PRA RANCANGAN PABRIK PEMBUATAN ASAM OKSALAT DARI ALANG-ALANG DENGAN METODE PELEBURAN ALKALI DENGAN KAPASITAS 3.000 TONTAHUN

  

PRA RANCANGAN PABRIK PEMBUATAN ASAM

OKSALAT DARI ALANG-ALANG DENGAN METODE

PELEBURAN ALKALI DENGAN KAPASITAS 3.000 TON/TAHUN TUGAS AKHIR

  

Diajukan Untuk Memenuhi Persyaratan

Ujian Sidang Sarjana Teknik Kimia Oleh : ANDREW FAGUH SITANGGANG 120425002 DEPARTEMEN TEKNIK KIMIA PROGRAM STUDI TEKNIK KIMIA EKSTENSI FAKULTAS TEKNIK

  

UNIVERSITAS SUMATERA UTARA

MEDAN 2015

  

LEMBAR PENGESAHAN

PRA RANCANGAN PABRIK ASAM OKSALAT DARI ALANG-ALANG DENGAN

METODE PELEBURAN ALKALI DENGAN KAPASITAS 3000 TON/TAHUN

TUGAS AKHIR

  

Diajukan Untuk Memenuhi Persyaratan

Ujian Sarjana Teknik Kimia

Oleh :

ANDREW FAGUH SITANGGANG

  

NIM : 120425002

Telah Diperiksa / Disetujui Oleh :

Dosen Pembimbing

Dr. Ir. Iriany, M.Si

  

NIP. 19640613 199003 2 001

Dosen Penguji I Dosen Penguji II Dosen Penguji III Dr. Ir. Iriany. M.Si Ir. Renita Manurung, MT Dr. Eng. Rondang Tambun, ST. MT NIP. 196406131990032001 NIP : 196812141997022002 NIP : 197206122000121001

  

Mengetahui,

Kooerdinator Tugas Akhir

Mhd. Hendra S. Ginting, ST. MT

NIP : 19700919 199903 1 001

  

DEPARTEMEN TEKNIK KIMIA

FAKULTAS TEKNIK

UNIVERSITAS SUMATERA UTARA

MEDAN

2015

KATA PENGANTAR

  Puji dan syukur penulis ucapkan kehadirat Allah SWT atas rahmat dan anugerah-Nya sehingga penulis dapat menyelesaikan Tugas Akhir yang berjudul

  

“Pra Rancangan Pabrik Pembuatan Asam Oksalat dari Alang-Alang dengan

Metode Peleburan Alkali dengan Kapasitas 3.000 Ton/Tahun”. Tugas Akhir ini dikerjakan sebagai syarat untuk kelulusan dalam sidang sarjana.

  Selama mengerjakan Tugas akhir ini penulis begitu banyak mendapatkan bantuan dari berbagai pihak. Oleh karena itu, dalam kesempatan ini perkenankanlah penulis mengucapkan terima kasih kepada:

  Dr. Ir. Iriany, M.Si

  1. sebagai Dosen Pembimbing yang telah membimbing dan Ibu memberikan masukan selama menyelesaikan tugas akhir ini.

  Dr. Eng. Irvan, MT selaku Ketua Departemen Teknik Kimia.

  2. Bapak

  Ibu Dr. Ir. Fatimah, MT selaku sekretaris Departemen Teknik Kimia 3.

  4. Bapak Mhd. Hendra S.Ginting, ST, MT, selaku Koordinator Tugas Akhir.

  5. Seluruh Dosen Pengajar dan Pegawai administrasi Departemen Teknik Kimia, Fakultas Teknik, Universitas Sumatera Utara yang telah memberikan ilmu kepada penulis selama menjalani studi.

  6. Orang tua saya Tunggul Michael Sitanggang dan Chairani Perangin-angin, dan kakak saya Yanuarti Tika Anggreni Sitanggang, Juniarti Angelina Sitanggang,dan Paskah Aprianti Sitanggang yang selalu mendukung penulis dalam melaksanakan studi dan dalam proses pengerjaan skripsi ini.

  7. Teman-teman angkatan 2011, 2012 dan 2013 Program Ekstensi Teknik Kimia yang memberikan dukungan dan semangat kepada penulis.

  8. Penulis menyadari bahwa Tugas Akhir ini masih terdapat banyak kekurangan dan ketidaksempurnaan. Oleh karena itu penulis sangat mengharapkan saran dan kritik yang sifatnya membangun demi kesempurnaan pada penulisan berikutnya. Semoga laporan ini dapat bermanfaat bagi kita semua.

  Medan, Januari 2015 Penulis,

  Andrew Faguh Sitanggang 120425002

INTI SARI

  Pabrik asam oksalat ini direncanakan akan berproduksi dengan kapasitas 3.000 ton tahun (378,788 kg/jam) dan beroperasi selama 330 hari dalam setahun. Pabrik ini diharapkan dapat memenuhi kebutuhan Indonesia terhadap kebutuhan asam oksalat dan ditargetkan dapat mengekspor asam oksalat.

  Lokasi pabrik yang direncanakan adalah di daerah Kuala Tanjung, Kabupaten

  2 Batubara, Sumatera Utara dengan luas tanah yang dibutuhkan sebesar 8.774 m untuk

  2 wilayah pabrik dan 2.000 m untuk perumahan.

  Tenaga kerja yang dibutuhkan untuk mengoperasikan pabrik sebanyak 141 orang. Bentuk badan usaha yang direncakan adalah Perseroan Terbatas dan bentuk organisasinya adalah organisasi garis dan staff.

  Hasil analisa terhadap aspek ekonomi pabrik asam oksalat ini adalah: = Rp 207.641.761.908,92,-

• = Rp 234.183.093.755,72,-

  Modal Inversatasi

• = Rp. 377.726.658.964

  Biaya Produksi Per Tahun

  Harga Jual Produk Per tahun = Rp. 72.127.977.076,30,-

• = 30,4 %

  Laba Bersih Per Tahun

• = 28,5 %

  Profit Margin (PM)

• = 34,7 %

  Break Even Point (BEP)

  Return on Investment (ROI) = 2,88 tahun

• = 62,9 %

  Pay Out Time (POT)

• = 45,67 %

  Return on Network (RON)

• Dari hasil analisa aspek ekonomi, maka dapat disimpulkan bahwa pabrik pembuatan asam oksalat ini layak untuk didirikan.

  Internal Rate of Return (IRR)

  Universitas Sumatera Utara

  3.8 Reaktor Asam Oksalat ................................................................ III-3

  2.3 Sifat

  3.7 Rotary Vacuum Filter .................................................................. III-3

  3.6 Vibrating Screen ......................................................................... III-2

  3.5 Tangki Pendingin ........................................................................ III-2

  3.4 Reaktor Kalsium Oksalat ............................................................ III-1

  3.3 Tangki Penyimpan Alang-Alang ................................................ III-1

  3.2 Rotary Cutter Knife ..................................................................... III-1

  3.1 Gudang Penyimpanan Alang-Alang ........................................... III-1

  

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

  25 Deskripsi Proses ......................................................................... II-12

  2.4 Proses Pembuatan Asam Oksalat ................................................. II-5

  2.3.1 Sifat- Sifat Utama ............................................................. II-3

  2.2 Tanaman Alang- Alang ................................................................ II-3

  

DAFTAR ISI

  2.1.2 Kegunaan Asam Oksalat ..................................................... II-1

  2.1.1 Sifat-sifat Asam Oksalat Dihidrat ....................................... II-1

  2.1 Asam Oksalat ............................................................................... II-1

  

BAB II TINJAUAN PUSTAKA ....................................................................... II-1

  1.4 Manfaat Pra Rancangan Pabrik ...................................................... I-2

  1.3 Tujuan Pra Rancangan Pabrik ........................................................ I-2

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

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

  

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

  

INTISARI ................................................................................................................... ii

DAFTAR ISI .............................................................................................................. iii

DAFTAR TABEL .................................................................................................... vii

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

DAFTAR LAMPIRAN ............................................................................................ xii

  

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

  Hal

• – Sifat Bahan Utama ............................................................ II-3

  3.9 Filter Press ................................................................................... III-4

  3.10 Evaporator ................................................................................... III-4

  3.11 Kristalizer .................................................................................... III-4

  3.12 Centrifuge .................................................................................... III-5

  3.13 Ball Mill ...................................................................................... III-6

  3.14 Vibrating Screen II ...................................................................... III-6

  

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

  4.1 Reaktor Kalsium Oksalat ............................................................ IV-1

  4.2 Tangki Pendingin ........................................................................ IV-1

  4.3 Rotary Vacuum Filter .................................................................. IV-2

  4.4 Reaktor Asam Oksalat ................................................................ IV-2

  4.5 Cooler I ....................................................................................... IV-2

  4.6 Filter Press ................................................................................... IV-2

  4.7 Evaporator ................................................................................... IV-3

  4.8 Cooler II ...................................................................................... IV-3

  4.9 Kristalizer .................................................................................... IV-3

  4.10 Centrifuge .................................................................................... IV-3

  

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

  5.1 Gudang Bahan Baku Alang-Alang (GB-01) ................................ V-1

  5.2 Rotary Cutter Knife (RCK-01) ..................................................... V-1

  5.3 Tangki Penampung Alang-Alang (TP-01) ................................... V-1

  5.4 Belt Conveyer (BC-01) ................................................................ V-2

  5.5 Tangki Penampung Ca(OH)

  2 (TP-02) .......................................... V-2

  5.6 Tangki Oksigen (TP-03) .............................................................. V-3

  5.7 Reaktor Asam Oksalar (R-01) ...................................................... V-3

  5.8 Screw Conveyer (SC-01) ............................................................. V-3

  5.9 Bucket Elevator (BE-01) .............................................................. V-3

  5.10 Tangki Pendingin (TP-04) ........................................................... V-4

  5.11 Screw Conveyer (SC-02) ............................................................. V-4

  5.12 Vibrating Screen (VS-01) ............................................................ V-4

  5.13 Screw Conveyer (SC-03) ............................................................. V-5

  5.14 Rotary Vacuum Filter (RVF-01) .................................................. V-5

  5.15 Bucket Elevator (BE-02) .............................................................. V-6

  5.16 Tangki Penampung H SO (TP-05) ............................................. V-6

  2

  

4

  5.17 Reaktor Asam Oksalat (R-02) ...................................................... V-6

  5.18 Cooler I (C-01) ............................................................................. V-7

  5.19 Filter Press (FP-01) ...................................................................... V-7

  5.20 Bak Penampung (BP-01) ............................................................. V-7

  5.21 Pompa (P-01) ............................................................................... V-8

  5.22 Evaporator (EV-01) ...................................................................... V-8

  5.23 Cooler (C-02) ............................................................................... V-9

  5.24 Kristalizer (K-01) ......................................................................... V-9

  5.25 Centrifuge (CF-01) ..................................................................... V-10

  5.26 Bak Penampung (BP-02) ........................................................... V-10

  5.27 Screw Conveyer (SC-04) ........................................................... V-10

  5.28 Ball Mill (BM-01) ...................................................................... V-11

  5.29 Vibrating Screen (VS-02) .......................................................... V-11

  5.30 Bak Penampung (BP-02) ........................................................... V-11

  5.31 Screw Conveyer (SC-05) ........................................................... V-11

  5.31 Gudang Penyimpan Produk(GB-02) .......................................... V-12

  

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

  6.1 Instrumentasi ............................................................................... VI-1

  6.2 Keselamatan Kerja ...................................................................... VI-3

  

BAB VII UTILITAS .......................................................................................... VII-1

  7.1 Unit Penyedia Uap (Steam) ...................................................... VII-1

  7.2 Unit Penyedia Air ..................................................................... VII-5

  7.3 Kebutuhan Bahan Kimia untuk Utilitas .................................. VII-14

  7.4 Unit Penyedia Listrik .............................................................. VII-14

  7.5 Unit Penyedia Bahan Bakar .................................................... VII-12

  7.6 Unit Pengolahan Limbah ........................................................ VII-18

  7.7 Spesifikasi Peralatan Utilitas .................................................. VII-22

  

BAB VIII LOKASI DAN TATA LETAK PABRIK .................................... VIII-1

  8.1 Lokasi Pabrik ........................................................................... VIII-1

  8.2 Tata Letak Pabrik ..................................................................... VIII-5

  

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

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

  9.1.1 Bentuk Organisasi Garis .................................................... IX-2

  9.1.2 Bentuk Organisasi Fungsional ........................................... IX-2

  9.1.3 Bentuk Organisasi Garis dan Staf ...................................... IX-3

  9.1.4 Bentuk Oraganisasi Fungsional dan Staf ........................... IX-3

  9.2 Bentuk Perusahaan ...................................................................... IX-4

  9.3 Uraian, Tugas, Wewenang, dan Tanggung Jawab ...................... IX-4

  9.3.1 Rapat Umum Pemegang Saham ........................................ IX-4

  9.3.2 Pemegang Saham ............................................................... IX-5

  9.3.3 Dewan Komisaris ............................................................... IX-5

  9.3.4 Dewan Direksi ................................................................... IX-5

  9.3.5 Pembagian Devisi dan Tugasnya ....................................... IX-6

  9.4 Status Karyawan dan Upah ......................................................... IX-9

  9.5 Jadwal Kerja Karyawan .............................................................. IX-9

  9.6 Jaminan Sosial dan Kesejahteraan Karyawan .......................... IX-11

  9.7 Sistem Pengajian ....................................................................... IX-14

  9.8 Fasilitas Tenaga Kerja .............................................................. IX-15

  

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

  10.1 Modal Investasi ............................................................................ X-1

  10.1.1 Modal Investasi Tetap/Fixed Capital Investment (FCI) X-1

  10.1.2 Modal Kerja/Working Capital (WC) ............................. X-3

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

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

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

  10.3 Perkiraan Rugi/Laba Usalah ........................................................ X-5

  10.4 Analisa Aspek Ekonomi .............................................................. X-5

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

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

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

  10.4.4 Pay Out Time (POT) ......................................................... X-7

  10.4.5 Return on Network ........................................................... X-7

  10.4.6 Internal Rate of Return ..................................................... X-7

  

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

DAFTAR PUSTAKA ............................................................................................... xii LAMPIRAN

  

DAFTAR TABEL

Tabel 3.12 Centrifuge ........................................................................................ III-5Tabel 6.1 Alat Instrument yang digunakan .................................................... VI-6Tabel 4.10 Centrifuge ........................................................................................ IV-3Tabel 4.9 Kristalizer ........................................................................................ IV-3Tabel 4.8 Cooler II........................................................................................... IV-3Tabel 4.7 Evaporator ....................................................................................... IV-3Tabel 4.6 Filter Press ....................................................................................... IV-3Tabel 4.5 Cooler I ............................................................................................ IV-2Tabel 4.4 Reaktor Asam Oksalat ..................................................................... IV-2Tabel 4.3 Rotary Vacuum Filter ...................................................................... IV-2Tabel 4.2 Tangki Pendigin............................................................................... IV-1Tabel 4.1 Reaktor Kalsium Oksalat ................................................................. IV-1Tabel 3.11 Vibrating Screen II .......................................................................... III-5Tabel 3.13 Ball Mill........................................................................................... III-5Tabel 3.11 Kristalizer ........................................................................................ III-4

  Hal

Tabel 3.10 Evaporator ....................................................................................... III-4Tabel 3.9 Filter Press ....................................................................................... III-4Tabel 3.8 Reaktor Asam Oksalat ..................................................................... III-3Tabel 3.7 Rotary Vacuum Filter ...................................................................... III-3Tabel 3.6 Vibrating Screen .............................................................................. III-2Tabel 3.5 Tangki Pendingin............................................................................. III-2Tabel 3.4 Reaktor Kalsium Oksalat ................................................................. III-1Tabel 3.3 Tangki Penyimpan Alang-Alang ..................................................... III-1Tabel 3.2 Rotary Cutter Knife ......................................................................... III-1Tabel 3.1 Gudang Penyimpan Alang-Alang.................................................... III-1

  Asam Oksalat.................................................................................. II-12

Tabel 2.1 Perbedaan Keuntungan dan Kerugian pada Berbagai Proses SintesaTabel 1.1 Impor Asam Oksalat di Indonesia ...................................................... I-2Tabel 6.2 Alat Pengaman yang digunakan ..................................................... VI-8Tabel 7.1 Kebutuhan Steam untuk Pemanas dan Proses ............................... VII-2Tabel 7.2 Kebutuhan Air Pendigin pada Peralatan Proses ............................ VII-6Tabel 7.3 Kebutuhan Air Proses .................................................................... VII-7Tabel 7.4 Karakteristik Air Sungai ................................................................ VII-8Tabel 7.5 Kebutuhan Bahan Kimia Untuk Utilitas ...................................... VII-14Tabel 7.6 Kebutuhan Tenaga Listrik Proses ................................................ VII-15Tabel 7.7 Kebutuhan Tenaga Listrik Utilitas .............................................. VII-16Tabel 7.8 Analog Perhitungan Pompa Utilitas ............................................ VII-23Tabel 8.1 Luas Lokasi Pabrik Asam Oksalat ............................................... VIII-6Tabel 8.2 Tata Letak Pabrik Asam Oksalat .................................................. VIII-7Tabel 9.1 Jadwal Kerja Karyawan Pabrik Asam Oksalat .............................. IX-10Tabel 9.2 Jumlah Karyawan Pabrik Asam Oksalat ....................................... IX-12Tabel 9.3 Sistem Pengajian ........................................................................... IX-14

  Tabel LA.1 Daftar Nilai Berat Molekul ............................................................. LA-1 Tabel LA.2 Komposisi Alang-alang .................................................................. LA-1 Tabel LA.3 Gudang Penyimpan Alang-alang .................................................... LA-2 Tabel LA.4 Rotary Cutter Knife ........................................................................ LA-2 Tabel LA.5 Tangki Penampung alang-Alang .................................................... LA-2 Tabel LA.6 Reaktor Asam Oksalat .................................................................... LA-5 Tabel LA.7 Tangki Pendingin............................................................................ LA-5 Tabel LA.8 Vibrating Screen ............................................................................. LA-8 Tabel LA.9 Rotary Vacuum Filter ................................................................... LA-10 Tabel LA.10 Reaktor Asam Oksalat .................................................................. LA-14 Tabel LA.11 Filter Press .................................................................................... LA-16 Tabel LA.12 Evaporator .................................................................................... LA-18 Tabel LA.13 Kristalizer ..................................................................................... LA-20 Tabel LA.14 Centrifuge ..................................................................................... LA-22 Tabel LA.15 Ball Mill........................................................................................ LA-25 Tabel LA.16 Vibrating Screen II ....................................................................... LA-28 Tabel LB.1 Reaktor Kalsium Oksalat ................................................................ LB-9 Tabel LB.2 Tangki Pendigin............................................................................ LB-12 Tabel LB.3 Rotary Vacuum Filter ................................................................... LB-14

  Tabel LB.4 Reaktor Asam Oksalat .................................................................. LB-21 Tabel LB.5 Cooler I ......................................................................................... LB-23 Tabel LB.6 Filter Press .................................................................................... LB-25 Tabel LB.7 Evporator ...................................................................................... LB-27 Tabel LB.8 Cooler II........................................................................................ LB-28 Tabel LB.9 Kristalizer ..................................................................................... LB-30 Tabel LB.10 Centrifuge ..................................................................................... LB-31 Tabel LE.1 Perincian Harga Bangunan, dan Sarana Bangunan ........................ LE-2 Tabel LE.2 Penafsiran Indeks Harga dengan Least Square .............................. LE-3 Tabel LE.3 Estimasi Harga Peralatan Proses .................................................... LE-5 Tabel LE.4 Estimasi Harga Peralatan Utilitas ................................................... LE-6 Tabel LE.5 Biaya Sarana Transportasi .............................................................. LE-8 Tabel LE.6 Perincian Gaji Pegawai................................................................. LE-11 Tabel LE.7 Perincian Biaya Kas selama 3 bulan ............................................ LE-13 Tabel LE.8 Perincian Modal Kerja .................................................................. LE-14 Tabel LE.9 Perhitungan Biaya Depresiasi....................................................... LE-15 Tabel LE.10 Data Perhitungan BEP .................................................................. LE-22 Tabel LE.11 Data Perhitungan IRR................................................................... LE-23

  

DAFTAR GAMBAR

  Hal

Gambar 2.1 Alang-Alang ..................................................................................... II-2Gambar 2.2 Proses Oksidasi Glukosa dengan Asam Nitrat ................................. II-6Gambar 2.3 Proses Oksidasi Etilen Glikol dengan Asam Nitrat .......................... II-7Gambar 2.5 Proses Oksidasi Propilen Glikol ....................................................... II-9Gambar 2.6 Proses Peleburan Alkali .................................................................. II-10Gambar 2.7 Proses Fermentasi Glukosa............................................................. II-11Gambar 7.1 Unit Penyedia Listrik Pabrik Asam Oksalat ................................ VII-14Gambar 8.1 Lokasi Pabrik Asam Oksalat ........................................................ VIII-4Gambar 8.2 Tata letak Pra Rncangan Pabrik Pembuatan Asam Oksalat ......... VIII-7Gambar 9.1 Struktur Organisasi Pabrik Asm Oksalat ....................................... IX-16

  Gambar LE.1 Grafik BEP ................................................................................. LE-22