PRA RANCANGAN UNIT HYDROTREATING NAPHTA …digilib.polban.ac.id/files/disk1/82/jbptppolban-gdl-bismidzikr... · memberikan rahmat dan karunia-Nya sehingga kami dapat menyelesaikan

PRA RANCANGAN UNIT HYDROTREATING

NAPHTA PRODUK CDU KILANG PERTAMINA

UP II DUMAI

Preliminary Design of Hydrotreating Unit of Naphta from CDU

in Pertamina UP II Dumai Plant

TUGAS AKHIR

Oleh :

BISMI DZIKRI FARDINA NIM : 08414003

FADLILAH SUKRI PERTAMI NIM : 08414008

POLBAN

PROGRAM STUDI-DIV TEKNIK KIMIA PRODUKSI BERSIH JURUSAN TEKNIK KIMIA

POLITEKNIK NEGERI BANDUNG 2012

PRA RANCANGAN UNIT HYDROTREATING NAPHTA PRODUK CDU KILANG PERTAMINA UP II DUMAI

Preliminary Design of Hydrotreating Unit of Naphta from CDU

in Pertamina UP II Dumai Plant

TUGAS AKHIR

Diajukan untuk memenuhi salah satu persyaratan dalam menyelesaikan pendidikan program Diploma IV Teknik Kimia Produksi Bersih

Oleh : BISMI DZIKRI FARDINA NIM : 08414003 FADLILAH SUKRI PERTAMI NIM : 08414008

PROGRAM STUDI D-IV TEKNIK KIMIA PRODUKSI BERSIH JURUSAN TEKNIK KIMIA

POLITEKNIK NEGERI BANDUNG 2012

KATA PENGANTAR

Puji dan syukur kami panjatkan kehadirat Allah SWT yang senantiasa

memberikan rahmat dan karunia-Nya sehingga kami dapat menyelesaikan laporan

Tugas Akhir Pra-Rancangan Pabrik yang berjudul Perancangan Unit

Hydrotreating Naphta Produk CDU Kilang Pertamina UP II Dumai .

Tugas Akhir Pra Rancangan Pabrik ini disusun sebagai penerapan dari

ilmu teknik kimia yang telah kami dapatkan di bangku kuliah dan sebagai satu

syarat untuk memperoleh gelar Sarjana Terapan di Jurusan Teknik Kimia,

Program Studi Teknik Kimia Produksi Bersih, Politeknik Negeri Bandung.

Kami menyadari bahwa laporan penelitian industri ini masih sangat jauh

dari sempurna. Oleh karena itu, kami menerima dengan tangan terbuka segala

saran dan kritik yang membangun dari semua pihak demi perbaikan ke depannya.

Akhir kata, kami berharap semoga laporan Tugas Akhir Pra-Rancangan Pabrik ini

dapat memberikan manfaat kepada setiap pembaca.

Bandung, Juli 2012

Penyusun

UCAPAN TERIMAKASIH

Pada kesempatan ini penyusun ingin menyampaikan rasa terima kasih

yang sebesar-besarnya atas segala bantuan, dukungan, kerja sama, dan saran yang

telah diberikan antara lain kepada :

1. Dr. Ir. Ahmad Rifandi, M.Sc., selaku Koordinator Tugas akhir dan

pembimbing 1 tugas akhir.

2. Rintis Manfaati, S.T, M.T., selaku dosen pembimbing 2 tugas akhir.

3. Ir. Dwi Nirwantoro, M.T., selaku Ketua Jurusan Teknik Kimia Politeknik

Negeri Bandung.

4. Ir. Ninik Lintang, MT. selaku Ketua Prodi Teknik Kimia Produksi Bersih,

beserta staff pengajar Prodi Teknik Kimia Produksi Bersih

5. Orang tua yang tak henti-hentinya memberikan doa dan dukungan.

6. Teman-teman TKPB 2008 selaku teman seperjuangan selama 4 tahun di

bangku kuliah Politeknik Negeri Bandung.

7. Semua pihak yang telah membantu penulisan laporan ini, yang tidak dapat

disebutkan satu per satu.

Bandung, Juli 2012

Penyusun

ABSTRAK Naphtha adalah salah satu turunan minyak bumi yang dikonversi lebih lanjut menjadi bahan bakar minyak. Kendala yang dijumpai pada kilang minyak bumi dalam mengonversi naphtha menjadi bahan bakar minyak yaitu adanya pengotor-pengotor dalam naphtha yang akan menyebabkan katalis platina (Pt) pada unit platforming menjadi tidak aktif. Pengotor-pengotor yang ada dalam naphtha antara lain senyawa ikatan oksigen, sulphur, nitrogen dan garam mineral. Oleh karena itu, sebelum masuk ke unit platforming, pengotor-pengotor di dalam naphtha tersebut harus dihilangkan terlebih dahulu. Kadar maksimal sulfur dan nitrogen sebagai persyaratan umpan untuk unit platforming masing-masing adalah 0,5 ppm. Pengolahan awal untuk menghilangkan atau mengurangi kadar pengotor pada umpan unit platforming adalah menggunakan unit hydrotreating. Proses desulfurisasi dan denitrogenasi ini berlangsung dalam fase gas pada reaktor fixed bed yang bekerja secara adiabatis dengan bantuan katalis. Pada kondisi saat ini, katalis A untuk unit hydrotreating skala pilot plant di R&D Pertamina Pulogadung, Jakarta diganti dengan katalis B,dengan menggunakan katalis yang sama akan dibuat rancangan unit hydrotreating yang merupakan scale-up dari skala pilot plant di R&D Pertamina Pulogadung, Jakarta ke skala industri kilang Pertamina UP II, Dumai. Peralatan proses yang akan dibuat rancangan scale-up nya diantaranya furnace, reaktor fixed-bed, stripper, separator, kondensor, cooler, scrubber, dan dryer, serta peralatan pendukung lainnya seperti pompa dan kompressor. Unit hydrotreating ini memiliki kapasitas 70 m3/jam , Kebutuhan bahan baku naphtha sebanyak 46. 774 kg/jam dan hidrogen sebanyak 915,586 kg/jam. Untuk kebutuhan utilitas, unit hydrotreating ini membutuhkan steam 21,72 kg/jam, air 261.586 kg/jam, fuel oil 273,13 L/jam, dan listrik 791,03 kWh. Unit hydrotreating ini beroperasi selama 24 jam dalam sehari dan 330 hari dalam setahun. Tenaga kerja yang diperlukan adalah 15 orang operator dan seorang supervisor. Modal tetap yang dibutuhkan sebesar $ 496,243,663.3. Biaya produk yang dibutuhkan sebesar $ 526,374,547.8. Hasil evaluasi menunjukkan keuntungan sebelum pajak sebesar $ 89,430,405.76. Break Even Point (BEP) rata-rata selama 15 tahun (pada umur alat 15 tahun) adalah 38,02 %. Internal Rate of Return (IRR) 15%, dan Return of Investment (ROI) sebesar 15,6 %. Berdasarkan hasil perhitungan kelayakan ekonomi tersebut, maka dapat disimpulkan bahwa rancangan unit hydrotreating ini layak dikaji lebih lanjut untuk didirikan. Kata kunci : naphtha, hydrotreating, platforming, desulfurisasi, denitrogenasi, reactor fixed bed

ABSTRACT

Naphtha is a petroleum derivative that will be further converted into fuel oil. The existence of impurities in naphtha will encountered a constraint in petroleum refineries. It will cause the performance of the platinum (Pt) catalyst on the platforming unit. Impurities present in the naphtha are consist of oxygen compounds, sulfur, nitrogen and mineral salts. Therefore, before being fed into the platforming unit, impurities in naphtha must be removed first by using desulfurization process and denitrogenation process on a hydrotreating unit. The maximum sulfur and nitrogen content allowed in the feed of the platforming unit is 0.5 ppm each. Desulfurization process and denitrogenation process take place in the gas phase in a fixed bed reactor which run in adiabatic condition with the aid of a catalyst. The catalyst used is a B catalyst. Reactor performance with B catalyst has now been tested in the R & D Pertamina, Pulogadung Jakarta at pilot scale. Preliminary design of a naphta hydrotreating unit in this project work is based on data resulted from pilot scale studies. The design capacity of hydrotreating unit is 10.6 MBSD (70 m3/hr) and planned to be built in the refinery plant Pertamina UP II Dumai. Equipment designed for the hydrotreating unit consists of furnace, reactor, condenser, separator, stripper, cooler, scrubber, dryers, and other support equipments. The needs of utilities for the hydrotreating unit are 21.72 kg steam / hour, water 261 586 kg / hour, fuel oil 273.13 liters/hour, and 791.03 kWh electricity. Hydrotreating unit will be run on the basis of 24 hours a day and 330 days a year. Labor required is 15 people operators and one supervisor. Fixed capital required of $ 496,243,663.3. The cost of the production is $ 526,374,547.8. Economic evaluation shows a profit before tax is $ 89,430,405.76, average Break Even Point (BEP) during 15 years operated is 38.02%. Internal Rate of Return (IRR) 15%, and Return on Investment (ROI) is 15.6%. Based on calculations of economic feasibility, it can be concluded that the proposed project of hydrotreating unit is feasible.

Key words: naphtha, hydrotreating, platforming, desulfurization, denitrogenation, fixed

bed reactor

DAFTAR ISI

HALAMAN DEPAN

HALAMAN JUDUL

LEMBAR PENGESAHAN

KATA PENGANTAR .......................................................................................i

UCAPAN TERIMAKASIH..............................................................................ii

ABSTRAK .........................................................................................................iii

ABSTRACT ........................................................................................................iv

DAFTAR ISI ......................................................................................................v

DAFTAR TABEL .............................................................................................vii

DAFTAR GAMBAR .........................................................................................viii

DAFTAR LAMPIRAN .....................................................................................ix

BAB I PENDAHULUAN

1.1 Latar Belakang ....................................................................................1

1.2 Ruang Lingkup dan Rumusan Masalah Perancangan ........................5

1.3 Tujuan Perancangan ...........................................................................5

BAB II DASAR DASAR PERANCANGAN

2.1 Bahan Baku ........................................................................................6

2.2 Bahan Penunjang ................................................................................8

2.3 Produk .................................................................................................10

2.4 Kapasitas Perancangan .......................................................................11

2.5 Lokasi Proyek dan Rona Lingkungan ................................................11

2.6 Standar-standar dan Kode Perancangan .............................................13

BAB III KAJIAN PUSTAKA

3.1 Hydrotreating ......................................................................................14

3.2 Katalis .................................................................................................17

3.3 Deskripsi Proses Unit Hydrotreating ..................................................23

3.4 Variabel Proses Hydrotreating............................................................25

3.5 Perancangan Alat ................................................................................31

BAB IV NERACA MASSA DAN ENERGI

4.1 Neraca Massa ......................................................................................44

4.2 Neraca Energi .....................................................................................49

BAB V PERANCANGAN ALAT DAN DIAGRAM ALIR PROSES

5.1 Perancangan Alat ................................................................................54

5.2 Diagram Alir Proses ...........................................................................68

BAB VI UTILITAS DAN LIMBAH PROSES

6.1 Unit Pengadaan dan Pengolahan Air ..................................................69

6.2 Unit Pengadaan Steam ........................................................................73

6.3 Unit Pengadaan Bahan Bakar .............................................................73

6.4 Unit Penyediaan dan Penyaluran Listrik ............................................73

6.5 Unit Pengolahan Limbah ....................................................................75

BAB VII TATA LETAK UNIT HYDROTREATING

7.1 Lay Out Unit Hydrotreating ................................................................77

7.2 Lay Out Peralatan ...............................................................................79

BAB VIII STRUKTUR ORGANISASI DAN TATA KERJA

8.1 Struktur Organisasi UP II Dumai .......................................................81

8.2 Struktur Organisasi Hidroskimming Complex ....................................84

8.3 Struktur Organisasi Naphtha Hydrotreating Unit ..............................84

8.4 Peraturan Kerja ...................................................................................85

BAB IX ANALISIS EKONOMI

9.1 Biaya Investasi ....................................................................................86

9.2 Biaya Produksi ....................................................................................88

9.3 Keuntungan (profit) ............................................................................89

9.4 Analisis Kelayakan .............................................................................90

DAFTAR PUSTAKA

LAMPIRAN

DAFTAR TABEL

Tabel 1.1 Kondisi operasi pada reaktor hydrotreating ....................................... 3

Tabel 2.1 Karakteristik Heavy Naphtha dari Hydrocracker ............................... 7

Tabel 2.2 Karakteristik Coker Naphtha .............................................................. 7

Tabel 2.3 Kriteria Katalis Hydrotreating ........................................................... 9

Tabel 2.4 Data katalis untuk proses hydrotreating............................................. 10

Tabel 2.5 Standar dan Kode Perancangan .......................................................... 13

Tabel 4.1 Neraca massa masukan dan keluaran reaktor hydrotreating .............. 44

Tabel 4.2 Neraca massa masukan dan keluaran separator ................................. 45

Tabel 4.3 Neraca massa masukan dan keluaran stripper .................................... 46

Tabel 4.4 Neraca massa masukan dan keluaran recycle gas .............................. 44

Tabel 4.5 Neraca massa total unit hydrotreating ................................................ 48

Tabel 4.6 Neraca energi di reaktor hydrotreating............................................... 49

Tabel 4.7 Neraca energi di kondensor ................................................................ 50

Tabel 4.8 Neraca energi di separator .................................................................. 50

Tabel 4.9 Neraca energi di stripper .................................................................... 51

Tabel 4.10 Neraca energi di cooler ...................................................................... 52

Tabel 4.11 Neraca energi di scrubber ................................................................... 52

Tabel 4.12 Neraca energi di dryer ........................................................................ 53

Tabel 4.13 Neraca energi di kompresssor ............................................................ 53

Tabel 5.1 Spesifikasi reaktor hydrotreating di Research and Development

Pertamina Pulogadung, Jakarta .......................................................... 54

Tabel 5.2 Perhitumgan setiap aliran pipa ........................................................... 68

Tabel 6.1 Perincian kebutuhan listrik untuk alat proses ..................................... 74

Tabel 6.2 Perincian kebutuhan listrik untuk alat utilitas .................................... 74

Tabel 7.1 Perincian luas tanah bangunan unit hydrotreating ............................. 78

Tabel 9.1 Fixed-Capital investment (FCI) ......................................................... 87

Tabel 9.2 Total Production Cost ........................................................................ 89

DAFTAR GAMBAR

Gambar 1.1 Diagram alir proses hydrotreating skala pilot plant di R & D

Pertamina Jakarta........................................................................... 2

Gambar 1.2 Diagram Alir Unit Hydrotreating di Kilang .................................. 3

Gambar 2.1 Peta lokasi Kilang Pertamina UP II Dumai ................................... 12

Gambar 3.1. Reaksi Hidrodesulfurisasi .............................................................. 15

Gambar 3.2 Reaksi Hidrodenitrogenasi ............................................................ 16

Gambar 3.3 Bentuk katalis hydrotreating.......................................................... 18

Gambar 3.4 Diagram Alir Unit Hydrotreating di Kilang .................................. 24

Gambar 4.1 Diagram Alir Reaktor Hydrotreating............................................. 44

Gambar 4.2 Diagram Alir Separator ................................................................. 45

Gambar 4.3 Diagram Alir Stripper .................................................................... 46

Gambar 4.4 Diagram Alir Recycle Gas Hydrogen ............................................ 47

Gambar 5.1 Reaktor hydrotreating .................................................................... 55

Gambar 5.2 Separator ........................................................................................ 56

Gambar 5.3 Furnace .......................................................................................... 57

Gambar 5.4 Stripper .......................................................................................... 59

Gambar 5.5 Kondensor...................................................................................... 60

Gambar 5.6 Cooler ............................................................................................ 61

Gambar 5.7 Scrubber ......................................................................................... 62

Gambar 5.8 Dryer .............................................................................................. 63

Gambar 5.9 Kompressor.................................................................................... 64

Gambar 5.10 Pompa umpan naphtha .................................................................. 64

Gambar 5.11 Pompa produk naphtha .................................................................. 65

Gambar 7.1 Lay out tata letak unit naphta hydrotreating .................................. 79

Gambar 7.2 Lay out peralatan ........................................................................... 80

Gambar 8.1 Struktur Organisasi UP II Dumai .................................................. 83

Gambar 8.2 Struktur organisasi Kilang HSC .................................................... 84

DAFTAR LAMPIRAN

LAMPIRAN A NERACA MASSA DAN ENERGI

A.1 Neraca Massa ....................................................................................... A-1

A.2 Neraca Energi ....................................................................................... A-20

LAMPIRAN B PERANCANGAN ALAT

B.1 Reaktor ................................................................................................. B-1

B.2 Separator ............................................................................................... B-10

B.3 Furnace ................................................................................................. B-13

B.4 Stripper ................................................................................................. B-32

B.5 Kondensor ............................................................................................ B-36

B.6 Cooler ................................................................................................... B-47

B.7 Scrubber ............................................................................................... B-56

B.8 Dryer ..................................................................................................... B-59

B.9 Kompressor .......................................................................................... B-62

B.10 Pompa Umpan Naphta ......................................................................... B-66

B.11 Pompa Produk Naphta .......................................................................... B-68

LAMPIRAN C ANALISIS EKONOMI

C.1 Dasar Perhitungan ................................................................................ C-1

C.2 Perhitungan Biaya ................................................................................ C-1

C.3 Analisis Kelayakan ............................................................................... C-13

LAMPIRAN D FORM BIMBINGAN TUGAS AKHIR

LAMPIRAN E FORM PERBAIKAN SEMINAR TUGAS AKHIR

CURRICULUM VITAE

Nama : Fadlilah Sukri Pertami Alamat : Jl. Perjuangan III no. 23 RT 01.

RW 06. Kel. Karya Mulya Kec. Kesambi. Cirebon 45135

Telepon : 085722788839 E Mail : [email protected] Tempat / Tgl lahir : Cirebon / 21 Juni 1990 Jenis kelamin : Perempuan Agama : Islam Status : Single Kebangsaan : Indonesia

Nama : Bismi Dzikri Fardina Alamat : Jl. K.S. Tubun Gg Kabupaten II/4

,45123 Cirebon Telepon : 085793837979 E Mail : [email protected] Tempat / Tgl lahir : Cirebon / 27 Mei 1990 Jenis kelamin : Perempuan Agama : Islam Status : Single Kebangsaan : Indonesia

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