DAFTAR ISI

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

LEMBAR PENGESAHAN .................................................................................. ii

LEMBAR PERBAIKAN ..................................................................................... iii

INTISARI ............................................................................................................. iv

KATA PENGANTAR ............................................................................................v

DAFTAR ISI ........................................................................................................ vii

DAFTAR TABEL .............................................................................................. xiii

DAFTAR GAMBAR .......................................................................................... xvi

DAFTAR LAMPIRAN .................................................................................... xviii

BAB I PEMBAHASAN UMUM ..........................................................................1

1.1. Pendahuluan ..............................................................................................1

1.2. Sejarah dan Perkembangan .......................................................................3

1.3. Macam-macam Proses Pembuatan ............................................................5

1.4. Sifat Fisika dan Kimia ............................................................................11

1.4.1. Bahan Baku ...................................................................................11

1.4.2. Katalis ...........................................................................................13

1.4.3. Produk ...........................................................................................14

BAB II PERENCANAAN PABRIK ...................................................................16

2.1. Alasan Pendirian Pabrik ........................................................................16

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 2.2. Pemilihan Kapasitas...............................................................................17

2.3. Pemilihan Bahan Baku ..........................................................................21

2.4. Pemilihan Proses....................................................................................23

2.5. Uraian Proses ........................................................................................23

BAB III LOKASI DAN TATA LETAK PABRIK ............................................31

3.1. Lokasi Pabrik .........................................................................................31

3.1.1. Faktor Utama .................................................................................32

3.1.1.1. Penyediaan Bahan Baku ...................................................32

3.1.1.2. Pemasaran ........................................................................32

3.1.1.3. Sumber Daya Manusia .....................................................34

3.1.1.4. Sarana Transportasi ..........................................................34

3.1.2. Faktor Pendukung .........................................................................34

3.1.2.1. Kondisi Tanah dan Daerah ..............................................34

3.1.2.2. Kebijakan Pemerintah ......................................................34

3.2. Tata Letak Pabrik ...................................................................................35

3.2.1. Tata Letak Area Pabrik .................................................................35

3.2.2. Tata Letak Alat Proses ..................................................................37

3.3. Luas Tanah .............................................................................................40

BAB IV NERACA MASSA ................................................................................ 44

BAB V NERACA PANAS ...................................................................................50

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BAB VI UTILITAS ..............................................................................................56

6.1. Unit Pengelolaan dan Penyediaan Air ....................................................56

6.1.1. Unit Pengolahan Air ......................................................................56

6.1.2. Unit Penyediaan Air ......................................................................65

6.1.2.1. Air Pendingin ...................................................................65

6.1.2.2. Air Boiler .........................................................................67

6.1.2.3. Air Proses .........................................................................68

6.1.2.4. Air Domestik ....................................................................69

6.2. Unit Penyediaan Steam ..........................................................................71

6.2.1. Steam Pemanas ............................................................................71

6.2.2. Steam Turbin ................................................................................72

6.3. Unit Penyediaan Tenaga Listrik .............................................................73

6.3.1. Listrik Peralatan ...........................................................................73

6.3.2. Pencahayaan .................................................................................74

6.3.2.1. Pencayahaan Pabrik ........................................................74

6.4. Unit Penyediaan Bahan Bakar ..............................................................77

6.5. Unit Penyediaan Udara Tekan ..............................................................80

BAB VII SPESIFIKASI PERALATAN .............................................................82

BAB VIII ORGANISASI PERUSAHAAN ......................................................109

8.1. Bentuk Perusahaan ...............................................................................109

8.2. Struktur Organisasi ..............................................................................110

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 8.3. Tugas dan Wewenang ...........................................................................113

8.3.1. Pemegang Saham ........................................................................113

8.3.2. Dewan komisaris .........................................................................114

8.3.3. Direktur Utama ...........................................................................115

8.3.4. General Manager ........................................................................116

8.3.5. Kepala Departemen .....................................................................117

8.3.5.1. Kepala Departemen Produksi dan Logistik....................117

8.3.5.2. Kepala Departemen Teknik............................................118

8.4. Waktu Kerja .........................................................................................121

8.4.1. Karyawan Non-Shift ....................................................................122

8.4.2. Karyawan Shift ............................................................................122

8.4.3. Karyawan Borongan....................................................................124

8.5. Penentuan Jumlah Pekerja.....................................................................124

8.6. Sistem Penggajian .................................................................................130

8.7. Jaminan dan Fasilitas Tenaga Kerja ......................................................130

8.8. Keselamatan dan Kesehatan Kerja (K3) ...............................................132

8.9. Instrumentasi .........................................................................................142

BAB IX PENGOLAHAN LIMBAH .................................................................152

9.1. Limbah Cair ..........................................................................................152

9.1.1. Limbah Cair Domestik dan Proses ..............................................155

9.1.1.1. Desain Bak Pemisah Lemak/Minyak .............................156

9.1.1.2. Desain Bak Equalisasi ....................................................157

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 9.1.1.3. Desain Bak Pegendapan Awal .......................................157

9.1.1.4. Bak Biofilter Anaerob ....................................................158

9.1.1.5. Bak Biofilter Aerob ........................................................159

9.1.1.6. Bak Pengendapan Akhir .................................................161

9.2. Limbah Padat .........................................................................................165

BAB X ANALISA EKONOMI .........................................................................165

10.1. Keuntungan (Profitabilitas) ..................................................................166

10.2. Lama Waktu Pengembalian Modal .....................................................167

10.2.1. Lama Pengembalian Modal TCI ..............................................167

10.2.2. Pay Out Time (POT) ................................................................168

10.3. Total Modal Akhir................................................................................169

10.3.1. Net Profit Over Total Life of The Project (NPOTLP) .............169

10.3.2. Total Capital Sink (TCS) .........................................................171

10.4. Laju Pengembalian Modal ...................................................................172

10.4.1. Rate of Return on Investment (ROI).........................................172

10.4.2. Rate of Return based on Discounted Cash Flow (DCF) ..........172

10.5. Break Even Point .................................................................................173

BAB X1 TUGAS KHUSUS ...............................................................................177

11.1. Reaktor CSTR (Continous Stirred Tank Reaktor) ...............................177

11.2. Karakteristik Reaktor CSTR ................................................................180

11.3. Prinsip Reaktor CSTR ..........................................................................182

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 11.4. Perhitungan Reaktor CSTR (R-01) .....................................................183

BAB XII PENUTUP...........................................................................................192

12.1. Kesimpulan .........................................................................................192

12.2. Saran ....................................................................................................193

DAFTAR PUSTAKA .........................................................................................194

LAMPIRAN ........................................................................................................197

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 DAFTAR TABEL

Tabel 1.1. Pabrik Etilen Glikol di Dunia .................................................................5

Tabel 1.2. Kandungan Tandan Kosong Kelapa Sawit...........................................11

Tabel 1.3. Spesfikasi Kandungan Fisik Tandan Kosong Kelapa Sawit ................11

Tabel 1.4. Analisis Ultimat dan Proksimat Tandan Kosong Kelapa Sawit ...........12

Tabel 1.5. Spesifikasi Lignin .................................................................................12

Tabel 1.6. Spesifikasi Bahan Pendukung Natrium Hidroksida .............................12

Tabel 1.7. Spesifikasi Bahan Pendukung H2O ......................................................13

Tabel 1.8. Spesifikasi Bahan Pendukung Amoniak ..............................................13

Tabel 1.9. Spesifikasi Bahan Pendukung Nikel ....................................................13

Tabel 1.10. Spesifikasi Produk Utama Etilen Glikol ............................................14

Tabel 1.11. Spesifikasi Produk Samping Erythrose ..............................................15

Tabel 2.1. Data Impor dan Ekspor Etilen Glikol di Indonesia ..............................18

Tabel 2.2. Pertumbuhan Impor dan Ekspor Etilen Glikol .....................................19

Tabel 2.3. Prediksi Produksi Pabrik Etilen Glikol dalam Negeri ..........................20

Tabel 2.4. Jumlah Produksi Kelapa Sawit Provinsi Jambi ....................................22

Tabel 2.5. Perbandingan Proses Pembuatan Etilen Glikol ....................................23

Tabel 2.6. Mass Balance .......................................................................................29

Tabel 3.1. Produsen Industri PSF/PFY di Indonesia .............................................33

Tabel 3.2. Produsen Industri PET di Indonesia .....................................................33

Tabel 3.3. Produsen Industri PET di Indonesia .....................................................33

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Tabel 3.4. Keterangan Luas Pabrik Etilen Glikol..................................................40

Tabel 6.1. Parameter Standar Baku Mutu Air Domestik ......................................57

Tabel 6.2. Parameter Standar Baku Mutu Air Umpan Boiler ...............................58

Tabel 6.3. Kebutuhan Air Pendingin .....................................................................65

Tabel 6.4. Kebutuhan Air Proses ...........................................................................68

Tabel 6.5. Kebutuhan Air Domestik......................................................................71

Tabel 6.6. Kebutuhan Steam Pemanas ..................................................................72

Tabel 6.7. Kebutuhan Steam Turbin ......................................................................73

Tabel 6.8. Kebutuhan Listrik Peralatan .................................................................73

Tabel 6.9. Lumen berdasarkan Luas Bangunan ....................................................75

Tabel 6.10. Lumen berdasarkan Luas Luas Ruangan............................................75

Tabel 6.11. Penentuan Jenis Lampu ......................................................................75

Tabel 6.12. Perhitungan Daya Lampu ...................................................................76

Tabel 6.13. Total Limbah Lignin pada Rotary Filter (RF-02) ..............................78

Tabel 6.14. Total Kebutuhan Bahan Bakar ...........................................................80

Tabel 8.1. Waktu Kerja Karyawan Non-Shift .....................................................122

Table 8.2. Waktu Kerja Karyawan Shift ..............................................................123

Tabel 8.3. Jadwal Kerja Karyawan Pabrik ..........................................................123

Tabel 8.4. Jumlah Karyawan ...............................................................................127

Tabel 8.5. Jumlah Karyawan Shift.......................................................................128

Tabel 8.6. Jumlah Karyawan Non-Shift ..............................................................129

Tabel 8.7. Perincian Gaji Karyawan....................................................................130

Tabel 8.8. Alat Pelindung Diri ............................................................................141

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Tabel 8.9. Sitem Pengontrolan pada Pabrik ........................................................148

Tabel 9.1. Baku Mutu Air Limbah ......................................................................154

Tabel 9.2. Jumlah Limbah Cair Proses ................................................................155

Tabel 10.1. Angsuran Pengembalian Modal TCI ................................................168

Tabel 10.2. Kesimpulan Analisis Ekonomi .........................................................176

Tabel 11.1. Neraca Massa Reaktor CSTR (R-01) ...............................................180

Tabel 11.2. Neraca Panas Reaktor CSTR (R-01) ................................................180

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 DAFTAR GAMBAR

Gambar 1.1. Reaksi Etilen Oksida Melalui Etilen Karbonat ..................................8

Gambar 2.1. Flowsheet Pembuatan Etilen Glikol dari TKKS .............................28

Gambar 2.2. Diagram Alir Proses Pembuatan Etilen Glikol dari TKKS .............30

Gambar 3.1. Peta Digital Lokasi Pabrik Etlien glikol ..........................................31

Gambar 3.2. Layout Pabrik ...................................................................................42

Gambar 3.3. Layout Peralatan ..............................................................................43

Gambar 8.1. Intrumentasi pada Reaktor .............................................................149

Gambar 8.2. Intrumentasi pada Digester ............................................................149

Gambar 8.3. Intrumentasi pada Heater ..............................................................149

Gambar 8.4. Intrumentasi pada Cooler ..............................................................149

Gambar 8.5. Intrumentasi pada Kolom Distilasi ................................................149

Gambar 8.6. Intrumentasi pada Reboiler ............................................................150

Gambar 8.7. Intrumentasi pada Knock Out Drum ..............................................150

Gambar 8.8. Intrumentasi pada Mixer ................................................................150

Gambar 8.9. Intrumentasi pada Pompa ..............................................................150

Gambar 8.10. Intrumentasi pada Kompresor......................................................150

Gambar 8.11. Intrumentasi pada Tangki ............................................................151

Gambar 8.12. Struktur Organisasi ......................................................................152

Gambar 9.1. Diagram Alir Pengolahan Limbah Cair .........................................154

Gambar 9.2. Bak Limbah Tampak Atas .............................................................163

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Gambar 9.3. Bak Limbah Tampak Depan ..........................................................164

Gambar 10.1. Break Even Point .........................................................................174

Gambar 11.1. Reaktor CSTR..............................................................................177

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 DAFTAR LAMPIRAN

LAMPIRAN A. Neraca Massa ...........................................................................197

LAMPIRAN B. Neraca Panas ............................................................................209

LAMPIRAN C. Spesifikasi Peralatan ................................................................265

LAMPIRAN D. Analisa Ekonomi ......................................................................565

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