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LAPORAN TUGAS AKHIR
PRARANCANGAN PABRIK ASAM OKSALAT DIHYDRATE
DARI MOLASSES DAN ASAM NITRAT
KAPASITAS 17.000 TON/TAHUN
Oleh :
FITRIYANI ARISKA PUTRI
D 500 110 015
Dosen Pembimbing :
Ir. Ahmad M. Fuadi, M.T., Ph.D.
Emi Erawati, S.T., M.Eng.
JURUSAN TEKNIK KIMIA FAKULTAS TEKNIK
UNIVERSITAS MUHAMMADIYAH SURAKARTA
2017
iv
INTISARI
Di era kemajuan teknologi di berbagai bidang pembangunan yang sedang
berjalan pesat, salah satu prospek pembangunan masa depan yaitu membangun pabrik
yang mempunyai daya saing dengan produk-produk luar negeri. Salah satunya yaitu
dengan membangun pabrik asam oksalat. Asam oksalat termasuk kedalam asam
dikarboksilat yang paling sederhana (HOOC-COOH). Asam oksalat dihidrat
(C2H2O4-H2O). Asam oksalat merupakan bahan kimia intermediat (bahan antara)
dalam bahan pencampuran zat warna dalam industri tekstil dan cat, menetralkan
kelebihan alkali pada pencucian dan sebagai bleaching. Asam oksalat pada industri
logam digunakan sebagai bahan pelapis logam dari kerak. Sedangkan dalam pabrik
polimer dipakai sebagai inisiator.
Pabrik ini beroperasi dengan kapasitas 17.000 ton/tahun, dengan
pertimbangan dapat memenuhi kebutuhan dalam negeri dan mengurangi
ketergantungan import. Bahan baku yang digunakan dalam perancangan ini adalah
molasses 727,08397 kg/jam dan asam nitrat (HNO3) 1606,13340 kg/jam dengan
bantuan katalis asam sulfat (H2SO4) 460,11965 kg/jam dan vanadium pentoksida
(V2O5) 0,04601 kg/jam. Reaksi ini berlangsung pada fase cair-cair, reversible,
eksotermis, dan bersifat nonisothermal dalam reaktor CSTR dengan kondisi operasi
suhu 71oC dan tekanan 1 atm. Untuk menunjang proses produksi, maka perlu
didirikan unit pendukung proses atau utilitas yang meliputi unit penyediaan air
sebesar 445.064,654 kg/jam, listrik yang dipelukan sebesar 1324,22655 kW, udara
tekan sebesar 150 m3/jam, dan kebutuhan bahan bakar sebesar 908,679 liter/jam serta
laboratorium.
Perancangan pabrik asam oksalat dihidrat dengan luas area sebesar 9600 m2
direncanakan akan dibangun pada tahun 2020 dan berlokasi di Gresik, Jawa Timur.
Pabrik asam oksalat ini berbentuk perseroan terbatas (PT) dengan sistem organisasi
line dan staff. Dengan jumlah karyawan yang dibutuhkan 115 orang dimana sistem
kerja yang terdiri dari karyawan shift dan non-shift. Dari analisa ekonomi yang
dilakukan terhadap pabrik ini dengan modal tetap Rp 95.761.307.111 dan modal kerja
pabrik sebesar Rp 64.759.961.590 diperoleh Return of Investment (ROI) sebelum
pajak yaitu 32,5% dan setelah pajak adalah 24,4%. Sedangkan Pay Out Time (POT)
sebelum dan sesudah pajak yaitu 2,35 tahun dan 2,91 tahun. Break Event Point dan
Shut Down Point sebesar 42,45% dan 22,96%. Untuk Discounted Cash Flow (DCF)
terhitung sebesar 37,64%. Berdasarkan perhitungan analisa ekonomi maka dapat
disimpulakan bahwa pabri ini layak didirikan.
Abstract
In the era of technological advances in various fields of rapid development, one of the future
development prospects of building a factory that has competitiveness with overseas products.
One of them is by building a plant oxalic acid. Oxalic acid is included in the simplest
dicarboxylic acid (HOOC-COOH). The design of oxalic acid dihydrate plant with an area of
9600 m2 is planned to be built in 2020 and located in Gresik, East Java. The plant operates
with a capacity of 17,000 tons / year, with consideration to meet domestic demand and reduce
import dependence. The raw materials used in this design are molasses 727,08397 kg / hr and
nitric acid (HNO3) 1606,13340 kg / hr with the help of catalyst (H2SO4) 460,11965 kg / h
and (V2O5) 0.04601 kg / hr. This reaction takes place in the liquid-liquid phase, reversible,
exothermic, and nonisothermal in a CSTR reactor with operating conditions of temperature
71oC and 1 atm pressure. To support the production process, it is necessary to establish a
process support unit or utility which includes a water supply unit of 445,064,654 kg / hour,
the required electricity of 1324,22655 kW, compressed air of 150 m3 / hour, and fuel
requirement of 908,679 liters / Hr and laboratory. With the number of employees required
115 people where the work system consisting of employees shift and non-shift. From the
economic analysis conducted on this factory with fixed capital Rp 95.761.307.111 and
working capital of factory Rp 64.759.961.590 obtained Return of Investment (ROI) before
tax is 32,5% and after tax is 24,4%. While Pay Out Time (POT) before and after taxes are
2.35 years and 2.91 years. Break Event Point and Shut Down Point by 42.45% and 22.96%.
For Discounted Cash Flow (DCF) accounted for 37.64%. Based on the calculation of
economic analysis it can be concluded that this factory worthy established.
Keywords: Dihydrate Oxalic Acid, Oxidation Process of Nitrate Acid, CSTR
v
MOTTO
“Jadikanlah sabar dan sholat sebagai penolongmu. Dan sesungguhnya yang demikian
itu sungguh berat kecuali bagi orang-orang yang khusyu.”
(Q.S Al Baqarah: 45)
“Sesungguhnya bersama kesulitan dan kemudahan. Maka apabila engkau telah selesai
(dari suatu urusan), teteplah bekerja kerja keras (untuk urusan yang lain). Dan hanya
kepada Tuhanmulah engkau berharap ”
(Q.S Al-Insyirah: 6-8)
“Allah akan meninggikian orang-orang beriman diantaramu dan orang-orang yang
diberi ilmu pengetahuan beberapa derajat”
(Q.S Al-Mujadalah: 11)
Sebaik-baik manusia adalah orang yang paling bermanfaat bagi orang lain”
(HR. Ahmad)
“Boleh jadi kamu membenci sesuatu, padahal ia amat baik bagimu dan boleh jadi
(pula) kamu menyukai sesuatu padahal ia amat buruk bagimu. Allah mengetahui
sedang kamu tidak mengetahui “
(QS. 2 :216)
ivi
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:
Ibu, Bapak dan Adik-adikku tercinta yang telah memberikan dukungan dan
semangat sehingga saya bisa menyelesaikan tugas akhir ini.
Partnerku Efany Sara, terima kasih telah menjadi partner TPP ku. Terima kasih
untuk kesabaran, persahabatan dan kerjasamanya untuk menyelesaikan tugas
akhir ini.
Sahabatku tercinta Diah,Erlin,Warih,Ayu,Ika,Devi,Sima,Nur,Lusti yang selalu
setia menyemangatiku dan membantuku jika aku mengalami kesulitan dalam
mengerjakan TPP ini.
Ikatan Mahasiswa Muhammadiyah Komisariat Averroes dan Koordinator
Komisariat IMM UMS yang sudah memberikan banyak pengalaman, pelajaran,
dan kenangan yang mendalam untuk saya.
Sahabat Teknik Kimia 2011 yang telah bersama-sama dalam perkuliahan yang
menyenangkan. Terima kasih atas doa dan semangat dari kalian semua. Semoga
kita semua menjadi orang-orang yang sukses duania akhirat dan bisa
bermanfaat untuk sesama.
vii
KATA PENGANTAR
Puji syukur kehadirat Allah SWT berkat limpahan rahmat dan hidayah-Nya
penulis dapat menyelesaikan tugas akhir ini yang berjudul “Prarancangan Pabrik
Asam Oksalat Dihydrate dari Molasses dan Asam Nitrat dengan Kapasitas
17.000 Ton per Tahun”. Tidak lupa sholawat serta salam senantiasa tercurahkan
kepada nabi besar Muhammad SAW, keluarga, sahabat, dan para pengikut –
pengikutnya.
Tugas Prarancangan Pabrik ini merupakan salah satu syarat yang wajib
ditempuh untuk menyelesaikan proram statra-1 jurusan Teknik Kimia, Fakultas
Teknik, Universitas Muhammadiyah Surakarta.
Pada kesempatan ini, penulis mengucapkan 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. Allah SWT yang telah melimpahkan rizki dan karunia-Nya
2. Rois Fatoni, S.T., M.Sc., Ph.D selaku kepala jurusan Teknik Kimia
3. Ir.Ahmad M. Fuadi, M.T., Ph.D selaku dosen pembimbing 1 yang selalu sabar
membimbing dan memberi arahan selama proses pembuatan TPP.
4. Emi Erawati, S.T.,M.Eng selaku dosen pembimbing 2 yang selalu sabar
membimbing dan memberi arahan selama proses pembuatan TPP.
5. Seluruh dosen dan staf karyawan Teknik Kimia Universitas Muhammadiyah
Surakarta
6. Bapak dan ibu tercinta, yang telah memberikan doa, kasih sayang, perhatian,
dan dukungan secara matererial maupun spiritual.
7. Segenap civitas akademika dan teman-teman mahasiswa Teknik Kimia FT
Universitas Muhammadiyah Surakarta khususnya angkatan 2011.
viii
Penulis menyadari bahwa dalam penyusunan Laporan Pnelitian ini masih jauh
dari sempurna. Untuk itu penulis mengharapkan saran dan kritik yang membangun
untuk kesempurnaan laporan ini
Surakarta, April 2017
Penulis
x
DAFTAR ISI
HALAMAN JUDUL ........................................................................................................ ..... i
HALAMAN PENGESAHAN .............................................................................................. ii
PERNYATAAN KEASLIAN SKRIPSI ............................................................................ iii
INTISARI ............................................................................................................................. iv
MOTTO ................................................................................................................................. v
PERSEMBAHAN ................................................................................................................ vi
KATA PENGANTAR ...................................................................................................... ... vii
DAFTAR ISI .................................................................................................................. ..... viii
DAFTAR TABEL ............................................................................................................... xiii
DAFTAR GAMBAR ........................................................................................................... xv
BAB I PENDAHULUAN ............................................................................................... .... 1
1.1 Latar Belakang Pendirian Pabrik ....................................................................... 1
1.2 Kapasitas Pabrik ................................................................................................ 2
1.3 Penentuan Lokasi Pabrik ................................................................................... 5
1.4 Tinjauan Pustaka ............................................................................................... 7
1.4.1 Macam-macam proses .................................................................................... 8
1.4.2 Kegunaan produk .......................................................................................... 10
1.4.3 Sifat fisis dan kimia bahan baku dan produk ................................................ 12
1.5 Tinjauan Proses ............................................................................................... 15
BAB II DESKRIPSI PROSES ......................................................................................... 17
2.1 Spesifikasi Bahan Baku dan Produk ................................................................ 17
2.1.1 Bahan baku ........................................................................................ 17
2.1.2 Spesifikasi katalis .............................................................................. 18
2.1.3 Spesifikasi produk ............................................................................. 19
2.2 Konsep Dasar ................................................................................................... 19
2.2.1 Dasar reaksi ....................................................................................... 19
2.2.2 Fase reaksi ......................................................................................... 19
2.2.3 Kondisi operasi .................................................................................. 17
2.2.4 Tinjauan kinetika ............................................................................... 20
2.2.5 Tinjauan termodinamika .................................................................... 21
2.3 Diagram Alir Proses ......................................................................................... 23
2.3.1 Langkah proses .................................................................................. 23
2.3.1.1 Tahap persiapan bahan baku ............................................................. 24
2.3.1.2 Tahap reaksi pembentukan asam oksalat ........................................... 25
xi
2.3.1.3 Tahap pengkristalan asam oksalat ...................................................... 26
2.3.1.4 Tahap pengeringan asam oksalat ....................................................... 26
2.3.1.5 Tahap pengemasan asam oksalat ....................................................... 27
2.3.2 Diagram alir proses ............................................................................ 27
2.4 Nearca Massa dan Neraca Panas ........................................................................ 29
2.4.1 Neraca massa ..................................................................................... 29
2.4.2 Neraca panas ...................................................................................... 38
2.5 Tata Letak Peralatan ........................................................................................... 45
2.5.1 Tata letak pabrik ............................................................................... 45
2.5.2 Tata letak peralatan proses ............................................................... 49
BAB III SPESIFIKASI ALAT PROSES ........................................................................... 52
3.1 Absorber ............................................................................................................ 52
3.2 Akumulator ........................................................................................................ 52
3.3 Belt Conveyor 1 .................................................................................................. 53
3.4 Belt Conveyor 2 .................................................................................................. 53
3.5 Belt Conveyor 3 .................................................................................................. 54
3.6 Bin Produk ......................................................................................................... 54
3.7 Blower 1 ............................................................................................................. 55
3.8 Blower 2 .............................................................................................................. 55
3.9 Bucket Elevator 1 ............................................................................................... 56
3.10 Bucket Elevator 2 ............................................................................................... 56
3.11 Centrifuge 1 ........................................................................................................ 56
3.12 Centrifuge 2 ........................................................................................................ 57
3.13 Centrifuge 3 ......................................................................................................... 58
3.14 Evaporator ........................................................................................................... 58
3.15 Filter Udara ........................................................................................................ 60
3.16 Heat Exchanger .................................................................................................. 61
3.17 Condensor ........................................................................................................... 65
3.18 Kristalizer 1 ........................................................................................................ 66
3.19 Kristalizer 2 ......................................................................................................... 67
3.20 Menara Distilasi ................................................................................................. 67
3.21 Mother Liquor Tank ............................................................................................ 68
3.22 Pompa ................................................................................................................. 69
3.23 Reaktor ................................................................................................................ 77
3.24 Rotary Dryer ....................................................................................................... 78
3.25 Tangki Redisolving ............................................................................................. 79
3.26 Tangki Penyimpanan .......................................................................................... 80
3.27 Reaktor Pipa ( Plug Flow Reactor) ..................................................................... 83
BAB IV UNIT PENDUKUNG PROSES ......................................................................... 84
4.1 Unit Pendukung Proses (utilitas) .......................................................................... 85
4.1.1 Unit pengadaan air ............................................................................. 86
4.1.2 Unit pengadaan steam ....................................................................... 94
xii
4.1.3 Unit pengadaan listrik ........................................................................ 97
4.1.4 Unit pengadaan bahan bakar ............................................................ 101
4.2 Laboratorium ................................................................................................. .... 103
4.2.1 Laboratorium fisik ........................................................................... 103
4.2.2 Laboratorium analitik ...................................................................... 103
4.2.3 Laboratorium penelitian dan pengembangan .................................. 103
4.2.4 Analisa air ....................................................................................... 103
4.2.5 Analisa sampel ................................................................................ 103
4.3 Unit Pengolahan Limbah ................................................................................... 104
BAB V MANAJEMEN PERUSAHAAN ...................................................................... 105
5.1 Bentuk Perusahaan ............................................................................................ .105
5.2 Struktur Organisasi ........................................................................................... .106
5.2.1 Pemegang saham .............................................................................. 106
5.2.2 Dewan komisaris .............................................................................. 107
5.2.3 Direktur .......................................................................................... ..107
5.2.4 Kepala bagian ................................................................................ ..108
5.2.5 Karyawan ........................................................................................ 109
5.2.6 Sekretaris ......................................................................................... 111
5.2.7 Staf ahli ........................................................................................... 111
5.3 Sistem Kepegawaian dan Sistem Gaji ........................................................... ....111
5.4 Pembagian Jam Kerja Karyawan ................................................................. .... 112
5.4.1 Karyawan non shift ......................................................................... 112
5.4.2 Karyawan shift ................................................................................ 112
5.5 Status Karyawan dan Sistem Upah ................................................................... 113
5.6 Penggolongan Jabatan, Jumlah Karyawan, dan Gaji ........................................ 114
5.6.1 Penggolongan jabatan ...................................................................... 114
5.6.2 Jumlah karyawan dan gaji ............................................................... 115
5.7 Kesejahteraan Sosial Karyawan ........................................................................ 117
5.8 Kesehatan dan Keselamatan Kerja .................................................................... 117
5.9 Manajemen Produksi ......................................................................................... 117
5.9.1 Perencanaan produksi ...................................................................... 118
5.9.2 Pengendalian produksi ..................................................................... 119
BAB VI ANALISA EKONOMI .................................................................................... 121
6.1 Dasar Perhitungan .............................................................................................. 121
6.2 Perhitungan biaya .............................................................................................. 123
6.2.1 Investasi modal (Capital Investment) .............................................. 123
6.2.2 Biaya produksi (Manufacturing Cost) ..............................................124
6.2.3 Pengeluaran umum (General Expenses) .......................................... 124
6.3 Analisis Kelayakan ............................................................................................ 124
6.3.1 Percent return on investment (ROI) ................................................ 125
6.3.2 Pay out time (POT) ......................................................................... 125
6.3.3 Break even point (BEP) ................................................................... 125
xiii
6.3.4 Shut down point (SDP) ................................................................... 126
6.3.5 Discounted cash flow ...................................................................... 126
6.4 Hasil Perhitungan .............................................................................................. 126
6.4.1 Total fixed capital investment ......................................................... 126
6.4.2 Working capital ............................................................................... 127
6.4.3 Total capital investment (TCI) ........................................................ 127
6.4.4 Direct anufacturing cost .................................................................. 127
6.4.5 Inderect manufacturing cost .............................................................127
6.4.6 Fixed manufacturing cost ................................................................ 128
6.4.7 Total manufacturing cost (TMC) ..................................................... 128
6.4.8 General expenses ............................................................................. 128
6.4.9 Total prodution cost (TPC) .............................................................. 129
6.4.10 Analisis kelayakan ............................................................................130
KESIMPULAN .................................................................................................................. 131
DAFTAR PUSTAKA
LAMPIRAN
DIAGRAM ALIR PROSES
xiv
DAFTAR TABEL
Tabel 1.1 Data Impor Asam Oksalat .................................................................................... 3
Tabel 1.2 Penawaran dan Permintaan Asam Oksalat pada Tahun 1992(ton) ....................... 4
Tabel 1.3 Kapasitas Produksi Industri Asam Oksalat yang Ada .......................................... 5
Tabel 2.1 Data ∆G dan ∆H masing-masing komponen ........................................................ 22
Tabel 2.2 Neraca Massa Total Masuk .................................................................................. 29
Tabel 2.3 Neraca Massa Total Keluar .................................................................................. 30
Tabel 2.4 Neraca Massa di Tangki Treatment Molasses ...................................................... 31
Tabel 2.5 Neraca Massa di Centrifuge 1................................................................................ 31
Tabel 2.6 Neraca Massa di Reaktor ....................................................................................... 32
Tabel 2.7 Neraca Massa di Kristalizer 1................................................................................. 32
Tabel 2.8 Neraca Massa di Centrifuge 2 ................................................................................ 33
Tabel 2.9 Neraca Massa di Tangki Redisolving .................................................................... 33
Tabel 2.10 Neraca Massa di Kristalizer 2 .............................................................................. 34
Tabel 2.11 Neraca Massa di Centrifuge 3 ............................................................................. 34
Tabel 2.12 Neraca Massa di Rotary Dryer ............................................................................ 35
Tabel 2.13 Neraca Massa di MLT ......................................................................................... 35
Tabel 2.14 Neraca Massa di Evaporator ............................................................................... 36
Tabel 2.15 Neraca Massa di WHB ....................................................................................... 36
Tabel 2.16 Neraca Massa di Absorber .................................................................................. 37
Tabel 2.17 Neraca Massa di Menara Distilasi ...................................................................... 37
Tabel 2.18 Neraca Panas di Tangki Treatment Molasses ..................................................... 38
Tabel 2.19 Neraca Panas di Centrifuge 1 .............................................................................. 38
Tabel 2.20 Neraca Panas di Reaktor ..................................................................................... 39
Tabel 2.21 Neraca Panas di Kristalizer 1 .............................................................................. 39
Tabel 2.22 Neraca Panas di Centrifuge 2 .............................................................................. 40
Tabel 2.23 Neraca Panas di Tangki Redisolving .................................................................. 40
Tabel 2.24 Neraca Panas di Kristalizer 2 .............................................................................. 41
Tabel 2.25 Neraca Panas di Centrifuge 3 .............................................................................. 41
xv
Tabel 2.26 Neraca Panas di Rotary Dryer ............................................................................ 42
Tabel 2.27 Neraca Panas di MLT ......................................................................................... 42
Tabel 2.28 Neraca Panas di Evaporator ................................................................................ 43
Tabel 2.29 Neraca Panas di WHB ........................................................................................ 43
Tabel 2.30 Neraca Panas di Absorber ................................................................................... 44
Tabel 2.31 Neraca Panas di Menara Distilasi ........................................................................ 44
Tabel 2.32 Luas Bangunan Pabrik ......................................................................................... 47
Tabel 4.1 Kebutuhan air untuk pendingin .............................................................................. 93
Tabel 4.2 Kebutuhan air untuk umpan boiler ......................................................................... 93
Tabel 4.3 Kebutuhan air untuk perkantoran dan pabrik ......................................................... 94
Tabel 4.4 Kebutuhan air proses .............................................................................................. 94
Tabel 4.5 Kebutuhan Listrik Proses ....................................................................................... 97
Tabel 4.6 Kebutuhan Listrik Utilitas ...................................................................................... 98
Tabel 4.7 Kebutuhan Listrik untuk Penerangan ..................................................................... 99
Tabel 4.8 Total Kebutuhan Listrik Pabrik ............................................................................ 100
Tabel 5.1 Sistem Pembagian Kelompok Shift ...................................................................... 113
Tabel 5.2 Penggolongan Jabatan Perusahaan ....................................................................... 114
Tabel 5.3 Jumlah Karyawan Sesuai dengan Jabatan dan Gaji ............................................. 115
Tabel 5.4 Pembagian Karyawan Proses Tiap Shift .............................................................. 116
Tabel 6.1 Cost Index Chemical Plant ................................................................................... 122
Tabel 6.2 Total Fixed Capital Investment ............................................................................ 126
Tabel 6.3 Working Capital ................................................................................................... 127
Tabel 6.4 Direct Manufacturing Cost .................................................................................. 127
Tabel 6.5 Indirect Manufacturing Cost ................................................................................ 127
Tabel 6.6 Fixed manufacturing Cost .................................................................................... 128
Tabel 6.7 Total Manufacturing Cost .................................................................................... 128
Tabel 6.8 General Expenses ................................................................................................. 128
Tabel 6.9 Anlisa Kelayakan ................................................................................................. 130
xvi
DAFTAR GAMBAR
Gambar 1.1 Konsumsi Asam Oksalat di Dunia pada Tahun 1992 ....................................... 24
Gambar 2.2 Tata Letak Peralatan Proses .............................................................................. 51
Gambar 5.1 Struktur Organisasi Perusahaan Asam Oksalat Dihydrat ................................ 120
Gambar 6.1 Grafik Hubungan antara Tahun dan Cost Index .............................................. 123
Gambar 6.2 Grafik Analisa Kelayakan ................................................................................ 131