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TUGAS AKHIR
PRARANCANGAN PABRIK n-BUTIL AKRILAT
DARI ASAM AKRILAT DAN n-BUTANOL
KAPASITAS 40.000 TON/TAHUN

Disusun oleh:
Diah Sri Umpati I0518023
Nisriina ‘Abidah Qurrotul’aini I0518069

HALAMAN JUDUL

Program Studi Sarjana Teknik Kimia

Fakultas Teknik Universitas Sebelas Maret
Surakarta
2022

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DAFTAR ISI
HALAMAN JUDUL ................................................................................................ i
LEMBAR PENGESAHAN .................................................................................... ii
LEMBAR KONSULTASI ..................................................................................... iii
KATA PENGANTAR ......................................................................................... viii
DAFTAR ISI .......................................................................................................... ix
DAFTAR TABEL ................................................................................................ xiii
DAFTAR GAMBAR .............................................................................................xv
INTISARI ............................................................................................................. xvi
BAB I PENDAHULUAN ........................................................................................1
1.1. Latar Belakang Pendirian Pabrik................................................................. 1
1.2. Penentuan Kapasitas Rancangan Pabrik...................................................... 2
1.2.1. Kebutuhan Dalam Negeri .................................................................. 2
1.2.2. Peluang Ekspor n-Butil Akrilat ......................................................... 3
1.2.3. Ketersediaan Bahan Baku dan Katalis .............................................. 5
1.2.4. Kapasitas Produksi n-Butil Akrilat di Dunia .................................... 5
1.2.5. Kapasitas Perancangan Pabrik n-Butil Akrilat.................................. 6
1.3. Penentuan Lokasi Pabrik ............................................................................. 7
1.4. Tinjauan Pustaka ....................................................................................... 10
1.4.1. Macam-macam Proses .................................................................... 10
1.4.2. Tinjauan Proses Secara Umum ....................................................... 12
1.4.3. Kegunaan Produk ............................................................................ 13
1.4.4. Sifat Fisis dan Kimia ....................................................................... 14
BAB II DESKRIPSI PROSES ...............................................................................18
2.1. Spesifikasi Bahan Baku, Bahan Pendukung, dan Produk ......................... 18
2.1.1. Spesifikasi Bahan Baku................................................................... 18
2.1.2. Spesifikasi Bahan Pendukung ......................................................... 18
2.1.3. Spesifikasi Produk........................................................................... 18
2.2. Konsep Proses ........................................................................................... 19
2.2.1. Dasar Reaksi.................................................................................... 19
2.2.2. Sistem Katalis.................................................................................. 19
2.2.3. Mekanisme Reaksi .......................................................................... 20
2.2.4. Fase Reaksi dan Kondisi Reaksi ..................................................... 20
2.3. Tinjauan Termodinamika .......................................................................... 21

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2.3.1. Menghitung Panas Reaksi Keseluruhan .......................................... 21

2.3.2. Menghitung Energi Gibbs ............................................................... 24
2.4. Tinjauan Kinetika ...................................................................................... 26
2.4.1. Perbandingan Mol Reaktan ............................................................. 28
2.5. Diagram Alir Proses dan Tahapan Proses ................................................. 28
2.5.1. Diagram Alir Kualitatif dan Kuantitatif .......................................... 28
2.5.2. Diagram Alir Proses ........................................................................ 28
2.5.3. Tahapan Proses................................................................................ 28
2.6. Neraca Massa dan Neraca Panas ............................................................... 33
2.6.1. Neraca Massa .................................................................................. 33
2.6.2. Neraca Panas ................................................................................... 34
2.7. Tata Letak Peralatan dan Pabrik................................................................ 35
2.7.1. Analisis Potensi dan Dampak Bahaya............................................. 35
2.7.2. Tata Letak Peralatan ........................................................................ 38
2.7.3. Tata Letak Pabrik ............................................................................ 39
BAB III SPESIFIKASI ALAT...............................................................................43
3.1. Tangki Penyimpanan ................................................................................. 43
3.2. Vaporizer ................................................................................................... 45
3.3. Separator.................................................................................................... 47
3.4. Reaktor ...................................................................................................... 48
3.5. Dekanter .................................................................................................... 51
3.6. Kondensor Total ........................................................................................ 52
3.7. Reboiler ..................................................................................................... 54
3.8. Heat Exchanger ......................................................................................... 56
3.9. Pompa ........................................................................................................ 60
BAB IV UNIT PENDUKUNG PROSES DAN LABORATORIUM ...................64
4.1. Unit Pendukung Proses ............................................................................. 64
4.1.1. Unit Pengadaan Air ......................................................................... 65
4.1.2. Unit Pengadaan Steam..................................................................... 73
4.1.3. Unit Pengadaan Udara Tekan.......................................................... 73
4.1.4. Unit Penyedia Listrik ...................................................................... 74
4.1.5. Unit Pengadaan Bahan Bakar.......................................................... 81
4.2. Laboratorium ............................................................................................. 83
4.2.1. Laboratorium Analisis Bahan Baku ................................................ 85

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4.2.2. Laboratorium Analisis Produk ........................................................ 85

4.2.3. Laboratorium Analisis Air .............................................................. 85
4.2.4. Laboratorium Penelitian dan Pengembangan.................................. 86
4.3. Unit Pengolahan Limbah ........................................................................... 86
4.3.1. Limbah Padat .................................................................................. 86
4.3.2. Limbah Cair .................................................................................... 87
4.3.3. Limbah Gas ..................................................................................... 88
BAB V MANAJEMEN PERUSAHAAN ..............................................................89
5.1. Bentuk Perusahaan .................................................................................... 89
5.2. Struktur Organisasi .................................................................................... 90
5.3. Tugas dan Wewenang ............................................................................... 93
5.3.1. Pemegang Saham ............................................................................ 93
5.3.2. Dewan Komisaris ............................................................................ 93
5.3.3. Dewan Direksi................................................................................. 93
5.3.4. Staf Ahli .......................................................................................... 94
5.3.5. Kepala Bagian ................................................................................. 95
5.3.6. Kepala Seksi .................................................................................... 97
5.4. Pembagian Jam Kerja Karyawan .............................................................. 97
5.4.1. Karyawan Non-Shift / Harian .......................................................... 98
5.4.2. Karyawan Shift ................................................................................ 98
5.4.3. Status Karyawan dan Sistem Upah ................................................. 99
5.4.4. Penggolongan Jabatan, Jumlah, Pendidikan, dan Gaji Karyawan 100
5.5. Kesejahteraan Sosial Karyawan .............................................................. 102
5.6. Keselamatan dan Kesehatan Kerja .......................................................... 104
5.6.1. Keselamatan Kerja ........................................................................ 104
5.6.2. Kesehatan Kerja ............................................................................ 105
5.7. Manajemen Produksi ............................................................................... 106
5.7.1. Perencanaan Produksi ................................................................... 106
5.7.2. Pengendalian Produksi .................................................................. 107
BAB VI ANALISA EKONOMI ..........................................................................109
6.1. Dasar Perhitungan Analisis Ekonomi ..................................................... 109
6.2. Estimasi Harga Peralatan......................................................................... 110
6.3. Estimasi Penanaman Modal Total (Total Capital Investment ) .............. 112
6.3.1. Modal Tetap (Fixed Capital Investment) ...................................... 112

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6.3.2. Modal Kerja (Working Capital Investment) .................................. 113

6.4. Estimasi Biaya Total Produksi ................................................................ 114
6.4.1. Biaya Manufacturing .................................................................... 114
6.4.2. Biaya Pengeluaran Umum (General Expense) ............................. 116
6.5. Analisis Profitabilitas .............................................................................. 117
6.5.1. Estimasi Laba Tahunan ................................................................. 117
6.5.2. Kriteria Profitabilitas Non-discounted .......................................... 119
6.5.3. Kriteria Profitabilitas Discounted ................................................. 121
6.6. Evaluasi Resiko dalam Perhitungan Profitabilitas .................................. 122
6.6.1. Break Event Point (BEP) .............................................................. 122
6.6.2. Shut down point (SDP) .................................................................. 123
6.6.3. Kesimpulan Kriteria Profitabilitas ................................................ 125
6.6.4. Estimasi Ketidakpastian ................................................................ 125
DAFTAR PUSTAKA ..........................................................................................129
LAMPIRAN .........................................................................................................133

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DAFTAR TABEL
Tabel 1.1 Data Impor n-Butil Akrilat di Indonesia (BPS, 2020) .............................2
Tabel 1.2 Data Impor n-Butil Akrilat di Malaysia, Thailand, Filipina, dan Singapura
(UN Data, 2018) .......................................................................................................4
Tabel 1.3 Ketersediaan Bahan Baku n-Butil Akrilat ...............................................5
Tabel 1.4 Kapasitas Produksi Pabrik n-Butil Akrilat di Dunia ................................5
Tabel 1.5 Perbandingan Beberapa Proses Produksi n-Butil Akrilat .................... 12
Tabel 2.1 Nilai ∆Hf 298 Setiap Komponen ..............................................................22
Tabel 2.2 Data Kapasitas Panas Setiap Komponen (Yaws, 2003) .........................22
Tabel 2.3 Parameter Konstanta Adsorpsi untuk Masing-Masing Komponen........27
Tabel 2.4 Neraca Massa Total ................................................................................33
Tabel 2.5 Neraca Panas Total.................................................................................34
Tabel 2.6 Potensi Bahaya dan Kontrol Paparan .....................................................36
Tabel 3.1 Spesifikasi Tangki Penyimpanan Bahan Baku ......................................43
Tabel 3.2 Spesifikasi Tangki Penyimpanan Produk ..............................................44
Tabel 3.3 Spesifikasi Vaporizer .............................................................................45
Tabel 3.4 Spesifikasi Separator ..............................................................................47
Tabel 3.5 Spesifikasi Reaktor ................................................................................48
Tabel 3.6 Spesifikasi Dekanter ..............................................................................51
Tabel 3.7 Spesifikasi Kondensor Total ..................................................................52
Tabel 3.8 Spesifikasi Reboiler ...............................................................................54
Tabel 3.9 Spesifikasi Heat Exchanger (E-101 dan E-104) ....................................56
Tabel 3.10 Spesifikasi Heat Exchanger (E-106)....................................................58
Tabel 3.11 Spesifikasi Pompa (P-101 A/B dan P-102 A/B) ..................................60
Tabel 3.12 Spesifikasi Pompa (P-103 A/B dan P-104 A/B) ..................................61
Tabel 3.13 Spesifikasi Pompa (P-105 A/B dan P-106 A/B) ..................................62
Tabel 4.1 Kebutuhan Air Konsumsi dan Sanitasi ..................................................68
Tabel 4.2 Persyaratan Kualitas Air Pendingin (Broughton, 1994) ........................69
Tabel 4.3 Kebutuhan Air Pendingin.......................................................................69
Tabel 4.4 Kebutuhan Air Total ..............................................................................72
Tabel 4.5 Kebutuhan Listrik untuk Keperluan Proses ...........................................75

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Tabel 4.6 Kebutuhan Listrik untuk Keperluan Utilitas ..........................................76

Tabel 4.7 Jumlah Amature Titik Lampu Berdasarkan Luas Bangunan .................77
Tabel 4.8 Kebutuhan Listrik untuk Penerangan.....................................................78
Tabel 4.9 Total Kebutuhan AC ..............................................................................79
Tabel 4.10 Rincian Listrik Personal Computer (PC) .............................................80
Tabel 4.11 Kebutuhan Listrik Total .......................................................................80
Tabel 4.12 Analisis Bahan Baku, Produk, dan Air ................................................84
Tabel 5. 1 Jadwal Pembagian Kerja Karyawan .....................................................99
Tabel 5.2 Penggolongan Jabatan, Jumlah, Pendidikan, dan Gaji Karyawan ...... 100
Tabel 6.1 Harga Bahan Baku dan Produk ............................................................109
Tabel 6.2 Harga Alat Proses.................................................................................110
Tabel 6.3 Harga Alat Utilitas ...............................................................................111
Tabel 6.4 Modal Tetap .........................................................................................113
Tabel 6.5 Modal Kerja .........................................................................................114
Tabel 6.6 Modal Total ..........................................................................................114
Tabel 6.7 Biaya Langsung....................................................................................115
Tabel 6.8 Biaya Tidak Langsung .........................................................................115
Tabel 6.9 Biaya Tetap ..........................................................................................115
Tabel 6.10 Biaya Manufacturing..........................................................................116
Tabel 6.11 Biaya Pengeluaran Umum .................................................................116
Tabel 6.12 Biaya Total Produksi ..........................................................................116
Tabel 6.13 Biaya Tetap (Fa).................................................................................122
Tabel 6.14 Biaya Bervariasi (Va).........................................................................122
Tabel 6.15 Biaya yang Diatur (Ra) ......................................................................122
Tabel 6.16 Analisis Kelayakan ............................................................................125
Tabel 6.17 Hasil Analisis Ketidakpastian FCI .....................................................126
Tabel 6.18 Hasil Analisis Ketidakpastian Harga Produk .....................................126
Tabel 6.19 Hasil Analisis Ketidakpastian Harga Bahan Baku .............................127
Tabel 6.20 Hasil Analisis Ketidakpastian Laju Bunga ........................................128

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DAFTAR GAMBAR
Gambar 1.1 Peta Lokasi Pabrik n-Butil Akrilat .......................................................8
Gambar 2.1 Mekanisme Reaksi Esterifikasi ..........................................................20
Gambar 2.2 Ilustrasi Perhitungan ∆Hrtotal ..............................................................21
Gambar 2.3 Diagram Alir Kualitatif dan Kuantitatif .............................................31
Gambar 2. 4 Diagram Alir Proses ..........................................................................32
Gambar 2.5 Tata Letak Peralatan Proses ..............................................................39
Gambar 2.6 Tata Letak Pabrik ...............................................................................42
Gambar 4.1 Diagram Alir Proses Pengolahan Air .................................................67
Gambar 4.2 Diagram Pengolahan Air Limbah ......................................................87
Gambar 5.1 Struktur Organisasi Perusahaan .........................................................92
Gambar 6.1 Diagram Arus Kas non-Discounted .................................................118
Gambar 6.2 Diagram Arus Kas Discounted .........................................................120
Gambar 6.3 Grafik Analisis Kelayakan Ekonomi................................................124

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