pra rancangan pabrik - ubharajaya repository

PRA RANCANGAN PABRIK

PEMBUATAN GLISEROL DARI CRUDE PALM OIL (CPO)

DENGAN PROSES HIDROLISIS KAPASITAS 3.000

TON/TAHUN

SKRIPSI

Diajukan untuk Memenuhi Persyaratan Memperoleh

Gelar Sarjana Teknik Kimia

Oleh :

MUHAMAD SOFIAN

2014 1023 5027

PROGRAM STUDI TEKNIK KIMIA

FAKULTAS TEKNIK

UNIVERSITAS BHAYANGKARA JAKARTA RAYA

2018

Prarancangan Pabrik..., Muhamad, Fakultas Teknik 2018

ABSTRAK

Dari hasil analisa dan perhitungan dapat diambil kesimpulan sebagai berikut:

1. Kapasitas Pra Rancangan Pabrik Pembuatan gliserol dari Crude Palm Oil

(CPO), gliserol direncanakan 3.000 ton/tahun.

2. Bentuk badan usaha adalah Perseroan Terbatas (PT) dengan bentuk

organisasi garis dan staf.

3. Lokasi pabrik direncanakan didirikan di daerah Garut, tepatnya kp.Cimari

Ds Cigadog Kabupaten Garut.

4. Luas tanah yang dibutuhkan adalah 9.500 m2.

5. Jumlah tenaga kerja yang dibutuhkan adalah 145 orang.

6. Dari hasil analisa ekonomi Pabrik Pembuatan Gliserol ini adalah sebagai

berikut :

Modal Investasi : Rp 970.100.642.693,-

Biaya Produksi : Rp 1.435.631.534.180,-

Hasil Penjualan : Rp 1.811.338.512.984,-

Laba Bersih : Rp 261.679.910.737,-

Profit Margin : 20,64 %

Break Even Point : 23,76 %

Return on Investment : 26,97 %

Return on Network : 44,96 %

Pay Out Time : 3,7 tahun

Internal Rate of Return : 35,43 %

Dari hasil analisa evaluasi ekonomi dapat disimpulkan bahwa Pabrik

Pembuatan Gliserol dari Crude Palm Oil (CPO) ini layak untuk didirikan.


iii

DAFTAR ISI

Hal

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

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

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

1.1 Latar Belakang ..................................................................................................... 1

1.2 Kapasitas Prarancangan ....................................................................................... 6

1.3 AlasanPemilihan Lokasi Pabrik ........................................................................... 8

BAB II TINJAUAN PUSTAKA ......................................................................................... 11

2.1 Dasar Teori ........................................................................................................... 11

2.2 Gliserol ................................................................................................................. 11

2.3 Kinetika Reaksi .................................................................................................... 14

BAB III SPESIFIKASI BAHAN DAN URAIAN PROSES .............................................. 18

3.1 Sifat-Sifat Bahan Baku dan Produk ..................................................................... 18

3.2 Deskripsi Proses ................................................................................................... 21

BAB IV NERACA MASSA ............................................................................................... 22

4.1 Reaktor Hidrolisis (R-01) ..................................................................................... 22

4.2 Separator (SP-01) ................................................................................................. 23

4.3 Grease Separator (SP-02) ..................................................................................... 23

4.4 Evaporator (EV-01) .............................................................................................. 23

4.5 Flash Distilasi (FD-01) ......................................................................................... 24

BAB V NERACA PANAS ................................................................................................. 25

5.1 Heat Exchanger Air (HE-01) ............................................................................... 25

5.2 Heat Exchanger CPO (HE-02) ............................................................................. 25

5.3 Reaktor Hidrolisis (R-01) ..................................................................................... 26

5.4 Separator (SP-01) ................................................................................................. 26

5.5 Grease Separator (SP-02) ..................................................................................... 27

5.6 Evaporator (EV-01) .............................................................................................. 27

5.7 Heat Exchanger Flash Distilasi (HE-04) .............................................................. 27

5.8 Flash Distilasi (FD-01) ......................................................................................... 28

5.9 Heat Exchanger Gliserol (HE-05) ........................................................................ 28


iv

BAB VI SPESIFIKASI ALAT ............................................................................................ 29

6.1 Tangki Bahan Baku Air (T-01) ............................................................................ 29

6.2 Tangki Bahan Baku CPO (T-02) ......................................................................... 29

6.3 Tangki Produk Asam Lemak (T-03) .................................................................... 30

6.4 Tangki Penampungan CPO (T-05) ...................................................................... 31

6.5 Tangki Produk Gliserol (T-04) ............................................................................ 31

6.6 Heat Exchanger Air (HE-01) ............................................................................... 32

6.7 Heat Exchanger CPO (HE-02) ............................................................................. 32

6.8 Heat Exchanger Pendingin Asam Lemak (HE-03) .............................................. 33

6.9 Separator (SP-01) ................................................................................................. 33

6.10 Grease Separator (SP-02) ................................................................................... 34

6.11 Tangki Evaporator (EV-01) ............................................................................... 35

6.12 Flash Distilasi (FD-01) ....................................................................................... 35

6.13 Pompa Tangki Air (PO-01) ................................................................................ 36

6.14 Pompa Tangki CPO (PO-02) ............................................................................. 36

6.15 Pompa Evaporator (PO-03) ................................................................................ 37

6.16 Pompa Flash Distilasi (PO-04)........................................................................... 37

BAB VII UTILITAS ........................................................................................................... 39

7.1 Kebutuhan Uap..................................................................................................... 39

7.2 Kebutuhan Air ...................................................................................................... 40

7.3 Kebutuhan Listrik ................................................................................................ 48

7.4 Kebutuhan Bahan Bakar ...................................................................................... 48

7.5 Unit Pengolahan Limbah...................................................................................... 50

7.6 Spesifikasi Peralatan ............................................................................................ 53

BAB VIII LOKASI DAN TATA LETAK PABRIK .......................................................... 54

8.1 Lokasi Pabrik ....................................................................................................... 54

8.2 Tata Letak Pabrik ................................................................................................. 59

8.3 Perincian Luas Tanah ........................................................................................... 61

BAB IX ORGANISASI DAN MANAJEMEN PERUSAHAAN ....................................... 63

9.1 Organisasi Perusahaan ......................................................................................... 63

9.2 Manajemen Perusahaan ........................................................................................ 66

9.3 Bentuk Hukum Badan Usaha ............................................................................... 68


iv

9.4 Uraian Tugas, Wewenang dan Tanggungjawab................................................... 69

9.5 Sistem Kerja ......................................................................................................... 72

9.6 Jumlah Karyawan dan Tingkat Pendidikan.......................................................... 73

9.7 Sistem Penggajian ................................................................................................ 74

9.8 Fasilitas Tenaga Kerja .......................................................................................... 75

BAB X EVALUASI EKONOMI ........................................................................................ 77

10.1 Modal Investasi .................................................................................................. 77

10.2 Biaya Produksi Total .......................................................................................... 81

10.3 Total penjualan ................................................................................................... 82

10.4 Bonus Perusahaan .............................................................................................. 82

10.5 Perkiraan Rugi/Laba Usaha................................................................................ 82

10.6 Analisa Aspek Ekonomi ..................................................................................... 82

BAB XI KESIMPULAN ..................................................................................................... 86

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

LAMPIRAN


DAFTAR TABEL

Halaman

Tabel 1.1 Komponen penyusun minyak sawit (CPO) ........................................... 2

Tabel 1.2 Komponen penyusun trigliserida .......................................................... 2

Tabel 1.3 Harga produk dari turunan asam lemak ................................................ 3

Tabel 1.4 Industri Asam Lemak di Indonesia ....................................................... 3

Tabel 1.5 Data impor asam lemak......................................................................... 4

Tabel 1.6 Daftar harga gliserol.............................................................................. 4

Tabel 1.7 Produksi Minyak Sawit Di Indonesia ................................................... 5

Tabel 1.8 Data impor gliserol (2012 – 2016) ........................................................ 6

Tabel 1.9 Pabrik yang sudah beroperasi dalam pembuatan gliserol ..................... 6

Tabel 1.10 Tabel kebutuhan gliserol di Indonesia ................................................ 7

Tabel 2.1 Perbandingan beberapa metode pengolahan gliserol ............................ 11

Tabel 4.1 Neraca massa pada reaktor hidrolisis .................................................... 22

Tabel 4.2 Neraca massa pada separator ................................................................ 23

Tabel 4.3 Neraca massa pada grease separator ..................................................... 23

Tabel 4.4 Neraca massa pada evaporator .............................................................. 23

Tabel 4.5 Neraca massa pada flash distilasi .......................................................... 24

Tabel 5.1 Neraca panas heat exchanger air ........................................................... 25

Tabel 5.2 Neraca panas heat exchanger CPO ....................................................... 25

Tabel 5.3 Neraca panas pada reaktor hidrolisis .................................................... 26

Tabel 5.4 Neraca panas pada separator ................................................................. 26

Tabel 5.5 Neraca panas pada grease Separator ..................................................... 27

Tabel 5.6 Neraca panas pada evaporator ............................................................... 27

Tabel 5.7 Neraca panas heat exchanger flash distilasi .......................................... 28

Tabel 5.8 Neraca panas flash distilasi ................................................................... 28

Tabel 5.9 Neraca panas heat exchanger asam lemak ............................................ 28


Tabel 5.10 Neraca panas pada heat exchanger gliserol ......................................... 29

Tabel 7.1 Kebutuhan Uap Pabrik Pembuatan Gliserol ......................................... 39

Tabel 7.2 Kebutuhan Air Pendingin pada Alat ..................................................... 40

Tabel 7.3 kebutuhan air proses pada alat .............................................................. 42

Tabel 7.4 Pemakaian air untuk berbagai kebutuhan ............................................. 43

Tabel 7.5 Perincian Kebutuhan Listrik ................................................................. 49

Tabel 8.1 Perincian Luas Tanah ............................................................................ 61

Tabel 9.2 Jumlah Karyawan dan Kualifikasinya .................................................. 73

Tabel 9.3 Perincian Gaji Karyawan ...................................................................... 75


DAFTAR GAMBAR

Halaman

Gambar 1.1 Lokasi Pabrik ....................................................................................................... 8

Gambar 8.1 Lay Out Perusahaan. .......................................................................................... 62

Gambar 9.1 Struktur Organisasi Perusahaan ......................................................................... 66


pra rancangan pabrik - ubharajaya repository

Documents