PRA RANCANGAN PABRIK PEMBUATAN ASAM OKSALAT DARI ALANG-ALANG DENGAN METODE PELEBURAN ALKALI DENGAN KAPASITAS 2.500 TONTAHUN

  PRA RANCANGAN PABRIK PEMBUATAN ASAM OKSALAT DARI ALANG-ALANG DENGAN METODE PELEBURAN ALKALI DENGAN KAPASITAS 2.500 TON/TAHUN TUGAS AKHIR Diajukan Untuk Memenuhi Persyaratan Ujian Sidang Sarjana Teknik Kimia Oleh : RAHMAD DENNIE AGUSTIN POHAN 120425009 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 2.500

TON/TAHUN

  

TUGAS AKHIR

Diajukan Untuk Memenuhi Persyaratan

Ujian Sarjana Teknik Kimia

Oleh :

  

RAHMAD DENNIE AGUSTIN POHAN

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. RondangTambun, 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 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 2.0500 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: 1.

  Ibu Dr. Ir. Iriany, M.Si sebagai Dosen Pembimbing yang telah membimbing dan memberikan masukan selama menyelesaikan tugas akhir ini.

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

  3. Ibu Dr. Ir. Fatimah, MT selaku sekretaris Departemen Teknik Kimia 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 Edison Pohan dan Ivone Victoria Laemers, abang saya Muhammad Henry Pohan dan kakak saya Fitry Patricia Pohan, Evy Junita Pohan 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.

  Penulis,

  Rahmad Dennie Agustin Pohan

  120425009 Pabrik asam oksalat ini direncanakan akan berproduksi dengan kapasitas 2.500 ton tahun (315.657 kg/jam) dan beroperasi selama 330 hari dalam setahun. Pabrik ini diharapkan dapat memenuhi kebutuhan Indonesia terhadap kebutuhan asam oksalat dan ditargetkan dapat mengimpor asam oksalat.

  

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.

  

Lokasi pabrik yang direncanakan adalah di daerah Kuala Tanjung, Kabupaten

Batubara, Sumatera Utara dengan luas tanah yang dibutuhkan sebesar 8.774 m ² untuk wilayah pabrik dan 2.000 m ² untuk perumahan karyawan.

  Hasil analisa terhadap aspek ekonomi pabrik asam oksalat ini adalah:

• Modal Inversatasi = Rp 170.468.165.821,-
• Biaya Produksi Per Tahun = Rp 196.284.469.644,-
• Harga Jual Produk Per tahun = Rp. 288.530.476.532,-
• Laba Bersih Per Tahun = Rp. 60.205621.243,-
• Profit Margin (PM) = 30,4 %
• Break Even Point (BEP) = 28,3 %
• Return on Investment (ROI) = 35,3 %
• Pay Out Time (POT) = 2,83 tahun
• Return on Network (RON) = 58,8 %
• Internal Rate of Return (IRR) = 46,59 %

  Dari hasil analisa aspek ekonomi, maka dapat disimpulkan bahwa pabrik pembuatan

  asam oksalat ini layak untuk didirikan.

  DAFTAR ISI

  Hal

  

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

  

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

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

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

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

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

  

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

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

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

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

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

  

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

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

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

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

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

  2.3 Sifat

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

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

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

  

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

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

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

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

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

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

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

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

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

  4.5 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

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

  5.16 Tangki Penampung H

  2 SO 4 (TP-05) ............................................. V-6

  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

  

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

  

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

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

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

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

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

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

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

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

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

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

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

  

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

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

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

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

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

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

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

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

  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

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

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

  

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

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

  Hal

Tabel 3.8 Reaktor Asam Oksalat ..................................................................... III-3Tabel 4.1 Reaktor Kalsium Oksalat ................................................................. IV-1Tabel 3.11 Vibrating Screen II .......................................................................... III-5Tabel 3.13 Ball Mill........................................................................................... III-5Tabel 3.12 Centrifuge ........................................................................................ III-5Tabel 3.11 Kristalizer ........................................................................................ III-4Tabel 3.10 Evaporator ....................................................................................... III-4Tabel 3.9 Filter Press ....................................................................................... III-4Tabel 3.7 Rotary Vacuum Filter ...................................................................... III-3Tabel 1.1 Impor Asam Oksalat di Indonesia ...................................................... I-2Tabel 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 4.2 Tangki Pendigin............................................................................... IV-1Tabel 4.4 Reaktor Asam Oksalat ..................................................................... IV-2Tabel 7.3 Kebutuhan Air Proses .................................................................... VII-7Tabel 8.2 Tata Letak Pabrik Asam Oksalat .................................................. VIII-7Tabel 8.1 Luas Lokasi Pabrik Asam Oksalat ............................................... VIII-6Tabel 7.8 Analog Perhitungan Pompa Utilitas ............................................ VII-23Tabel 7.7 Kebutuhan Tenaga Listrik Utilitas .............................................. VII-16Tabel 7.6 Kebutuhan Tenaga Listrik Proses ................................................ VII-15Tabel 7.5 Kebutuhan Bahan Kimia Untuk Utilitas ...................................... VII-14Tabel 7.4 Karakteristik Air Sungai ................................................................ VII-8Tabel 7.2 Kebutuhan Air Pendigin pada Peralatan Proses ............................ VII-6Tabel 4.5 Cooler I ............................................................................................ IV-2Tabel 7.1 Kebutuhan Steam untuk Pemanas dan Proses ............................... VII-2Tabel 6.2 Alat Pengaman yang digunakan ..................................................... VI-8Tabel 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 9.1 Jadwal Kerja Karyawan Pabrik Asam Oksalat .............................. IX-10Tabel 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.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

  .................. 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

  Hal LAMPIRAN A PERHITUNGAN NERACA PANAS ........................................ LA-1 LAMPIRAN B PERHITUNGAN NERACA PANAS ........................................ LB-1 LAMPIRAN C PERHITUNGAN SPESIFIKASI PERALATAN ...................... LC-1 LAMPIRAN D PERHITUNGAN SPESIFIKASI ALAT UTILITAS ................ LD-1 LAMPIRAN E PERHITUNGAN ANALISA EKONOMI ................................. LE-1