PRARANCANGAN PABRIK ALUMUNIUM SULFAT DARI ASAM SULFAT DAN KAOLIN KAPASITAS 25.000 TON PER TAHUN A. HALAMAN JUDUL
Oleh : Ahmad Masrokan 500 110 010
Dosen Pembimbing : Ir. Haryanto AR.,MS Rois Fatoni, S.T., M.Sc., Ph.D
PROGRAM STUDI TEKNIK KIMIA FAKULTAS TEKNIK UNIVERSITAS MUHAMMADIYAH SURAKARTA SURAKARTA 2016
INTISARI
Prarancangan pabrik Alumunium sulfat bertujuan untuk memasok kebutuhan Alumunium Sulfat secara domestik. Aluminium sulfat Al2(SO4)3 yang lebih dikenal dengan tawas merupakan salah satu bahan kimia yang diperlukan untuk pengolahan air di PDAM dan berbagai macam kegiatan industri. makanan dan minuman. Proses yang digunakan untuk pembentukan Alumunium Sulfat menggunakan reaksi heterogen fase cair dan padat yang menghasilkan produk samping Na2SO4, FeSO4 dan Fe. Proses reaksi berlangsung di dalam reaktor CSTR/RATB. Reaksi terjadi pada suhu 90 0C dengan tekanan 1 atm selama 180 menit dengan konversi raksi didalam reaktor sebesar 85 %, reaksi ini bersifat eksotermis dan berjalan searah. Produk alumunium sulfat yang dihasilkan sebanyak 3.156.5656 kg/jam, untuk menghasilkan produk sesuai perhitungan, maka dibutuhkan bahan baku asam sulfat sebanyak 4.747.003 kg/jam dan kaolin sebanyak 1.646,9195 kg/jam. Unit pendukung proses (utilitas) meliputi penyediaan air pendingin 18.539,8128 kg/jam, air untuk kebutuhan steam sebesar 540,8879 kg/jam yang di produksi dari boiler dengan bahan bakar solar sebesar 79,014 L/jam, air untuk sanitasi sebesar 2.099,0872 kg/jam. Pabrik alumunium sulfat ini membutuhkan listrik sebesar 406,610 disediakan dari PLN dan disediakan sebuah generator set sebagai cadangan. Kebutuhan udara tekan sebesar 30 m3/jam. Pabrik ini direncanakan berdiri di Karawang, Jawa Barat pada tahun 2020 dengan luas 23.780 m2 dengan jumlah karyawan sebanyak 158 orang. Dari analisis ekonomi terhadap pabrik Alumunium Sulfat menunjukkan keuntungan sebelum pajak Rp 90.900.115.811 per tahun setelah dipotong pajakkeuntungan mencapai Rp 68.175.086.858. Percent Return On Investment (ROI) sebelum pajak 38,77% dan setelah pajak 29,08%. Pay Out Time (POT) sebelum pajak 2,05 tahun dan setelah pajak 2,56 tahun. Break Even Point (BEP) sebesar 47,78% dan Shut Down Point (SDP) sebesar 27,97% dan Discounted Cash Flow(DCF) terhitung sebesar 43,17%. Dari data analisis kelayakan di atas disimpulkan, bahwa pabrik ini menguntungkan dan layak untuk didirikan.
Kata Kunci : Alumunium sulfat, Asam sulfat, CSTR/RATB
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ABSTRACT
Alumunium sulphate factory aims to supply alumunium Suphate needs domestically. Alumunium sulphate Al2(SO4)3 known alum is one of the necessary chemicals for water treatment in waterworks and a variety of industry events, food an drinks. The process used for the formation of alumunium sulphate using heterogeneous phase reaction liquid and solid which produces a by product of Na2SO4, FeSO4 and Fe. Reaction process taking place in the reactor CSTR/RATB. The reaction occurs at a temperature of 90 OC whith pressure 1 atm for 180 minutes with conversion in reaction of 85%, it is an exothermic reaction an direct running. Alumunium sulphate products are produced as much as 3.156,5656 kg/hour, to produce appropriate calculation then it takes as much sulfuric acid raw materials 4.747,003 kg/hour and kaolin as much as 1.646,9195 kg/hour. The supporting unit processes (utilities) include provision of water cooling 18.539,8128 kg/hour, water steam for the needs of 540,8879 kg/hour which in the production of diesel fuel with boilers of 79,014 Liter/hour, water for sanitation of 2.099,0872 kg/hour. Aluminium sulphate factory needs electricity of 406,610 kW provided from PLN and provided a generator set as a backup. Compressed air requirement of 30 m3/hour. This factory is planned to stand at karawang, West Java, by 2020 with the number of employess with 23.780 m2 as much as 158 people. Economic analysis of alumunium sulphate factory demonstrated against a profit before tax of Rp 90.900.115.811 per year after the cut profit reacher Rp 68.175.086.858. Return on Investment (ROI) before tax 38,77%, after tax 29,08%. Pay Out Time (POT) before tax 2,05 years dan after tax 2,56 years. Break even Point (BEP) of 47,78%, Shut Down Point (SDP) of 27,97% and Discounted Cash Flow (DCF) accounting of 43,25%. Feasibility analysisi of the data above, it was concluded that the factory is profitable and viable to set up.
Key word : Alumunium sulphate, Sulfuric acid, CSTR/RATB
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MOTTO “Sesungguhnya sesudah kesulitan itu ada kemudahan. Maka apabila kamu telah selesai (dari suatu urusan) kerjakan dengan sungguh-sungguh (urusan) yang lain, dan hanya kepada Tuhan mullah kamu berharap.” (Q.S Asy-Syarh: 6-8) “Allah akan meninggikian orang-orang beriman diantara mu dan orang-orang yang diberi ilmu pengetahuan beberapa derajat” (Q.S Al-Mujadalah: 11) “If There is a will, there is away: Jika ada kemauan pasti ada jalan “
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PERSEMBAHAN
Segala puji syukur selalu tercurah kepada-Mu Yaa Allah atas segala nikmat dan karunia-Mu penulis dapat menyelesaikan tugas akhir ini. Tugas akhir ini saya persembahkan untuk: 1. Ibu,Bapak dan adik tercinta yang telah memberikan dukungan dan semangat sehingga saya bisa menyelesaikan tugas akhir ini. 2. Partner saya Warih Nurtyasti, terima kasih telah menjadi partner TPP ku. Terima kasih untuk kesabaran, persahabatan dan kerjasamanya untuk menyelesaikan tugas akhir ini. 3. Keluarga besar Badan Eksekutif Mahasiswa Fakultas Teknik UMS dan Dewan Perwakilan Mahasiswa Fakultas Teknik UMS yang sudah memberikan banyak pengalaman, pelajaran, dan kenangan yang mendalam untuk saya. Temen-teman Teknik Kimia 2011 yang telah bersama-sama dalam perkuliahan yang menyenangkan. Terimakasih atas doa dan semangat dari kalian semua.
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KATA PENGANTAR
Puji syukur penulis panjatkan kepada Allah SWT atas limpahan rahmat, taufik dan hidayah-Nya sehingga penulis dapat menyelesaikan Tugas Akhir dengan judul “Prarancangan Pabrik Alumunium Sulfat dari Asam Sulfat dan Kaolin Kapasitas 25.000 Ton/Tahun”. Sholawat serta salam selalu penulis haturkan kepada Nabi Besar Muhammad SAW yang kita nantikan syafa’atnya di Yaumul Qiyamah nanti. Tugas Prarancangan Pabrik merupakan salah satu syarat yang wajib ditempuh untuk menyelesaikan program strata 1 di Program Studi Teknik Kimia, Fakultas Teknik, Universitas Muhammadiyah Surakarta. Pada kesempatan ini, penulis ucapkan terima kasih kepada pihak-pihak yang
telah
memberikan
dukungan,
bimbingan,
dan
bantuan
hingga
terselesaikannya laporan tugas akhir ini. Adapun pihak-pihak tersebut, antara lain: 1. Ir. Haryanto AR,.MS sebagai dosen pembimbing I 2. Rois Fatoni, S.T., M.Sc., Ph.D sebagai dosen pembimbing II 3. Seluruh dosen dan staf Teknik Kimia Universitas Muhammadiyah Surakarta 4. Segenap civitas akademika dan teman-teman mahasiswa Teknik Kimia FT UMS khususnya angkatan 2011. Penulis berharap semoga laporan ini bermanfaat bagi semua pihak yang membaca.
Surakarta,
Agustus 2016
Penulis
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DAFTAR ISI HALAMAN JUDUL ........................................................................................ i HALAMAN PENGESAHAN ......................................................................... ii HALAMAN KEASLIAN SKRIPSI ............................................................... iii INTISARI ......................................................................................................... iv MOTTO ............................................................................................................ vi PERSEMBAHAN ............................................................................................ vii KATA PENGANTAR ...................................................................................... viii DAFTAR ISI .................................................................................................... ix DAFTAR TABEL ............................................................................................ xiv DAFTAR GAMBAR ....................................................................................... xvi BAB I ................................................................................................................. 1 PENDAHULUAN ............................................................................................. 1 1.1 Latar Belakang Pendirian Pabrik ...................................................... 1 1.2 Kapasitas Pabrik ............................................................................... 2 1.3 Pemilihan Lokasi Pabrik .................................................................. 5 1.4 Tinjauan Pustaka .............................................................................. 7 1.4.1 Macam-macam Proses ............................................................. 7 1.4.2 Pemilihan Proses ...................................................................... 9 1.4.3 Kegunaan Produk ..................................................................... 10 1.4.4 Sifat Fisis dan Kimia ................................................................ 11 BAB II ............................................................................................................... 14 DESKRIPSI PROSES ...................................................................................... 14 2.1 Spesifikasi Bahan Baku dan Produk ................................................ 14 2.1.1 Spesifikasi Bahan Baku ............................................................. 14 2.1.2 Spesifikasi Bahan Tambahan .................................................... 14 2.1.3 Spesifikasi Produk ..................................................................... 15 2.2 Konsep Proses .................................................................................. 15 2.2.1 Dasar Proses ............................................................................. 15 2.2.2 Kondisi Operasi ........................................................................ 15 2.2.3 Tinjauan Termodinamika ......................................................... 15 2.2.4 Tinjauan Kinetika ..................................................................... 17
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2.3 Deskripsi Proses ............................................................................... 18 2.3.1 Langkah Proses ........................................................................ 19 2.3.2 Diagram Alir Proses ................................................................. 19 2.4 Neraca Massa dan Neraca Panas ...................................................... 22 2.4.1 Neraca Massa ........................................................................... 22 2.4.2 Neraca Panas ............................................................................ 26 2.5 Tata Letak Pabrik dan Peralatan ...................................................... 30 2.5.1 Tata Letak Pabrik ..................................................................... 30 2.5.2 Tata Letak Peralatan ................................................................. 34 BAB III ............................................................................................................. 36 SPESIFIKASI ALAT PROSES ....................................................................... 36 3.1 Belt Conveyor.................................................................................... 36 3.1.2 Belt Conveyor-01 ............................................................... 36 3.1.2 Belt Conveyor-02 .................................................................. 36 3.1.3 Belt Conveyor-03 ................................................................ 37 3.2 Blower ............................................................................................... 37 3.3 Bucket Elevator ................................................................................. 37 3.3.1 Bucket Elevator -01 .................................................................. 37 3.3.2 Bucket Elevator -02 .................................................................. 38 3.4 Centrifuge ......................................................................................... 38 3.4.1 Centrifuge-01 ............................................................................ 38 3.4.2 Centrifuge-02 ............................................................................ 39 3.5 Cooler ............................................................................................... 40 3.6 Filter ................................................................................................. 40 3.7 Gudang .............................................................................................. 41 3.7.1 Gudang Al2O3............................................................................ 41 3.7.2 Gudang Al2(SO4)3.18H2O ......................................................... 41 3.8 Heater ............................................................................................... 42 3.8.1 Heater-01 .................................................................................. 42 3.8.2 Heater-02 .................................................................................. 42 3.9 Hopper .............................................................................................. 43 3.10 Kristalizer ........................................................................................ 43 3.11 Pompa ............................................................................................. 44 3.11.1 Pompa-01 ................................................................................ 44 x
3.11.2 Pompa-02 ................................................................................ 44 3.11.3 Pompa-03 ................................................................................ 45 3.11.4 Pompa-04 ................................................................................ 46 3.11.5 Pompa-05 ................................................................................ 46 3.11.6 Pompa-06 ................................................................................ 47 3.11.7 Pompa-07 ................................................................................ 48 3.12 Reaktor ............................................................................................ 48 3.12.1 Reaktor-01 ............................................................................... 48 3.12.2 Reaktor-02 ............................................................................... 49 3.13 Rotary Dryer ................................................................................... 50 3.14 Silo .................................................................................................. 51 3.15 Tangki Penyimpanan ...................................................................... 51 BAB IV ............................................................................................................... 53 UNIT PENDUKUNG PROSES DAN LABORATORIUM .......................... 53 4.1 Unit Pendukung Proses ..................................................................... 53 4.1.1 Unit Penyediaan air dan Pengoahan air ................................... 54 4.1.2 Unit Penyediaan Steam ............................................................ 66 4.1.3 Unit Penyediaan Listrik............................................................. 68 4.1.4 Unit Penyediaan Bahan Bakar .................................................. 74 4.1.5 Unit Penyediaan Limbah ........................................................... 84 4.1.6 Unit Penyediaan Tekanan Udara ............................................... 85 4.2 Laboratorium..................................................................................... 86 4.2.1 Laboratorium Fisik ................................................................... 87 4.2.2 Laboratorium Analitik .............................................................. 87 4.2.3 laboratorium Penelitian dan Pengembangan ............................ 87 4.2.4 Analisis Air .............................................................................. 87 4.2.5 Analisa Sampel ......................................................................... 88 BAB V ............................................................................................................... 89 MANAJEMEN PERUSAHAAN ..................................................................... 89 5.1 Bentuk Perusahaan .......................................................................... 89 5.2 Struktur Organisasi ......................................................................... 90 5.3 Tugas dan Wewenang ..................................................................... 93 5.3.1 Pemegang Saham ...................................................................... 93 5..3.2 Direktur Utama......................................................................... 93 xi
5.3.3 Staf Ahli .................................................................................... 94 5.3.4 Kepala Bagian ........................................................................... 94 5.3.5 Kepala Seksi .............................................................................. 97 5.4 Pembagian Jam Kerja Karyawan ...................................................... 97 5.4.1 Karyawan Non Shift .................................................................. 97 5.4.2 Karyawan Shift.......................................................................... 98 5.5 Sistem Kepegawaian dan Upah ........................................................ 99 5.6 Penggolongan Jabatan, Jumlah Karyawan dan Gaji ......................... 100 5.6.1 Pengelolaan Jabatan .................................................................. 100 5.6.2 Jumlah Karyawan dan Gaji ....................................................... 100 5.7 Kesejahteraan Sosial Karyawan ........................................................ 101 5.8 Kesehatan dan Keselamatan Kerja.................................................... 102 5.9 Manajemen Produksi ........................................................................ 103 5.9.1 Perencanaan Produksi ............................................................... 103 5.9.2 Pengendalian Produksi .............................................................. 104 BAB VI .............................................................................................................. 106 ANALISIS EKONOMI .................................................................................... 106 6.1 Dasar Perhitungan ............................................................................. 106 6.2 Perhitungan Biaya ............................................................................. 109 6.2.1 Investasi Modal (Capital Investment) ....................................... 109 6.2.2 Biaya Produksi (Manufacturing Cost) ...................................... 109 6.2.3 Pegeluaran Umum (General Expenses) .................................... 109 6.3 Analisis Kelayakan ........................................................................... 110 6.3.1 Percent Return On Investment (ROI) ........................................ 110 6.3.2 Pay Out Time (POT) ................................................................. 110 6.3.3 Break Even Point (BEP)............................................................ 110 6.3.4 Shut Down Point (SDP) ............................................................ 111 6.3.5 Discounted Cash Flow .............................................................. 111 6.4 Hasil Perhitungan .............................................................................. 111 6.4.1 Total Fixed Capital Investment ................................................. 111 6..4.2 Working Capital ....................................................................... 112 6.4.3 Total Capital Investment (TCI) ................................................. 112 6.4.4 Direct Manufacturing Cost ........................................................ 112 6.4.5 Indirect Manufacturing Cost ..................................................... 113 xii
6.4.6 Fixed Manufacturing Cost......................................................... 113 6.4.7 Total Manufacturing Cost (TMC) ............................................. 113 6.4.8 General Expenses ...................................................................... 114 6.4.9 Total Production Cost (TPC) .................................................... 114 6.4.10 Perhitungan Keuntungan Produksi .......................................... 114 6.4.11 Analisis Kelayakan.................................................................. 115 6.5 Kesimpulan ....................................................................................... 120 DAFTAR PUSTAKA........................................................................................ 122 LAMPIRAN ...................................................................................................... 124
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DAFTAR TABEL Tabel 1.1 Data ekspor dan impor aluminium sulfat ........................................... 2 Tabel 1.2 Data kapasitas produksi pabrik alumunium sulfat di Indonesia ......... 4 Tabel 1.3 Data kapasitas produksi pabrik aluminium sulfat di dunia................. 4 Tabel 1.4 Perbandingan proses pembuatan aluminium sulfat ............................ 10 Tabel 2.1 Harga ΔHf° dan ΔGf° ......................................................................... 16 Tabel 2.2 Neraca massa pada reaktor-01 ............................................................ 22 Tabel 2.3 Neraca massa pada reaktor-02 ............................................................ 23 Tabel 2.4 Neraca massa pada centrifuge-01 ....................................................... 23 Tabel 2.5 Neraca massa pada kristaliser ............................................................ 24 Tabel 2.6 Neraca massa pada centrifuge-02 ...................................................... 24 Tabel 2.7 Neraca massa pada rotary dryer ......................................................... 25 Tabel 2.8 Neraca massa total setelah recycle ..................................................... 25 Tabel 2.9 Neraca panas heater-01 ...................................................................... 26 Tabel 2.10 Neraca panas pada reaktor-01 .......................................................... 26 Tabel 2.11 Neraca panas pada reaktor-02 .......................................................... 27 Tabel 2.12 Neraca panas pada centrifuge-01 ...................................................... 27 Tabel 2.13 Neraca panas pada cooler ................................................................. 28 Tabel 2.14 Neraca panas pada kristalizer ........................................................... 28 Tabel 2.15 Neraca panas pada centrifuge-02 ...................................................... 29 Tabel 2.16 Neraca panas pada rotary dryer........................................................ 29 Tabel 2.17 Neraca panas pada heater-02 ............................................................ 30 Tabel 2.18 Perincian luas tanah bangunan pabrik .............................................. 32 Tabel 4.1 Data kebutuhan air pendingin ........................................................... 64 Tabel 4.2 Data kebutuhan steam ........................................................................ 64 Tabel 4.3 Data kebutuhan air sanitasi ................................................................ 65 Tabel 4.4 Kebutuhan air total ............................................................................ 66 Tabel 4.5 Data kebutuhan listrik untuk proses .................................................. 69 Tabel 4.6 Data kebutuhan listrik untuk utilitas .................................................. 70 Tabel 4.7 Data kebutuhan listrik untuk penerangan ........................................... 72 Tabel 4.8 Data kebutuhan listrik total ................................................................ 73 Tabel 5.1 Jadwal kerja kelompok shift .............................................................. 99
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Tabel 5.2 Penggolongan jabatan, jumlah karyawan dan gaji ............................ 100 Tabel 6.1 Cost index chemical plant................................................................... 107 Tabel 6.2 Total fixed capital investment ............................................................. 111 Tabel 6.3Working capital investment ................................................................. 112 Tabel 6.4 Total capital investment...................................................................... 112 Tabel 6.5 Direct manufacturing cost .................................................................. 112 Tabel 6.6 Indirect manufacturing cost................................................................ 113 Tabel 6.7 Fixed manufacturing cost ................................................................... 113 Tabel 6.8 Total anufacturing cost ....................................................................... 113 Tabel 6.9 General expenses ................................................................................ 114 Tabel 6.10 Total production ............................................................................... 114 Tabel 6.11 Fixed cost .......................................................................................... 116 Tabel 6.12 Variable cost ..................................................................................... 117 Tabel 6.13 Regulated cost................................................................................... 117 Tabel 6.14 Analisa kelayakan ............................................................................ 119
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DAFTAR GAMBAR Gambar 1.1Hubungan aluminium sulfat dengan tahun ekspor .......................... 3 Gambar 1.2 Hubungan aluminium sulfat dengan tahun impor .......................... 3 Gambar 2.1 Diagram alir kualititatif prarancangan pabrik aluminium sulfat ... 20 Gambar 2.2 Diagram alir kuantitatif prarancangan pabrik aluminium sulfat .... 21 Gambar 2.3 Tata letak prarancangan pabrik aluminium sulfat .......................... 33 Gambar 2.4 Tata letak peralatan proses pabrik aluminium sulfat ..................... 35 Gambar 4.1 Denah utilitas prarancangan pabrik aluminium sulfat ................... 58 Gambar 5.1 Susunan struktur organisasi perusahaan ........................................ 92 Gambar 6.1 Hubungan tahun dengan cost index ............................................... 108 Gambar 6.2 Analisis kelayakan ekonomi pabrik aluminium sulfat ................... 119 Gambar 6.3 Cash Flow pabrik aluminium sulfat ............................................... 120
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