Cavela, Arnetta Khatrunada (2026) Laporan Magang Mandiri PT. Petrokimia Gresik Troubleshooting Upaya Minimisasi Produk Off-Spec Kadar H₂O pada Pupuk Phosgreen di Unit NPK II yang Melebihi Batas 5% serta Strategi Mitigasinya. Project Report. [s.n.]. (Unpublished)
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Abstract
Permasalahan utama dalam proses manufaktur dan granulasi pupuk Phosgreen di Unit NPK II Departemen Produksi IIB PT Petrokimia Gresik adalah terjadinya deviasi kualitas berupa tingginya kadar air (H2O) produk akhir yang secara konsisten mencapai rata-rata 8%, melebihi batas maksimum spesifikasi rencana mutu sebesar 5%. Untuk menginvestigasi fenomena ini, dilakukan evaluasi teknis berbasis neraca massa dan neraca energi pada unit pengeringan (drying section). Hasil analisis menggunakan diagram sebab-akibat menunjukkan bahwa tingginya konsetrasi air tersebut dipicu oleh ketidakseimbangan neraca bahan di hulu dan penurunan performa termal alat. Penggunaan bahan baku alternatif ROP sludge dengan kadar air input sebesar 20% terbukti melampaui batas toleransi desain (maksimum 13%), sehingga meningkatkan beban evaporasi secara signifikan pada rotary dryer. Di sisi lain, analisis termodinamika menunjukkan bahwa efisiensi termal rotary dryer hanya mencapai rata-rata 52,64%, berada di bawah standar teoretis minimum industri sebesar 65%. Penurunan koefisien perpindahan panas konvektif ini dipicu oleh timbulnya resistansi termal tambahan akibat akumulasi kerak (scaling/fouling) pada shell internal drum serta tingginya laju alir udara panas yang memicu heat loss berlebih ke lingkungan. Sebagai strategi mitigasi untuk meminimalkan produk off-spec, diusulkan modifikasi operasional berupa pengeringan awal (pre-drying) bahan baku, pembersihan fouling berkala, optimasi parameter temperatur udara pengering, serta penurunan throughput kapasitas pabrik menjadi 25 ton/jam guna memperpanjang waktu tinggal (residence time) granul demi mengoptimalkan transfer massa dan panas selama proses pengeringan.
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The primary issue in the manufacturing and granulation process of Phosgreen fertilizer at the NPK II Unit (Production Department IIB, PT Petrokimia Gresik) is a quality deviation characterized by high moisture content (H2O) in the final product; levels consistently average 8%, exceeding the maximum limit of 5% specified in the quality plan. To investigate this phenomenon, a technical evaluation based on mass and energy balances was conducted on the drying section. Analysis using a cause-and-effect diagram revealed that the high moisture concentration was triggered by a material balance imbalance upstream and a decline in the equipment's thermal performance. The use of ROP sludge as an alternative raw material—with an input moisture content of 20%—exceeded the design tolerance limit (maximum 13%), thereby significantly increasing the evaporation load on the rotary dryer. Furthermore, thermodynamic analysis indicated that the rotary dryer's thermal efficiency averaged only 52.64%, falling below the industry's minimum theoretical standard of 65%. This reduction in the convective heat transfer coefficient was caused by additional thermal resistance resulting from scale/fouling accumulation on the drum's internal shell, as well as a high hot air flow rate that led to excessive heat loss to the environment. As a mitigation strategy to minimize off-specification products, operational modifications are proposed: pre-drying of raw materials, periodic fouling removal, optimization of drying air temperature parameters, and a reduction in plant throughput capacity to 25 tons/hour to extend granule residence time, thereby optimizing mass and heat transfer during the drying process.
| Item Type: | Monograph (Project Report) |
|---|---|
| Uncontrolled Keywords: | Kata Kunci: Pupuk Phosgreen, Rotary Dryer, Efisiensi Termal. Keywords: Phosgreen Fertilizer, Rotary Dryer, Thermal Efficiency. |
| Subjects: | T Technology > TP Chemical technology > TP155.7 Chemical processes. |
| Divisions: | Faculty of Vocational > 24305-Industrial Chemical Engineering Technology |
| Depositing User: | Cavela Arnetta Khatrunada |
| Date Deposited: | 20 Jul 2026 01:53 |
| Last Modified: | 20 Jul 2026 01:53 |
| URI: | http://repository.its.ac.id/id/eprint/135094 |
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