Efisiensi energi dan evaluasi keselamatan pada modifikasi penggantian katalis unit Desulfurizer di PT. Kaltim Methanol Industri (KMI), Bontang, Indonesia

https://doi.org/10.22146/jrekpros.68759

Dwi Agus Dermawan(1), Reno Imam Arthapersada(2), Muhammad Kurniawan Adiputra(3), Indra P Hakim(4), Imam Karfendi Putro(5), Rochim Bakti Cahyono(6*)

(1) PT. Kaltim Methanol Industri (KMI). Wisma KIE Lt.1, Jl. Paku Aji, Kawasan Industri Pupuk Kaltim, Bontang 75313, Kalimantan Timur
(2) PT. Kaltim Methanol Industri (KMI). Wisma KIE Lt.1, Jl. Paku Aji, Kawasan Industri Pupuk Kaltim, Bontang 75313, Kalimantan Timur
(3) PT. Kaltim Methanol Industri (KMI). Wisma KIE Lt.1, Jl. Paku Aji, Kawasan Industri Pupuk Kaltim, Bontang 75313, Kalimantan Timur
(4) PT. Kaltim Methanol Industri (KMI). Wisma KIE Lt.1, Jl. Paku Aji, Kawasan Industri Pupuk Kaltim, Bontang 75313, Kalimantan Timur
(5) PT. Kaltim Methanol Industri (KMI). Wisma KIE Lt.1, Jl. Paku Aji, Kawasan Industri Pupuk Kaltim, Bontang 75313, Kalimantan Timur
(6) Department of Chemical Engineering, Faculty of Engineering, Universitas Gadjah Mada Indonesia
(*) Corresponding Author

Abstract


A B S T R A K

Metanol sebagai salah satu bahan kimia dasar dapat digunakan secara langsung sebagai campuran bahan bakar untuk internal combustion engines atau bahan baku antara (intermediate chemicals) untuk memproduksi beragam bahan kimia penting seperti formaldehyde, asam asetat, dimethyl ether (DME), dan methyl tertiary butyl ether (MTBE). PT. KMI memproduksi metanol dengan bahan baku gas alam melalui proses steam reforming. Penelitian ini bertujuan untuk mendapatkan produk yang berkualitas dan proses produksi yang efisien, dibutuhkan metana yang terbebas dari pengotor sulfur. Untuk itu diperlukan unit desulfurizer berupa fixed bed berisi katalis CoMo pada unit 010-D03 dan adsorben penjerap sulfur pada unit 010-D01. Pada tahun 2019 telah dilakukan penggantian katalis 3 in 1 yang mampu menghilangkan sulfur dalam satu tangki fixed bed (010-D01). Berdasarkan data dari logbook operasi pabrik berupa pressure drop, flowrate, suhu, dan komposisi dilakukan evaluasi penghematan energi dan keselamatan dari modifikasi ini. Penggantian katalis baru pada tangki 010-D01 yang memungkinkan tangki CoMo dioperasikan dalam kondisi kosong sehingga mengurangi pressure drop di dalam sistem. Adanya penurunan pressure drop mengakibatkan konsumsi steam pada kompresor NG menjadi berkurang sehingga didapatkan penghematan energi sebesar 379 kg/jam yang setara dengan 40913 USD/tahun atau 8545 MMBtu/tahun. Untuk menjamin keselamatan dari modifikasi, dilakukan evaluasi terhadap potensi deflagration-detonation dan api menggunakan komponen segitiga api. Berdasarkan parameter keberadaan oksigen, diagram flammability, dan autoignition temperature, modifikasi yang mengoperasikan tangki 010-D03 dalam kondisi kosong, aman dari bahaya terbentuknya api dan ledakan. Dengan demikian, modifikasi penggantian katalis dan pengosongan tangki 010-D03 terkonfirmasi meningkatkan efisiensi energi dan menghemat pemakaian sumber daya alam, sehingga mendorong aplikasi nyata sustainable development di dunia industri. 

Kata kunci: CoMo katalis; energi kompresi; unit desulfurizer; pressure drop


ABSTRACT 

As one of the essential chemicals, methanol can be used directly as fuel mixer for internal combustion engines or intermediate chemicals which can be utilized to produce various final chemicals such as formaldehyde, acetate acid, dimethyl ether (DME), dan methyl tertiary butyl ether (MTBE). PT. KMI produces methanol based on natural gas through steam reforming process. The study aims to get good product quality and efficient process production, the raw material of methane should be avoided from any impurities, especially sulphur. To get those target, PT. KMI installed desulfurizer unit that consist of CoMo fixed bed catalyst on 010-D03 unit and adsorbent on 010-D01 unit. As improvement on 2019, the engineer found the 3 in 1 catalyst which success to preclude the sulphur trace element in the one vessel of 010-D01 unit. Based on the logbook data from plant operation such as pressure drop, flowrate, temperature and gas composition could be performed the evaluation to minimize the energy consumption and safety level of those modification. The replacement using new catalyst (3 in 1) on the 010-D01 unit allowed the system to operate the CoMo vessel (010-D03) with empty condition that could reduce pressure drop within the system. Based on the pressure drop reducing, the consumption of steam for running the NG compressor decreased and obtained the energy saving around 379 kg of steam/hour, which was equal to 40913 USD/year or 8545 MMBtu/year. In order to ensure the safety of this modification, the evaluation of fire and deflagration-detonation potential was done using triangle diagram. Based on the availability of oxygen, flammable region and autoignition temperature, the modification of 010-D01 unit which cause the empty operation of 010-D03 unit was safe from fire and explosion hazard. Therefore, the process modification through catalyst replacement could increase energy efficiency and natural resources saving for real action of sustainable development in the industrial sector. 

Keyword: CoMo catalyst; compression energy; desulfurizer unit; pressure drop




Keywords


CoMo catalyst; compression energy; desulfurizer unit; pressure drop

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DOI: https://doi.org/10.22146/jrekpros.68759

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