HALAMAN DEPAN

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No. : KP / J0.02.0223 / AK / 2005

LAPORAN KERJA PRAKTEK

PENGOLAHAN LUMPUR

PT. APAC INTI CORPORA

Disusun untuk memenuhi tugas mata kuliahKerja Praktek ( TKL 403 P )

Disusun Oleh :

MEGA NORA BUDIANA

NIM. L2J 002 722

PROGRAM STUDI TEKNIK LINGKUNGAN

FAKULTAS TEKNIK

UNVERSITAS DIPONEGORO

SEMARANG

2006

i



LEMBAR PENGESAHAN

Laporan Kerja Praktek

PENGOLAHAN LUMPUR

PT. APAC INTI CORPORA

Diajukan guna memenuhi Tugas Mata Kuliah Kerja Praktek (TKL -150P)

Program Studi Teknik Lingkungan Fakultas Teknik

Universitas Diponegoro

Laporan Kerja Praktek ini disahkan dan disetujui di :

Semarang, Juni 2006

Menyetujui,

Penguji I Penguji II

Wiharyanto Oktiawan, ST, MT Ir. Nasrullah, MS

NIP : 132 258 048 NIP : 130 891 848

Koordinator Kerja Praktek, Dosen Pembimbing,

Badrus Zaman, ST, MT Junaidi, ST NIP : 132 257 831 NIP : 132 205 671

Mengetahui,

Ketua Program Studi Teknik Lingkungan,

Ir. Nasrullah, MS

NIP : 130 891 848

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KATA PENGANTAR

Puji syukur kehadirat Tuhan Yang Maha Esa atas segala berkat dan

tuntunanNya, sehingga penyusun dapat menyelesaikan laporan kerja praktek

“Pengolahan Lumpur PT. APAC INTI CORPORA” dengan baik.

Laporan ini disusun sebagai persyaratan kelulusan mata kuliah Kerja

Praktek (TKL 403 P) yang wajib ditempuh oleh mahasiswa Program Studi

Teknik Lingkungan Fakultas Teknik Universitas Diponegoro.

Kelancaran kerja praktek ini tidak lepas dari dukungan dari berbagai

pihak. Dalam kesempatan ini kami menyampaikan rasa terima kasih kepada :

1. Direktur dan staff HRD PT. APAC INTI CORPORA atas ijin dan

kesempatan yang diberikan.

2. Bp. Sudaryanto selaku Asisten Manager Proses WWT PT. APAC INTI

CORPORA sekaligus pembimbing lapangan pelaksanaan Kerja Praktek.

3. Bp. Ir. Nasrullah, MS; selaku Ketua Program Studi Teknik Lingkungan

Universitas Diponegoro.

4. Bp. Junaidi, ST.; selaku dosen pembimbing Kerja Praktek.

5. Para staff laboratorium, mekanik dan proses WWT PT. APAC INTI

CORPORA atas ilmu dan kerjasama yang diberikan.

6. Orang tua dan teman-teman atas segala dukungannya.

Penyusun menyadari bahwa laporan ini tidak lepas dari berbagai

kekurangan, oleh karena itu penyusun menerima semua kritik dan saran untuk

kemajuan. Akhir kata, semoga laporan ini dapat bermanfaat bagi semua pihak.

Semarang, 24 Mei 2006

Penyusun

Mega Nora Budiana

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DAFTAR ISI

Halaman Judul..................................................................................................i

Lembar Pengesahan..........................................................................................ii

Kata Pengantar..................................................................................................iii

Daftar Isi...........................................................................................................iv

Daftar Tabel......................................................................................................viii

Daftar Gambar..................................................................................................ix

BAB I PENDAHULUAN

1.1 Latar Belakang.........................................................................................I-1

1.2 Tujuan Pelaksanaan Kerja Praktek..........................................................I-2

1.3 Ruang Lingkup Pelaksaan Kerja Praktek................................................I-2

I.3.1 Ruang Lingkup Lokasi...........................................................I-2

I.3.2 Ruang Lingkup Materi...........................................................I-2

I.3.3 Ruang Lingkup Waktu...........................................................I-2

1.4 Sistematika Penulisan Laporan................................................................I-3

BAB II TINJAUAN PUSTAKA

2.1 Umum......................................................................................................II-1

2.2 Proses Produksi Tekstil............................................................................II-1

2.2.1 Tahap Persiapan.....................................................................II-22.2.2 Tahap Penggelantangan.........................................................II-3

2.2.3 Tahap Pencelupan..................................................................II-3

2.2.4 Tahap Pencapan.....................................................................II-3

2.2.5 Tahap Penyempurnaan...........................................................II-3

2.3 Pengertian Air Buangan...........................................................................II-5

2.4 Analisis Karakteristik Air Buangan.........................................................II-5

2.5 Efek Buruk Air Buangan.........................................................................II-9

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2.6 Unit Operasi Dan Proses IPAL................................................................II-10

2.6.1 Pengolahan Pendahuluan ( Pre Treatment )............................II-10

2.6.2 Pengolahan Tingkat I ( Primary Treatment )..........................II-13

2.6.3 Pengolahan Tingkat II (Secondary Treament ).......................II-18

2.6.4 Pengolahan Tingkat III (Tertiary Treatment )........................II-22

2.7 Unit Pengolahan Lumpur (Sludge Treatment ).........................................II-24

2.7.1 Tahap Pendahuluan ( Preliminary Treatment ).......................II-26

2.7.2 Proses Pemekatan (Thickening ).............................................II-27

2.7.3 Proses Stabilisasi (Stabilitation)............................................II-30

2.7.4 Conditioning ..........................................................................II-32

2.7.5 Proses Pengurangan Kadar Air ( Dewatering ).......................II-33

2.7.6 Heat Drying (Pengeringan)....................................................II-40

2.7.7 Thermal Reduction (Pemakaran Dengan Suhu Tinggi).........II-42

2.7.8 Ultimate Disposal ( Pembuangan Akhir )................................II-42

2.8 Penanganan Limbah Lumpur B3 dengan Insenerator.............................II-43

2.8.1.......................................................................................Kara

kteristik Limbah Insenerator..................................................II-43

2.8.2.......................................................................................Wakt

u Tinggal Padatan Dalam Insenerator....................................II-45

2.8.3.......................................................................................Keun

tungan Dan Kerugian Insenerator..........................................II-45

2.9 Pencemaran Udara Akibat Pemakaian Insenerator..................................II-47

2.9.1 Macam-macam zat pencemar................................................II-47

2.9.2 Alat Pengendali Pencemaran Udara......................................II-47

2.9.3 Baku Mutu Pencemaran Udara..............................................II-49

2.10 Limbah B3...............................................................................................II-50

BAB III METODOLOGI PELAKSANAAN KERJA PRAKTEK

3.1 Waktu dan Tempat Pelaksanaan Kerja Praktek.......................................III-1

3.2 Tahapan Pelaksanaan Kerja Praktek........................................................III-1

3.2.1 Tahap Persiapan.....................................................................III-1

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3.2.2 Tahap Pelaksanaan.................................................................III-1

3.2.3 Tahap Penyusunan Laporan...................................................III-2

BAB IV GAMBARAN UMUM LOKASI KERJA PRAKTEK

4.1 Sejarah Singkat PT. APAC INTI CORPORA...................................IV-1

4.2 Lokasi PT. APAC INTI CORPORA.................................................IV-2

4.3 Visi , Misi dan Panca Darma PT. APAC INTI CORPORA.............IV-6

4.4 Hasil Produksi PT. APAC INTI CORPORA....................................IV-6

4.5 Pemasaran dan Distribusi..................................................................IV-7

4.6 Sumber Daya Manusia.......................................................................IV-8

4.7 Struktur Organisasi............................................................................IV-10

4.8 Bahan Baku dan Uraian Proses Produksi..........................................IV-14

4.8.1 Bahan Baku.........................................................................IV-14

4.8.2 Uraian Proses Produksi.......................................................IV-15

4.9 Penggunaan Energi di PT. APAC INTI CORPORA.........................IV-24

4.10 Kondisi Awal Pengelolaan Lingkungan PT. APAC INTI CORPORA

sebelum Menerapkan Sistem Manajemen Lingkungan ISO 14001

........................................................................................................IV-24

4.11 Perolehan Sertifikat Sistem Manajemen Lingkungan ISO 14001..IV-26

4.12 Pengolahan Air Limbah..................................................................IV-28

4.12.1 Deskripsi Proses IPAL........................................................IV-28

4.12.2 Pengendali Kinerja Operasional IPAL...............................IV-39

4.12.3 Aspek Manajemen WWT...................................................IV-40

4.13 Unit Pengolahan Lumpur ...............................................................IV-43

4.13.1 Deskripsi Operasi dan Proses.............................................IV-43

4.14 Bahan Bakar....................................................................................IV-52

4.15 Pengendalian Pencemaran Udara...................................................IV-53

4.15.1 Cyclone IV-54

4.15.2 Water Scrubber ..................................................................................IV-55

4.15.3 Exhaust Fan.......................................................................................IV-57

4.15.4 Effluent udara insenerator..................................................................IV-59

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BAB V ANALISA DAN PEMBAHASAN

5.1 Sumber Limbah Cair..........................................................................V-1

5.2 Karakteristik Limbah Cair.................................................................V-2

5.3 Sumber dan Karakteristik Lumpur....................................................V-3

5.3.1 Lumpur Yang Berasal Dari Bak Pengendap Pertama.........V-4

5.3.2 Lumpur Yang Berasal Dari Bak Pengendap Kedua...........V-5

5.4 Unit-unit Pengolahan Lumpur...........................................................V-6

5.4.1 SHTT (Sludge Holding Thickener Tank )............................V-7

5.4.2 Decanter Sentrifuge............................................................V-10

5.4.3 Hopper (Penampung) .........................................................V-13

5.4.4 Rotary Dryer .......................................................................V-15

5.4.5 Rotary Incenerator ..............................................................V-19

5.5 Neraca Massa Pengolahan Lumpur...................................................V-22

5.6 Pasir Hasil Insenerator.......................................................................V-24

BAB VI KESIMPULAN DAN SARAN

6.1 Kesimpulan..............................................................................................VI-1

6.2 Saran........................................................................................................VI-1

Daftar Pustaka...................................................................................................xii

Lampiran

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DAFTAR TABEL

Tabel 2.1 Karakteristik Air Buangan Berdasarkan Unsur Pencemar.............II-5

Tabel 2.2 Karakteristik Padatan Dan Lumpur Selama Proses Pengolahan Air

Limbah............................................................................................II-25

Tabel 2.3 Baku Mutu Emisi Udara Untuk Insenerator...................................II-50

Tabel 4.1 Luas Gedung PT. APAC INTI CORPORA....................................IV-3

Tabel 4.2 Bahan Baku Produksi.....................................................................IV-14

Tabel 4.3 Penggunaan Material di Unit Sizing................................................IV-14

Tabel 4.4 Bahan Penolong di Unit Rope Dyeing dan Slasher.........................IV-15

Tabel 4.5. Biaya Operasional Pengolahan Limbah Cair Bulan Desember 2005

PT.APAC INTI CORPORA...........................................................IV-41

Tabel 4.6. Emisi Udara Insenerator Dibandingkan Dengan Baku Mutu..........IV-59

Tabel 5.1 Karakteristik Limbah Cair di Inlet Equalisasi Bulan Desember 2005

........................................................................................................V-3

Tabel 5.2 Volume Lumpur Primary tanggal 13-20 Desember 2005...............V-5

Tabel 5.3 Volume Lumpur Secondary tanggal 13-20 Desember 2005...........V-6

Tabel 5.4 Karakteristik Kimia Filtrat Decanter...............................................V-12

Tabel 5.5 Karakteristik Fisik dan Kimia Padatan Hasil Decanter...................V-13

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DAFTAR GAMBAR

Gambar 2.1 Proses Produksi Tekstil.............................................................II-4

Gambar 2.2 Contoh Bar Screen....................................................................II-12

Gambar 2.3 TAR in-line...............................................................................II-13

Gambar 2.4 TAR off-line.............................................................................II-13

Gambar 2.5 Primary Clarifier ......................................................................II-17

Gambar 2.6 Activated Sludge.......................................................................II-21

Gambar 2.7 Conventional Activated Sludge.................................................II-21

Gambar 2.8 Gravity Thickener .....................................................................II-28

Gambar 2.9 Centrifugation Thickening ........................................................II-29

Gambar 2.10 Anaerobic Sludge Digester .......................................................II-32

Gambar 2.11 Hydrocyclone............................................................................II-34

Gambar 2.12 Tubular Bowl ............................................................................II-35

Gambar 2.13 Chamber Bowl ..........................................................................II-36

Gambar 2.14 Imperforate Basket ....................................................................II-37

Gambar 2.15 Disk Stack Separator ................................................................II-38

Gambar 2.16 Decanter ...................................................................................II-38

Gambar 2.17 Sludge Drying Bed ....................................................................II-40

Gambar 2.18 Alternatif Proses Pengolahan Limbah B3.................................II-52

Gambar 3.1 Diagram Alir Tahapan Pelaksanaan Kerja Praktek..................III-3

Gambar 4.1 Peta Lokasi PT APAC INTI CORPORA.................................IV-4

Gambar 4.2 Denah Lokasi PT. APAC INTI CORPORA.............................IV-5

Gambar 4.3 Struktur Organisasi PT. APAC INTI CORPORA....................IV-11

Gambar 4.4 Diagram alir proses produksi pada PT. APAC INTI CORPORA

...............................................................................................IV-16

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Gambar 4.5 Diagram Alir Proses di Unit Spinning ..............................................IV-17

Gambar 4.6 Diagram Alir Proses di Unit Grey.....................................................IV-20

Gambar 4.7 Diagram Alir Proses di Unit Denim.................................................. IV-22

Gambar 4.8 Diagram Alir Proses di Unit Laundry...............................................IV-23

Gambar 4.9 Diagram Alir Waste Water Treatment ..............................................IV-29

Gambar 4.10. Bak ekualisasi............................................................................IV-31

Gambar 4.11. Bak koagulasi.............................................................................IV-32

Gambar 4.12. Dossing alum dan kapur............................................................IV-32

Gambar 4.13 Bak Pengendap Pertama............................................................IV-33

Gambar 4.14 Bak Penampung Lumpur Dari Bak Pengendap Pertama (SHT I)

...............................................................................................IV-34

Gambar 4.15. Bak Aerasi..................................................................................IV-35

Gambar 4.16. Tempat pembiakan bakteri.........................................................IV-35

Gambar 4.17 Dossing nutrisi untuk bakteri (TSP, Tapioka & Urea).......... ....IV-36

Gambar 4.18. Bak Pengendap Kedua...............................................................IV-37

Gambar 4.19 Bak Penampung Lumpur Dari Bak Pengendap Kedua (SHT II)

...............................................................................................IV-37

Gambar 4.20. Sand and Carbon Filter..............................................................IV-38

Gambar 4.21 Bak kontrol / Kolam effluent......................................................IV-39

Gambar 4.22 Struktur Organisasi WWT Divisi EH&S....................................IV-40

Gambar 4.23 Skema Lumpur PT. APAC INTI CORPORA............................IV-44

Gambar 4.24 SHTT (Sludge Holding Thickener Tank)...................................IV-45

Gambar 4.25 Dossing polimer kationik............................................................IV-46

Gambar 4.26 Decanter sentrifuge.....................................................................IV-47Gambar 4.27 Screw sebagai media untuk mengalirkan lumpur

ke proses berikutnya.................................................................IV-47

Gambar 4.28 Filtrat decanter............................................................................IV-48

Gambar 4.29 Hopper........................................................................................IV-48

Gambar 4.30 Lumpur dari decanter yang dikarungi

apabila unit dryer dan incinerator rusak.....................................IV-49

Gambar 4.31 Rotary Dryer...............................................................................IV-49

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Gambar 4.32 Isi Rotary Dryer ..........................................................................IV-50

Gambar 4.33 Insenerator..................................................................................IV-51

Gambar 4.34 Isi Insenerator.............................................................................IV-51

Gambar 4.35 Pasir effluent incinerator.............................................................IV-52

Gambar 4.36 Burner dan FO............................................................................IV-53

Gambar 4.37 Cyclone.......................................................................................IV-55

Gambar 4.38 Water Scrubber ...........................................................................IV-57

Gambar 4.39 Prinsip Kerja Exhaust Fan..........................................................IV-57

Gambar 4.40 Exhaust Fan................................................................................IV-58

Gambar 4.41 Cerobong.....................................................................................IV-58

Gambar 5.1 Denah SHTT.................................................................................V-7

Gambar 5.2 Potongan A-A SHTT....................................................................V-8

Gambar 5.3 Denah Decanter Sentrifuge...........................................................V-10

Gambar 5.4 Potongan A-A Decanter Sentrifuge..............................................V-11

Gambar 5.5 Denah Hopper ...............................................................................V-14

Gambar 5.6 Potongan A-A Hopper ..................................................................V-14

Gambar 5.7 Denah Rotary Dryer ......................................................................V-16

Gambar 5.8 Potongan A-A Rotary Dryer .........................................................V-16

Gambar 5.9 Denah Insenerator.........................................................................V-19

Gambar 5.10 Potongan A-A Insenerator..........................................................V-20

Gambar 5.11 Neraca Massa Lumpur................................................................V-23

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