pengendalian Produksi ...............................................................73
 
BAB IX ANALISA EKONOMI
  9.1 Penafsiran Harga Alat ..........................................................................76
9.2 Dasar perhitungan ................................................................................78
  9.3 Perhitungan Biaya ................................................................................78
9.3.1 Total Capital Investment ............................................................78
  9.3.2 Total Production Cost ...............................................................80
9.3.3 Keuntungan (Profit) ...................................................................82
  9.3.4 Analisa Kelayakan ....................................................................83
BAB X KESIMPULAN .........................................................................................88
 
DAFTAR PUSTAKA
LAMPIRAN
 

vi
 
 

 
DAFTAR TABEL
 

 
Halaman
 
Tabel 1.1 Data Pabrik Penghasil Asetaldehida Di Dunia .......................................... 2
  Tabel 1.2 Data Impor Asetaldehida di Indonesia ....................................................... 2
Tabel 4.1 Neraca Massa di Holding Tank ............................................................... 19
Tabel
  4.2 Neraca Massa di Reaktor ........................................................................ 19
Tabel 4.3 Neraca Massa di Absorber ....................................................................... 20
  4.4 Neraca Massa di Kolom Distilasi I .......................................................... 20
Tabel
Tabel 4.5 Neraca Massa di Kolom Distilasi II ......................................................... 20
  Tabel 4.6 Neraca Panas di Holding Tank ................................................................. 21
Tabel 4.7 Neraca Panas di Vaporizer ....................................................................... 21
Tabel 4.8 Neraca Panas di Furnace ......................................................................... 21
Tabel 4.9 Neraca Panas di Reaktor .......................................................................... 21
Tabel 4.10 Neraca Panas di WHB............................................................................ 22
Tabel 4.11 Neraca Panas di Cooler-01 .................................................................... 22
Tabel 4.12 Neraca Panas di Cooler-02 .................................................................... 22
Tabel 4.13 Neraca Panas di Absorber ...................................................................... 22
Tabel 4.14 Neraca Panas di Kolom Distilasi I ......................................................... 23
Tabel 4.15 Neraca Panas di Kolom Distilasi II ........................................................ 23
Tabel 5.1 Spesifikasi dan Skema Alat Reaktor ........................................................ 22
Tabel 5.2 Spesifikasi dan Skema Alat Absorber...................................................... 25
Tabel 5.3 Spesifikasi dan Skema Alat Kolom Distilasi I ......................................... 26
Tabel 5.4 Spesifikasi dan Skema Alat Kolom Distilasi II ....................................... 27
Tabel 5.5 Spesifikasi dan Skema Alat Vaporizer .................................................... 28
Tabel 5.6 Spesifikasi dan Skema Alat WHB ........................................................... 39
Tabel 5.7 Spesifikasi dan Skema Alat Cooler-01 .................................................... 30
Tabel 5.8 Spesifikasi dan Skema Alat Cooler-02 .................................................... 31
Tabel 5.9 Spesifikasi dan Skema Alat Kondensor ................................................... 32
Tabel 5.10 Spesifikasi dan Skema Alat Kondensor ................................................. 33
Tabel 5.11 Spesifikasi dan Skema Alat Reboiler ..................................................... 34
Tabel 5.12 Spesifikasi dan Skema Alat Reboiler ..................................................... 35
Tabel 5.13 Spesifikasi dan Skema Alat Furnace ..................................................... 36
Tabel 5.14 Spesifikasi dan Skema Alat Accumulator .............................................. 37
Tabel 5.15 Spesifikasi dan Skema Alat Accumulator .............................................. 38
Tabel 5.16 Spesifikasi dan Skema Alat Storage Tank Bahan Baku ........................ 39
Tabel 5.17 Spesifikasi dan Skema Alat Storage Tank Produk Asetaldehida ........... 39
Tabel 5.18 Spesifikasi dan Skema Alat Storage Tank Produk Hidrogen ................ 40
Tabel 5.19 Spesifikasi dan Skema Alat Holding Tank ............................................ 40
Tabel 5.20 Spesifikasi dan Skema Alat Pompa P-101 A/B ..................................... 41
Tabel 5.21 Spesifikasi dan Skema Alat Pompa P-102 A/B ..................................... 41
Tabel 5.22 Spesifikasi dan Skema Alat Pompa P-103 A/B ..................................... 42

vii
 
 

 
Tabel 5.23 Spesifikasi dan Skema Alat Pompa P-201 A/B ..................................... 42
  Tabel 5.24 Spesifikasi dan Skema Alat Pompa P-202 A/B ..................................... 42
Tabel 5.25 Spesifikasi dan Skema Alat Pompa P-203 A/B .................................... 43
 
Tabel 5.26 Spesifikasi dan Skema Alat Pompa P-204 A/B ..................................... 43
Tabel
  5.27 Spesifikasi dan Skema Alat Pompa P-205 A/B ..................................... 43
Tabel 6.1 Kebutuhan Listrik untuk Proses ............................................................... 44
  Tabel 6.2 Kebutuhan Listrik untuk Penerangan 24 Jam .......................................... 45
Tabel 6.3 Kebutuhan Listrik untuk Penerangan 12 Jam .......................................... 45
  Tabel 8.1 Jadwal Kerja Masing-masing Regu ......................................................... 67
Tabel 8.2 Perincian Jumlah Karyawan .................................................................... 69
  8.3 Perincian Golongan dan Gaji ................................................................... 70
Tabel
Tabel 9.1 Indeks Harga ............................................................................................ 76
  9.2 Purchased Equipment Cost ...................................................................... 78
Tabel
Tabel 9.3 Fixed Capital Investment ......................................................................... 79
 
Tabel 9.4 Biaya Bahan Baku dan katalis ................................................................. 80
Tabel 9.5 Biaya Utilitas............................................................................................ 81
Tabel 9.6 Biaya Produksi Langsung ........................................................................ 81
Tabel 9.7 Biaya Tidak Langsung ............................................................................. 81
Tabel 9.8 Fixed Manufacturing Cost ....................................................................... 81
Tabel 9.9 Total Manufacturing Cost ........................................................................ 82
Tabel 9.10 Total General Expanse .......................................................................... 82
Tabel 9.11 Perhitungan Break Event Point .............................................................. 83
Tabel 9.12 Perhitungan Net Cash Flow Diagram .................................................... 85

viii
 
 

 
DAFTAR GAMBAR

 
Halaman
 
Gambar 2.1 Peta Lokasi Pabrik Asetaldehida ........................................................ 9
  Gambar 6.1 Diagram Kebutuhan Air ................................................................... 47
Gambar 6.2 Diagram Kebutuhan Bahan Bakar dan Listrik ................................. 50
  Gambar 7.1 Layout Pabrik Asetaldehida ............................................................. 53
Gambar 7.2 Layout Peralatan Proses ................................................................... 54
Gambar
  8.1 Struktur Organisasi Pabrik Asetaldehida ........................................ 59
Gambar 9.1 Indeks Harga Perlatan ...................................................................... 77
 
Gambar 9.2 Break Event Point ............................................................................ 84
Gambar 9.3 Net Cash Flow Diagram .................................................................. 86
 

ix
 
 

 
DAFTAR LAMPIRAN

 
Halaman
 
LAMPIRAN A PERHITUNGAN NERACA MASSA
  1. Kolom Distilasi I ................................................................................................ 1
2. Kolom Distilasi II ............................................................................................... 3
  3. Reaktor ................................................................................................................ 4
4. Absorber ............................................................................................................. 6
 
LAMPIRAN B PERHITUNGAN NERACA PANAS
1.   Holding Tank ..................................................................................................... 3
2. Vaporizer............................................................................................................. 4
  3. Furnace ................................................................................................................ 6
4. Reaktor ................................................................................................................ 7
5. Waste Heat Boiler (WHB) .................................................................................. 9
6. Cooler-01 ......................................................................................................... 11
7. Cooler-02 .......................................................................................................... 12
8. Absorber ............................................................................................................ 13
9. Kolom Distilasi I ............................................................................................... 14
10. Kolom Distilasi II ........................................................................................... 19

LAMPIRAN C PERHITUNGAN SPESIFIKASI PERLATAN

1. Tangki Penyimpanan Etanol (T-101 A/B) .......................................................... 1
2. Tangki Penyimpanan Asetaldehida (T-102 A/B) ............................................... 3
3. Tangki Penyimpanan Hidrogen (T-103 A/B) ..................................................... 6
4. Holding Tank (T-104 A/B) ................................................................................. 9
5. Vaporizer (HE-101) .......................................................................................... 11
6. Furnace (F-101) ................................................................................................ 16
7. Reaktor (R-101) ................................................................................................ 24
8. Waste Heat Boiler (HE-102) ............................................................................. 39
9. Cooler (HE-103) ............................................................................................... 45
10. Cooler (HE-104) ............................................................................................. 50
11. Absorber (T-201) ........................................................................................... 55
12. Kolom Distilasi I (T-202) ............................................................................... 63
13. Kondensor (HE-201) ...................................................................................... 85
14. Reboiler (HE-202) .......................................................................................... 94
15. Accumulator (ACC-201) ................................................................................ 99
16. Kolom Distilasi II (T-203) ........................................................................... 102
17. Kondensor (HE-203) .................................................................................... 125
18. Reboiler (HE-204) ....................................................................................... 134
19. Accumulator (ACC-202) .............................................................................. 139
20. Pompa ........................................................................................................... 142

LAMPIRAN D FORM BIMBINGAN TUGAS AKHIR

x
 
 

xi
 
 

 
DAFTAR PUSTAKA

 
Aries, R.S and Newton, R.D., 1955, Chemical Engineering Cost Estimation, Mc
  Grow – Hill Book Company, New York.

  Biro Pusat Statistik,1995-2001, “Statistik Perdagangan Luar Negeri Indonesia”,

Indonesia foreign, Trade Statistic Import, yogjakarta.
 
Brown, G.G., 1978, Unit Operation, John Wiley and Sons Inc, New York Modern
 
Asia Edition, Charles Tuttle Co, Tokyo.
  Brownell, L.E., and Young, E.H., 1979, ” Process Equipment Design ”, Willey
Eastern Ltd., New Delhi.
Coulson, J.M., 1983, “ Chemical Engineering ”, Aucklond, Mc. Graw Hill,
International Student Edition, Singapore.
Faith, Keyes & Clark., 1955, Industrial Chemical, 4th ed, John Wiley and Sons,
Inc., New York.
Foust, S, and Wenzel L.A., 1979, “ Principles of Unit Operations ”, 2 nd.ed. John
Willey and Sons, New York.
Frank, L, Jr., 1974, “ Equipment Design Hand Book for Refineries and Chemical
Plants “, Vol. 1 & 2, Texas.
Hill, C.G, 1996, “ An Introduction to Chemical Engineering Kinetics and Reactor
Design “, John Wiley and Sons. Inc, New York
Kern, D.Q., 1950, Process Heat Transfer, 24th ed., Mc.Graw – Hill International
Editions, Singapore.
nd
Kirk Othmer, 1983, ” Encyclopedia of Chemical Technology “, 2 .ed. Vol.7.
Interscience Willey.
Levenspiel, O, 1972, “ Chemical Reaction Engineering”, 2nd ed., John Willey and
Sons Inc., Singapore.
Ludwig, E.E., 1965, “ Applied Process Design for Chemical and Petrochemical
Plant “, Vol. 1-3, Gulf Publishing Co., Houston.
Mc. Adams, W. H., 1954, “Heat Transmision”, 3th ed., Kogakusha Co. Ltd.,
Tokyo.

 
 

 
Mc. Ketta, John, 1983, “ Encyclopedia Chemical Process and Design”, Marchell
 
Dekker Inc., New York.
 
Perry, R.H., and Green, D.W., 1984, “ Perry’s Chemical Engineers Hand Book “,
  6th. ed. Mc. Graw Hill Co., International Student edition, Kogakusha,
  Tokyo.
Petter, M.S., and Timmerhauss, H.C., 1990, “ Plant Design and Economics for
 
Chemical Engineering “, 3rd. Ed. Mc. Graw Hill, kogakusha, Tokyo.
 
Powell, S.T., 1954, Water Conditioning for Industry, Mc.Graw Hill Kogakusha
  Book Company, Inc., Tokyo
  Rase, H.F and Barrow, M.H, 1957, “ Chemical Reactor Design for Process Plant
“, John wiley and Sons. Inc, New York
Smith, J.M, 1973, “ Chemical Engineering Kinetic’s “, 3rd ed, Mc GrawHill Book
Kogakusha, Tokyo
Smith, J.M., and Van Ness,H.C., 1975, “ Introduction to Chemical Engineering
Thermodynamics “, 3 rd. Ed. Mc. Graw Hill, kogakusha, Tokyo.
Sularso., 1996, Pompa dan Kompressor, cetakan VI, P.T Pradnya Paramita,
Jakarta.
Treyball, R.E., 1968, “ Mass Transfer Operations “, 2nd. Ed. Mc. Graw Hill,
International Student Edition, Singapore.
Ulrich, G.G., 1984, “ A Guide to Chemical Engineering Process Design and
Economics “, John Willey and Sons, New York.
Wallas, Stanley M. 1988. Chemical Process Equipment. Butterworths. Boston
Soeswanto, B., dan Endang S.R. 2001. Pengolahan Air Industri. Jurusan Teknik
Kimia Polban, Bandung
http/www. the canadian journal of chemical engineering, vol.57, april, 1979
http/www.icisprising.com., diakses tanggal 25 Maret 2012
http/www.che.com., di akses tanggal 8 Juni 2012
http/www.acidatama.com., di akses tanggal 19 Februari 2012