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PRA RANCANGAN PEMBUATAN GLUKOSA MONOHIDRAT

DARI UBI KAYU (CASSAVA) DENGAN KAPASITAS

PRODUKSI 9.400 TON/TAHUN

TUGAS AKHIR

Diajukan untuk Memenuhi Persyaratan Ujian Sarjana Sains Terapan

OLEH :

NIM : 035201043

REHULINA SEMBIRING

DEPARTEMEN TEKNIK KIMIA

PROGRAM STUDI TEKNOLOGI KIMIA INDUSTRI

FAKULTAS TEKNIK

UNIVERSITAS SUMATERA UTARA

MEDAN

2008

Universitas Sumatera Utara



INTISARI

Pati adalah salah satu jenis polisakarida yang amat luas tersebar di alam. Pati

disimpan sebagai cadangan makanan bagi tumbuhan di dalam biji buah (padi, jagung), di

dalam umbi (ubi kayu, ubi jalar, garut) dan pada batang (sagu, aren). Peranan ubi kayu

sebagai bahan baku sangat banyak dibutuhkan, karena dewasa ini banyak industri kecil

maupun industri besar menggunakan ubi kayu sebagai bahan baku dari produk yang

dihasilkan, misalnya sebagai bahan pakan, industri pati, industri sirup glukosa, dan

industri yang merupakan gula cair. Pra-rancangan pabrik pembuatan Glukosa Monohidrat

ini dibuat dengan proses hidrolisa dengan cara mengasamkan suspensi pati.

Direncanakan Pabrik Glukosa Monohidrat ini memproduksi sekitar 9.400

ton/tahun dengan 300 hari kerja dalam satu tahun. Lokasi pabrik direncanakan di

Labuhan Deli, Sumatera Utara dengan luas areal 10.000 m2

• Modal Investasi = Rp. 286.321.678.504,-

, tenaga kerja yang

dibutuhkan berjumlah 100 orang dengan bentuk badan usaha Perseroan Terbatas (PT)

yang dipimpin oleh seorang General Manager dengan struktur oganisasi sistem garis dan

staf.

Hasil ekonomi Pabrik Pembuatan Glukosa Monohidrat dari Ubi Kayu (Cassava)

adalah sebagai berikut :

• Biaya Produksi = Rp. 67.987.316.760,-

• Laba Bersih = Rp. 80.736.356.428,-

• Profit Margin = 62,91 %

• Break Even Point (BEP) = 30,79 %

• Return On Investment (ROI) = 28,20 %

• Pay Out Time (POT) = 3,5 tahun

• Return On Network (RON) = 40,33 %

• Internal Rate of Return (IRR) = 35,17 %




DAFTAR ISI

KATA PENGANTAR .................................................................................... i

INTI SARI ...................................................................................................... iii

DAFTAR ISI ................................................................................................... iv

DAFTAR TABEL .......................................................................................... ix

DAFTAR GAMBAR ...................................................................................... xi

BAB I PENDAHULUAN ............................................................................... I-1

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

1.2 Perumusan Masalah .......................................................................... I-2

1.3 Tujuan Perancangan .......................................................................... I-2

1.4 Manfaat Perancangan ........................................................................ I-3

BAB II TINJAUAN PUSTAKA DAN DESKRIPSI PROSES ................... II-1

2.1 Pemanfaatan Ubi Kayu ..................................................................... II-1

2.2 Pati .................................................................................................... II-2

2.3 Uraian Proses .................................................................................... II-32.4 Spesifikasi Bahan Baku dan Produk ................................................. II-4

2.4.1 Bahan Baku ................................................................................. II-4

2.4.2 Produk ......................................................................................... II-5

BAB III NERACA MASSA ........................................................................... III-1

3.1 Neraca Massa Rotary Cooler (CO) ................................................... III-1

3.2 Neraca Massa Mixer (MX) ................................................................ III-1

3.3 Neraca Massa Reaktor Hidrolisa (RH) ............................................. III-2

3.4 Neraca Massa Filter Press-01 (FP-01) ............................................. III-2

3.5 Neraca Massa Reaktor Netralisasi (RN) ........................................... III-2

3.6 Neraca Massa Tangki Dekanter (DK) .............................................. III-3

3.7 Neraca Massa Tangki Decolorizing (TD) ......................................... III-3

3.8 Neraca Massa Filter Press 02 (FP-02) ............................................. III-3

3.9 Neraca Massa Evaporator (EV) ........................................................ III-3

3.10 Neraca Massa Crystalizer (CR)....................................................... III-4




3.11 Neraca Massa Screw Conveyor (SC)............................................... III-4

3.12 Neraca Massa Rotary Dryer (RD)................................................... III-4

BAB IV NERACA PANAS ............................................................................ IV-1

4.1 Neraca Panas Mixer (MX) ................................................................ IV-1

4.2 Neraca Panas Reaktor Hidrolisa (RH) .............................................. IV-1

4.3 Neraca Panas Cooler (CO)................................................................ IV-2

4.4 Neraca Panas Filter Press-01 (FP-01) .............................................. IV-2

4.5 Neraca Panas Reaktor Netralisasi (RN) ............................................ IV-2

4.6 Neraca Panas Tangki Dekanter (DK) ................................................ IV-3

4.7 Neraca Panas Tangki Decolorizing (TD) ......................................... IV-3

4.8 Neraca Panas Filter Press 02 (FP-02) .............................................. IV-3

4.9 Neraca Panas Evaporator (EV) ......................................................... IV-3

4.10 Neraca Panas Crystalizer (CR)........................................................ IV-4

4.11 Neraca Panas Screw Conveyor (SC) ............................................... IV-4

4.12 Neraca Panas Rotary Dryer (RD).................................................... IV-4

4.13 Neraca Panas Rotary Cooler (RC) .................................................. IV-4

BAB V SPESIFIKASI PERALATAN .......................................................... V-1

5.1 Gudang Bahan Baku (GBB).............................................................. V-1

5.2 Tangki HCl (T-01) ............................................................................ V-1

5.3 Tangki NaOH (T-02)......................................................................... V-2

5.4 Mixer (MX) ....................................................................................... V-3

5.5 Reaktor Hidrolisa (RH) .................................................................... V-3

5.6 Cooler (CO) ...................................................................................... V-4

5.7 Filter Press 01 (FP-01) .................................................................... V-5

5.8 Reaktor Netralisasi (RN) .................................................................. V-5

5.9 Tangki Dekanter (DK)....................................................................... V-6

5.10 Tangki Decolorizing (TD) ............................................................... V-6

5.11 Filter press 02 (FP-02) .................................................................. V-7

5.12 Tangki Evaporator (EV) .................................................................. V-7

5.13 Crystalizer (CR) .............................................................................. V-8

5.14 Screw Conveyor (SC) ..................................................................... V-8

5.15 Rotary Dryer (RD) .......................................................................... V-9




5.16 Rotary Cooler (RC) ......................................................................... V-9

5.17 Gudang Produk (GP) ...................................................................... V-9

5.18 Tangki N 2 (T-03) ............................................................................. V-10

5.19 Belt Conveyor (BC-01) .................................................................... V-10

5.20 Bucklet Elevator-01 (BE-01) ........................................................... V-11

5.21 Belt Conveyor (BC-02) ................................................................... V-11



5.24 Bucklet Elevator-02 (BE-02) .......................................................... V-12

5. 25 Pompa HCl (P-01) ........................................................................ V-13

5.26 Pompa Mixer (P-02) ...................................................................... V-13

5.27 Pompa Cooler (P-03) ..................................................................... V-13

5.28 Pompa Filter Press 01 (P-04) ........................................................ V-13

5.29 Pompa Reaktor Netralisasi (P-05) ................................................. V-14

5.30 Pompa Dekanter (P-06) ................................................................. V-14

5.31 Pompa NaOH (P-07) ...................................................................... V-14

5.32 Pompa Decolorizing (P-08) ........................................................... V-14

5.33 Pompa Umpan Evaporator (P-09) ................................................. V-15

5.34 Pompa Evaporator (P-10) .............................................................. V-15

BAB VI INSTRUMENTASI DAN KESELAMATAN KERJA ................. VI-1

6.1 Instrumentasi ..................................................................................... VI-8

6.2 Keselamatan Kerja ............................................................................ VI-9

6.2.1 Pencegahan terhadap Bahaya Kebakaran dan Peledakan ........... VI-10

6.2.2 Peralatan Perlindungan Diri ........................................................ VI-10

6.2.3 Keselamatan Kerja Terhadap Listrik .......................................... VI-11

6.2.4 Pencegahan Terhadap Gangguan Kesehatan .............................. VI-11

6.2.5 Pencegahan Terhadap Bahaya Mekanis ...................................... VI-11

BAB VII UTILITAS DAN PENGOLAHAN LIMBAH ............................. VII-1

7.1 Kebutuhan Air ................................................................................... VII-1

7.1.1 Screening ..................................................................................... VII-6

7.1.2 Klarifikasi .................................................................................... VII-6




7.1.3 Filtrasi ......................................................................................... VII-7

7.1.4 Demineralisasi ............................................................................ VII-8

7.1.5 Deaerator ..................................................................................... VII-11

7.2 Kebutuhan Bahan Kimia ................................................................... VII-11

7.3 Kebutuhan Listrik.............................................................................. VII-12

7.4 Kebutuhan Bahan Bakar ................................................................... VII-12

7.5 Unit Pengolahan Limbah................................................................... VII-14

7.5.1 Pengolahan Limbah dengan Sistem Activated Sludge

(Lumpur Aktif) ........................................................................... VII-15

BAB VIII LOKASI DAN TATA LETAK PABRIK ................................... VIII-18.1 Lokasi Pabrik .................................................................................... VIII-1

8.1.1 Faktor Utama ............................................................................... VIII-1

8.1.2 Faktor Khusus ............................................................................. VIII-2

8.2 Tata Letak Pabrik .............................................................................. VIII-3

8.3 Perincian Luas Tanah ........................................................................ VIII-4

BAB IX ORGANISASI DAN MANAJEMEN PERUSAHAAN ................ XI-1

9.1 Organisasi Perusahaan ...................................................................... IX-1

9.2Manajemen Perusahaan ...................................................................... IX-3

9.3 Bentuk Hukum Badan Usaha ............................................................ IX-4

9.4 Uraian Proses .................................................................................... IX-5

9.4.1 General Manager ......................................................................... IX-5

9.4.2 Manajer Finansial dan Marketing ............................................... IX-6

9.4.3 Manajer SDM/Umum ................................................................. IX-6

9.4.4 Manajer Produksi ........................................................................ IX-6

9.4.5 Manajer Teknik ........................................................................... IX-6

9.4.6 Kepala Seksi Pembelian .............................................................. IX-7

9.4.7 Kepala Seksi Marketing ............................................................. IX-7

9.4.8 Kepala Seksi Personalia .............................................................. IX-7

9.4.9 Kepala Seksi General Affair ....................................................... IX-7

9.4.10 Kepala Seksi Keamanan ............................................................ IX-7

9.4.11 Kepala Seksi Instrumentasi ....................................................... IX-7




9.4.12 Kepala Seksi Maintanance dan Listrik ...................................... IX-8

9.4.13 Kepala Seksi Proses .................................................................. IX-8

9.4.14 Kepala Seksi Utilitas ................................................................. IX-8

9.4.15 Kepala Seksi Laboratorium ....................................................... IX-8

9.5 Tenaga Kerja dan Jam Kerja ............................................................. IX-8

9.5.1 Jumlah dan Tingkat Pendidikan Tenaga Kerja ........................... IX-8

9.5.2 Pengaturan Jam Kerja ................................................................. IX-9

9.6 Kesejahteraan Tenaga Kerja .......................................................... IX-11

BAB X ANALISA EKONOMI ..................................................................... X-1

10.1 Modal Investasi ............................................................................... X-110.1.1 Modal Investasi Tetap / Fixed Capital Investment (FCI).......... X-1

10.1.2 Modal Kerja / Working Capital (WC) ...................................... X-2

10.2 Biaya Produksi Total (BPT) / Total Cost (TC) ............................... X-4

10.2.1 Biaya Tetap (BT) / Fixed Cost (FC) ......................................... X-4

10.2.2 Biaya Variabel (BV) / Variable Cost (VC) ............................... X-4

10.3 Total Penjualan (Total Sales) .......................................................... X-5

10.4 Perkiraan Rugi/Laba Usaha............................................................. X-5

10.5 Analisa Aspek Ekonomi .................................................................. X-5

10.5.1 Profit Margin (PM) ...................................................................... X-5

10.5.2 Break Even Point (BEP)............................................................... X-5

10.5.3 Return on Investment (ROI) ......................................................... X-6

10.5.4 Pay Out Time (POT) .................................................................... X-6

10.5.5 Return on Network (RON) ........................................................... X-7

10.5.6 Internal Rate of Return (IRR) ...................................................... X-7

BAB XI KESIMPULAN ................................................................................ XI-1

DAFTAR PUSTAKA

LAMPIRAN A PERHITUNGAN NERACA MASSA ................................ LA-1

LAMPIRAN B PERHITUNGAN NERACA PANAS ................................. LB-1

LAMPIRAN C SPESIFIKASI ALAT .......................................................... LC-1

LAMPIRAN D SPESIFIKASI PERALATAN UTILITAS ........................ LD-1

LAMPIRAN E ANALISA EKONOMI ........................................................ LE-1




DAFTAR TABEL

Tabel 1.1 Data Glukosa Monohidrat di Indonesia ...................................... I-2

Tabel 2.1 Kandungan Zat Racun pada Ubi Kayu ....................................... II-1

Tabel 2.2 Standart Kualitas Ubi Kayu ......................................................... II-2

Tabel 2.3 Komposisi Kimia Beberapa Bagian Hasil Tanaman Kayu dan

Tepung Tapioka ........................................................................... II-5

Tabel 3.1 Neraca Massa Rotary Cooler (CO) ............................................... III-1

Tabel 3.2 Neraca Massa Mixer (MX) ............................................................ III-1

Tabel 3.3 Neraca Massa Reaktor Hidrolisa (RH) ......................................... III-2

Tabel 3.4 Neraca Massa Filter Press-01 (FP-01) ......................................... III-2

Tabel 3.5 Neraca Massa Reaktor Netralisasi (RN) ....................................... III-2

Tabel 3.6 Neraca Massa Tangki Dekanter (DK)........................................... III-3

Tabel 3.7 Neraca Massa Tangki Decolorizing (TD) ..................................... III-3

Tabel 3.8 Neraca Massa Filter Press 02 (FP-02)..........................................III-3

Tabel 3.9 Neraca Massa Evaporator (EV) .................................................... III-3

Tabel 3.10 Neraca Massa Crystalizer (CR) ...................................................III-4

Tabel 3.11 Neraca Massa Screw Conveyor (SC)........................................... III-4

Tabel 3.12 Neraca Massa Rotary Dryer (RD) ............................................... III-4

Tabel 4.1 Neraca Panas Mixer (MX) ............................................................ IV-1

Tabel 4.2 Neraca Panas Reaktor Hidrolisa (RH) ......................................... IV-1

Tabel 4.3 Neraca Panas Cooler (CO) ............................................................ IV-2

Tabel 4.4 Neraca Panas Filter Press-01 (FP-01).......................................... IV-2

Tabel 4.5 Neraca Panas Reaktor Netralisasi (RN) ....................................... IV-2

Tabel 4.6 Neraca Panas Tangki Dekanter (DK) ........................................... IV-3

Tabel 4.7 Neraca Panas Tangki Decolorizing (TD) ..................................... IV-3

Tabel 4.8 Neraca Panas Filter Press 02 (FP-02) .......................................... IV-3

Tabel 4.9 Neraca Panas Evaporator (EV)..................................................... IV-3

Tabel 4.10 Neraca Panas Crystalizer (CR).................................................... IV-4

Tabel 4.11 Neraca Panas Screw Conveyor (SC) ........................................... IV-4

Tabel 4.12 Neraca Panas Rotary Dryer (RD)................................................ IV-4

Tabel 4.13 Neraca Panas Rotary Cooler (RC) .............................................. IV-4




Tabel 7.1 Kebutuhan Air Proses Pada Berbagai Alat ................................ VII-2

Tabel 7.2 Kebutuhan Uap Sebagai Media Pemanas Pada Berbagai Alat VII-3

Tabel 7.3 Kebutuhan Air Pendingin Pada Berbagai Alat .......................... VII-3

Tabel 7.4 Pemakaian Air Untuk Berbagai Kebutuhan .............................. VII-4

Tabel 7.5 Kualitas Air Sungai Deli ............................................................... VII-5

Tabel 7.6 Kebutuhan Bahan Kimia .............................................................. VII-11

Tabel 7.7 Kebutuhan Listrik ......................................................................... VII-12

Tabel 8.1 Perincian Luas Tanah Pabrik Pembuatan Glukosa Monohidrat VIII-4

Tabel 9.1 Jumlah Tenaga Kerja Beserta Tingkat Pendidikannya ............ IX-9

Tabel 9.2 Jadwal Kerja Karyawan Shift...................................................... IX-10




DAFTAR GAMBAR

Gambar 6.1 Tangki Penyimpanan Beserta Instrumennya ........................ VI-4

Gambar 6.2 Reaktor Beserta Instrumennya ............................................... VI-5

Gambar 6.3 Filter press Beserta Instrumennya .......................................... VI-5

Gambar 6.4 Evaporator Beserta Instrumennya .......................................... VI-6

Gambar 6.5 Pompa Beserta Instrumennya ................................................ VI-6

Gambar 6.6 Cooler Beserta Instrumennya ................................................ VI-7

Gambar 6.7 Rotary Dryer Beserta Instrumennya....................................... VI-7

Gambar 7.1 Flow Diagram Penolahan Limnah Secara Activated Sludge VII-16

Gambar 8.1 Tata Letak Pabrik Glukosa Monohidrat ................................ VIII-5

Gambar 9.1 Struktur Organisasi Pabrik Glukosa Monohidrat ................ IX-12


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