DAFTAR ISI

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

HALAMAN PENGESAHAN....................................................................................ii

INTISARI................................................................................................................iii

KATA PENGANTAR..............................................................................................iv

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

DAFTAR TABEL...................................................................................................xii

DAFTAR GAMBAR..............................................................................................xiii

DAFTAR LAMPIRAN...........................................................................................xiv

BAB I PENDAHULUAN

1.1 Sejarah Berdirinya Pabrik..................................................................1

1.2 Gambaran Umum Pabrik...................................................................3

1.2.1 Bahan Baku..............................................................................3

1.2.2 Unit-unit Dalam pabrik..............................................................5

1.2.2.1 Unit Ammonia...............................................................5

1.2.2.2 Unit Urea.......................................................................7

1.2.2.3 Unit Utilitas....................................................................8

1.2.2.4 Unit Pengantongan.......................................................9

1.2.3 Organisasi Perusahaan............................................................9

1.2.3.1 Struktur Organisasi dan Job Diskripsi......................10

1.2.3.2 Fasilitas Penunjang.................................................14

1.2.3.3 Jumlah dan Pendidikan Karyawan di Tiap Bagian. .14

1.2.3.4 Kesehatan dan Keselamatan Kerja.........................16

1.2.3.5 Jaminan Sosial........................................................19

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1.2.4 Sistem Pemasaran Hasil Produksi.........................................20

1.3 Lay Out Pabrik.................................................................................21

BAB II TINJAUAN PUSTAKA

2.1 Bahan Baku........................................................................................24

2.2 Proses Pembuatan Urea....................................................................26

2.2.1 Jenis Pembuatan Urea...........................................................26

2.2.2 Prinsip Proses dan Operasi....................................................28

2.2.3 Faktor-faktor yang Mempengaruhi Pembuatan Urea.............29

2.3 Produk Utama....................................................................................31

2.3.1 Spesifikasi Produk Pupuk Urea.................................................32

2.3.2 Sifat-sifat Umum Pupuk Urea....................................................32

2.3.3 Sifat-Sifat Kimia dan Fisika Urea...............................................33

2.4 Pengembangan Proses......................................................................34

BAB III DISKRIPSI PROSES

3.1 Persiapan Bahan Baku....................................................................36

3.1.1 Ammonia................................................................................36

3.1.2 Karbondioksida.......................................................................36

3.2 Diskripsi Proses...............................................................................37

3.2.1 Seksi Sintesa.......................................................................38

3.2.2 Seksi Purifikasi....................................................................44

3.2.2.1 High Pressure Decomposer/HPD (DA-201)............46

3.2.2.2 Low Pressure Decomposer/LPD (DA-202)..............47

3.2.2.3 Gas Separator (DA-203)..........................................48

3.2.3 Seksi Recovery............................................................................49

3.2.3.1 Recovery Gas dari High Pressure Decomposer...............49

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3.2.3.2 Recovery Gas dari Low Pressure Decomposer...............51

3.2.3.3 Off Gas Recovery System................................................52

3.2.4 Seksi Kristalisasi dan Pembutiran................................................53

3.2.4.1 Pengkristalan....................................................................53

3.2.4.2 Pemisahan........................................................................55

3.2.4.3 Pengeringan.....................................................................56

3.2.4.4 Pembutiran.......................................................................57

3.3 Diagram Alir Proses Pembuatan......................................................58

BAB IV SPESIFIKASI PESAWAT

4.1 Spesifikasi Pesawat........................................................................59

4.1.1 Spesifikasi Pesawat Pada Seksi Sintesa...............................59

4.1.2 Spesifikasi Pesawat Pada Seksi Purifikasi............................65

4.1.3 Spesifikasi Pesawat Pada Seksi Recovery............................71

4.1.4 Spesifikasi Pesawat Pada Seksi Kristalisasi..........................78

4.2 Gambar Pesawat Utama dan Cara Kerja.........................................81

4.2.1 Urea Synthesis Reaktor (DC-101).........................................81

4.2.2 High Pressure Decomposer (DA-201)...................................83

4.2.3 Low Pressure Decomposer (DA-202)....................................85

4.2.4 Gas Separator (DA-203)........................................................87

4.2.5 Crystalizer (FA-201)...............................................................89

4.2.6 Off Gas Absorber (DA-402)....................................................91

4.2.7 High Pressure Absorber (DA-401)........................................93

4.2.8 High Pressure Absorber Cooler (EA-401)..............................95

4.2.9 Low Pressure Absorber (EA-406)..........................................97

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BAB V NERACA MASSA DAN NERACA PANAS

5.1 Perhitungan Neraca Massa.............................................................99

5.2 Perhitungan Neraca Panas...........................................................114

BAB VI UTILITAS DAN PENGOLAHAN LIMBAH

6.1 Utilitas............................................................................................126

6.1.1 Unit Penyediaan Air..............................................................126

6.1.1.1 Proses Pengolahan Air Kebutuhan Pabrik .................127

6.1.1.2 Pengolahan Air umpan Ketel......................................131

6.1.1.3 Unit Air Pendingin.....................................................137

6.1.1.4 Air Minum..................................................................139

6.1.2 Unit Penyediaan Energi Listrik.............................................140

6.1.3 Unit Penyediaan Steam .......................................................141

6.1.4 Unit Penyediaan Udara Tekan Kering..................................144

6.2 Unit Pengolahan Limbah...............................................................144

6.2.1 Jenis dan Sumber Limbah ...................................................145

6.2.2 Penanganan Limbah............................................................146

6.2.2.1 Limbah Cair..............................................................146

6.2.2.2 Limbah Gas..............................................................149

6.2.2.3 Limbah Padat............................................................149

BAB VII LABORATORIUM

7.1 Analisa Bahan Baku......................................................................151

7.1.1 Penetapan % Gas Amonia ..................................................151

7.1.2 Penetapan Kadar Gas CO2..................................................152

7.2 Analisa Bahan Setengah Jadi.......................................................153

7.2.1 High Pressure Absorber Cooler...........................................153

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7.2.2 Low Pressure Absorber........................................................154

7.2.3 Gas Separator......................................................................156

7.2.4 Crystalizer............................................................................157

7.2.5 Dust Chamber......................................................................158

7.3 Analisa Produk..............................................................................159

7.3.1 Kadar Biuret.........................................................................159

7.3.2 Kadar Air..............................................................................160

7.3.3 Total Nitrogen.......................................................................161

7.3.4 Kadar Besi............................................................................162

7.3.5 Free Amonia.........................................................................163

7.3.6 Prill Size (Ayakan)................................................................164

BAB VIII KESIMPULAN DAN SARAN

8.1 Kesimpulan....................................................................................166

8.2 Saran.............................................................................................167

DAFTAR PUSTAKA...........................................................................................168

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DAFTAR TABEL

Tabel 1. Kebutuhan Bahan Baku...........................................................................4

Table 2.. Kandungan Amonia Cair. ………………………………………..………….5

Tabel 3. Kandungan Gas CO2................................................................................5

Tabel 4. Jam Kerja Shift.......................................................................................16

Tabel 5. Kandungan Amonia Cair........................................................................25

Tabel 6. Kandungan Gas Karbondioksida...........................................................26

Tabel 7. Spesifikasi Produk Pupuk Urea..............................................................32

Tabel 8. Sifat Fisika Pupuk Urea..........................................................................34

Tabel 9. Karakteristik Bahan Baku dan Karakteristik Umpan Air Pabrik............127

Tabel 10. Karakteristik Air Umpan Ketel atau Boiler..........................................137

Tabel 11. Karakteristik Umpan Air Pabrik dan Karakteristik Air Pendingin........139

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DAFTAR GAMBAR

Gambar 1. Stuktur Organisasi PT. Pupuk Kujang................................................13

Gambar 2. Lay Out PT. Pupuk Kujang.................................................................23

Gambar 3. Diagram Total Recycle Proces...........................................................36

Gambar 4. Diagram Alir Unit Urea 1A PT. Pupuk Kujang....................................58

Gambar 5. Urea Synthesis reactor (DC-101).......................................................81

Gambar 6. High pressure Decomposer (DA-201)................................................83

Gambar 7. Low Pressure Decomposer (DA-202)................................................85

Gambar 8. Gas Separator (DA-203)....................................................................87

Gambar 9. Crystallizer (FA-201)..........................................................................89

Gambar 10. Off Gas Absorber (DA-402)..............................................................91

Gambar 11. High Pressure Absorber (DA-401)...................................................93

Gambar 12. High Pressure Absorber Cooler (EA-401)........................................95

Gambar 13. Low Pressure Absorber (DA-406)....................................................97

Gambar 14. Unit Pengolahan Air.......................................................................130

Gambar 15. Unit Demineralisasi .......................................................................134

Gambar 16. Proses Pertukaran Ion dan Regenerasi pada Ion Exchanger........134

Gambar 17. Daerator.........................................................................................135

Gambar 18. Cooling Tower................................................................................139

Gambar 19. Waste Heat Boiler..........................................................................143

Gambar 20. Package Boiler...............................................................................143

Gambar 21. Ammonia Removal.........................................................................148

Gambar 22. Aliran Neraca Massa PT. Pupuk Kujang Cikampek, Jawa Barat...208

Gambar 23. Aliran Neraca Panas PT. Pupuk Kujang Cikampek, Jawa Barat...309

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DAFTAR LAMPIRAN

Lampiran 1. Perhitungan Neraca Massa............................................................169

Lampiran 2. Perhitungan Neraca Panas............................................................209

Lampiran 3. Log Sheet Rekaman Mutu ............................................................309

Lamoiran 4. Tugas Sidang.................................................................................345

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