Pengembangan Sistem Pengendalian Risiko Proses Granulasi Skimming Slag Feronikel Berbasis Hasil Analisis Hazop

Hendri Saputro, Prof. Ir. Rochim Bakti Cahyono, ST., M.Sc. Ph.D., IPM

2026 | Tesis | MAGISTER TERAPAN KESELAMATAN DAN KESEHATAN KERJA

Proses granulasi skimming Slag feronikel merupakan salah satu tahapan kritis pada operasi smelter karena melibatkan interaksi antara Slag cair bersuhu tinggi dan water jet bertekanan tinggi yang berpotensi menimbulkan steam explosion, Slag splash, overpressure, serta gangguan keselamatan proses. Penelitian ini bertujuan mengembangkan sistem pengendalian risiko proses granulasi skimming Slag feronikel berbasis hasil analisis Hazard and Operability Study (HAZOP), melalui identifikasi potensi bahaya dan deviasi, penentuan variabel proses kritis, analisis risiko, serta evaluasi efektivitas pengendalian berdasarkan penurunan residual risk. Penelitian menggunakan pendekatan deskriptif kualitatif dan kuantitatif pada proses granulasi skimming Slag di PT Halmahera Jaya Feronikel. Analisis dilakukan menggunakan metode HAZOP pada tiga node utama, yaitu Node 1 Proses Skimming Slag, Node 2 Operasi Drill Gun, dan Node 3 Granulasi Slag. Penilaian risiko menggunakan matriks risiko 5×5 dengan membandingkan initial risk dan residual risk setelah penerapan rekomendasi pengendalian. Hasil penelitian menunjukkan bahwa deviasi risiko tertinggi pada masing-masing node adalah Fail to close pada Node 1 dengan initial risk 15, Oil Leak pada Node 2 dengan initial risk 12, dan Low  Pressure Water pada Node 3 dengan initial risk 16. Variabel proses kritis yang mempengaruhi keselamatan proses meliputi tekanan air, temperatur Slag, debit aliran air, kondisi sistem hidrolik, pompa, dan potensi penyumbatan nozzle. Sistem pengendalian risiko yang dikembangkan melalui kombinasi engineering control dan administrative control terbukti mampu menurunkan residual risk pada setiap node. Hasil validasi menunjukkan efektivitas penurunan risiko sebesar 40% pada Node 1, 50% pada Node 2, dan 75% pada Node 3. Dengan demikian, sistem pengendalian risiko berbasis HAZOP yang dikembangkan dinilai efektif dalam meningkatkan keselamatan proses dan keandalan operasi granulasi Slag feronikel.

The ferronickel skimming Slag granulation process is one of the critical stages in smelter operations beCause it involves the interaction between High-temperature molten Slag and High-pressure water jets, which may Cause steam explosions, Slag splash, overpressure, and other process safety disturbances. This study aimed to develop a risk control system for the ferronickel skimming Slag granulation process based on the results of Hazard and Operability Study (HAZOP) analysis through hazard and deviation identification, determination of critical process variables, risk analysis, and evaluation of control effectiveness based on residual risk reduction. This study employed qualitative and quantitative descriptive approaches on the skimming Slag granulation process at PT Halmahera Jaya Feronikel. The analysis was conducted using the HAZOP method on three main nodes, namely Node 1 Skimming Slag Process, Node 2 Drill Gun Operation, and Node 3 Slag Granulation. Risk assessment was carried out using a 5×5 risk matrix by comparing the initial risk and residual risk after the implementation of the proposed control recommendations. The results showed that the Highest risk deviations in each node were Fail to close in Node 1 with an initial risk value of 15, Oil Leak in Node 2 with an initial risk value of 12, and Low  Pressure Water in Node 3 with an initial risk value of 16. Critical process variables affecting process safety included water pressure, Slag temperature, water Flow  rate, hydraulic system condition, pump performance, and nozzle blockage potential. The developed risk control system, through a combination of engineering controls and administrative controls, was proven effective in reducing residual risk in each node. Validation results indicated risk reduction effectiveness of 40% in Node 1, 50% in Node 2, and 75% in Node 3. Therefore, the HAZOP-based risk control system developed in this study was considered effective in improving process safety and operational reliability in the ferronickel Slag granulation process.

Kata Kunci : HAZOP, skimming Slag, granulasi Slag, feronikel, pengendalian risiko, residual risk, keselamatan proses