Pra Desain Pabrik Garam Industri untuk Kebutuhan Industri Chlor Alkali Plant (CAP) dari Garam Rakyat

Harahap, Amin Abdillah and S, Kelvin Letare (2021) Pra Desain Pabrik Garam Industri untuk Kebutuhan Industri Chlor Alkali Plant (CAP) dari Garam Rakyat. Undergraduate thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

Garam adalah kumpulan senyawa kimia yang terdiri dari Natrium Klorida (NaCl) dengan zat-zat pengotor berupa CaSO4, MgSO4, MgCl2, dan lain-lain. Pemerolehan garam dapat dilakukan dengan beberapa cara yaitu penguapan air laut dengan sinar matahari, dan dari sumur air garam (brine). Berdasarkan penggunaannya, garam dibagi menjadi 2 yaitu garam konsumsi dan Garam industri. Berdasarkan Peraturan Pemerintahan Industri no. 84 tahun 2014, nilai kadar minimal NaCl pada garam konsumsi adalah 94%, kalau kadar NaCl pada garam industri dibutuhkan kadar yang lebih tinggi tergantung jenis industrinya. Pada industri petrokimia dibutuhkan kadar NaCl lebih dari 96%, pada industri perminyakan, tekstil, dan penyamakan kulit dibutuhkan kadar NaCl lebih dari 97,5%, pada industri petrokimia dibutuhkan kadar NaCl lebih dari 96%, dan pada industri farmasi dibutuhkan kadar NaCl lebih dari 99,8% dimana nilai pada farmasi adalah tertinggi.
Pra Desain Pabrik Garam Industri dari Garam Rakyat ini direncanakan mulai beroperasi tahun 2025 dengan kapasitas produksi sebesar 145.847,65 ton/tahun, dengan fokus pasar ke sektor industri Chlor Alkali Plant (CAP) karena bahan baku untuk semua pabrik CAP adalah garam impor. Lokasi pendirian pabrik ini direncanakan di Kecamatan Lemahabang,Kabupaten Cirebon, Jawa Barat Kecamatan Lemahabang dipilih menjadi lokasi pendirian pabrik karena merupakan kecamatan dengan ketersediaan bahan baku yang tinggi di Jawa Barat yaitu sebesar 435.439,00 ton. Di dekat Cirebon juga banyak perusahaan yang yang membutuhkan garam industri sebagai bahan baku PT. Asahimas Chemical,dan PT. Sulfindo Adiusaha, dan 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 21.000 kg/jam dapat dihasilkan produk garam industri sebesar 18.415 kg/jam. 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, garamrakyat 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 CaSO4, MgSO4 dan, MgCl2 hilang. Proses pencucian dilakukan secara 2 tahap, dimana pencucian I menggunakan Mixer Tank, sedangkan pecucian II menggunakan Screw Washer. Pada pencucian I, garam rakyat dari Silo I dialirkan ke Tangki Pengaduk. 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 menggunakan Screw Conveyor III 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 Screw Conveyor IV menuju Rotary Cooler. Dalam Rotary Cooler dilakukan proses pendinginan agar suhu garam tidak terlalu panas. Kemudian, garam dibawa oleh Belt Conveyor 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 Screw Conveyor V menuju Brine Mixer Tank I untuk dijadikan sebagai bahan baku pembuatan brine. Tahap keempat adalah tahap persiapan brine. Pada Brine Mixer Tank I, garam dicampurkan dengan air melalui proses pengadukan menggunakan agitator agar garam larut di dalam air.
Kemudian, brine dialirkan menuju Mixer Tank I dan Screw Washer. Selain itu, brine juga diperoleh dari recycle brine 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 yang dihasilkan akan dialirkan ke SWTP, sedangkan brine 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 145.847,65 ton/tahun, maka diperlukan total modal investasi sebesar Rp 495.722.143.602 dan total biaya produksi sebesar Rp 169.021.044.455 dengan estimasi hasil penjualan sebesar Rp 508.182.500.000 per tahun. Estimasi umur pabrik ini adalah 10 tahun dengan Internal Rate of Return (IRR) sebesar 24,16 %, Pay Out Time (POT) 3,886 tahun, dan Break Even Point (BEP) sebesar 27 %.
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Salt is a collection of chemical compounds whose main composition consists of Sodium Chloride (NaCl) with impurities in the form of CaSO4, MgSO4, MgCl2, and others. Salt could be obtained in several ways, namely evaporation of sea water by sunlight, and from salt water wells (brine). Based on its utilization, salt was divided into 2 groups namely consumption salt and industrial salt. Based on Pemerintahan Menteri Industri no. 84 of 2014, NaCl levels in consumption salt were a minimum of 94%, while NaCl levels in industrial salts were needed higher levels depending on the type of industry. , In the petrochemical industry NaCl levels of more than 96% were required, in the petroleum, textile and leather tanning industries, NaCl levels of more than 97,5% were required , and in the pharmaceutical industry more than 99,8% NaCl levels were required which is the highest.
The Pre Design Plant of Industrial Salt from Solar Salt was planned to start operating in 2025 with a production capacity of 145.847,65 tons/year, with the sales market thas is focused to Chlor Alkali Plant (CAP) because all CAP Plants uses imported salt as the main ingredient The location of the establishment of the plant was planned in Lemahabang District, Cirebon Regency, West Java. Lemahabang District was chosen as the location of the factory establishment because it was a district with high availability of raw materials in West Java, amounting to 435.439 tons. Near Cirebon Regency, there were also many companies that need industrial salt as raw material. PT. Asahimas Chemical,dan PT. Sulfindo Adiusaha could be used as the target market of this factory. In meeting its annual capacity, the plant will be operated continuously 24 hours per day for 330 days. With raw materials of 21.000 kg/hour could be produced industrial salt products of 18.415 kg/hour. The process of industrial salt production from community salt could be broken down into 4 process steps.
The first step was the pre-treatment of raw materials. Solar salt from the raw material warehouse is transported using Belt 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 of 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 CaSO4, MgSO4, MgCl2 were lost. The washing process was carried out in 2 step, where the 1st washing step was used a Mixer Tank 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 using Screw Conveyor III 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 from the Rotary Dryer would be carried by the Screw Conveyor IV to the Rotary Cooler. In the Rotary Cooler, the cooling process is carried out so that the salt temperature was not too hot. Then, the salt was carried by Bucket Elevator to Roll Crusher II for a size reduction 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 is 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 V to Brine Mixer Tank I to be used as raw material for making brine. The fourth step is the brine preparation. In Brine Mixer Tank I, salt was mixed with water through a stirring process using an agitator so that the salt dissolves in the water.
Then, the brine was flown to the Mixer Tank I and the Screw Washer. In addition, the brine was also obtained from the recycle brine 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 produce 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 SWTP, while the 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 145.847,65 tons/year, a total investment capital of Rp 495.722.143.602 and a total production cost of Rp 169.021.044.455 with an estimated sales proceeds of Rp 508.182.500.000 per year. The estimated age of this plant was 10 years with an Internal Rate of Return (IRR) of 24,16%, Pay Out Time (POT) 3,886 years, and Break Even Point (BEP) of 27%.

Item Type:	Thesis (Undergraduate)
Uncontrolled Keywords:	Garam Rakyat, Garam Industri, Chlor Alkali Plant, Solar Salt, Industrial Salt, Chlor Alkali Plant
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:	Amin Abdillah Harahap
Date Deposited:	14 Aug 2021 04:25
Last Modified:	14 Aug 2021 04:25
URI:	http://repository.its.ac.id/id/eprint/86161

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