Implementasi Sistem Kontrol Konsentrasi Asam Sulfat Pada Proses Pengenceran Menggunakan Tuning IMC-PI Untuk Memperbaiki Kualitas Produksi

Arivianto, Irvan Wahyu (2026) Implementasi Sistem Kontrol Konsentrasi Asam Sulfat Pada Proses Pengenceran Menggunakan Tuning IMC-PI Untuk Memperbaiki Kualitas Produksi. Other thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

Asam sulfat (H₂SO₄) merupakan salah satu produk kimia industri yang memiliki peranan penting dan digunakan secara luas dalam berbagai sektor, seperti industri pupuk, petrokimia, serta berbagai proses reaksi kimia lainnya. Pada proses produksi asam sulfat dalam skala industri, kestabilan kualitas dan konsentrasi produk menjadi faktor yang sangat penting karena berpengaruh langsung terhadap kualitas produk akhir. Salah satu industri asam sulfat di Gresik memproduksi asam sulfat menggunakan metode contac proses, dengan tahap akhir berupa pengenceran oleum menggunakan dilution water hingga mencapai konsentrasi target sekitar 98,5%. Pada kondisi eksisting, pengaturan konsentrasi di unit dilution tank masih dilakukan secara manual, yaitu dengan mengatur debit aliran air pengencer melalui katup berdasarkan referensi dari liquid analyzer, metode pengendalian ini masih memiliki kelemahan, karena rentan menimbulkan overshoot pada hasil produksi. Penelitian ini bertujuan merancang dan mengimplementasikan pengendali Internal Model Control - Proportional Integral (IMC-PI) menggunakan model First Order Plus Dead Time (FOPDT), model proses diperoleh melalui identifikasi menggunakan data step response untuk menentukan parameter gain proses, konstanta waktu, dan waktu tunda sebagai dasar penalaan parameter kontrol. Kinerja pengendali kemudian dievaluasi berdasarkan parameter Maximum Deviation, Mean Absolute Error (MAE), Root Mean Square Error (RMS), standar deviasi, range konsentrasi, Time Out of Specification, dan persentase Out of Specification. Hasil penelitian menunjukkan bahwa implementasi IMC-PI mampu meningkatkan performa pengendalian secara signifikan dibandingkan sistem eksisting. Nilai Maximum Deviation berhasil diturunkan dari 1,45% menjadi 0,0543%, MAE dari 0,5006% menjadi 0,0116%, RMSE dari 0,7901% menjadi 0,0150%, standar deviasi dari 0,6318% menjadi 0,0150%, serta range konsentrasi dari 2,3908% menjadi 0,1062%. Selain itu, Time Out of Specification berkurang dari 10728 detik (50,17%) menjadi 0 detik (0%), sehingga seluruh hasil pengujian berada dalam rentang spesifikasi operasi 98,40%–98,70%. Berdasarkan hasil tersebut, dapat disimpulkan bahwa metode IMC-PI berbasis FOPDT mampu meningkatkan akurasi, kestabilan, dan kualitas pengendalian konsentrasi asam sulfat pada proses dilution.
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Sulfuric acid (H₂SO₄) is one of the most important industrial chemicals and is widely used in various sectors, including the fertilizer, petrochemical, and chemical processing industries. In industrial sulfuric acid production, maintaining product quality and concentration stability is essential because it directly affects the quality of the final product. A sulfuric acid plant in Gresik produces sulfuric acid using the Contact Process, where the final stage involves diluting oleum with dilution water to achieve a target concentration of approximately 98.5%. Under the existing operating conditions, the concentration in the dilution tank is manually controlled by adjusting the dilution water flow through a control valve based on measurements from a liquid analyzer. However, this control strategy has limitations and is prone to producing overshoot in the product concentration. This study aims to design and implement an Internal Model Control–Proportional Integral (IMC-PI) controller based on a First Order Plus Dead Time (FOPDT) process model. The process model was identified using step response data to determine the process gain, time constant, and dead time, which were subsequently used for controller tuning. The controller performance was evaluated using several performance indices, namely Maximum Deviation, Mean Absolute Error (MAE), Root Mean Square Error (RMSE), Standard Deviation, Concentration Range, Time Out of Specification, and Percentage Out of Specification. The results demonstrate that the proposed IMC-PI controller significantly improves the control performance compared with the existing system. The Maximum Deviation was reduced from 1.45% to 0.0543%, MAE from 0.5006% to 0.0116%, RMSE from 0.7901% to 0.0150%, Standard Deviation from 0.6318% to 0.0150%, and the Concentration Range from 2.3908% to 0.1062%. Furthermore, the Time Out of Specification decreased from 10,728 seconds (50.17%) to 0 seconds (0%), indicating that all measured concentration values remained within the operating specification range of 98.40%–98.70%. Based on these results, it can be concluded that the FOPDT-based IMC-PI controller effectively improves the accuracy, stability, and overall performance of sulfuric acid concentration control in the dilution process.

Item Type:	Thesis (Other)
Subjects:	T Technology > TK Electrical engineering. Electronics Nuclear engineering > TK3070 Automatic control T Technology > TK Electrical engineering. Electronics Nuclear engineering > TK5105.5956 Quality of service. Reliability Including network performance
Divisions:	Faculty of Vocational > 36304-Automation Electronic Engineering
Depositing User:	Irvan Wahyu Arivianto
Date Deposited:	04 Aug 2026 03:22
Last Modified:	04 Aug 2026 03:22
URI:	http://repository.its.ac.id/id/eprint/142682

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