Optimasi Metode Mixed Acid Route Pabrik Pupuk NPK Menggunakan Double Screening

Sofani, Achmad Haris and Hapsari, Elisabeth Ratnani Wahyu (2021) Optimasi Metode Mixed Acid Route Pabrik Pupuk NPK Menggunakan Double Screening. Undergraduate thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

Pupuk majemuk NPK atau disebut NPK phonska adalah pupuk yang terdiri lebih dari satu unsur hara utama. Unsur hara tersebut bisa NP, NK, dan NPK. Pupuk ini dibuat dari urea, ammonium, ZA, DAP, MAP, TSP, KCL, ZK, Phospat, Zeolit, Dolomit, Kieserit, TE serta tambahan zat alami dari unsur hara lain. Komposisi pupuk Phonska yang mendasar terdiri atas Nitrogen 15%, Fosfat 15%, Kalium 15%, Sulfur 10 % dan kadar air maksimal 2%. Selama ini pembuatan pupuk NPK masih menggunakan metode mixed acid route dengan kondisi yang masih eksisting sampai saat ini, namun dalam metode ini proses screening hanya terjadi satu kali. Setelah proses srcreening produk akan memasuki cooler untuk dilakukan pendinginan dengan udara dingin agar urea yang terkandung didalamnya tidak rusak, penambahan udara dingin ini mengakibatkan ukuran granule menjadi lebih besar seiring meningkatnya moisture content, sehingga proses pendinginan yang terjadi mengakibatkan ukuran produk menjadi tidak seragam karena didalam produk onsize masih terdapat produk oversize. Akibatnya pada proses pelapisan (coating) terjadi caking dan pada saat disimpan di dalam final storage produk terjadi cracking. Untuk mengatasi hal tersebut maka diinovasikan ide optimasi proses dengan penambahan screening sesuai prinsip jacob standart dengan menggabungkan vibrating-double deck screen dengan polishing screen. Data perbandingan sebelum dan sesudah optimasi dengan jacob standart didapatkan bahwa UI (Uniform Indeks) meningkat dari 50 (proses single screening) menjadi 60 (proses double screening) dengan mengaplikasikan metode dua kali penyaringan yaitu memasang vibrating-double deck standart dan polishing screen. Selain itu dari ide optimasi ini dirancang sebuah pabrik NPK Phonksa dengan kapasitas 150.000 ton/tahun yang direncanakan beroperasi secara kontiyu selama 300 hari/tahun dengan basis waktu 24 jam/hari. Bahan baku yang dibutuhkan adalah NH3 sebesar 68.784,11 kg NH3/hari, H3PO4 sebesar 251.832,50 kg H3PO4 /hari, KCl sebesar 13.1341,21 kg KCl /hari, H2SO4 sebesar 72.807,86 kg H2SO4 /hari, CO(NH2)2 sebesar 29.855,34 kg CO(NH2)2 /hari, (NH4)2SO4 sebesar 65.135,57 kg (NH4)2SO4 /hari. Dari analisa ekonomi yang telah dilakukan dapat disimpulkan bahwa Pabrik NPK Phonska dengan proses mixed acid route layak didirikan karena memiliki nilai discount factor sebesar 39% pada perhitungan IRR dan NPV pada tingkat suku bunga bank 8 % dan laju inflasi 21,871 %, dengan estimasi pengembalian modal terjadi selama 4,77 tahun, serta titik impas penjualan produk sebesar 40,44% atau setara dengan 60.660.361,01 unit produk terjual per-tahun. Sehingga investasi awal modal sebesar Rp91.962.558.805,63 dan investasi modal diakhir pada masa konstruksi sebesar Rp155.351.713.014dinilai dapat memberikan manfaat bagi perusahaan sehingga proyek perencanaan Pabrik NPK Phonska dengan proses mixed acid route dapat di jalankan.
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NPK compound fertilizer or called NPK phonska is a fertilizer that consists of more than one main nutrient. These nutrients can be NP, NK, and NPK. This fertilizer is made from urea, ammonium, ZA, DAP, MAP, TSP, KCL, ZK, Phosphate, Zeolite, Dolomite, Kieserite, TE and additional natural substances from other nutrients. Phonska's basic fertilizer composition consists of 15% Nitrogen, 15% Phosphate, 15% Potassium, 10% Sulfur and a maximum water content of 2%. So far, the manufacture of NPK fertilizers is still using the mixed acid route method with conditions that still exist today, but in this method the screening process only occurs once. After the srcreening process the product will enter the cooler to be cooled with cold air so that the urea contained in it is not damaged, the addition of this cold air causes the granule size to become larger as the moisture content increases, so that the cooling process that occurs causes the product size to become non-uniform because it is inside the product. onsize there are still oversized products. As a result, in the coating process caking occurs and when stored in the final storage of the product cracking occurs. To overcome this, the idea of process optimization was innovated by adding screening according to the standard Jacob principle by combining a vibrating-double deck screen with a polishing screen. Comparative data before and after optimization with the standard Jacob found that the UI (Uniform Index) increased from 50 (single screening process) to 60 (double screening process) by applying two filtering methods, namely installing standard vibrating-double decks and polishing screens. In addition, from this optimization idea, a Phonksa NPK plant was designed with a capacity of 150,000 tons/year which is planned to operate continuously for 300 days/year on a 24-hour/day basis. The raw materials needed are NH3 of 68.784.11 kg NH3/day, H3PO4 of 251.832.50 kg H3PO4/day, KCl of 13.1341.21 kg KCl/day, H2SO4 of 72.807.86 kg H2SO4/day, CO(NH2)2 of 29,855.34 kg CO(NH2)2/day, (NH4)2SO4 of 65,135.57 kg (NH4)2SO4/day. From the economic analysis that has been carried out, it can be concluded that the Phonska NPK Plant with the mixed acid route process is feasible because it has a discount factor value of 21,871% in the IRR and NPV calculations at a bank interest rate of 8% and an inflation rate of 1.33%, with an estimated return capital occurred for 4.77 years, and the break-even point of product sales was 22.66% or equivalent to 60.660.361,01 units of product sold per year. So that the initial capital investment of Rp. Rp91.962.558.805,63 and the capital investment at the end of the construction period of Rp155.351.713.014is considered to provide benefits for the company so that the Phonska NPK Plant planning project with the mixed acid route process can be carried out.

Item Type:	Thesis (Undergraduate)
Uncontrolled Keywords:	Kata kunci : NPK Phosnka, Optimasi Mixed Acid Route, Screening, Crusher, Analisa Ekonomi Keywords : NPK Phonska, Mixed Acid Route Optimization, Screening, Crusher, Economic Analysis
Subjects:	T Technology > TS Manufactures > TS176 Manufacturing engineering. Process engineering (Including manufacturing planning, production planning)
Divisions:	Faculty of Vocational > 24305-Industrial Chemical Engineering Technology
Depositing User:	Elisabeth Ratnani Wahyu Hapsari
Date Deposited:	22 Aug 2021 06:33
Last Modified:	22 Aug 2021 06:33
URI:	http://repository.its.ac.id/id/eprint/87984

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