DAFTAR ISI

HALAMAN JUDUL...............................................................................................i
HALAMAN PERNYATAAN ORISINILITAS..................................................iii
HALAMAN PERSETUJUAN PEMBIMBING..................................................v
HALAMAN PERSETUJUAN PENGUJI...........................................................vi
KATA PENGANTAR..........................................................................................vii
DAFTAR ISI.........................................................................................................ix
DAFTAR GAMBAR...........................................................................................xii
DAFTAR TABEL..............................................................................................xiii
RINGKASAN....................................................................................................xvii
BAB I PENDAHULUAN.......................................................................................1
1.1 Latar Belakang...............................................................................................1
1.2 Kapasitas Produksi.........................................................................................3
1.3 Pemilihan Lokasi............................................................................................3
1.4 Informasi Umum Proses.................................................................................5
1.4.1 Proses Polimerisasi Larutan.....................................................................5
1.4.2 Proses Polimerisasi Suspensi...................................................................5
1.4.3 Proses Polimerisasi Emulsi......................................................................6
BAB II URAIAN PROSES....................................................................................7
2.1 Bahan Baku dan Produk.................................................................................7
2.1.1 Spesifikasi Bahan Baku dan Produk........................................................7
2.1.2 Standar Produk.........................................................................................9
2.2 Uraian Proses..................................................................................................9
2.2.1 Proses Pengolahan Awal..........................................................................9
2.2.2 Proses Utama.........................................................................................10

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 2.2.3 Proses Pemurnian Produk......................................................................11
BAB III NERACA MASSA DAN NERACA ENERGI....................................13
3.1 Neraca Massa...............................................................................................13
3.1.1 Neraca Massa Mixer (M-01).................................................................13
3.1.2 Neraca Massa Akumulator (ACC-01)...................................................13
3.1.3 Neraca Massa Akumulator (ACC-02)...................................................14
3.1.4 Neraca Massa Screw Conveyor (SC-01)...............................................14
3.1.5 Neraca Massa Reaktor (R-01)...............................................................14
3.1.6 Neraca Massa Evaporator (EV-01)........................................................15
3.1.7 Neraca Massa Tee (TEE-01).................................................................15
3.1.8 Neraca Massa Ekstruder (EX-01)..........................................................16
3.1.9 Neraca Massa Bucket Elevator (BE-01)................................................16
3.2 Neraca Energi...............................................................................................16
3.2.1 Neraca Energi Pompa (P-01).................................................................16
3.2.2 Neraca Energi Pompa (P-02).................................................................16
3.2.3 Neraca Energi Pompa (P-03).................................................................17
3.2.4 Neraca Energi Pompa (P-04).................................................................17
3.2.5 Neraca Energi Pompa (P-05).................................................................17
3.2.6 Neraca Energi Pompa (P-06).................................................................17
3.2.7 Neraca Energi Mixer (M-01).................................................................17
3.2.8 Neraca Energi Akumulator (ACC-01)...................................................18
3.2.9 Neraca Energi Akumulator (ACC-02)...................................................18
3.2.10 Neraca Energi Reaktor (R-01).............................................................18
3.2.11 Neraca Energi Evaporator (EV-01).....................................................18
3.2.12 Neraca Energi Heat Exchanger (HE-01).............................................19
3.2.13 Neraca Energi Extruder (EX-01).........................................................19
3.2.14 Neraca Energi Tee (TEE-01)...............................................................19
3.2.15 Neraca Energi Screw Conveyor (SC-01).............................................19
3.2.16 Neraca Energi Bucket Elevator (BE-01).............................................20

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 3.3 Neraca Massa Utilitas...................................................................................20
3.3.1 Kebutuhan Steam Di Evaporator (EV-01).............................................20
3.3.2 Kebutuhan Air Pendingin Di Reaktor (R-01)........................................20
3.3.3 Kebutuhan Air Pendingin Di Extruder (EX-01)....................................20
BAB IV SPESIFIKASI ALAT............................................................................21
BAB V TATA LETAK PABRIK........................................................................29
BAB VI ANALISA EKONOMI..........................................................................30
6.1 Data Dasar Perhitungan...............................................................................30
6.2 Perhitungan Biaya........................................................................................30
6.3 Analisa Kelayakan Ekonomi........................................................................30
6.3.1 Perhitungan Percent Return on Investment (ROI)................................30
6.3.2 Perhitungan Pay Out Time (POT).......................................................31
6.3.3 Perhitungan Break Even Point (BEP)..................................................31
6.3.4 Perhitungan Shut Down Point (SDP)...................................................32
6.3.5 Perhitungan Discount Cast Flow.........................................................32
BAB VII KESIMPULAN....................................................................................36
DAFTAR PUSTAKA...........................................................................................37
LAMPIRAN IA NERACA MASSA..................................................................IA-1
LAMPIRAN IB NERACA ENERGI ............................................................. IB-
1

LAMPIRAN IC PERHITUNGAN SPESIFIKASI ALAT ........................... IC-

1

LAMPIRAN ID ANALISA EKONOMI......................................................... ID-1

LAMPIRAN II DATA PENDUKUNG..........................................................

L.II.1

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 DAFTAR GAMBAR

Gambar 5.1 Tata Letak Pabrik Polistirena.........................................................30

Gambar 6.1 Grafik Analisa Break Event Point (BEP)…...................................35
Gambar D.1 Grafik CEPCI….........................................................................ID-4

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 DAFTAR TABEL

Tabel 1.1 Data Peluang Pasar Polistirena….........................................................2

Tabel 1.2 Pemilihan Lokasi Pembuatan Pabrik Polistirena..................................3

Tabel 2.1 Sifat Fisik Bahan Baku.........................................................................7

Tabel 2.2 Sifat Fisik Produk Utama......................................................................8

Tabel 2.3 Spesifikasi Produk Polistirena..............................................................9

Tabel 4.1 Spesifikasi Tangki Penyimpanan dan Silo............................................22

Tabel 4.2 Spesifikasi Mixer dan Accumulator......................................................23

Tabel 4.3 Spesifikasi Evaporator..........................................................................24

Tabel 4.4 Spesifikasi Reaktor CSTR....................................................................24

Tabel 4.5 Spesifikasi Screw Conveyor.................................................................25

Tabel 4.6 Spesifikas Pompa…..............................................................................25

Tabel 4.7 Spesifikasi Heat Exchanger...................................................................27

Tabel 4.8 Spesifikasi Extruder...............................................................................28

Tabel A.1 Lampiran Neraca Massa Mixer 1 (M-01)……………………........L.A.3

Tabel A.2 Lampiran Neraca Massa Akumulator (ACC-01)……………........L.A.3

Tabel A.3 Lampiran Neraca Massa Akumulator (ACC-02)……………........L.A.5

Tabel A.4 Lampiran Neraca Screw Conveyor (SC-01)…………......…….......L.A.7

Tabel A.5 Lampiran Neraca Massa Reaktor (R-01)…………………….........L.A.7

Tabel A.6 Lampiran Neraca Massa Evaporator (EV-01)..........……..,.............L.A.9

Tabel A.7 Lampiran Neraca Massa Tee (TEE-01)………………....................L.A.11

Tabel A.8 Lampiran Neraca Massa Extruder (EX-01)…………….................L.A.12

Tabel A.9 Lampiran Neraca Massa Bucket Elevator (BE-01)……................L.A.13

Tabel B.1 Data Kapasitas Panas Komponen (Cair)……………………..…...L.B.1

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Tabel B.2 Data Kapasitas Panas Komponen (Padat)……………...….............L.B.2

Tabel B.3 Lampiran neraca energi mixer (M-01)……………...................…....L.B.7

Tabel B.4 Lampiran neraca energi akumulator (ACC-01)……………...…....L.B.8

Tabel B.5 Lampiran neraca energi akumulator (ACC-02)……………...........L.B.10

Tabel B.6 Lampiran neraca energi reaktor (R-01)……………................….....L.B.12

Tabel B.7 Lampiran neraca energi evaporator (EV-01)………..…..................L.B.14

Tabel B.8 Data Saturated Steam..............................…………….................…..L.B.15

Tabel B.9 Neraca Panas Evaporator..............................…………….................L.B.15

Tabel B.10 Lampiran neraca energi ekstruder (EX-01)………..…..................L.B.16

Tabel B.11 Lampiran neraca energi pipa cabang dua (TEE-01)….................L.B.17

Tabel B.12 Lampiran neraca energi screw conveyor (SC-01)………..….......L.B.18

Tabel B.13 Lampiran neraca energi bucket elevator (BE-01)………..….......L.B.18

Tabel B.14 Lampiran neraca energi heat exchanger (HE-01)………..….......L.B.19

Tabel D.1 Chemical Engineering Plant Cost Index……….……………...…..L.D.2

Tabel D.2 Perincian Harga Peralatan Proses Pabrik Metil Metakrilat…........L.D.6

Tabel D.3 Biaya Peralatan Instalasi……………………………………….L.D.8

Tabel D.4 Biaya Sistem Perpipaan…………………………………...…....L.D.8

Tabel D.5 Biaya Instrumentas……………………………………………….L.D.8

Tabel D.6 Biaya Bangunan…………………………………...……..…....….L.D.9

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Tabel D.7 Biaya Utilitas.....................................................................................L.D.9

Tabel D.8 Biaya Lain-lain………………………………………………….L.D.9

Tabel D.9 Biaya Teknik dan Konstruksi……………………………..……..L.D.10

Tabel D.10 Biaya Tak Terduga……………………………………………L.D.10

Tabel D.11 Biaya Kontraktor……………………….…………………...…..L.D.10

Tabel D.12 Biaya Tetap………………………………………………….......L.D.10

Tabel D.13 Perhitungan Physical Plant Cost (PPC) ………………….....L.D.11

Tabel D.14 Perhitungan Direct Plant Cost (DPC) …………………..…….L.D.12

Tabel D.15 Perhitungan Fixed Capital Investment (FCI) ……………..…...L.D.12

Tabel D.16 Perhitungan Total Capital Investment (TCI) ……………….....L.D.13

Tabel D.17 Biaya Pengawasan……………………………………………...L.D.13

Tabel D.18 Biaya Pemeliharaan………………………………………...…...L.D.14

Tabel D.19 Biaya Lain-lain…………………………………………….…...L.D.14

Tabel D.20 Indirect Manufacturing Cost…………………………………...L.D.14

Tabel D.21 Fixed Manufacturing Cost……………………………...……...L.D.15

Tabel D.22 General Expenses……………………………………………...L.D.15

Tabel D.23 Pembelian Bahan Baku pertahun……………………………...L.D.15

Tabel D.24 Penjualan Produk pertahun……………………………….…...L.D.16

Tabel D.25 Biaya bahan pendukung dan utilitas pertahun……………...L.D.16

Tabel D.26 Gaji Karyawan pertahun…………………….………………...L.D.17

Tabel D.27 Perhitungan Direct Manufacturing Cost (DMC)…...................L.D.18

Tabel D.28 Perhitungan Indirect Manufacturing Cost (IMC) ….………...L.D.19

Tabel D.29 Perhitungan Fixed Manufacturing Cost (FMC)....….……...…...L.D.20

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Tabel D.30 Perhitungan Manufacturing Cost (MC) ….……............…...........L.D.21

Tabel D.31 Perhitungan Total Plant Cost (TPC)....….……...…......................L.D.21

Tabel D.32 Data BEP dan SDP...............................….……...…......................L.D.24

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 RINGKASAN

Polistirena (C8H8)n adalah adalah sebuah polimer dengan stirena

monomer, yaitu sebuah hidrokarbon cair yang dibuat secara komersial dari

minyak bumi. Produk polistirena yang pertama kali diproduksi untuk

dikomersialkan adalah homopolimer stirena yang juga dikenal sebagai polistirena

kristal. Polistirena kristal ini juga dikenal sebagai General Purpose Polystyrene

(GPPS), yang lebih tahan panas daripada produk polimer termoplastik lainnya.

Kegunaan polistirena cukup luas, antara lain untuk isolator atau bahan pelapis

pada kawat atau kabel, resin, peralatan rumah tangga dari plastik, botol, mainan

anak-anak, casing CD dan DVD, furniture dan sebagainya (Kirk Othmer, 1982).

Dengan melihat kenyataan tersebut maka perlu didirikannya pabrik polistirena

untuk memenuhi kebutuhan pasar. Pembuatan Polistirena menggunakan proses

polimerisasi larutan. Sebelum masuk ke reaktor, bahan baku utama yaitu stirena

monomer, etil benzene dan inisiator benzoil peroksida melewati proses treatment

terlebih dahulu. Stirena monomer bereaksi didalam reaktor alir tangka

berpengaduk untuk menghasilkan polistirena dengan perbandingan rasio reaktan

dan etil benzena sebesar 1:8 dimana reaksi berlangsung eksotermis pada kondisi

suhu 90oC, tekanan 1 atm, waktu tinggal 10 menit dan konversi 70%. Polistirena

yang terbentuk akan masuk ke evaporator untuk memekatkan produk polistirena

dan memisahkan antara komponen padat dan cairan yang tidak bereaksi,

selanjutnya produk polistirena masuk ke extruder. Pada extruder terjadi

pembentukan pellet berukuran 1/8 in. Berdasarkan analisa ekonomi diperoleh nilai

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ROI sebelum pajak 56%; ROI setelah pajak 39,20%; POT sebelum pajak 1,56

tahun, POT setelah pajak 2,12 tahun, BEP sebesar 42,63%; SDP sebesar 33,23%

dan nilai DCF sebesar 52,34%. Dengan beberapa parameter ekonomi tersebut,

maka dapat disimpulkan behwa perancangan pabrik polistirena ini layak untuk

didirikan.

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