PRADESIGN OF XYLITOL PLANT BY HYDROGENATION PROCESS OF XYLOSE CAPACITY 25.000 TONS/YEAR (Design Reactor (RE-201)) PRARANCANGAN PABRIK XYLITOL DENGAN PROSES HIDROGENASI XILOSA KAPASITAS 25.000 TON/TAHUN (Perancangan Reaktor (RE-201))
ABSTRACT
PRADESIGN OF XYLITOL PLANT
BY HYDROGENATION PROCESS OF XYLOSE
CAPACITY 25.000 TONS/YEAR
(Design Reactor (RE-201))
By
NINA JULIANA ROBERTA TURNIP
Xylitol plant produced by reacting xylose and hydrogen was plan to be in
industrial plant in Tarahan, Katibung, Lampung Selatan. Plant was established by
considering the availability of raw materials, transportation facilities, readily
available labor and environmental conditions.
Plant's production capacity is planned 25.000 tons/year, with operating time of 24
hour/day and 330 working days in a year. The raw materials used are much
xylose 2612,793 kg/hr and hydrogen 34,663 kg/hr.
Labor needed as many as 182 people with a business entity form Limited
Liability Company (PT) which is headed by a Director who is assisted by the
Director of Production and Director of Finance with line and staff organizational
structure. From the economic analysis is obtained:
Fixed Capital Investment (FCI)
= Rp 640.768.653.202,Working Capital Investment (WCI)
= Rp 113.076.821.153,Total Capital Investment (TCI)
= Rp 753.845.474.355,Break Even Point (BEP)
= 32%
Shut Down Point (SDP)
= 28%
Pay Out Time after Taxes (POT)a
= 2,9 year
Return on Investment after Taxes (ROI)a
= 21,1 %
Internal Rate Return (IRR)
= 27%
Annual Net Profit (Pa)
= Rp 158.973.102.325/year
Consider the summary above, it is proper establishment of xylitol plant to studied
further, because the plant is profitable and has good prospects.
ABSTRAK
PRARANCANGAN PABRIK XYLITOL
DENGAN PROSES HIDROGENASI XILOSA
KAPASITAS 25.000 TON/TAHUN
(Perancangan Reaktor (RE-201))
Oleh
NINA JULIANA ROBERTA TURNIP
Pabrik xylitol berbahan baku xilosa dan hidrogen, akan didirikan di Tarahan,
Katibung, Lampung Selatan. Pabrik ini berdiri dengan mempertimbangkan
ketersediaan bahan baku, sarana transportasi yang memadai, tenaga kerja yang
mudah didapatkan dan kondisi lingkungan.
Pabrik direncanakan memproduksi xylitol sebanyak 25.000 ton/tahun, dengan
waktu operasi 24 jam/hari, 330 hari/tahun. Bahan baku yang digunakan adalah
xilosa sebanyak 2612,793 kg/jam dan hidrogen sebanyak 34,663 kg/jam.
Jumlah karyawan sebanyak 182 orang dengan bentuk perusahaan adalah
Perseroan Terbatas (PT) menggunakan struktur organisasi line dan staff.
Dari analisis ekonomi diperoleh:
Fixed Capital Investment (FCI)
= Rp 640.768.653.202,Working Capital Investment (WCI)
= Rp 113.076.821.153,Total Capital Investment (TCI)
= Rp 753.845.474.355,Break Even Point (BEP)
= 32%
Shut Down Point (SDP)
= 28%
Pay Out Time after Taxes (POT)a
= 2,9 tahun
Return on Investment after Taxes (ROI)a
= 21,1 %
Internal Rate Return (IRR)
= 27%
Annual Net Profit (Pa)
= Rp 158.973.102.325/tahun
Mempertimbangkan paparan di atas, sudah selayaknya pendirian pabrik xylitol ini
dikaji lebih lanjut, karena merupakan pabrik yang menguntungkan dan
mempunyai masa depan yang baik.
PRARANCANGAN PABRIK XYLITOL
DENGAN PROSES HIDROGENASI XILOSA
KAPASITAS 25.000 TON/TAHUN
(Perancangan Reaktor (RE-201))
Oleh
NINA JULIANA ROBERTA TURNIP
(Skripsi)
Sebagai salah satu syarat untuk mencapai gelar
Sarjana Teknik
Pada
Jurusan Teknik Kimia
Fakultas Teknik Universitas Lampung
FAKULTAS TEKNIK
UNIVERSITAS LAMPUNG
BANDAR LAMPUNG
2014
RIWAYAT HIDUP
Penulis dilahirkan di Bandar Lampung pada tanggal 21 Juli
1990, sebagai anak pertama dari tiga bersaudara, dari pasangan
Bapak T. Turnip dan Ibu Niar Nainggolan.
Lulus dari Sekolah Dasar (SD) di SD Xaverius Tanjung Karang pada tahun 2002,
Sekolah Lanjutan Tingkat Pertama (SLTP) di SLTP Fransiskus pada tahun 2005
dan Sekolah Menengah Atas (SMA) di SMAN Fransiskus pada tahun 2008.
Tahun 2008, penulis terdaftar sebagai Mahasiswa Jurusan Teknik Kimia Fakultas
Teknik Universitas Lampung melalui jalur PKAB. Aktif di organisasi
HIMATEMIA-FT Unila sebagai Kepala Divisi Kerohanian Kristiani pada tahun
2010-2011.
Pada tahun 2011, penulis melakukan Kerja Praktek di PT PERTAMINA RU VI,
Balongan, Indramayu, Cirebon, Jawa Barat di Unit Process Engineering. Pada
tahun 2012-2013 melakukan penelitian dengan judul “Pengaruh Penambahan
Cairan Rumen pada Pembuatan Biogas Sistem Co Digestion Kotoran Sapi dan
Stillage dengan Starter Effluent Digester PT. Indonesia Ethanol Industry”.
MOTO
Sebuah Karya kecilku....
Dengan segenap hati kupersembahkan tugas akhir ini kepada:
Tuhan Yesus Kristus
Atas kehendak-Nya semua ini ada
Atas anugerah-Nya semua ini aku dapatkan
Atas kekuatan dari-Nya aku bisa bertahan.
Orang tuaku sebagai tanda baktiku, terima kasih atas segalanya,
doa, kasih sayang, pengorbanan, dan keikhlasannya.
Ini hanyalah setitik balasan yang tidak bisa dibandingkan dengan berjutajuta pengorbanan dan kasih sayang
yang tidak pernah berakhir.
Guru-guruku sebagai tanda hormatku,
terima kasih atas ilmu yang telah diberikan.
Serta tak lupa kupersembahkan kepada Almamaterku tercinta,
semoga kelak berguna dikemudian hari.
SANWACANA
Puji dan syukur penulis panjatkan kepada Tuhan Yesus Kristus, atas karunia dan
rahmatNya, sehingga tugas akhir ini dengan judul “Prarancangan Pabrik Xylitol
Dengan Proses Hidrogenasi Xilosa Kapasitas 25.000 Ton/Tahun” dapat
diselesaikan dengan baik.
Tugas akhir ini disusun dalam rangka memenuhi salah satu syarat guna
memperoleh derajat kesarjanaan (S-1) di Jurusan Teknik Kimia Fakultas Teknik
Universitas Lampung.
Penyusunan tugas akhir ini tidak lepas dari bantuan dan dukungan dari beberapa
pihak. Oleh karena itu penulis mengucapkan terima kasih kepada:
1.
Kedua orangtua dan keluarga yang telah memberikan cinta kasih, semangat,
doa, dan bantuan materiil kepada penulis.
2. Bapak Ir. Azhar, M.T., selaku Ketua Jurusan Teknik Kimia Universitas
Lampung.
3. Bapak Darmansyah, S.T.,M.T., selaku dosen pembimbing I, yang telah
memberikan pengarahan, masukan, bimbingan, kritik dan saran selama
penyelesaian tugas akhir.
4. Bapak Muhammad Hanif, S.T., M.T., selaku Dosen Pembimbing II, atas ilmu,
saran, masukan dan pengertiannya dalam penyelesaian tugas akhir. Semoga
ilmu bermanfaat yang diberikan dapat berguna dikemudian hari.
5. Bapak Ir. Azhar, M.T. dan Ibu Sri Ismiyati D.,S.T.,M.Eng., selaku Dosen
Penguji yang telah memberikan saran dan kritik, juga selaku dosen atas semua
ilmu yang telah penulis dapatkan. Serta seluruh Dosen Teknik Kimia
Universitas Lampung, atas semua ilmu dan bekal masa depan yang akan selalu
bermanfaat.
6. Keluargaku tercinta atas pengorbanan, doa, cinta dan kasih sayang yang selalu
mengiringi disetiap langkahku. Adik-adikku Stephanus dan Ruth atas doa dan
semangat.
7. Mba Norma Astuningsih, selaku rekan seperjuangan dalam suka dan duka
yang telah membantu penulis dalam penyelesaian laporan tugas akhir.
8. Seluruh saudara/i di Teknik Kimia Unila dan angkatan 2008, terkhususnya
Adelina, Yuliana, Andani, Anissa, Wirna, dan Melania, beserta teman-teman
naposo di gereja. Terimakasih atas bantuan semangatnya selama penulis
menyelesaikan tugas akhir ini.
9. Semua pihak yang telah membantu dalam penyusunan tugas akhir ini.
Penulis berharap agar skripsi ini dapat diterima dan bermanfaat bagi
perkembangan ilmu pengetahuan.
Bandar Lampung, Mei 2014
Penulis,
Nina Juliana R. Turnip
DAFTAR ISI
Halaman
DAFTAR ISI ........................................................................................................
DAFTAR TABEL ..............................................................................................
DAFTAR GAMBAR ...........................................................................................
xi
xiii
xvii
I. PENDAHULUAN
A. Latar Belakang ............................................................................................
B. Kegunaan Produk ........................................................................................
C. Ketersediaan Bahan Baku............................................................................
D. Analisis Pasar .............................................................................................
E. Kapasitas Pabrik ..........................................................................................
F. Penentuan Lokasi Pabrik..............................................................................
1
4
5
5
11
12
II. DESKRIPSI PROSES
A. Jenis-Jenis Proses ........................................................................................
B. Kelayakan Ekonomi ...................................................................................
C. Kelayakan Teknis .......................................................................................
D. Pemilihan Proses ........................................................................................
E. Tahap Produksi Xylitol ...............................................................................
15
18
21
24
26
III. SPESIFIKASI BAHAN DAN PRODUK
A. Bahan Baku ...............................................................................................
B. Produk ........................................................................................................
29
33
IV. NERACA MASSA DAN ENERGI
A. Neraca Massa ............................................................................................
B. Neraca Energi .............................................................................................
35
37
V. SPESIFIKASI PERALATAN
A. Peralatan Proses .........................................................................................
B. Peralatan Utilitas .......................................................................................
40
52
xii
VI. UTILITAS DAN PENGOLAHAN LIMBAH
A. Unit Pendukung Proses .............................................................................
B. Pengolahan Limbah ...................................................................................
C. Laboratorium .............................................................................................
D. Instumentasi Dan Pengendalian Proses .....................................................
71
87
94
98
VII. TATA LETAK DAN LOKASI PABRIK
A. Lokasi Pabrik ............................................................................................
B. Tata Letak Pabrik ......................................................................................
C. Prakiraan Areal Lingkungan .....................................................................
105
108
109
VIII. SISTEM MANAJEMEN DAN ORGANISASI PERUSAHAAN
A. Bentuk Perusahaan ....................................................................................
B. Struktur Organiasi Perusahaan ..................................................................
C. Tugas dan Wewenang................................................................................
D. Status Karyawan dan Sistem Penggajian .................................................
E. Manajemen Produksi ................................................................................
F. Pengaturan Waktu Produksi ......................................................................
G. Pembagian Jam Kerja Karyawan ...............................................................
H. Penggolongan Jabatan dan Jumlah Karyawan ..........................................
I. Kesejahteraan Karyawan ...........................................................................
113
114
116
123
124
128
129
131
136
IX. INVESTASI DAN EVALUASI EKONOMI
A. Investasi .....................................................................................................
B. Evaluasi Ekonomi......................................................................................
C. Discounted Cash Flow ..............................................................................
141
145
148
X. KESIMPULAN DAN SARAN
A. Kesimpulan ...............................................................................................
B. Saran ..........................................................................................................
149
149
DAFTAR PUSTAKA
LAMPIRAN F TUGAS KHUSUS
DAFTAR TABEL
Tabel
Halaman
1.1. Jenis-jenis Gula Alkohol dengan Kegunaannya ....................................
2
1.2. Beberapa Produsen Pengguna Xyliol ......................................................
3
1.3. Data Impor Other Polyhydric Alcohol Indonesia ...................................
6
1.4. Penggunaan Xylitol di Indonesia (kg/tahun) ..........................................
7
1.5. Jumlah Penduduk Indonesia ...................................................................
8
1.6. Industri Xylitol di Dunia dan Kapaitas Produksi ...................................
9
1.7. Harga Bahan Baku dan Produk ..............................................................
11
2.1. Data Energi Gibbs dan Energi Pembentukan Standar ............................
21
2.2. Perbandingan Proses Pembuatan Xylitol ................................................
24
4.1. Neraca Massa Mixing Tank (MT-101) ....................................................
35
4.2. Neraca Massa Reaktor ............................................................................
35
4.3. Neraca Massa Internal Filter (S-201) ...................................................
36
4.4. Neraca Massa Evaporator ......................................................................
37
4.5. Neraca Energi Mixing Tank (MT-101) ...................................................
37
4.6. Neraca Energi Preheater (HE-101) .......................................................
37
4.7. Neraca Energi Storage Hidrogen (ST-101) ............................................
38
4.8. Neraca Energi Expansion Valve (EX-101) ............................................
38
4.9. Neraca Energi Preheater (HE-102) .......................................................
38
4.10. Neraca Energi Reaktor (RE-201) ...........................................................
38
4.11. Neraca Energi Expansion Valve (EX-102) .............................................
38
4.12. Neraca Energi Expansion Valve (EX-103) .............................................
39
4.13. Neraca Energi Evaporator (EV-301).......................................................
39
4.14. Neraca Energi Evaporator (EV-302).......................................................
39
4.15. Neraca Energi Cooler (CO-301) ............................................................
39
xiv
5.1. Solid Storage (SS-101)............................................................................
40
5.2. Screw Conveyor (SC-101) ......................................................................
41
5.3. Bucket Elevator (BE-101) .......................................................................
41
5.4. Feeder (FE-101) ......................................................................................
42
5.5. Mixing Tank (MT-101) ...........................................................................
42
5.6. Xylose Solution Storage Tank (ST-101) ..................................................
43
5.7. Preheater (HE-101) ...............................................................................
44
5.8. Hydrogen Storage Tank (ST-102)..........................................................
45
5.9. Expansion Valve (EX-101) .....................................................................
45
5.10. Preheater (HE-102) ...............................................................................
45
5.11. Reaktor (RE-201) ...................................................................................
46
5.12. Expansion Valve (EX-102) .....................................................................
47
5.13. Expansion Valve (EX-103) .....................................................................
48
5.14. Evaporator Efek I (EV-301) ....................................................................
48
5.15. Evaporator Efek 2 (EV-302) ..................................................................
49
5.16. Cooler (CO-301) ....................................................................................
49
5.17. Product Storage Tank (ST-103 ) ............................................................
50
5.18. Process Pump (PP-101) .........................................................................
50
5.19. Process Pump (PP-102) .........................................................................
51
5.20. Process Pump (PP-103) ..........................................................................
51
5.21. Process Pump (PP-104) ..........................................................................
52
5.22. Bak Sedimentasi (BS-401) .....................................................................
52
5.23. Bak Penggumpal (BP-401) ....................................................................
52
5.24. Tangki Alum (ST-401) ...........................................................................
53
5.25. Tangki Soda Kaustik (ST-402) ..............................................................
53
5.26. Tangki Kaporit (ST-403) ........................................................................
54
5.27. Klarifier (CL-401) ...................................................................................
55
5.28. Sand Filter (SF-401) ...............................................................................
55
5.29. Filter Water Tank (FWT-401) ...............................................................
56
5.30. Domestic Water Tank (DOWT-401) ......................................................
56
5.31. Hydran Water Tank (HWT-401)............................................................
57
5.32. Hot Basin (HB-401) ................................................................................
57
xv
5.33. Cooling Tower (CT-401) .......................................................................
58
5.34. Cold Basin (CB-401) .............................................................................
58
5.35. Tangki Asam Sulfat (ST-404) ................................................................
58
5.36. Tangki Dispersant (ST-405) ..................................................................
59
5.37. Tangki Inhibitor (ST-406) ......................................................................
59
5.38. Cation Exchanger (CE-4-1) ...................................................................
60
5.39. Anion Exchanger (AE-401) ....................................................................
61
5.40. Demin Water Tank (DWT-401) .............................................................
61
5.41. Deaerator (DE-401) ...............................................................................
62
5.42. Tangki Hidrazin (ST-407) ......................................................................
62
5.43. Boiler Feed Water Tank (BFWT-401) ...................................................
63
5.44. Boiler (B-401) ........................................................................................
63
5.45. Tamgki Bahan Bakar (ST-408) ..............................................................
64
5.46. Diesel Generator (GS-401) ....................................................................
64
5.47. Pompa Utilitas 1 (PU-401) ......................................................................
64
5.48. Pompa Utilitas 2 (PU-402) ....................................................................
65
5.49. Pompa Utilitas 3 (PU-403) .....................................................................
65
5.50. Pompa Utilitas 4 (PU-404) .....................................................................
66
5.51. Pompa Utilitas 5 (PU-405) .....................................................................
66
5.52. Pompa Utilitas 6 (PU-406) .....................................................................
67
5.53. Pompa Utilitas 7 (PU-407) ......................................................................
67
5.54. Pompa Utilitas 8 (PU-408) ......................................................................
67
5.55. Pompa Utilitas 9 (PU-409) ......................................................................
68
5.56. Pompa Utilitas 10 (PU-410) ...................................................................
68
5.57. Pompa Utilitas 11 (PU-411) ...................................................................
69
5.58. Pompa Utilitas 12 (PU-412) ...................................................................
69
5.59. Pompa Utilitas 13 (PU-413) ...................................................................
70
6.1. Baku Mutu Air Domestik .......................................................................
72
6.2. Baku Mutu Air Proses (Termasuk Air Umpan Boiler) ...........................
74
6.3. Kebutuhan Air Proses ............................................................................
75
6.4. Kebutuhan Air Pendingin .......................................................................
76
6.5. Kebutuhan Steam ...................................................................................
77
xvi
6.6. Waktu Cuplik Beberapa Jenis Variabel Proses ...................................... 102
6.7. Aplikasi Umum Valve dalam Proses Industri ....................................... 104
7.1. Daerah Aliran Sungai di Kabupaten Lampung Selatan ......................... 107
8.1. Jadwal Sistem Produksi Saat Start Up ................................................... 128
8.2. Jadwal Kerja Masing-Masing Regu ...................................................... 130
8.3. Prasyarat Tingkat Pendidikan ................................................................ 131
8.4. Jumlah Operator pada Alat Proses ......................................................... 133
8.5. Jumlah Operator pada Alat Utilitas ........................................................ 134
8.6. Jumlah Karyawan Kantor ....................................................................... 134
9.1. Fixed Capital Investment ....................................................................... 142
9.2. Manufacturing Cost ............................................................................... 143
9.3. General Expenses ................................................................................... 144
9.4. Administrative Cost ................................................................................ 144
9.5. Acceptable Percentage Return on Investment ........................................ 145
9.6. Acceptable Percentage Pay Out Period ................................................. 146
9.7. Hasil Analisa Kelayakan Ekonomi ......................................................... 148
DAFTAR GAMBAR
Gambar
1.1.
1.2.
1.3.
2.1.
6.1.
7.1.
7.2.
7.3.
8.1.
9.1.
9.2.
Halaman
Impor Other Polyhydric Alcohol di Indonesia .......................................
Konsumsi Xylitol Terhadap Jumlah Penduduk .....................................
Lokasi Pabrik ........................................................................................
Diagram Alir Proses ..............................................................................
Industrial Control System Operation .....................................................
Lokasi Pabrik ..........................................................................................
Tata Letak Pabrik ....................................................................................
Tata Letak Alat Proses ............................................................................
Struktur Organisasi Perusahaan .............................................................
Analisa Ekonomi .....................................................................................
Kurva Cummulative Cash Flow ..............................................................
6
9
14
28
101
109
110
111
115
147
148
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PRADESIGN OF XYLITOL PLANT
BY HYDROGENATION PROCESS OF XYLOSE
CAPACITY 25.000 TONS/YEAR
(Design Reactor (RE-201))
By
NINA JULIANA ROBERTA TURNIP
Xylitol plant produced by reacting xylose and hydrogen was plan to be in
industrial plant in Tarahan, Katibung, Lampung Selatan. Plant was established by
considering the availability of raw materials, transportation facilities, readily
available labor and environmental conditions.
Plant's production capacity is planned 25.000 tons/year, with operating time of 24
hour/day and 330 working days in a year. The raw materials used are much
xylose 2612,793 kg/hr and hydrogen 34,663 kg/hr.
Labor needed as many as 182 people with a business entity form Limited
Liability Company (PT) which is headed by a Director who is assisted by the
Director of Production and Director of Finance with line and staff organizational
structure. From the economic analysis is obtained:
Fixed Capital Investment (FCI)
= Rp 640.768.653.202,Working Capital Investment (WCI)
= Rp 113.076.821.153,Total Capital Investment (TCI)
= Rp 753.845.474.355,Break Even Point (BEP)
= 32%
Shut Down Point (SDP)
= 28%
Pay Out Time after Taxes (POT)a
= 2,9 year
Return on Investment after Taxes (ROI)a
= 21,1 %
Internal Rate Return (IRR)
= 27%
Annual Net Profit (Pa)
= Rp 158.973.102.325/year
Consider the summary above, it is proper establishment of xylitol plant to studied
further, because the plant is profitable and has good prospects.
ABSTRAK
PRARANCANGAN PABRIK XYLITOL
DENGAN PROSES HIDROGENASI XILOSA
KAPASITAS 25.000 TON/TAHUN
(Perancangan Reaktor (RE-201))
Oleh
NINA JULIANA ROBERTA TURNIP
Pabrik xylitol berbahan baku xilosa dan hidrogen, akan didirikan di Tarahan,
Katibung, Lampung Selatan. Pabrik ini berdiri dengan mempertimbangkan
ketersediaan bahan baku, sarana transportasi yang memadai, tenaga kerja yang
mudah didapatkan dan kondisi lingkungan.
Pabrik direncanakan memproduksi xylitol sebanyak 25.000 ton/tahun, dengan
waktu operasi 24 jam/hari, 330 hari/tahun. Bahan baku yang digunakan adalah
xilosa sebanyak 2612,793 kg/jam dan hidrogen sebanyak 34,663 kg/jam.
Jumlah karyawan sebanyak 182 orang dengan bentuk perusahaan adalah
Perseroan Terbatas (PT) menggunakan struktur organisasi line dan staff.
Dari analisis ekonomi diperoleh:
Fixed Capital Investment (FCI)
= Rp 640.768.653.202,Working Capital Investment (WCI)
= Rp 113.076.821.153,Total Capital Investment (TCI)
= Rp 753.845.474.355,Break Even Point (BEP)
= 32%
Shut Down Point (SDP)
= 28%
Pay Out Time after Taxes (POT)a
= 2,9 tahun
Return on Investment after Taxes (ROI)a
= 21,1 %
Internal Rate Return (IRR)
= 27%
Annual Net Profit (Pa)
= Rp 158.973.102.325/tahun
Mempertimbangkan paparan di atas, sudah selayaknya pendirian pabrik xylitol ini
dikaji lebih lanjut, karena merupakan pabrik yang menguntungkan dan
mempunyai masa depan yang baik.
PRARANCANGAN PABRIK XYLITOL
DENGAN PROSES HIDROGENASI XILOSA
KAPASITAS 25.000 TON/TAHUN
(Perancangan Reaktor (RE-201))
Oleh
NINA JULIANA ROBERTA TURNIP
(Skripsi)
Sebagai salah satu syarat untuk mencapai gelar
Sarjana Teknik
Pada
Jurusan Teknik Kimia
Fakultas Teknik Universitas Lampung
FAKULTAS TEKNIK
UNIVERSITAS LAMPUNG
BANDAR LAMPUNG
2014
RIWAYAT HIDUP
Penulis dilahirkan di Bandar Lampung pada tanggal 21 Juli
1990, sebagai anak pertama dari tiga bersaudara, dari pasangan
Bapak T. Turnip dan Ibu Niar Nainggolan.
Lulus dari Sekolah Dasar (SD) di SD Xaverius Tanjung Karang pada tahun 2002,
Sekolah Lanjutan Tingkat Pertama (SLTP) di SLTP Fransiskus pada tahun 2005
dan Sekolah Menengah Atas (SMA) di SMAN Fransiskus pada tahun 2008.
Tahun 2008, penulis terdaftar sebagai Mahasiswa Jurusan Teknik Kimia Fakultas
Teknik Universitas Lampung melalui jalur PKAB. Aktif di organisasi
HIMATEMIA-FT Unila sebagai Kepala Divisi Kerohanian Kristiani pada tahun
2010-2011.
Pada tahun 2011, penulis melakukan Kerja Praktek di PT PERTAMINA RU VI,
Balongan, Indramayu, Cirebon, Jawa Barat di Unit Process Engineering. Pada
tahun 2012-2013 melakukan penelitian dengan judul “Pengaruh Penambahan
Cairan Rumen pada Pembuatan Biogas Sistem Co Digestion Kotoran Sapi dan
Stillage dengan Starter Effluent Digester PT. Indonesia Ethanol Industry”.
MOTO
Sebuah Karya kecilku....
Dengan segenap hati kupersembahkan tugas akhir ini kepada:
Tuhan Yesus Kristus
Atas kehendak-Nya semua ini ada
Atas anugerah-Nya semua ini aku dapatkan
Atas kekuatan dari-Nya aku bisa bertahan.
Orang tuaku sebagai tanda baktiku, terima kasih atas segalanya,
doa, kasih sayang, pengorbanan, dan keikhlasannya.
Ini hanyalah setitik balasan yang tidak bisa dibandingkan dengan berjutajuta pengorbanan dan kasih sayang
yang tidak pernah berakhir.
Guru-guruku sebagai tanda hormatku,
terima kasih atas ilmu yang telah diberikan.
Serta tak lupa kupersembahkan kepada Almamaterku tercinta,
semoga kelak berguna dikemudian hari.
SANWACANA
Puji dan syukur penulis panjatkan kepada Tuhan Yesus Kristus, atas karunia dan
rahmatNya, sehingga tugas akhir ini dengan judul “Prarancangan Pabrik Xylitol
Dengan Proses Hidrogenasi Xilosa Kapasitas 25.000 Ton/Tahun” dapat
diselesaikan dengan baik.
Tugas akhir ini disusun dalam rangka memenuhi salah satu syarat guna
memperoleh derajat kesarjanaan (S-1) di Jurusan Teknik Kimia Fakultas Teknik
Universitas Lampung.
Penyusunan tugas akhir ini tidak lepas dari bantuan dan dukungan dari beberapa
pihak. Oleh karena itu penulis mengucapkan terima kasih kepada:
1.
Kedua orangtua dan keluarga yang telah memberikan cinta kasih, semangat,
doa, dan bantuan materiil kepada penulis.
2. Bapak Ir. Azhar, M.T., selaku Ketua Jurusan Teknik Kimia Universitas
Lampung.
3. Bapak Darmansyah, S.T.,M.T., selaku dosen pembimbing I, yang telah
memberikan pengarahan, masukan, bimbingan, kritik dan saran selama
penyelesaian tugas akhir.
4. Bapak Muhammad Hanif, S.T., M.T., selaku Dosen Pembimbing II, atas ilmu,
saran, masukan dan pengertiannya dalam penyelesaian tugas akhir. Semoga
ilmu bermanfaat yang diberikan dapat berguna dikemudian hari.
5. Bapak Ir. Azhar, M.T. dan Ibu Sri Ismiyati D.,S.T.,M.Eng., selaku Dosen
Penguji yang telah memberikan saran dan kritik, juga selaku dosen atas semua
ilmu yang telah penulis dapatkan. Serta seluruh Dosen Teknik Kimia
Universitas Lampung, atas semua ilmu dan bekal masa depan yang akan selalu
bermanfaat.
6. Keluargaku tercinta atas pengorbanan, doa, cinta dan kasih sayang yang selalu
mengiringi disetiap langkahku. Adik-adikku Stephanus dan Ruth atas doa dan
semangat.
7. Mba Norma Astuningsih, selaku rekan seperjuangan dalam suka dan duka
yang telah membantu penulis dalam penyelesaian laporan tugas akhir.
8. Seluruh saudara/i di Teknik Kimia Unila dan angkatan 2008, terkhususnya
Adelina, Yuliana, Andani, Anissa, Wirna, dan Melania, beserta teman-teman
naposo di gereja. Terimakasih atas bantuan semangatnya selama penulis
menyelesaikan tugas akhir ini.
9. Semua pihak yang telah membantu dalam penyusunan tugas akhir ini.
Penulis berharap agar skripsi ini dapat diterima dan bermanfaat bagi
perkembangan ilmu pengetahuan.
Bandar Lampung, Mei 2014
Penulis,
Nina Juliana R. Turnip
DAFTAR ISI
Halaman
DAFTAR ISI ........................................................................................................
DAFTAR TABEL ..............................................................................................
DAFTAR GAMBAR ...........................................................................................
xi
xiii
xvii
I. PENDAHULUAN
A. Latar Belakang ............................................................................................
B. Kegunaan Produk ........................................................................................
C. Ketersediaan Bahan Baku............................................................................
D. Analisis Pasar .............................................................................................
E. Kapasitas Pabrik ..........................................................................................
F. Penentuan Lokasi Pabrik..............................................................................
1
4
5
5
11
12
II. DESKRIPSI PROSES
A. Jenis-Jenis Proses ........................................................................................
B. Kelayakan Ekonomi ...................................................................................
C. Kelayakan Teknis .......................................................................................
D. Pemilihan Proses ........................................................................................
E. Tahap Produksi Xylitol ...............................................................................
15
18
21
24
26
III. SPESIFIKASI BAHAN DAN PRODUK
A. Bahan Baku ...............................................................................................
B. Produk ........................................................................................................
29
33
IV. NERACA MASSA DAN ENERGI
A. Neraca Massa ............................................................................................
B. Neraca Energi .............................................................................................
35
37
V. SPESIFIKASI PERALATAN
A. Peralatan Proses .........................................................................................
B. Peralatan Utilitas .......................................................................................
40
52
xii
VI. UTILITAS DAN PENGOLAHAN LIMBAH
A. Unit Pendukung Proses .............................................................................
B. Pengolahan Limbah ...................................................................................
C. Laboratorium .............................................................................................
D. Instumentasi Dan Pengendalian Proses .....................................................
71
87
94
98
VII. TATA LETAK DAN LOKASI PABRIK
A. Lokasi Pabrik ............................................................................................
B. Tata Letak Pabrik ......................................................................................
C. Prakiraan Areal Lingkungan .....................................................................
105
108
109
VIII. SISTEM MANAJEMEN DAN ORGANISASI PERUSAHAAN
A. Bentuk Perusahaan ....................................................................................
B. Struktur Organiasi Perusahaan ..................................................................
C. Tugas dan Wewenang................................................................................
D. Status Karyawan dan Sistem Penggajian .................................................
E. Manajemen Produksi ................................................................................
F. Pengaturan Waktu Produksi ......................................................................
G. Pembagian Jam Kerja Karyawan ...............................................................
H. Penggolongan Jabatan dan Jumlah Karyawan ..........................................
I. Kesejahteraan Karyawan ...........................................................................
113
114
116
123
124
128
129
131
136
IX. INVESTASI DAN EVALUASI EKONOMI
A. Investasi .....................................................................................................
B. Evaluasi Ekonomi......................................................................................
C. Discounted Cash Flow ..............................................................................
141
145
148
X. KESIMPULAN DAN SARAN
A. Kesimpulan ...............................................................................................
B. Saran ..........................................................................................................
149
149
DAFTAR PUSTAKA
LAMPIRAN F TUGAS KHUSUS
DAFTAR TABEL
Tabel
Halaman
1.1. Jenis-jenis Gula Alkohol dengan Kegunaannya ....................................
2
1.2. Beberapa Produsen Pengguna Xyliol ......................................................
3
1.3. Data Impor Other Polyhydric Alcohol Indonesia ...................................
6
1.4. Penggunaan Xylitol di Indonesia (kg/tahun) ..........................................
7
1.5. Jumlah Penduduk Indonesia ...................................................................
8
1.6. Industri Xylitol di Dunia dan Kapaitas Produksi ...................................
9
1.7. Harga Bahan Baku dan Produk ..............................................................
11
2.1. Data Energi Gibbs dan Energi Pembentukan Standar ............................
21
2.2. Perbandingan Proses Pembuatan Xylitol ................................................
24
4.1. Neraca Massa Mixing Tank (MT-101) ....................................................
35
4.2. Neraca Massa Reaktor ............................................................................
35
4.3. Neraca Massa Internal Filter (S-201) ...................................................
36
4.4. Neraca Massa Evaporator ......................................................................
37
4.5. Neraca Energi Mixing Tank (MT-101) ...................................................
37
4.6. Neraca Energi Preheater (HE-101) .......................................................
37
4.7. Neraca Energi Storage Hidrogen (ST-101) ............................................
38
4.8. Neraca Energi Expansion Valve (EX-101) ............................................
38
4.9. Neraca Energi Preheater (HE-102) .......................................................
38
4.10. Neraca Energi Reaktor (RE-201) ...........................................................
38
4.11. Neraca Energi Expansion Valve (EX-102) .............................................
38
4.12. Neraca Energi Expansion Valve (EX-103) .............................................
39
4.13. Neraca Energi Evaporator (EV-301).......................................................
39
4.14. Neraca Energi Evaporator (EV-302).......................................................
39
4.15. Neraca Energi Cooler (CO-301) ............................................................
39
xiv
5.1. Solid Storage (SS-101)............................................................................
40
5.2. Screw Conveyor (SC-101) ......................................................................
41
5.3. Bucket Elevator (BE-101) .......................................................................
41
5.4. Feeder (FE-101) ......................................................................................
42
5.5. Mixing Tank (MT-101) ...........................................................................
42
5.6. Xylose Solution Storage Tank (ST-101) ..................................................
43
5.7. Preheater (HE-101) ...............................................................................
44
5.8. Hydrogen Storage Tank (ST-102)..........................................................
45
5.9. Expansion Valve (EX-101) .....................................................................
45
5.10. Preheater (HE-102) ...............................................................................
45
5.11. Reaktor (RE-201) ...................................................................................
46
5.12. Expansion Valve (EX-102) .....................................................................
47
5.13. Expansion Valve (EX-103) .....................................................................
48
5.14. Evaporator Efek I (EV-301) ....................................................................
48
5.15. Evaporator Efek 2 (EV-302) ..................................................................
49
5.16. Cooler (CO-301) ....................................................................................
49
5.17. Product Storage Tank (ST-103 ) ............................................................
50
5.18. Process Pump (PP-101) .........................................................................
50
5.19. Process Pump (PP-102) .........................................................................
51
5.20. Process Pump (PP-103) ..........................................................................
51
5.21. Process Pump (PP-104) ..........................................................................
52
5.22. Bak Sedimentasi (BS-401) .....................................................................
52
5.23. Bak Penggumpal (BP-401) ....................................................................
52
5.24. Tangki Alum (ST-401) ...........................................................................
53
5.25. Tangki Soda Kaustik (ST-402) ..............................................................
53
5.26. Tangki Kaporit (ST-403) ........................................................................
54
5.27. Klarifier (CL-401) ...................................................................................
55
5.28. Sand Filter (SF-401) ...............................................................................
55
5.29. Filter Water Tank (FWT-401) ...............................................................
56
5.30. Domestic Water Tank (DOWT-401) ......................................................
56
5.31. Hydran Water Tank (HWT-401)............................................................
57
5.32. Hot Basin (HB-401) ................................................................................
57
xv
5.33. Cooling Tower (CT-401) .......................................................................
58
5.34. Cold Basin (CB-401) .............................................................................
58
5.35. Tangki Asam Sulfat (ST-404) ................................................................
58
5.36. Tangki Dispersant (ST-405) ..................................................................
59
5.37. Tangki Inhibitor (ST-406) ......................................................................
59
5.38. Cation Exchanger (CE-4-1) ...................................................................
60
5.39. Anion Exchanger (AE-401) ....................................................................
61
5.40. Demin Water Tank (DWT-401) .............................................................
61
5.41. Deaerator (DE-401) ...............................................................................
62
5.42. Tangki Hidrazin (ST-407) ......................................................................
62
5.43. Boiler Feed Water Tank (BFWT-401) ...................................................
63
5.44. Boiler (B-401) ........................................................................................
63
5.45. Tamgki Bahan Bakar (ST-408) ..............................................................
64
5.46. Diesel Generator (GS-401) ....................................................................
64
5.47. Pompa Utilitas 1 (PU-401) ......................................................................
64
5.48. Pompa Utilitas 2 (PU-402) ....................................................................
65
5.49. Pompa Utilitas 3 (PU-403) .....................................................................
65
5.50. Pompa Utilitas 4 (PU-404) .....................................................................
66
5.51. Pompa Utilitas 5 (PU-405) .....................................................................
66
5.52. Pompa Utilitas 6 (PU-406) .....................................................................
67
5.53. Pompa Utilitas 7 (PU-407) ......................................................................
67
5.54. Pompa Utilitas 8 (PU-408) ......................................................................
67
5.55. Pompa Utilitas 9 (PU-409) ......................................................................
68
5.56. Pompa Utilitas 10 (PU-410) ...................................................................
68
5.57. Pompa Utilitas 11 (PU-411) ...................................................................
69
5.58. Pompa Utilitas 12 (PU-412) ...................................................................
69
5.59. Pompa Utilitas 13 (PU-413) ...................................................................
70
6.1. Baku Mutu Air Domestik .......................................................................
72
6.2. Baku Mutu Air Proses (Termasuk Air Umpan Boiler) ...........................
74
6.3. Kebutuhan Air Proses ............................................................................
75
6.4. Kebutuhan Air Pendingin .......................................................................
76
6.5. Kebutuhan Steam ...................................................................................
77
xvi
6.6. Waktu Cuplik Beberapa Jenis Variabel Proses ...................................... 102
6.7. Aplikasi Umum Valve dalam Proses Industri ....................................... 104
7.1. Daerah Aliran Sungai di Kabupaten Lampung Selatan ......................... 107
8.1. Jadwal Sistem Produksi Saat Start Up ................................................... 128
8.2. Jadwal Kerja Masing-Masing Regu ...................................................... 130
8.3. Prasyarat Tingkat Pendidikan ................................................................ 131
8.4. Jumlah Operator pada Alat Proses ......................................................... 133
8.5. Jumlah Operator pada Alat Utilitas ........................................................ 134
8.6. Jumlah Karyawan Kantor ....................................................................... 134
9.1. Fixed Capital Investment ....................................................................... 142
9.2. Manufacturing Cost ............................................................................... 143
9.3. General Expenses ................................................................................... 144
9.4. Administrative Cost ................................................................................ 144
9.5. Acceptable Percentage Return on Investment ........................................ 145
9.6. Acceptable Percentage Pay Out Period ................................................. 146
9.7. Hasil Analisa Kelayakan Ekonomi ......................................................... 148
DAFTAR GAMBAR
Gambar
1.1.
1.2.
1.3.
2.1.
6.1.
7.1.
7.2.
7.3.
8.1.
9.1.
9.2.
Halaman
Impor Other Polyhydric Alcohol di Indonesia .......................................
Konsumsi Xylitol Terhadap Jumlah Penduduk .....................................
Lokasi Pabrik ........................................................................................
Diagram Alir Proses ..............................................................................
Industrial Control System Operation .....................................................
Lokasi Pabrik ..........................................................................................
Tata Letak Pabrik ....................................................................................
Tata Letak Alat Proses ............................................................................
Struktur Organisasi Perusahaan .............................................................
Analisa Ekonomi .....................................................................................
Kurva Cummulative Cash Flow ..............................................................
6
9
14
28
101
109
110
111
115
147
148
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