Ratnasari, Delyana and Tulaini, Sahara (2019) Pabrik Gliserol Monostearat. Undergraduate thesis, Institut Teknologi Sepuluh Nopember.
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Abstract
Peraturan Presiden No. 5/2006 tentang Kebijakan Energi Nasional menyebutkan kuota bahan bakar nabati (BBN) jenis biodiesel pada tahun 2011-2015 sebesar 3 persen dari konsumsi energi nasional atau setara dengan 1,5 juta kilo liter. Padahal kapasitas produksi biodiesel dalam negeri baru mencapai 680 ribu kilo liter. Target ketersediaan 1,5 juta kilo liter, produksi biodiesel di Indonesia masih kurang 820 ribu kilo liter. (Budiman, 2012). Dengan perkiraan rata-rata konversi biodiesel 90%, maka gliserol yang dihasilkan adalah 10% dari produksi. Sehingga akan dihasilkan gliserol yang akan terus bertambah disetiap tahunnya. Pembuatan turunan gliserol ini dimaksudkan agar produk mempunyai nilai ekonomi yang lebih tinggi. Salah satu turunan gliserol yang dapat dikembangkan dan bernilai ekonomi tinggi adalah Gliserol Monostearat sebagai zat aditif pada makanan.
Berdasarkan analisa pasar yang dilakukan oleh Grand View Research (2017), ditinjau dari macam produk pengemulsi makanan, diprediksikan hingga tahun 2025 monogliserida menempati urutan pertama bahan pengemulsi dengan permintaan tertinggi karena kebutuhan pengemulsi berbasis bahan baku alami sangat dipertimbangkan untuk keuntungan jangka panjang. Hal ini berarti permintaan akan gliserol monostearat sebagai salah satu jenis monogliserida akan terus naik di masa mendatang. Hal ini merupakan peluang bisnis yang perlu dimanfaatkan.
Pabrik direncanakan beroperasi secara kontinyu 24 jam selama 300 hari per tahun dengan kapasitas produksi 10.000 ton/tahun dengan kebutuhan bahan baku asam stearat sebanyak 7.948,8 ton/tahun dan gliserol sebanyak 2.445,12 ton/tahun. Asam stearat yang digunakan memiliki kemurnian 92%, sedangkan gliserol memiliki kemurnian 99,7%. Keduanya diproduksi oleh PT Wilmar yang memiliki kapasitas produksi 132.000 ton/tahun. Pabrik direncanakan didirikan di daerah Kabupaten Mojokerto, Jawa Timur pada tahun 2021 karena dekat dengan sumber bahan baku, memiliki posisi pemasaran yang strategis, memiliki akses jalan raya yang baik, dekat dengan pelabuhan, dekat dengan sumber air sungai sehingga kebutuhan air mudah terpenuhi, serta mudah dalam proses perizinan pendirian pabrik.
Proses pembuatan gliserol monostearat dibagi menjadi tiga tahapan proses utama di antaranya:
1. Tahap Pre-treatment yang terdiri dari proses pencampuran dan pemanasan bahan baku asam stearat, gliserol, serta NaOH untuk mencapai kondisi operasi reaktor.
2. Tahap Esterifikasi merupakan tahap reaksi antara asam stearat dan gliserol dengan katalis NaOH membentuk gliserol monostearat.
3. Tahap Pemurnian terdiri dari proses pemisahan flash, netralisasi, dan kristalisasi. Gliserol diuapkan pada tahap flash distillation untuk di-recycle. NaOH pada campuran produk dinetralkan pada tahap netralisasi dengan penambahan asam fosfat. Produk gliserol monostearat keluar sebagai padatan dari proses kristalisasi.
Sumber dana investasi berasal dari modal sendiri sebesar 40% biaya investasi dan pinjaman sebesar 60% biaya investasi dengan bunga sebesar 12,5 % per tahun. Berdasarkan perhitungan analisa ekonomi, diperoleh biaya investasi total / Total Cost Investment sebesar Rp 146.431.896.036,48 dan total biaya produksi (TPC) sebesar Rp 271.419.387.521,33; interest rate sebesar 12,5 %; laju pengembalian modal / Internal Rate of Return (IRR) sebesar 27,15 %, laju inflasi sebesar 4,36 % per tahun, waktu pengembalian modal / Pay Out Time (POT) sebesar 4,53 tahun; titik impas / Break Even Period (BEP) sebesar 39.84%; dan periode construction selama 24 bulan. Berdasarkan analisa BEP, POT, dan IRR, pabrik Gliserol Monostearat ini layak untuk didirikan.
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President Policy No. No. 5/2006 about National Energy Regulation states that biofuel capacity in 2011-2015 has the value of 3% from national energy consumption or equal to 1,5 million kiloliters. Whereas the national production capacity of biodiesel in Indonesia still reaches 680 thousands of kiloliters. The supply target of 1,5 million kiloliters in Indonesia still has 820 thousands kiloliters less (Budiman, 2012). With the approximation of 90% biodiesel conversion, the gliserol that is produced as by-product is 10% biodiesel production capacity. Thus we know that glycerol will keep being produced and increased annually. The production of glycerol-derived product is aimed for increasing its economic value. One of the glycerol-derived products that can be developed and has high economic value is Glycerol Monostearate which has the role as food additive.
Based on the market research done by Grand View Research (2017), according to various product of food emulsifiers, it had been predicted that in 2025 monoglycerides will be at the top of food emulsifiers demand, because the demand of emulsifiers based on natural raw materials is very considered for long term usage.This means that the demand of glycerol monostearate as one of monoglycerides will keep rising in the near future. This is the chance for business opportunity that needs to be utilized.
This plant is planned to be operated continuously for 24 hours 300 days per year with the production capacity of 10.000 tonnes/year with the raw material of stearic acid 7.948,8 tonnes/yearand glycerol 2.445,12 tonnes/year. The stearic acid that will be used has the purity of 92%, while the glycerol has the purity of 99,7%. Both of the rawmaterials are produced by PT Wilmar that has the capacity of 132.000 tonnes/year. The plant is planned to be established in Kabupaten Mojokerto, Jawa Timur in 2021 because it is near to the source of raw materials, has a strategic position of marketing, has a good access roads, has the nearest river as the water source, and the ease of plant establishment permission.
The process of glycerol monostearate production is divided into to three steps:
1. Pre-treatment step which consists of mixing and pre-heating process of raw materials of stearic acid, glycerol, and NaOH to reach the optimum condition of reactor.
2. Esterification step is the step of reaction between stearic acid and glycerol with the catalyst of NaOH to form glycerol monostearate.
3. Separation step which consists of flash sepraration, neutralization, and crystallization.Glycerol is being vaporized in flash distillation process to be recycled. NaOH in the mixture of product is being neutralized in neutralization process with the addition of phosphoric acid. Glycerol monostearate will be in the form of solid state after being through crystallization process.
The investation source is obtained from personal capital (40%) and bank loan (60%) with 12,5%/year of interest. Based on the calculation of economical analysis, the Total Cost Investment (TCI)has the value of Rp 146.431.896.036,48 andthe Total Production Cost (TPC) has the value of Rp 271.419.387.521,33; the interest rate is 12,5 %; Internal Rate of Return (IRR) is 27,15 %, inflation rateis 4,36 %/year, Pay Out Time (POT) is 4,53 years; Break Even Point (BEP) is 39.84%; and construction period of 24 months. According to the BEP, POT, and IRR analysis, the Gliserol Monostearat plantis feasible to be established.
| Item Type: | Thesis (Undergraduate) |
|---|---|
| Additional Information: | RSK 668.2 Rat p-1 2019 |
| Uncontrolled Keywords: | Pra Desain Pabrik, Gliserol Monostearat, Esterifikasi |
| Subjects: | T Technology > TP Chemical technology > TP156 Crystallization. Extraction (Chemistry). Fermentation. Distillation. Emulsions. T Technology > TP Chemical technology > TP370 Food processing and manufacture T Technology > TP Chemical technology > TP669 Oils, fats, and waxes |
| Divisions: | Faculty of Industrial Technology and Systems Engineering (INDSYS) > Chemical Engineering > 24201-(S1) Undergraduate Thesis |
| Depositing User: | Ratnasari Delyana |
| Date Deposited: | 17 May 2022 01:48 |
| Last Modified: | 17 May 2022 01:48 |
| URI: | http://repository.its.ac.id/id/eprint/61857 |
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