Laporan Magang 1 Oktober 2025-30 Januari 2026 di PT Wilmar Nabati Indonesia Gresik

Dewi, Putri Elvita (2026) Laporan Magang 1 Oktober 2025-30 Januari 2026 di PT Wilmar Nabati Indonesia Gresik. Project Report. [s.n.]. (Unpublished)

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Abstract

Pelaksanaan program magang mandiri di PT. Wilmar Nabati Indonesia, Gresik bertujuan untuk menjembatani kesenjangan kompetensi antara dunia pendidikan tinggi vokasi—khususnya Program Studi Teknologi Rekayasa Kimia Industri, Institut Teknologi Sepuluh Nopember—dengan kebutuhan riil pada industri pengolahan minyak kelapa sawit terintegrasi. Laporan magang ini mencakup pemahaman komprehensif terhadap seluruh alur proses pabrik, evaluasi neraca massa dan energi pada reaktor hidrogenasi Refined Palm Stearin (RPS) menjadi Hydrogenated Refined Palm Stearin (HRPS), analisis keselamatan proses menggunakan metode Hazard and Operability Study (HAZOP) pada Plate Heat Exchanger (E-113), serta penyelesaian masalah (troubleshooting) terkait optimalisasi pendinginan blowdown sistem boiler pada unit utilitas. Proses hidrogenasi RPS dengan bantuan katalis nikel terbukti mampu menurunkan Iodine Value (IV) dari 22,91 menjadi 0,24 melalui reaksi eksotermik dengan kenaikan temperatur (Delta T) sebesar 38,5°C dan konsumsi gas hidrogen sebanyak 249,37 Nm^3. Di sisi lain, analisis HAZOP berhasil mengidentifikasi potensi penyimpangan parameter aliran, temperatur, dan tekanan pada unit penukar panas E-113, serta merumuskan rekomendasi pemasangan sistem kendali otomatis dan katup pelepas tekanan (safety valve) untuk meminimalkan risiko operasional. Pada bagian troubleshooting, evaluasi terhadap sistem eksisting menunjukkan bahwa pendinginan air blowdown boiler menggunakan air demineralisasi berjalan tidak optimal akibat keterbatasan gaya dorong termal (driving force), sehingga temperatur outletnya tidak mampu mencapai spesifikasi air umpan tambahan (make-up water) yaitu $\pm30$°C. Sebagai langkah optimalisasi, diusulkan konfigurasi pendinginan dua tahap secara seri: tahap pertama menggunakan Plate Heat Exchanger-1 (PHE-1) untuk menurunkan temperatur blowdown dari 77°C menjadi 47,1°C dengan memanfaatkan air demineralisasi, dilanjutkan dengan tahap kedua pada PHE-2 menggunakan media hot-well water ber-temperatur 17°C dengan laju alir 8,28 m^3/jam (260-270 m^3/hari) untuk mencapai temperatur akhir 32°C. Perhitungan beban panas manual pada PHE-2 menghasilkan nilai sebesar 223,84 kW, yang menunjukkan konsistensi yang sangat baik dengan hasil validasi simulasi software Aspen EDR (242 kW). Analisis hidrodinamika mengonfirmasi bahwa penurunan tekanan (pressure drop) operasi berada pada kondisi aman, yakni sebesar 0,79 bar pada sisi panas dan 0,41 bar pada sisi dingin, jauh di bawah batas maksimum yang diizinkan sebesar 3 bar. Optimalisasi ini berhasil meningkatkan efisiensi energi termal sistem utilitas sekaligus berkontribusi pada program konservasi air di lingkungan industri.
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The independent internship program at PT. Wilmar Nabati Indonesia, Gresik, aims to bridge the competency gap between vocational higher education—specifically the Industrial Chemical Engineering Technology Study Program at Institut Teknologi Sepuluh Nopember—and the practical requirements of the integrated palm oil processing industry. This internship report encompasses a comprehensive understanding of plant process flows, evaluation of mass and energy balances in the hydrogenation reactor converting Refined Palm Stearin (RPS) into Hydrogenated Refined Palm Stearin (HRPS), process safety analysis utilizing the Hazard and Operability Study (HAZOP) method on the Plate Heat Exchanger (E-113), and troubleshooting targeted at optimizing boiler blowdown cooling within the utility network. The RPS hydrogenation process using a nickel catalyst successfully reduced the Iodine Value (IV) from 22.91 to 0.24 via an exothermic reaction, resulting in a temperature rise (Delta T) of 38.5°C and hydrogen gas consumption of 249.37 Nm^3. Concurrently, the HAZOP analysis effectively identified potential deviations in flow, temperature, and pressure parameters across the E-113 heat exchanger unit, formulating mitigation strategies such as automated control loops and pressure safety valves to minimize operational risks. In the troubleshooting section, evaluation of the existing system revealed that cooling the boiler blowdown water solely with demineralized water was sub-optimal due to a constrained thermal driving force, leaving the outlet temperature unable to satisfy the make-up cooling water specification of 30°C To resolve this, a two-stage serial cooling configuration is proposed: the first stage (Plate Heat Exchanger-1) reduces the blowdown temperature from 77°C to 47.1°C using demineralized water, followed by the second stage (PHE-2) utilizing hot-well water at 17°C with a flow rate of 8.28 m^3/hour (260-270 m^3/day) to achieve a final target temperature of 32°C. Manual thermal calculations for PHE-2 yielded a heat load of 223.84 kW, demonstrating excellent consistency with the Aspen EDR software simulation validation (242 kW). Hydrodynamic evaluation confirmed safe hydraulic profiles, with pressure drops of 0.79 bar on the hot side and 0.41 bar on the cold side, well below the maximum allowable design threshold of 3 bar. This optimization successfully enhances the thermal efficiency of the utility network while actively contributing to industrial water conservation initiatives.

Item Type:	Monograph (Project Report)
Uncontrolled Keywords:	Hidrogenasi, Neraca Massa dan Energi, HAZOP, Blowdown Boiler, Plate Heat Exchanger, Aspen EDR. Hydrogenation, Mass and Energy Balance, HAZOP, Boiler Blowdown, Plate Heat Exchanger, Aspen EDR
Subjects:	T Technology > TP Chemical technology > TP155.7 Chemical processes.
Divisions:	Faculty of Vocational > 24305-Industrial Chemical Engineering Technology
Depositing User:	Putri Elvita Dewi
Date Deposited:	20 Jul 2026 02:43
Last Modified:	20 Jul 2026 02:43
URI:	http://repository.its.ac.id/id/eprint/135443

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