TUGAS AKHIR

PRARANCANGAN PABRIK

PABRIK DISODIUM PHOSPHATE HEPTAHYDRATE DARI

SODIUM CARBONATE DAN PHOSPHORIC ACID KAPASITAS

55.000 TON/ TAHUN

Oleh :

ALWAFI CHOIRUL WIBOWO

NIM. D500100060

Dosen Pembimbing :

1. KUSMIYATI, S.T., M.T., Ph.D.

2. KUN HARISMAH, Ph.D.

JURUSAN TEKNIK KIMIA FAKULTAS TEKNIK

UNIVERSITAS MUHAMMADIYAH SURAKARTA

SURAKARTA

2016

iii

PERSEMBAHAN

Karya ini kupersembahkan kepada:

Ibu serta Bapak tercinta, terimakasih atas segala do’a, dukungan, kasih

sayang, pengorbanan dan pendidikan yang telah diberikan selama ini. Hanya

do’a dan bakti yang dapat aku beri untuk membalas kasih sayangmu.

Teman-teman Teknik Kimia 2010 seperjuangan terima kasih atas do’a dan

dukungannya.

Semua Teknik Kimia UMS yang tidak bisa disebutkan satu persatu terima kasih

atas kebersamaannya selama ini. Kenangan indah saat kita bersama semoga bisa

terulang lagi.

Terimakasih buat semuanya…

iv

KATA PENGANTAR

Puji syukur kehadirat Allah SWT karena berkat rahmat dan perlindungan-

Nya sehingga penulis dapat menyelesaikan laporan tugas akhir dengan judul

Prarancangan Pabrik Disodium Phosphate Heptahydrate dari Sodium

Carbonate dan Phosphoric Acid Kapasitas 55.000 Ton/ Tahun.

Dalam penyusunan tugas akhir ini penulis memperoleh banyak bantuan

baik berupa dukungan moral maupun spiritual dari berbagai pihak. Oleh karena

itu penulis mengucapkan terima kasih kepada:

1. Kedua orang tua

2. Ibu Kusmiyati, S.T., M.T., P.hD. selaku dosen pembimbing I

3. Ibu Kun Harismah, P.hD. selaku dosen pembimbing II

4. Bapak Rois Fatoni,S.T.,M.Sc.,P.hD. selaku Ketua Jurusan Teknik Kimia

Universitas Muhammadiyah Surakarta.

5. Gita Indah B. selaku patner penulis dalam mengerjakan laporan ini.

6. Teman-teman Teknik Kimia UMS atas dukungan semangat dan moril

yang diberikan.

Penulis menyadari bahwa laporan ini masih jauh dari sempurna, oleh karena

itu penulis memohon kerendahan hati atas kekurangan dan keterbatasan laporan

ini. Penulis juga mengharapkan kritik dan saran dari pembaca. Semoga laporan

tugas akhir ini bermanfaat.

Surakarta, Februari 2016

Penulis

vi

DAFTAR ISI

HALAMAN JUDUL ....................................................................................... i

HALAMAN PENGESAHAN ......................................................................... ii

HALAMAN PERNYATAAN ORIGINALITAS ............................................ iii

PERSEMBAHAN ............................................................................................ iv

KATA PENGANTAR .................................................................................... v

DAFTAR ISI ................................................................................................... vi

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

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

INTISARI ........................................................................................................ xii

ABSTRACT ..................................................................................................... xiii

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

1.1. Latar Belakang Pendirian Pabrik .............................................. 1

1.2. Kapasitas Rancangan Produksi................................................. 2

1.2.1 Ketersediaan Bahan Baku ................................................ 2

1.2.2 Kebutuhan Disodium Phosphate Heptahydrate di

Indonesia............................................................................3

1.2.3 Kapasitas Minimum...........................................................3

1.3. Pemilihan Lokasi Pabrik........................................................... 4

1.4. Tinjauan Pustaka ...................................................................... 5

1.4.1 Macam-Macam Proses ............................................. 6

1.4.2 Kegunaan Produk ..................................................... 7

1.4.3 Sifat Fisis Dan Kimia ............................................... 8

1.4.4 Tinjauan Proses Secara Umum ................................ 11

BAB II DISKRIPSI PROSES ........................................................................ 12

2.1 Spesifikasi Bahan Baku dan Produk ........................................ 12

2.1.1 Spesifikasi Bahan Baku ........................................... 12

2.1.2 Spesifikasi Produk ................................................... 13

2.2 Konsep Proses ……………………………………………….13

2.2.1 Konsep Dasar ........................................................... 13

2.2.2 Tinjauan Termodinamika ........................................ 13

2.2.3 Tinjauan Kinetika .................................................... 15

2.3 Langkah Proses ........................................................................ 15

2.4 Neraca Massa dan Neraca Panas .............................................. 20

2.4.1 Neraca Massa ........................................................... 21

2.4.2 Neraca Panas ............................................................ 26

2.5 Tata Letak Pabrik dan Peralatan ............................................. 31

2.5.1 Tata Letak Pabrik ..................................................... 31

2.5.2 Tata Letak Peralatan ............................................... 35

vii

BAB III SPESIFIKASI ALAT ........................................................................ 37

3.1 Belt Conveyor ........................................................................... 37

3.2 Bucket Elevator ........................................................................ 38

3.3 Ball Mill .................................................................................... 38

3.4 Blower....................................................................................... 39

3.5 Centrifuge ................................................................................. 40

3.6 Cooler 1 .................................................................................... 40

3.7 Cooler 2 .................................................................................... 41

3.8 Cooler 3 .................................................................................... 41

3.9 Cooler 4 .................................................................................... 42

3.10 Cooling Conveyor ..................................................................... 42

3.11 Cyclone ..................................................................................... 43

3.12 Evaporator ................................................................................ 43

3.13 Heater1 ..................................................................................... 44

3.14 Heater 2 .................................................................................... 44

3.15 Heater 3 .................................................................................... 45

3.16 Kristalizer ................................................................................. 45

3.17 Kompressor............................................................................... 46

3.18 Mixer......................................................................................... 46

3.19 Pompa ....................................................................................... 47

3.20 Reaktor ..................................................................................... 50

3.21 Rotary Dryer ............................................................................. 51

3.22 Screen ....................................................................................... 52

3.23 Screw Conveyor ........................................................................ 52

3.24 Silo ............................................................................................ 53

3.25 Tangki Penyimpanan ................................................................ 55

BAB IV UNIT PENDUKUNG PROSES DAN LABORATORIUM ............. 57

4.1 Unit Pendukung ....................................................................... 57

4.1.1 Unit Penyediaan Air ................................................ 58

4.1.2 Pengolahan Air ........................................................ 60

4.1.3 Unit Kebutuhan Air ................................................. 72

4.1.4 Unit Pengadaan Steam ............................................. 72

4.1.5 Unit Pengadaan Tenaga Listrik ............................... 74

4.1.6 Unit Pengadaan Bahan Bakar .................................. 78

4.1.7 Unit Pengadaan Udara Tekan .................................. 79

4.1.8 Unit Pengolahan Limbah ......................................... 79

4.2 Laboratorium ............................................................................ 80

4.2.1 Program Kerja Laboratorium................................... 81

4.2.2 Metode Analisa ........................................................ 81

viii

4.2.3 Alat-Alat Utama Laboratorium ............................... 82

4.3 Keselamatan dan Kesehatan Kerja ........................................... 83

BAB V MANAJEMEN PERUSAHAAN ....................................................... 85

5.1 Bentuk Perusahaan .................................................................. 85

5.2 Organisasi Perusahaan .............................................................. 85

5.3 Penggolongan Karyawan, Jam Kerja dan Sistem Gaji ............. 88

5.4 Kesejahteraan Sosial ................................................................. 90

5.5 Manajemen Produksi ................................................................ 91

BAB VI ANALISIS EKONOMI .................................................................... 92

6.1 Total Capital Investment (TCI) ................................................ 97

6.2 Working Capital Investment ..................................................... 98

6.3 Manufacturing Cost .................................................................. 98

6.4 General Expenses........................................................................99

6.5 Analisis Ekonomi........................................................................99

BAB VII PEMBAHASAN DAN KESIMPULAN .......................................... 103

7.1 Pembahasan ............................................................................. 103

7.2 Kesimpulan .............................................................................. 103

Daftar Pustaka ................................................................................................. 104

ix

DAFTAR TABEL

Tabel 1.1 Data Kapasitas Produksi Industri Kimia dalam Negeri ................ 1

Tabel 1.2 Data Kebutuhan Ekspor dan Impor Bahan Kimia di Indonesia ... 1

Tabel 1.3 Data Ekspor-Impor Disodium Phosphate di Indonesia ................ 3

Tabel 1.4 Perbandingan Proses Pembuatan Na2HPO4.................................7

Tabel 2.1 Data ∆Hfo pada suhu 298 K .......................................................... 13

Tabel 2.2 Neraca Massa Total ...................................................................... 21

Tabel 2.3 Neraca Massa di Mixer ................................................................. 22

Tabel 2.4 Neraca Massa di Reaktor 1 ........................................................... 22

Tabel 2.5 Neraca Massa di Reaktor 2 ........................................................... 22

Tabel 2.6 Neraca Massa di Reaktor 3 ........................................................... 23

Tabel 2.7 Neraca Massa di Reaktor 4 ........................................................... 23

Tabel 2.8 Neraca Massa di Evaporator ........................................................ 23

Tabel 2.9 Neraca Massa di Kristalizer ......................................................... 24

Tabel 2.10 Neraca Massa di Centrifuge ......................................................... 24

Tabel 2.11 Neraca Massa di Rotary Dryer ..................................................... 24

Tabel 2.12 Neraca Massa di Cyclone ............................................................. 25

Tabel 2.13 Neraca Massa di Cooling Conveyor ............................................. 25

Tabel 2.14 Neraca Massa di Ball Mill ............................................................ 25

Tabel 2.15 Neraca Massa di Screen ............................................................... 26

Tabel 2.16 Neraca Panas di Heat Exchanger 1 .............................................. 26

Tabel 2.17 Neraca Panas di Heat Exchanger 2 .............................................. 26

Tabel 2.18 Neraca Panas di Reaktor 1 ............................................................ 27

Tabel 2.19 Neraca Panas di Reaktor 2 ............................................................ 27

Tabel 2.20 Neraca Panas di Reaktor 3 ............................................................ 28

Tabel 2.21 Neraca Panas di Reaktor 4 ............................................................ 28

Tabel 2.22 Neraca Panas di Cooler 1 ............................................................. 29

Tabel 2.23 Neraca Panas di Cooler 2 ............................................................. 29

Tabel 2.24 Neraca Panas di Cooler 3 ............................................................. 29

Tabel 2.25 Neraca Panas di Cooler 4 ............................................................. 29

Tabel 2.26 Neraca Panas di Evaporator ......................................................... 30

Tabel 2.27 Neraca Panas di Kristalizer .......................................................... 30

Tabel 2.28 Neraca Panas di Rotary Dryer ...................................................... 30

Tabel 2.29 Neraca Panas di Heater ................................................................ 31

Tabel 2.30 Neraca Panas di Cooling Conveyor .............................................. 31

Tabel 2.31 Luas Bangunan Pabrik .................................................................. 33

Tabel 4.1 Jumlah Total Kebutuhan Air ........................................................ 72

Tabel 4.2 Kebutuhan Pengadaaan Steam ..................................................... 72

Tabel 4.3 Konsumsi Listrik untuk Keperluan Proses dan Utilitas ............... 75

x

Tabel 4.4 Konsumsi Listrik Untuk Penerangan ........................................... 77

Tabel 5.1 Penggolongan Karyawan .............................................................. 88

Tabel 6.1 Cost Index Chemichal Plant ......................................................... 93

Tabel 6.2 Indeks Harga Alat Tahun 2003-2010 ........................................... 94

Tabel 6.3 Total Fixed Capital Invesment ..................................................... 97

Tabel 6.4 Working Capital Investment ......................................................... 98

Tabel 6.5 Manufacturing Cost ...................................................................... 98

Tabel 6.6 General Expense ........................................................................... 99

Tabel 6.7 Fixed Cost .................................................................................... 100

Tabel 6.8 Variable Cost ................................................................................ 100

Tabel 6.9 Regulated Cost ............................................................................. 101

Tabel 6.10 Analisa Kelayakan ........................................................................ 102

xi

DAFTAR GAMBAR

Gambar 1.1 Grafik Kebutuhan Impor di Indonesia ................................... 3

Gambar 1.2 Peta Rencana Lokasi Pabrik ................................................... 5

Gambar 2.1 Diagram Alir Kualitatif .......................................................... 18

Gambar 2.2 Diagram Alir Kuantitatif ........................................................ 19

Gambar 2.3 Diagram Alir Neraca Massa ................................................... 20

Gambar 2.4 Tata Letak Pabrik ................................................................... 34

Gambar 2.5 Tata Letak Peralatan Proses ................................................... 36

Gambar 5.1 Bagan Struktur Organisasi Perusahaan .................................. 86

Gambar 6.1 Chemical Engineering Cost Index .......................................... 94

Gambar 6.2 Grafik Analisis Ekonomi ........................................................ 102

xii

INTISARI

Disodium phosphate heptahydrate banyak digunakan dalam industri kimia

seperti sebagai bahan baku pada pembuatan deterjen, sebagai bahan pelunak

air (water treatment), untuk pencelup tekstil, untuk penyamakan kulit dan

bahan pada industri kertas. Untuk memenuhi kebutuhan dalam negeri yang

masih harus diimpor dari luar negeri dan adanya peluang ekspor yang masih

terbuka, maka dirancang pabrik disodium phosphate heptahydrate dengan

kapasitas 55.000 ton/tahun dengan bahan baku H3PO4 3.161,9136 kg/jam dan

Na2CO3 7.468,1387 kg/jam.

Pabrik direncanakan berdiri di Kawasan Industri Gresik, Jawa Timur pada

tahun 2017 dengan luas 45.160m2. Jumlah total kebutuhan air 143.500 kg/jam,

air diperoleh dari sungai Bengawan Solo. Kebutuhan steam total adalah

8.480,8250 kg/ jam, digunakan boiler kapasitas 16.566.328,173 Btu/jam.

Bahan bakar pabrik yang digunakan adalah solar sebesar 20,621 m3/jam.

Kebutuhan listrik pabrik sebesar 2200 kW. Listrik diperoleh dari PLN dan

generator. Udara tekan diperoleh dari dua kompressor yang berkapasitas

masing-masing 100 m3/ jam.

Dari hasil analisis ekonomi diperoleh, Return on Investment (ROI)

sebelum dan sesudah pajak sebesar 45,41% dan 31,79%, Pay OutTime (POT)

sebelum dan sesudah pajak selama 1,81 tahun dan 2,39 tahun, Break-even

Point (BEP) 50%, dan Shutdown Point (SDP) 37,37%. Sedangkan Discounted

Cash Flow (DCF) sebesar 29,80%. Jadi dari segi ekonomi, pabrik disodium

phosphate heptahydrate ini layak untuk dipertimbangkan pendiriannya.

Kata Kunci : disodium phosphate heptahydrate, H3PO4, Na2CO3.

xiii

ABSTRACT

Disodium phosphate heptahydrate is widely used in the chemical industry

as a raw material in the manufacture of detergents, as plasticizers (water

treatment), for textile dyes, leather tanning and materials for the paper industry.

To meet domestic demand still remains to be imported from abroad and their

export opportunities that are still open, disodium phosphate heptahydrate designed

plant with a capacity of 55,000 tons/year with H3PO4 raw materials 3161.9136

kg/h and Na2CO3 7468.1387 kg/hour.

The factory is planned to stand in the Industrial Area Gresik, East Java in

2017 with an area of 45.160m2. The total amount of water needs of 143,500

kg/hour, the water extracted from the river Bengawan Solo. Total steam

requirement is 8480.8250 kg/h, used boilers 16,566,328.173 capacity Btu/hr. The

fuel used is diesel plant of 20.621 m3/hour. The electricity needs of the plant

amounted to 2200 kW. Electricity is obtained from the PLN and generator.

Compressed air is obtained from two compressor with a capacity each of 100

m3/h.

From the results of the economic analysis is obtained, Return on

Investment (ROI) before and after tax of 45.41% and 31.79%, Pay OutTime

(POT) before and after tax for 1.81 years and 2.39 years, Break-even Point (BEP)

50%, and Shutdown Point (SDP) 37.37%. While the Discounted Cash Flow

(DCF) of 29.80%. So in terms of economic, disodium phosphate heptahydrate

plant is worth considering establishment.

Keyword: disodium phosphate heptahydrate, H3PO4, Na2CO3.