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TUGAS AKHIR
PRARANCANGAN PABRIK TITANIUM DIOKSIDA
DARI ILMENIT DENGAN PROSES KLORIDA
KAPASITAS 130.000 TON/TAHUN

HALAMAN JUDUL

Disusun Oleh:
Ayut Triwulan (I 0518006)
Raihan Naufal Widian (I 0518073)

PROGRAM STUDI SARJANA TEKNIK KIMIA

FAKULTAS TEKNIK UNIVERSITAS SEBELAS MARET
SURAKARTA
2022
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Prarancangan Pabrik Titanium Dioksida

dari Ilmenit dengan Proses Klorida
Kapasitas 130.000 Ton/Tahun

DAFTAR ISI

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

LEMBAR PENGESAHAN ......................................................................................... ii
LEMBAR KONSULTASI .......................................................................................... iii
KATA PENGANTAR ................................................................................................. v
DAFTAR ISI ............................................................................................................... vi
DAFTAR TABEL ....................................................................................................... xi
DAFTAR GAMBAR ................................................................................................ xiii
INTISARI .................................................................................................................. xiv
BAB I PENDAHULUAN
1.1 Latar Belakang Pendirian Pabrik .......................................................... 1
1.2 Penentuan Kapasitas Rancangan Pabrik ............................................... 2
I.2.1 Kebutuhan Titanium Dioksida di Indonesia ............................... 2
I.2.2 Ketersediaan Bahan Baku ........................................................... 3
I.2.3 Kapasitas Produksi Pabrik Titanium Dioksida di Dunia ............ 3
I.2.4 Perhitungan Kapasitas Produksi Titanium Dioksida .................. 5
1.3 Penentuan Lokasi Pabrik ...................................................................... 7
1.3.1 Bahan Baku ................................................................................. 7
1.3.2 Pemasaran ................................................................................... 7
1.3.3 Utilitas ......................................................................................... 7
1.3.4 Tenaga Kerja ............................................................................... 7
1.3.5 Transportasi dan Telekomunikasi ............................................... 8
1.4 Tinjauan Pustaka .................................................................................. 9
1.4.1 Macam-Macam Proses ................................................................ 9
1.4.2 Tinjauan Proses Secara Umum ................................................. 11
1.4.3 Kegunaan Produk ...................................................................... 12
1.4.4 Sifat-sifat Fisik dan Kimia ........................................................ 12
BAB II DESKRIPSI PROSES ................................................................................... 16
2.1. Spesifikasi Bahan Baku dan Produk................................................... 16

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Prarancangan Pabrik Titanium Dioksida

dari Ilmenit dengan Proses Klorida
Kapasitas 130.000 Ton/Tahun

2.1.1 Spesifikasi Bahan Baku ............................................................ 16

2.1.2. Spesifikasi Produk..................................................................... 17
2.2 Konsep Dasar Proses .......................................................................... 17
2.2.1 Dasar Reaksi ............................................................................. 17
2.2.2 Kondisi Operasi......................................................................... 18
2.3 Tinjauan Kinetika ............................................................................... 18
2.4 Tinjauan Termodinamika ................................................................... 20
2.5 Diagram Alir Proses dan Tahapan Proses .......................................... 25
2.5.1 Diagram Alir Kualitatif dan Kuantitatif .................................... 25
2.5.2 Diagram Alir Proses .................................................................. 25
2.5.3 Tahapan Proses ......................................................................... 29
2.6 Neraca Massa dan Nerasa Panas ........................................................ 31
2.6.1 Neraca Massa ............................................................................ 31
2.6.2. Neraca Panas ............................................................................. 33
2.7 Layout Pabrik dan Peralatan ............................................................... 34
2.7.1 Analisis Potensi Bahaya ............................................................ 34
2.7.2 Tata Letak Pabrik ...................................................................... 38
2.7.3 Tata Letak Peralatan Pabrik ...................................................... 41
BAB III SPESIFIKASI PERALATAN PROSES ...................................................... 43
3.1 Reaktor Klorinasi................................................................................ 43
3.2 Reaktor Oksidasi ................................................................................ 44
3.3 Tangki Cl2........................................................................................... 45
3.4 Tangki FeCl3....................................................................................... 46
3.5 Silo Ilmenit ......................................................................................... 47
3.6 Silo Kokas .......................................................................................... 47
3.7 Silo TiO2 ............................................................................................. 48
3.8 Silo NaOH .......................................................................................... 48
3.9 Separator 1 .......................................................................................... 49
3.10 Separator 2 .......................................................................................... 50
3.11 Pre Heater 1 ....................................................................................... 51
3.12 Pre Heater 2 ....................................................................................... 52

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Prarancangan Pabrik Titanium Dioksida

dari Ilmenit dengan Proses Klorida
Kapasitas 130.000 Ton/Tahun

3.13 Pre Heater 3 ....................................................................................... 54

3.14 Kondenser Partial 1 ............................................................................ 55
3.15 Kondenser Partial 2 ............................................................................ 57
3.16 Absorber ............................................................................................. 58
3.17 Grate Cooler 1 .................................................................................... 59
3.18 Grate Cooler 2 .................................................................................... 60
3.19 Pompa 1 .............................................................................................. 60
3.20 Pompa 2 .............................................................................................. 61
3.21 Pompa 3 .............................................................................................. 62
3.22 Kompressor 1...................................................................................... 63
3.23 Kompressor 2...................................................................................... 63
3.24 Kompressor 3...................................................................................... 64
3.25 Screw Conveyor 1 .............................................................................. 64
3.26 Screw Conveyor 2 .............................................................................. 65
3.27 Belt Conveyor 1.................................................................................. 65
3.28 Belt Conveyor 2.................................................................................. 66
3.29 Belt Conveyor 3.................................................................................. 66
3.30 Expansion Valve 1.............................................................................. 66
3.31 Expansion Valve 2.............................................................................. 67
3.32 Tee 1 ................................................................................................... 67
3.33 Mixer .................................................................................................. 68
3.34 Cyclone R-01 ...................................................................................... 68
3.35 Cyclone R-02 ...................................................................................... 69
BAB IV UNIT PENDUKUNG PROSES DAN LABORATORIUM ....................... 70
4.1. Unit Pendukung Proses....................................................................... 70
4.1.1. Unit Pengadaan Air ................................................................... 71
4.1.2 Unit Pengadaan Udara Tekan ................................................... 78
4.1.3 Unit Pengadaan Listrik.............................................................. 78
4.1.4 Unit Pengolahan Limbah .......................................................... 82
4.1.5 Laboratorium............................................................................. 84
BAB V MANAJEMEN PERUSAHAAN .................................................................. 88

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Prarancangan Pabrik Titanium Dioksida

dari Ilmenit dengan Proses Klorida
Kapasitas 130.000 Ton/Tahun

5.1. Bentuk Perusahaan ............................................................................. 88

5.2. Struktur Organisasi ............................................................................. 88
5.3. Tugas dan Wewenang......................................................................... 90
5.3.1. Pemegang Saham ...................................................................... 90
5.3.2. Dewan Komisaris ...................................................................... 91
5.3.3. Dewan Direksi........................................................................... 91
5.3.4. Staf Ahli .................................................................................... 92
5.3.5. Kepala Bagian ........................................................................... 92
5.3.6. Kepala Divisi............................................................................. 94
5.4. Pembagian Jam Kerja Karyawan........................................................ 94
5.4.1. Karyawan Non-shift .................................................................. 94
5.4.1. Karyawan Shift .......................................................................... 94
5.5. Sistem Karyawan dan Upah ............................................................... 95
5.6. Penggolongan Jabatan, Jumlah Karyawan, dan Gaji.......................... 96
5.7. Keselamatan, Kesehatan Kerja, dan Kesejahteraan Sosial Karyawan 98
5.7.1. Keselamatan Kerja .................................................................... 98
5.7.2. Kesehatan Kerja ...................................................................... 100
5.7.3 Kesejahteraan Sosial Karyawan .............................................. 100
BAB VI ANALISIS EKONOMI ............................................................................. 102
6.1. Dasar Perhitungan ............................................................................ 102
6.2. Estimasi Harga Peralatan .................................................................. 103
6.3. Estimasi Penanaman Modal Total (Total Capital Investment)......... 106
6.3.1. Modal Tetap (Fixed Capital Investment) ................................ 106
6.3.2. Modal Kerja (Working Capital Investment)............................ 107
6.4. Estimasi Biaya Total Produksi ......................................................... 109
6.4.1. Biaya Manufacturing .............................................................. 109
6.4.2. Biaya Pengeluaran Umum (General Expense) ....................... 111
6.5. Analisa Profitabilitas ........................................................................ 112
6.5.1. Estimasi Laba Tahunan ........................................................... 112
6.5.2. Kriteris Profitabilitas Non-discounted (Tidak Dipotong) ....... 113
6.5.3. Kriteris Profitabilitas Discounted (Dipotong) ......................... 115

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Prarancangan Pabrik Titanium Dioksida

dari Ilmenit dengan Proses Klorida
Kapasitas 130.000 Ton/Tahun

6.6. Evaluasi Risiko dalam Perhitungan Profitabilitas ............................ 117

6.6.1. Break Event Point (BEP) ........................................................ 117
6.6.2. Shut Down Point (SDP) .......................................................... 118
6.6.3. Estimasi Ketidakpastian .......................................................... 120
6.7. Kesimpulan Kriteria Profitabilitas .................................................... 123
DAFTAR PUSTAKA .............................................................................................. 124
LAMPIRAN ............................................................................................................. 129