Pra Desain Pabrik Garam Industri dari Garam Rakyat dengan Metode Double Washing

Amelia Virda, Selvi and Mega Agata, Metika (2021) Pra Desain Pabrik Garam Industri dari Garam Rakyat dengan Metode Double Washing. Undergraduate thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

Indonesia merupakan negara kepulauan yang memiliki luas daratan 1.922.570 km2 dan luasan perairan 3.257.483 km2, seharunya Indonesia berpotensi untuk menghasilkan garam dalam jumlah yang besar serta berkualitas. Namun, berbanding terbalik dengan kondisi Sumber Daya Alam yang dimiliki setiap tahunnya negara kita melakukan impor garam dengan kualitas yang lebih tinggi. Garam Industri dalam negeri umumnya tidak memiliki kualitas yang baik, seperti yang diketahui bersama bahwa garam industri di Indonesia dibagi menjadi 3 kelompok nerdasarkan kadar NaCl yaitu KW-1 (>95%), KW-2 (85%<garam <95%) dan KW-3 (<85%). Garam industri pada peraturan Menteri Perindustrian No. 88 Tahun 2014 adalah garam yang digunakan sebagai bahan baku/bahan penolong yang digunakan pada proses produksi pada industri kimia, industri aneka pangan, industri farmasi, industri perminyakan, industri penyamakan kulit dan water treatment.
Pra Desain Pabrik Garam Industri dari Garam Rakyat ini direncanakan mulai beroperasi tahun 2023 dengan kapasitas produksi sebesar 113.321 ton/tahun. Lokasi pendirian pabrik ini direncanakan di Kecamatan Pangarenga, Kabupaten Sampang, Madura, Jawa Timur. Kecamatan Pangarenga dipilih menjadi lokasi pendirian pabrik karena merupakan kecamatan dengan ketersediaan bahan baku yang tinggi di Jawa Timur yaitu sebesar 164.601 ton dengan luas lahan 1.866,5 Ha. Di Jawa Timur juga banyak perusahaan yang yang membutuhkan garam industri sebagai bahan baku. PT. Kertas Tjiwi Kimia, PT. Garindo Sejahtera Abadi, dan PT. Sumatraco Langgeng Makmur dapat dijadikan sebagai target pasar pabrik ini. Dalam pemenuhan kapasitas tahunan, pabrik akan beroperasi kontinyu 24 jam per hari selama 330 hari. Dengan bahan baku sebesar 124.603 Ton/tahun dapat dihasilkan produk garam industri sebesar 113.322 Ton/tahun. Proses produksi garam industri dari garam rakyat dapat diuraikan menjadi 4 tahapan proses.
Tahap pertama adalah tahap pre-treatment bahan baku. Garam rakyat dari gudang bahan baku diangkut meggunakan Belt Conveyor I menuju ke Roll Crusher I untuk dilakukan proses size reduction agar ukurannya menjadi lebih kecil dan proses pemecahan inti kristal dari garam rakyat. Lalu, garam rakyat dialirkan ke Screener I dan ditampung di Silo I sebelum dilakukan proses pencucian I.
Tahap kedua adalah tahap pencucian dan pemisahan. Pada tahap pencucian, garam dicuci mengunakan larutan brine agar pengotor seperti Ca dan Mg hilang. Proses pencucian dilakukan secara 2 tahap, dimana pencucian I menggunakan Mixer Tank I, sedangkan pecucian II menggunakan Screw Washer. Pada pencucian I, garam rakyat dari Silo I dialirkan ke Mixer Tank I. Selanjutnya, garam rakyat yang telah tercuci dikirimkan ke Screw Washer. Pencucian II ini dimaksudkan untuk menyempurnakan proses pencucian I mengingat garam rakyat yang berasal dari lahan pegaraman hanya berkadar NaCl 80-90 %. Kemudian, garam rakyat hasil pencucian dari Screw Washer dialirkan ke Centrifuge untuk dilakukan proses pemisahan. Pada Centrifuge, garam rakyat dipisahkan antara kristal garam dengan larutannya, dimana kristal garam akan menempel pada dinding Centrifuge, sedangkan larutannya akan keluar dari Centrifuge.
Tahap ketiga adalah tahap pengeringan dan pengemasan. Garam dari Centrifuge akan dialirkan menuju Rotary Dryer untuk dilakukan proses pengeringan. Proses pengeringan ini bertujuan untuk mengurangi kadar air dalam garam agar kemurnian garam dapat meningkat sesuai dengan standar SNI. Lalu, garam dari Rotary Dryer akan dibawa oleh Bucket Elevator III menuju Roll Crusher II untuk dilakukan proses size reduction agar ukurannya menjadi lebih kecil. Setelah itu, garam disortir pada alat Screener II untuk dipisahkan antara garam yang ukurannya telah sesuai standard dengan garam yang ukurannya tidak sesuai standard. Garam yang ukurannya telah sesuai standard akan ditampung dalam Silo II dan akan langsung menuju proses pengemasan, sedangkan garam yang tidak sesuai standard akan dibawa oleh Bucket Elevator IV menuju Roll Crusher II untuk dilakukan size reduction kembali.
Tahap keempat adalah tahap persiapan brine. Pada Brine Mixer Tank I, larutan brine dicampurkan dengan recycle brinevkemudian diaduk menggunakan agitator agar tercampur dengan baik. Kemudian, brine dialirkan menuju Mixer Tank I dan Screw Washer. Recycle brine berasal dari Mixer Tank I dan Screw Washer yang ditampung dalam Brine Tank I. Kemudian, brine tersebut dialirkan ke Brine Mixer Tank II untuk direaksikan dengan NaOH, Ca(OH)2, dan Na2CO3 agar terbentuk inti endapan dari pengotor dalam brine. Lalu, dilakukanlah pengendapan terhadap campuran brine dan koagulan di dalam Clarifier. Endapan pengotor akan dialirkan ke WWTP, sedangkan brine yang telah bersih akan dialirkan menuju Brine Tank II dan dialirkan menuju Brine Mixer Tank I.
Pra Desain Pabrik Garam Industri dari Garam Rakyat ini dirancang sebagai perusahaan yang berbadan hukum Perseroan Terbatas (PT) dengan sistem organisasi garis dan staff. Untuk dapat mendirikan pabrik dengan kapasitas produksi sebesar 113.321 ton/tahun, maka diperlukan total modal investasi sebesar Rp 119.333.651.791 dan total biaya produksi sebesar Rp 699.608.530.333 dengan estimasi hasil penjualan sebesar Rp 742.259.100.000 per tahun. Estimasi umur pabrik ini adalah 10 tahun dengan Internal Rate of Return (IRR) sebesar 20,05 %, Pay Out Time (POT) 5,4 tahun.
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Indonesia is an archipelagic country which has a land area of 1,922,570 km2 and a water area of 3,257,483 km2. Indonesia should have the potential to produce large quantities of high quality salt. However, it is inversely proportional to the condition of the Natural Resources owned every year, our country imports higher quality salt. Domestic industrial salt generally doesn’t have good quality, as is well known that industrial salt in Indonesia is divided into 3 groups based on NaCl levels, namely KW-1 (> 95%), KW-2 (85% <salt <95%) and KW-3 (<85%). Industrial salt in the Regulation of the Minister of Industry No. 88 of 2014 is salt used as raw material / auxiliary material used in the production process in the chemical industry, various food industries, the pharmaceutical industry, the petroleum industry, the leather tanning industry and water treatment, etc.
The Pre Design Plant of Industrial Salt from Solar Salt was planned to start operating in 2023 with a production capacity of 113,321 tons/ year. The location of the establishment of the plant was planned in Pangarenga District, Sampang Regency, Madura, East Java. Pangarenga Subdistrict was chosen as the location of the factory establishment because it was a district with high availability of raw materials in East Java, amounting to 164,601 tons with an area of 1,866.5 hectares. In East Java, there were also many companies that need industrial salt as raw material. PT. Kertas Tjiwi Kimia, PT. Garindo Sejahtera Abadi, and PT. Sumatraco Langgeng Makmur could be used as the target market of this factory. To fulfil the annual capacity, the plant will be operated continuously 24 hours per day for 330 days. With a raw material of 124,603 tons/ year, could be produced industrial salt products of 113,322 tons/ hour. The process of producing industrial salt from solar salt was divided into 4 stages of the process.
The first stage was the pre-treatment stage of raw materials. Solar salt from the raw material warehouse was transported using Screw Conveyor I to Roll Crusher I for a size reduction process, so that the size becomes smaller and the process of breaking the crystal core from the solar salt. Then, the solar salt was streamed to Screener I and stored in Silo I before the 1st washing process.
The second step was the washing and separation. In the washing step, the salt was washed using brine solution so that impurities such as Ca and Mg were lost. The washing process was carried out in 2 step, where the 1st washing step was used a Mixer Tank I and the 2nd washing step was used a Screw Washer. In 1st washing step, the solar salt from Silo I was streamed to Mixer Tank I. Furthermore, the washed solar salt was sent to the Screw Washer. The 2nd washing step was intended to perfect the 1st washing step considering that the solar salt content which come from soaking land was only 80- 90% NaCl. Then, the washed solar salt from the Screw Washer was streamed to the Centrifuge for the separation process. In Centrifuge, the solar salt was separated between salt crystals and the solution, where salt crystals would stick to the walls of the Centrifuge, while the solution would come out of the Centrifuge.
The third step was the drying and packaging. Salt from the centrifuge will be streamed to the Rotary Dryer for drying process. This drying process was aimed to reduce the water content in salt so that the purity of salt could be increase in accordance with SNI standards. Then, the salt was carried by Bucket Elevator III to Roll Crusher II for a size reduction the process to make it smaller. After that, the salt was sorted on a Screener II device to be separated between salts that have been sized according to standards and salts that were not sized according to standards. Salts whose size was in accordance with the standard would be accommodated in Silo II and would go directly to the packaging process, while salt that was not in accordance with the standard will be carried by Screw Conveyor IV to Roll Crusher II for size reduction again.
The fourth stage was the preparation stage of the brine. In Brine Mixer Tank I, the brine solution was mixed with recycle brine then stirred using an agitator to mix well. Then, the brine was flowed to Mixer Tank I and Screw Washer. The recycle brine was from Mixer Tank I and Screw Washer which was accommodated in Brine Tank I. Then, the brine was streamed to Brine Mixer Tank II to be reacted with NaOH, Ca(OH)2, and Na2CO3 to form a core of sediment from impurity in brine. Then, deposition of the brine and coagulant mixture was carried out in Clarifier. Dirt sediment would be streamed to WWTP, while clean brine would be streamed to Brine Tank II and streamed to Brine Mixer Tank I.
The Pre Design Plant of Industrial Salt from Solar Salt was designed as a Limited Liability Company (PT) with a line and staff organization system. To be able to set up a factory with a production capacity of 113.321 tons/year, a total investment capital of Rp 119,333,651,791 and a total production cost of Rp Rp 699.608.530.333 with an estimated sales proceeds of Rp 742.259.100.000 per year. The estimated age of this plant was 10 years with an Internal Rate of Return (IRR) of 20,05%, Pay Out Time (POT) 5,4 years.

Item Type:	Thesis (Undergraduate)
Subjects:	T Technology > TP Chemical technology 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:	Selvi Amelia Virda
Date Deposited:	19 Aug 2021 08:34
Last Modified:	19 Aug 2021 08:34
URI:	http://repository.its.ac.id/id/eprint/88420

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