Pra Desain Pabrik Pupuk NPK dengan Metode Mix Acid Route Berkapasitas 480.000 Ton/Tahun

Rachmawati, Nabillah and Astuti, Naning Retno (2023) Pra Desain Pabrik Pupuk NPK dengan Metode Mix Acid Route Berkapasitas 480.000 Ton/Tahun. Other thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

Indonesia merupakan negara agraris yang sebagian besar penduduknya bekerja sebagai petani. Hal ini menyebabkan sektor pertanian berperan besar terhadap pertumbuhan ekonomi di Indonesia karena industri pertanian dapat berdampak ke komoditas ekspor Indonesia. Salah satu faktor produksi pertanian yang terpenting adalah pupuk. Pupuk NPK merupakan pupuk anorganik yang dirumuskan pada konsentrasi yang sesuai dan kombinasi memberikan tiga nutrisi utama (Nitrogen, Phospat, Kalium). Secara garis besar, pembuatan pupuk NPK menggunakan proses mixed acid route, yaitu proses pencampuran dan pereaksian. Pada proses ini digunakan bahan baku padat berupa urea, ZA, KCl dan filler, sedangkan bahan baku liquid berupa H2SO4, H3PO4, dan NH3. Tahap pertama dari proses ini adalah pencampuran bahan baku padat di pug mill agar homogen. Kemudian bahan baku liquid direaksikan di neutralizer reactor untuk membentuk slurry. Reaksi yang terjadi di reaktor akan menghasilkan Ammonium sulfat cair, DAP, dan MAP. Semua bahan baku tersebut dimasukkan ke dalam granulator untuk membentuk butiran produk.Di dalam granulator juga terjadi reaksi yang sama dengan yang terjadi di reaktor. Produk keluar dari granulator kemudian masuk ke rotary dryer untuk dikeringkan dengan menggunakan udara panas hingga kadar air mencapai 0,5%. Produk kemudian dipisahkan berdasarkan ukuran, produk yang sesuai ukuran (onsize) akan masuk ke rotary cooler, produk yang oversize akan diperkecil ukurannya dengan menggunakan ball mill, sedangkan produk undersize akan langsung ditampung recycle belt conveyor. Setelah produk didinginkan di cooler, produk masuk ke coater untuk dilapisi dengan coating oil dan coating powder agar tidak terjadi caking pada saat penyimpanan produk. Setelah dari coater, produk ditampung di gudang penyimpanan dan siap dijual ke konsumen. Lokasi pabrik NPK dipilih untuk didirikan di Kawasan Industri Dumai, Riau, Sumatera. Target kapasitas produksi pupuk NPK kami adalah 480.000 ton/tahun. Sumber dana investasi pabrik ini berasal dari modal sendiri sebesar 30% biaya investasi dan pinjaman jangka pendek sebesar 70% biaya investasi dengan bunga sebesar 8% per tahun. Dari Analisa perhitungan ekonomi didapat hasil-hasil sebagai berikut, dimana nilai CAPEX: Rp498.261.388167, OPEX: Rp4.037.576.008.247 Internal Rate of Return: 20,32 %, Pay Out Time: 4,1 Tahun, Break Even Point: 28%, dan NPV: Rp365.729.800.923. Dari data tersebut dapat disimpulkan bahwa pabrik NPK ini layak untuk didirikan.
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Indonesia is an agricultural country where the majority of the population work as farmers. This causes the agricultural sector to play a major role in economic growth in Indonesia because the agricultural industry can have an impact on Indonesia's export commodities. One of the most important factors in agricultural production is fertilizer. NPK fertilizer is an inorganic fertilizer that is formulated at the appropriate concentration and in combination to provide three main nutrients (Nitrogen, Phosphate, and Potassium). Broadly speaking, the manufacture of NPK fertilizer uses the mixed acid route process, namely the mixing and reaction processes. In this process, solid raw materials are used in the form of urea, ZA, KCl, and fillers, while liquid raw materials are H2SO4, H3PO4, and NH3. The first stage of this process is mixing the solid raw materials in the pug mill to make it homogeneous. Then the liquid raw material is reacted in the neutralizer reactor to form a slurry. The reaction that occurs in the reactor will produce liquid Ammonium sulfate, DAP, and MAP. All of these raw materials are put into the granulator to form product granules. The same reactions occur in the granulator that occurs in the reactor. The product exits the granulator and then enters the rotary dryer to be dried using hot air until the moisture content reaches 0.5%. The products are then separated by size, the onsize products will enter the rotary cooler, the oversized products will be reduced in size using a ball mill, and the undersized products will be directly accommodated by the recycle belt conveyor. After the product is cooled in the cooler, the product enters the coater to be coated with coating oil and coating powder to prevent caking during product storage. After the coater, the product is accommodated in a storage warehouse and ready to be sold to consumers. The location for the NPK factory was chosen to be established in the Dumai Industrial Area, Riau, Sumatra. Our NPK fertilizer production capacity target is 480,000 tons per year. The source of investment funds for this factory comes from own capital of 30% of investment costs and short-term loans of 70% of investment costs with an interest of 8% per year. From the analysis of economic calculations, the following results are obtained, where the value of CAPEX: IDR 498.261.388167, OPEX: IDR 4.037.576.008.247 Internal Rate of Return: 20,32%, Pay Out Time: 4,1Years, Break Even Point: 28%, and NPV: 365.729.800.923IDR. From these data, it can be concluded that this NPK factory is feasible to establish.

Item Type:	Thesis (Other)
Uncontrolled Keywords:	Fertilizer, Mixed Acid Route, NPK, Mixed Acid Route, NPK, Pupuk
Subjects:	T Technology > TP Chemical technology > TP155.5 Chemical plants--Design and construction
Divisions:	Faculty of Industrial Technology and Systems Engineering (INDSYS) > Chemical Engineering > 24201-(S1) Undergraduate Thesis
Depositing User:	Nabillah Rachmawati
Date Deposited:	26 Jul 2023 01:24
Last Modified:	26 Jul 2023 01:24
URI:	http://repository.its.ac.id/id/eprint/99271

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