EVALUASI PROSES DI UNIT FRILLING TOWER SEBAGAI UPAYA MENGURANGI EMISI DEBU UREA DI PABRIK PUPUK KALTIM-1, 2 DAN 3 (Studi Kasus di PT. Pupuk Kalimantan Timur Tbk, Bontang)

Abstract

In this time, Urea dust from the top of Prilling Tower in Kaltim-1, Kaltim-2 and Kaltim-3 plant have bothered worker activities and cause damage of material in area of PT Pupuk Kaltim. The effect can happened in plant location and also in environmental around, so that need the existence of evaluation process in unit of prilling tower as effort to decrease emission of urea dust. This research aim to determine factors having an effect on to arising urea dust and comparing process technology among unit of prilling tower of Kaltim-1,2 and 3 plant to get information of smallest urea dust. Research method collect primary and secondary data, determining factors having an effect on, comparison of process technology on unit of prilling tower Kaltim-1,2,3 plant and determining the correlation of variables. Factors having an effect on to arising urea dust are not installed dust scrubber, cooler air flow, amount and flow urea seeding from fluidized bed cooler (FBC), dust cyclone, production rate, rotation of prilling bucket, concentration of 'LTC in prill urea, there is no operation procedure, urea level in FBC and environmental condition (humid weather and rain). Unit of prilling tower of Kaltim-2 plant gives lowest emission of urea dust, because it not use fluidization unit, amount of urea dust for urea seeding is lowest, that is 10,4 kg/hours and height of prilling tower is 80 meter. The correlation of urea dust with production rate and rotation of prilling bucket have the character of positively. If production rate and rotation of prilling bucket are increase, urea dust is increase too. Recommendation for minimize emission of urea dust from Kaltim-1 plant is reduction of cooler air flow, reduction of air flow of fluidization, addition of equipments (chiller), taking care of rotation of prilling bucket according to production rate. Kaltim-2 plant by taking care of rotation of prilling bucket according to production rate and Kaltim-3 plant by reduction of cooler air flow, reduction of air flow of fluidization, degradation of air temperature of fluidization, taking care of rotation of prilling bucket according to production rate. Keywords : Urea dust, Unit of Frilling tower, Frilling bucket, Production rate, Fluidized bed cooler Debu urea yang keluar dari bagian atas Unit Prilling Tower Pabrik (UPT) Kaltim-1, Kaltim-2 dan Kaltim-3 PT. Pupuk Kalimantan Timur, Tbk, saat ini sudah mengganggu aktivitas pekerja dan menyebabkan kerusakan material di area PT Pupuk Kaltim, baik di lokasi pabrik, perkantoran, maupun lingkungan di sekitarnya, sehingga perlu adanya evaluasi proses di unit prilling tower sebagai upaya mengurangi emisi debu urea tersebut. Penelitian ini bertujuan untuk menentukan faktor-faktor yang berpengaruh terhadap timbulan debu urea dan membandingkan teknologi proses antara unit prilling tower pabrik Kaltim-1, 2 dan 3 untuk memperoleh informasi timbulan debu yang paling kecil. Metode penelitian yang dilakukan yaitu kompilasi data primer dan sekunder, menentukan faktor-faktor yang berpengaruh, studi komparasi proses unit prilling tower pabrik Pupuk Kaltim-1, 2, 3 dan menentukan korelasi dad variabel berpengaruh yang bisa diambil data primer dan sekunder. Faktor-faktor yang berpengaruh terhadap timbulan debu urea adalah tidak dipasang alat penangkap debu urea, flow udara pendingin, flow dan jumlah urea dari fluidized bed cooler (FBC) sebagai urea seeding, dust cyclone kotor, rate produksi, putaran prill bucket, konsentrasi UFC di dalam urea prill, belum ada prosedur pengendalian, level urea di FBC dan kondisi lingkungan (hujan dan udara lembab). Unit prilling tower pabrik Kaltim-2 memberikan timbulan debu urea yang paling rendah, dikarenakan tidak menggunakan unit fluidisasi (fluidized bed cooler), jumlah debu urea sebagai urea seeding paling rendah, yaitu 10,4 kg/jam dan prilling tower paling tinggi, yaitu 80 meter. Korelasi debu urea dengan rate produksi dan putaran prill bucket bersifat positif. Semakin tinggi rate produksi dan putaran prill bucket, semakin tinggi timbulan debu urea. Rekomendasi untuk minimisasi timbulan debu urea untuk pabrik Kaltim-1 dengan pengurangan flow udara pendingin prilling tower, pengurangan flow udara fluidisasi, penambahan peralatan chiller, menjaga putaran prill bucket sesuai rate produksi. Pabrik Kaltim-2 dengan menjaga putaran prill bucket sesuai rate produksi dan pabrik Kaltim-3 dengan pengurangan flow udara pendingin prilling tower, pengurangan flow udara fluidisasi, penurunan temperatur udara fluidisasi, menjaga putaran prill bucket sesuai rate produksi Kata kunci : Debu urea, Unit prilling tower, Prill bucket, Rate produksi, Fluidized bed cooler