Universitas Surabaya Kata Pengantar

Kata Pengantar

Puji dan syukur ke hadirat Tuhan Yang Maha Esa atas segala berkat
dan karunia yang telah dicurahkan kepada penulis sehingga tugas akhir
dengan judul “Desain Proyek Pembuatan Methyl Methacrylate dari Methacrylic
Acid dan Methanol dengan Proses Esterifikasi Kapasitas 164.000 Ton/Tahun” dapat
terselesaikan dengan baik dan tepat pada waktunya. Penulis menyadari bahwa
dalam menyelesaikan tugas akhir ini telah mendapatkan banyak dukungan
dari berbagai pihak. Oleh karenanya, pada kesempatan ini penulis ingin
mengucapkan terima kasih kepada:

1. Bapak Dr. Aloisiyus Yuli Widianto selaku Kepala Program

StudiTeknik Kimia Universitas Surabaya.
2. Bapak Edy Purwanto, M.Eng.Sc selaku dosen pembimbing pertama
yang telah memberikan bimbingan, arahan, dan bantuan dalam
penyelesaian tugas akhir.
3. Ibu Prof. Lieke Riadi, Ph.D.selaku dosen pembimbing kedua yang
telah memberikan bimbingan, arahan, dan bantuan dalam
penyelesaian tugas akhir.
4. Orang tua, keluraga, serta teman – teman Program Studi Teknik
Kimia angkatan 2019 yang telah memberikan dukungan semangat dan
fasilitas sehingga tugas akhir ini dapat terselesaikan.

Penulis mohon maaf apabila terdapat kesalahan – kesalahan baik

berupa ejaan maupun kalimat yang menyinggung pembaca. Penulis berharap
pembaca dapat memperoleh manfaat yang berguna dari laporan penelitian
ini.

Surabaya, 28 Juli 2023

Penulis

Desain Proyek Pembuatan Methyl Methacrylate dari Methacrylic Acid dan

Methanol dengan Proses Esterifikasi Kapasitas 164.000 Ton/Tahun i
 Universitas Surabaya Daftar Isi

DAFTAR ISI
KATA PENGANTAR ................................................................................................ i
DAFTAR ISI ............................................................................................................. ii
DAFTAR GAMBAR ................................................................................................. vi
DAFTAR TABEL .................................................................................................... viii
INTISARI .................................................................................................................. x
BAB I PENDAHULUAN......................................................................................................I-5

I.1 Latar Belakang ..............................................................................................I-5

I.2 Sejarah Perkembangan Proses Produksi Secara Umum ................................I-6

I.3 Penentuan Kapasitas Rancangan Pabrik........................................................ I-8

I.4 Material Safety Data Sheet (MSDS)............................................................I-14

I.5 Kegunaan Produk ........................................................................................I-18

BAB II PEMILIHAN DAN URAIAN PROSES........................................................II-1

II.1 Jenis-Jenis Proses ...................................................................................... II-1

II.1.1 Esterifikasi …………………………………..…………………..II-1

II.1.2 Pemisahan Produk dengan Distilasi dan Dekanter.……………...II-1

II.2 Analisis Detail Terhadap Proses Serta Proses yang Dipilih .....................II-2

II.3 Diagram Alir Proses Secara Kualitatif ......................................................II-7

II.4 Uraian Proses.............................................................................................II-8

BAB III NERACA MASSA.......................................................................................III-1

III.1 Mixing Tank (M-210) ............................................................................ III-2

III.2 Plug Flow Reactor (R-240) ................................................................... III-4

III.3 Menara Distilasi I (D-310) .................................................................... III-5

III.4 Kondensor I (E-311).............................................................................. III-6

III.5 Reboiler I (E-316).................................................................................. III-7

III.6 Menara Distilasi II (D-320) ....................................................................III.8

Desain Proyek Pembuatan Methyl Methacrylate dari Methacrylic

Acid dan Methanol dengan Proses Esterifikasi Kapasitas 164.000 ii
Ton/Tahun
 Universitas Surabaya Daftar Isi

III.7 Kondensor II (E-321) ............................................................................. I.9

III.8 Reboiler II (E-324) ...............................................................................III.10

III.9 Decanter (E-420) ..................................................................................III.11

III.10 Overall ............................................................................................... III-12

BAB IV NERACA PANAS........................................................................................IV-1

IV.1 Mixing Tank (M-210) ............................................................................ IV-4

IV.2 Heater I (E-230) .................................................................................... IV-5

IV.3 Plug Flow Reactor (R-240)................................................................... IV-6

IV.4 Menara Distilasi I (D-310) .................................................................... IV-7

IV.5 Menara Distilasi II (D-320) ................................................................... IV-8

IV.6 Cooler (E-410) ...................................................................................... IV-9

BAB V SPESIFIKASI ALAT....................................................................................V-1

V.1 Tangki Penyimpanan Bahan Baku Metanol (F-110) ............................... V-1

V.2 Pompa Tangki Penyimpanan Metanol (L-111) ....................................... V-5

V.3 Mixing Tank (M-210) .............................................................................. V-8

V.4 Heater I (E-230) .................................................................................... V-10

V.5 Plug Flow Reactor (R-240) ................................................................... V-11

V.6 Menara Distilasi I (D-310)..................................................................... V-13

V.7 Kondensor I (E-311) .............................................................................. V-15

V.8 Reboiler I (E-316).................................................................................. V-17

V.9 Cooler (E-410)....................................................................................... V-19

BAB VI SISTEM UTILITAS....................................................................................VI-1

VI.1 Unit Penyedia Steam ............................................................................. VI-1

VI.2 Unit Penyedia dan Pengolahan Air ....................................................... VI-2

Desain Proyek Pembuatan Methyl Methacrylate dari Methacrylic

Acid dan Methanol dengan Proses Esterifikasi Kapasitas 164.000 iii
Ton/Tahun
 Universitas Surabaya Daftar Isi

VI.2.1 Kebutuhan Air Sungai… ............................................................. I-2

VI.3 Unit Pendingin (Brine CaCl2) ........................................................... VI-51

VI.4 Unit Penyedia Listrik ........................................................................ VI-52

VI.5 Unit Penyedia Bahan Bakar .............................................................. VI-55

BAB VII ANALISA EKONOMI.............................................................................VII-1

VII.1 Total Capital Investment (TCI)......................................................... VII-2

VII.1.1 Modal Tetap (Fixed Capital Investment / FCI)…..…………..VII-2

VII.1.2 Modal Kerja (Working Capital / WC)………………………..VII-3

VII.2 Total Production Cost (TPC)............................................................ VII-4

VII.2.1 Biaya Fabrikasi (Manufacturing Cost / MC)......................... VII-2

VII.2.2 Biaya Umum (General Expenses / GE)................................. VII-5

VII.3 Analisa Ekonomi............................................................................... VII-6

VII.3.1 Asumsi yang Diambil ............................................................ VII-6

VII.3.2 Perhitungan Investasi............................................................. VII-6

VII.3.3 Perhitungan Biaya Operasi .................................................... VII-8

VII.3.4 Tabel Cash Flow..................................................................... VII-9

VII.3.5 Rate on Equity (ROE)........................................................... VII-15

VII.3.6 Internal Rate of Return (IRR)............................................... VII-16

VII.3.7 Payout Time (POT)............................................................... VII-17

VII.3.8 Break Even Point (BEP) ....................................................... VII-18

BAB VIII DISKUSI DAN KESIMPULAN............................................................VIII-1

VIII.1 Diskusi ............................................................................................VIII-1

VIII.2 Kesimpulan.....................................................................................VIII-2

Desain Proyek Pembuatan Methyl Methacrylate dari Methacrylic

Acid dan Methanol dengan Proses Esterifikasi Kapasitas 164.000 iv
Ton/Tahun
 Universitas Surabaya Daftar Isi

DAFTAR PUSTAKA ............................................................................................. DP-1

LAMPIRAN A ............................................................................................................. A-1

LAMPIRAN B.............................................................................................................. B-1

LAMPIRAN C ............................................................................................................. C-1

LAMPIRAN D ............................................................................................................. D-1

Desain Proyek Pembuatan Methyl Methacrylate dari Methacrylic

Acid dan Methanol dengan Proses Esterifikasi Kapasitas 164.000 v
Ton/Tahun
 Universitas Surabaya Daftar Gambar

DAFTAR GAMBAR

Gambar II.1 Reaksi Esterifikasi Methyl Methacrylate (MMA) ........................................ I-2

Gambar II.2 Diagram Alir Proses Methyl Methacrylate (MMA)..................................... II.7
Gambar III.1 Skema Neraca Massa Mixing Tank ............................................................. III-2
Gambar III.2 Skema Neraca Massa Reaktor..................................................................... III-4
Gambar III.3 Skema Neraca Massa Menara Distilasi I..................................................... III-5
Gambar III.4 Skema Neraca Massa Kondensor I ............................................................. III-6
Gambar III.5 Skema Neraca Massa Reboiler I ................................................................. III-7
Gambar III.6 Skema Neraca Massa Menara Distilasi II ................................................... III-8
Gambar III.7 Skema Neraca Massa Kondensor II ............................................................ III-9
Gambar III.8 Skema Neraca Massa Reboiler II................................................................ III-10
Gambar III.9 Skema Neraca Massa Decanter................................................................... III-11
Gambar III.10 Skema Neraca Massa Overall ................................................................... III-12
Gambar IV.1 Skema Neraca Panas Mixing Tank.............................................................. IV-4
Gambar IV.2 Skema Neraca Panas Heater I .................................................................... IV-5
Gambar IV.3 Skema Neraca Panas Reaktor ..................................................................... IV-6
Gambar IV.4 Skema Neraca Panas Menara Distilasi I ..................................................... IV-7
Gambar IV.5 Skema Neraca Panas Menara Distilasi II .................................................... IV-8
Gambar IV.6 Skema Neraca Panas Cooler....................................................................... IV-9
Gambar V.1 Tangki Penyimpanan Bahan Baku Metanol................................................. V-1
Gambar V.2 Pompa Tangki Penyimpanan Metanol ......................................................... V-5
Gambar V.3 Mixing Tank ................................................................................................. V-8
Gambar V.4 Heater I ........................................................................................................ V-10
Gambar V.5 Plug Flow Reactor ....................................................................................... V-11
Gambar V.6 Menara Distilasi I......................................................................................... V-13
Gambar V.7 Kondensor I.................................................................................................. V-15
Gambar V.8 Reboiler I ..................................................................................................... V-17
Gambar V.9 Cooler .......................................................................................................... V-19
Gambar VI.1 Skema Unit Utilitas..................................................................................... VI-5
Gambar VI.2 Bak Penampung Air Sungai........................................................................ VI-8

Desain Proyek Pembuatan Methyl Methacrylate dari Methacrylic

Acid dan Methanol dengan Proses Esterifikasi Kapasitas 164.000 vi
Ton/Tahun
 Universitas Surabaya Daftar Gambar

Gambar VI.3 Rapid Mixing ............................................................................................. I-11

Gambar VI.4 Tangki Flokulasi ......................................................................................... VI-18
Gambar VI.5 Bak Sedimentasi ......................................................................................... VI-24
Gambar VI.6 Sand Filter .................................................................................................. VI-26
Gambar VI.7 Cation Exchanger ....................................................................................... VI-30
Gambar VI.8 Anion Exchanger ........................................................................................ VI-34
Gambar VI.9 Skema Refrigerator .................................................................................... VI-40
Gambar VI.10 Skema Pompa ........................................................................................... VI-44
Gambar VII.1 Grafik Nilai Break Even Point................................................................... VII-20

Desain Proyek Pembuatan Methyl Methacrylate dari Methacrylic

Acid dan Methanol dengan Proses Esterifikasi Kapasitas 164.000 vii
Ton/Tahun
 Universitas Surabaya Daftar Tabel

DAFTAR TABEL

Tabel I.1 Data Impor Methyl Methacrylate (MMA) di Indonesia .................................. I-4
Tabel 1.2 Data Perkiraan Konsumsi Methyl Methacrylate (MMA) di Indonesia............ I-6
Tabel 1.3 Daftar Produsen Methyl Methacrylate (MMA) di dunia.................................. I-7
Tabel 1.4 Tabel MSDS Bahan Baku dan Produk ............................................................. I-10
Tabel II.1 Perbandingan Kelebihan dan Kekurangan Proses Produksi Metil Metakrilat II-5
Tabel III.1 Neraca Massa Mixing Tank ............................................................................ III-2
Tabel III.2 Neraca Massa Reaktor .................................................................................... III-4
Tabel III.3 Neraca Massa Menara Distilasi I .................................................................... III-5
Tabel III.4 Neraca Massa Kondensor I ............................................................................. III-6
Tabel III.5 Neraca Massa Reboiler I................................................................................. III-7
Tabel III.6 Neraca Massa Menara Distilasi II................................................................... III-8
Tabel III.7 Neraca Massa Kondensor II............................................................................ III-9
Tabel III.8 Neraca Massa Reboiler II ............................................................................... III-10
Tabel III.9 Neraca Massa Decanter .................................................................................. III-11
Tabel III.10 Neraca Massa Overall................................................................................... III-12
Tabel IV.1 Kapasitas Kalor Zat Cair ................................................................................ IV-2
Tabel IV.2 Panas Pembentukan Standar Senyawa............................................................ IV-2
Tabel IV.3 Panas Penguapan Senyawa............................................................................. IV-2
Tabel IV.4 Densitas Cairan............................................................................................... IV-3
Tabel IV.5 Koefisien Ekspansi Termal Liquid ................................................................. IV-3
Tabel IV.6 Hasil Perhitungan Neraca Panas Mixing Tank................................................ IV-4
Tabel IV.7 Hasil Perhitungan Neraca Panas Heater I....................................................... IV-5
Tabel IV.8 Hasil Perhitungan Neraca Panas Reaktor ....................................................... IV-6
Tabel IV.9 Hasil Perhitungan Neraca Panas Menara Distilasi I ....................................... IV-7
Tabel IV.10 Hasil Perhitungan Neraca Panas Menara Distilasi II .................................... IV-8
Tabel IV.11 Hasil Perhitungan Neraca Panas Cooler....................................................... IV-9
Tabel V.1 Hasil Perhitungan Spesifikasi Tangki dan Dekanter........................................ V-1
Tabel V.2 Spesifikasi Alat Pompa.................................................................................... V-5
Tabel V.3 Spesifikasi Alat Mixing Tank........................................................................... V-8

Desain Proyek Pembuatan Methyl Methacrylate dari Methacrylic

Acid dan Methanol dengan Proses Esterifikasi Kapasitas 164.000 viii
Ton/Tahun
 Universitas Surabaya Daftar Tabel

Tabel V.4 Spesifikasi Alat Heater ................................................................................ V-10

Tabel V.5 Spesifikasi Alat Plug Flow Reactor................................................................. V-11
Tabel V.6 Spesifikasi Alat Menara Distilasi I .................................................................. V-13
Tabel V.7 Spesifikasi Alat Kondensor I ........................................................................... V-15
Tabel V.8 Reboiler I ......................................................................................................... V-17
Tabel V.9 Spesifikasi Alat Cooler .................................................................................... V-19
Tabel VI.1 Kebutuhan Steam Proses ................................................................................ VI-1
Tabel VI.2 Kebutuhan Air Sanitasi................................................................................... VI-4
Tabel VI.3 Spesifikasi Bak Penampung ........................................................................... VI-10
Tabel VI.4 Entalpi Aliran Masuk Boiler........................................................................... VI-37
Tabel VI.5 Perhitungan Nilai Kf Pompa 1........................................................................ VI-46
Tabel VI.6 Spesifikasi Alat Pompa................................................................................... VI-48
Tabel VI.7 Kebutuhan Brine Setiap Alat .......................................................................... VI-51
Tabel VI.8 Kebutuhan Listrik untuk Unit Proses dan Utilitas .......................................... VI-52
Tabel VI.9 Kebutuhan Listrik untuk Penerangan ............................................................. VI-53
Tabel VI.10 Perhitungan Koarse ...................................................................................... VI-58
Tabel VII.1 Tabel Rincian Gaji Karyawan ....................................................................... VII-2
Tabel VII.2 Tabel Perhitungan Modal Tetap .................................................................... VII-2
Tabel VII.3 Tabel Perhitungan Biaya Fabrikasi ............................................................... VII-4
Tabel VII.4 Tabel Perhitungan Biaya Umum ................................................................... VII-5
Tabel VII.5 Tabel Perhitungan Modal Sendiri pada Masa Konstruksi ............................. VII-7
Tabel VII.6 Tabel Perhitungan Modal Pinjaman pada Masa Konstruksi.......................... VII-7
Tabel VII.7 Tabel Biaya Operasi pada Masing-Masing Kapasitas Produksi.................... VII-8
Tabel VII.8 Susunan Tabel Cash Flow............................................................................. VII-9
Tabel VII.9 Tabel Perhitungan Cash Flow ....................................................................... VII-11
Tabel VII.10 Tabel Perhitungan Cash Flow (lanjutan)..................................................... VII-12
Tabel VII.11 Tabel Perhitungan Cash Flow (lanjutan)..................................................... VII-13
Tabel VII.12 Tabel Perhitungan Cash Flow (lanjutan)..................................................... VII-14
Tabel VII.13 Tabel Perhitungan Rate on Equity............................................................... VII-15
Tabel VII.14 Tabel Perhitungan Internal Rate of Return ................................................. VII-16
Tabel VII.15 Tabel Perhitungan Payout Time .................................................................. VII-17
Tabel VII.16 Tabel Perhitungan Break Even Point .......................................................... VII-18
Desain Proyek Pembuatan Methyl Methacrylate dari Methacrylic
Acid dan Methanol dengan Proses Esterifikasi Kapasitas 164.000 ix
Ton/Tahun