DAFTAR ISI

Lembar Pengesahan ........................................................................................... ii

ABSTRAK......................................................................................................... iii
Kata Pengantar .............................................................................. .....................v
Pernyataan Fabricating .................................................................................... vi
Daftar Isi .......................................................................................................... vii
Daftar Tabel ....................................................................................................... x
Daftar Gambar ............................................................................................... xiv
BAB I PENDAHULUAN
1.1 Latar Belakang Pendirian Pabrik................................................................................ 1
1.2 Spesifikasi Bahan Baku ............................................................................................. 2
1.3 Analisis Pasar................................................................................................. 3
1.4 Kebutuhan Urea Formaldehid ........................................................................ 7
1.5 Industri Penghasil Urea Formaldehid.............................................................. 8
1.6 Pemilihan Lokasi Pabrik ................................................................................ 9
1.6.1 Faktor primer ....................................................................................... 10
1.6.2 Faktor Sekunder................................................................................... 11
1.7 Tujuan Prancangan ....................................................................................... 11
1.8 Peta Lokasi Pabrik ....................................................................................... 12
BAB II DESKRIPSI PROSES
2.1 Proses Pembuatan Urea Formaldehid ........................................................... 16
2.2 Pemilihan Proses .......................................................................................... 17
2.3 Proses yang dipilih ....................................................................................... 19
2.4 Proses Pembuatan dengan DB Western ........................................................ 19
2.5 Diagram Alir Proses ..................................................................................... 21
2.6 Uraian Proses ............................................................................................... 22
2.7 Basis Perancangan........................................................................................ 24
2.8 Kondisi Lingkungan Ambien ....................................................................... 25
2.9 Mode Operasi............................................................................................... 26
BAB III Neraca Massa dan Neraca Energi
3.1 Neraca Massa ............................................................................................... 29
3.2 Neraca Panas ................................................................................................ 36

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3.3 Unit Pendukung Proses ................................................................................ 41

3.4 Unit Pengadaan Air ...................................................................................... 42
3.5 Unit Pengolahan Air ..................................................................................... 44
3.6 Kebutuhan Air.............................................................................................. 46
3.7 Unit Pembangkit dan Distribusi Listrik ........................................................ 51
3.8 Unit Pembangkit Steam (Steam Generation System) .................................... 52
3.9 Unit Penyedia Udara Instrument ................................................................... 53
3.10 Unit Penyedia Bahan Bakar ........................................................................ 53
BAB IV PERTIMBANGAN KESELAMATAN DAN LINGKUNGAN
4.1 Keselamatan dan Kesehatan Kerja secara Umum ......................................... 61
4.2 Kecelakaan Kerja ......................................................................................... 62
4.3 Alat Pelindung Diri (APD) .......................................................................... 64
4.4 Instalasi Pemadam Kebakaran ...................................................................... 67
4.5 Keselamatan dan Kesehatan Kerja Area Pabik ............................................. 68
4.6 Sifat dan Bahaya .......................................................................................... 69
4.7 Dampak Lingkungan dan Penanganan Limbah ............................................. 74
4.8 Pencegahan terhadap Bahaya Mekanis ......................................................... 78
4.9 Keselamatan Kerja terhadap Listrik .............................................................. 79
4.10 Pencegahan terhadap Gangguan Kesehatan ................................................ 79
4.11 Kesadaran dan Pengetahuan yang memadai bagi Karyawan ....................... 79
4.12 Stabilitas dan Reaktivitas ........................................................................... 81
4.13 Strategi Pengendalian dan Penanggulangan Limbah ................................... 81
BAB V SPESIFIKASI ALAT
5.1 Spesifikasi Peralatan Proses ......................................................................... 86
5.2 Spesifikasi Peralatan Utilitas ........................................................................ 97
BAB VI TATA LETAK DAN INSTRUMENTASI
6.1 Tata Letak Pabrik (Plant Layout) .............................................................. 109
6.2 Tata Letak Alat Proses ............................................................................... 112
6.3 Tata Letak Mesin/Alat Proses (Mechines Layout) ...................................... 113
BAB VII SKEMA LOGIKA DAN PENGENDALIAN ............................... 116
BAB VIII SISTEM MANAJEMEN OPERASI
8.1 Bentuk Perusahaan ..................................................................................... 122
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8.2 Struktur Organisasi .................................................................................... 123

8.3 Tugas dan Wewenang ................................................................................ 127
8.4 Pembagian Jam Kerja Karyawan ................................................................ 131
8.5 Status Karyawan dan Sistem Upah ............................................................. 133
8.6 Penggolongan Jabatan, Jumlah Karyawan dan Gaji .................................... 134
BAB IX INVESTASI DAN PERHITUNGAN EKONOMI
9.1 Penaksiran Harga Peralatan ........................................................................ 141
9.2 Dasar Perhitungan ...................................................................................... 145
9.3 Perhitungan Biaya ...................................................................................... 145
9.4 Analisa Kelayakan ..................................................................................... 146
9.5 Penentuan Total Capital Investment ........................................................... 148
9.6 Modal Kerja (Working Capital Investment) ............................................... 150
9.7 Biaya Produksi Total (Total Production Cost) ........................................... 150
BAB X PENUTUP ......................................................................................... 156
DAFTAR PUSTAKA ..................................................................................... 157
LAMPIRAN A NERACA MASSA................................................................ A-1
LAMPIRAN B NERACA ENERGI .............................................................. B-1
LAMPIRAN C SPESIFIKASI ALAT ........................................................... C-1
LAMPIRAN D UTILITAS ............................................................................ D-1
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DAFTAR TABEL

Tabel 1.1 Data Produksi Urea di Indonesia........................................................... 1

Tabel 1.2 Data Produksi Methanol di Indonesia ................................................... 2

Tabel 1.3 Sifat Fisika dan Kimia Methanol .......................................................... 2

Tabel 1.4 Sifat Urea ............................................................................................. 3

Tabel 1.5 Spesifikasi Nitrogen ............................................................................. 3

Tabel 1.6 Spesifikasi Oksigen .............................................................................. 4

Tabel 1.7 Karakteristik Katalis ............................................................................. 4

Tabel 1.8 Karakteristik H2O ................................................................................. 4

Tabel 1.9 Keterangan Produk ............................................................................... 5

Tabel 1.10 Keterangan Bahan Baku dan Bahan Pendukung .................................. 6

Tabel 1.11 Keterangan Harga GPM Produk ......................................................... 6

Tabel 1.12 Perusahaan Urea Formaldehid di Dunia .............................................. 7

Tabel 1.13 Data Impor Urea Formaldehid ............................................................ 7

Tabel 1.14 Perusahaan Perekatan di Indonesia jenis Industri Particle ................... 9

Tabel 1.15 Perusahaan Perekatan di Indonesia jenis Industri Plywood .................. 9

Tabel 2.1 Perbandingan Proses DB Western....................................................... 18

Tabel 3.1 Neraca Massa Vaporizer ..................................................................... 30

Tabel 3.2 Neraca Massa Filter ............................................................................ 30

Tabel 3.3 Neraca Massa Blower ......................................................................... 31

Tabel 3.4 Neraca Massa Heater-01 ..................................................................... 31

Tabel 3.5 Neraca Massa Reaktor ........................................................................ 32

Tabel 3.6 Neraca Massa Heater-02 ..................................................................... 33

Tabel 3.7 Neraca Massa Bucket Elevator ........................................................... 33

Tabel 3.9 Neraca Massa Mixing ......................................................................... 34

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Tabel 3.10 Neraca Massa Heater-03 ................................................................... 34

Tabel 3.11 Neraca Massa Absorber .................................................................... 35

Tabel 3.12 Neraca Massa Heater-04 ................................................................... 36

Tabel 3.13 Neraca Panas disekitar Vaporizer ..................................................... 36

Tabel 3.14 Neraca Panas disekitar Blower.......................................................... 37

Tabel 3.15 Neraca Panas disekitar Heater-01 ..................................................... 37

Tabel 3.16 Neraca Panas disekitar Reaktor ......................................................... 38

Tabel 3.17 Neraca Panas disekitar Heater-02 ..................................................... 39

Tabel 3.18 Neraca Panas disekitar Mixing.......................................................... 39

Tabel 3.19 Neraca Panas disekitar Heater-03 ..................................................... 39

Tabel 3.20 Neraca Panas disekitar Absorber....................................................... 40

Tabel 3.21 Neraca Panas Heater-04.................................................................... 41

Tabel 3.22 Kebutuhan air pembangkit steam ...................................................... 41

Tabel 3.23 Kebutuhan air proses ........................................................................ 47

Tabel 3.24 Kebutuhan air pendingin ................................................................... 47

Tabel 3.25 Kebutuhan air ................................................................................... 49

Tabel 3.26 Kebutuhan pabrik untuk utilitas ........................................................ 51

Tabel 3.27 Kebutuhan listrik untuk alat proses ................................................... 52

Tabel 3.28 Kebutuhan steam .............................................................................. 54

Tabel 4.1 Keselamatan dan Kesehatan Kerja di Pabrik ....................................... 68

Tabel 4.2 Klasifikasi Limbah dan Penanganannya.............................................. 76

Tabel 4.3 Material safety data sheet (MSDS) .................................................... 83

Tabel 4.4 Baku mutu limbah cair ....................................................................... 85

Tabel 5.1 Spesifikasi Filter Udara ...................................................................... 86

Tabel 5.2 Spesifikasi Blower .............................................................................. 86

Tabel 5.3 Spesifikasi tangki penyimpanan bahan baku ....................................... 87

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Tabel 5.4 Spesifikasi Vaporizer.......................................................................... 87

Tabel 5.5 Spesifikasi Gudang Penyimpanan/Werehouse ..................................... 88

Tabel 5.6 Spesifikasi Peralatan Penukar Panas ................................................... 89

Tabel 5.7 Spesifikasi Peralatan Penukar Panas ................................................... 89

Tabel 5.8 Spesifikasi Pompa Proses ................................................................... 91

Tabel 5.9 Spesifikasi Belt Conveyor ................................................................... 92

Tabel 5.10 Spesifikasi Bucket Elevator .............................................................. 93

Tabel 5.11 Spesifikasi Weight Feeder ................................................................ 93

Tabel 5.12 Spesifikasi Mixing Tank ................................................................... 94

Tabel 5.13 Spesifikasi Absorber ......................................................................... 97

Taberl 5.14 Spesifikasi WHB ............................................................................. 97

Tabel 5.15 Tangki pengendap awal .................................................................... 97

Tabel 5.16 Tangki penggumpal .......................................................................... 98

Tabel 5.17 Tangki pemurniaan ........................................................................... 98

Tabel 5.18 Tangki Penyaring ............................................................................. 99

Tabel 5.19 Tangki air bersih............................................................................... 99

Tabel 5.20 Tangki umpan boiler....................................................................... 100

Tabel 5.21 Tangki penampung air pendingin .................................................... 100

Tabel 5.22 Cooling Tower ................................................................................ 100

Tabel 5.23 Tangki Klorinasi ............................................................................. 101

Tabel 5.24 Tangki air bersih............................................................................. 102

Tabel 5.25 Tangki kation exchanger ................................................................ 102

Tabel 5.26 Tangki anion exchanger ................................................................. 103

Tabel 5.27 Spesifikasi pompa........................................................................... 105

Tabel 6.1 Rincian area bangunan pabrik urea ................................................... 111

Tabel 8.1 Jadwal Pembagian Kelompok shift ................................................... 132

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Tabel 8.2 Jadwal kerja karyawan masing-masing shift ..................................... 133

Tabel 8.3 Daftar penggolongan jabatan karyawan ............................................ 134

Tabel 8.4 Jumlah karyawan menurut jabatan .................................................... 135

Tabel 8.5 Perincian Golongan dan Gaji ............................................................ 135

Tabel 9.1 Index dari Chemical Engineering Plant Cost Index ........................... 142

Tabel 9.2 Daftar Harga Alat Proses .................................................................. 143

Tabel 9.3 Daftar Harga Alat Utilitas ................................................................. 144

Tabel 9.4 Modal tetap ...................................................................................... 149

Tabel 9.5 Modal Kerja ..................................................................................... 150

Tabel 9.6 Direct Manufacturing Cost ............................................................... 150

Tabel 9.7 Inderect Manufacturing Cost ............................................................ 150

Tabel 9.8 Fixed Manufacturing Cost ................................................................ 151

Tabel 9.9 General Expense .............................................................................. 151

Tabel 9.10 Analisis Kelayakan ......................................................................... 154

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DAFTAR GAMBAR

Gambar 1.1 Impor Urea Formaldehid di Indonesia ............................................... 8

Gambar 1.2 Lokasi Pabrik .................................................................................. 12

Gambar 2.1 Diagram Proses Urea Formaldehid .................................................. 19

Gambar 2.2 Diagram Alir Proses........................................................................ 21

Gambar 2.3 Diagram Kualitatif .......................................................................... 27

Gambar 3.1 Unit pengolahan air industri ............................................................ 50

Gambar 4.1 Skema Pengolahan gas buang absorber ........................................... 82

Gambar 4.2 Skema Instalasi Pengolahan Air Limbah ......................................... 84

Gambar 6.1 Sketsa tata letak peralatan proses .................................................. 112

Gambar 6.2 Letak keseluruhan pabrik .............................................................. 113

Gambar 7.1 Instrumentasi pada tangki methanol .............................................. 119

Gambar 7.2 Instrumentasi pada reaktor fixbed multitube .................................. 119

Gambar 7.3 Instrumentasi pada tangki absorber ............................................... 120

Gambar 7.4 Instrumentasi pada Heat Exchanger (Double Pipe) ....................... 121

Gambar 8.1 Struktur Organisasi Perusahaan ..................................................... 126

Gambar 9.1 Ekstrapolasi Indeks Harga............................................................. 142

Gambar 9.2 Grafik Analisis Kelayakan ............................................................ 155