Prarancangan Eco-Efficiency Pabrik Nanokitosan dari Cangkang Kepiting Kapasitas 31.868 ton/tahun
BOBBY NUGROHO WICAKSONO, Wiratni, S.T., M.T., Ph.D
2014 | Skripsi | TEKNIK KIMIAKonsep dasar pengembangan pabrik ini diorientasikan pada ide Blue Economy, dengan tujuan untuk mengoptimalkan penggunaan bahan baku lokal untuk mengembangkan konsep “self-sufficiency†dan “fair tradesâ€. Komoditas yang akan diproses untuk pabrik ini ialah limbah berupa cangkang kepiting. Cangkang kepiting ini akan diproduksi menjadi 2 produk utama yaitu suspensi nanokitosan untuk pengawet alami sebagai produk kerakyatan sehingga dijual dengan sangat murah, dan pharmaceutical grade chitosan powder sebagai produk komersial. Proses utama menggunakan bahan baku tepung cangkang kepiting ( 50 mesh ). Pada tahap awal, kitin diisolasi dari cangkang kepiting melalui proses isolasi kitin. Isolasi kitin terdiri dari proses deproteinasi ( konversi 82,57% ) selama 0,83 jam dan demineralisasi ( konversi 99,08%) selama 13,33 jam. Proses pembuatan kitin menjadi kitosan dan nanokitosan terdiri dari proses deasetilasi ( konversi 99,09% ) selama 6,67 jam dan produksi suspensi nanokitosan. Reaktan yang digunakan antara lain larutan NaOH dalam proses deproteinasi dan deasetilasi, dan larutan HCl dalam proses demineralisasi. Penjadawalan pabrik batch ini diatur berdasarkan waktu siklus proses menggunakan Gant Chart. Proses produksi nanokitosan didasarkan pada pengaturan pH dari kitosan terlarut yang ada didalam larutan asam asetat 1,5%, dimana pHnya akan dinaikkan hingga mendekati nilai pKanya ( 6,5 ). Proses peningkatan pH ini dengan cara penambahan residu larutan NaOH dari proses deasetilasi. Pabrik ini didesign dengan kapasitas nanokitosan sebesar 31.868 ton/tahun dan kitosan powder sebesar 1.607 ton/tahun. Pabrik ini juga memproduksi crude amino acid sebagai produk samping sebanyak 914 ton/tahun. Semua produk tersebut diproduksi dengan bahan baku cangkang kepiting sebesar 10.610,53 ton/tahun, CH3COOH 99% sebanyak 542,05 ton/tahun, NaOH solid sebanyak 5744,34 ton/tahun and HCl 33% sebanyak 18.286,24 ton/tahun. Kebutuhan utilitas pabrik ini terdiri dari air sebanyak 76,22 ton/jam; steam sebanyak 1.065,81 kg/jam; dan listrik sebesar 708,163 kW. Pabrik ini akan dibangun pada di Kabupaten Wajo, Sulawesi Selatan pada tahun 2017 diatas lahan sebesar 8 hektar. Total pekerja yang dibutuhkan untuk pengoperasionalan pabrik ini sebanyak 230 orang. Evaluasi ekonomi dapat digunakan untuk menentukan apakah pabrik ini menarik atau tidak. Evaluasi ekonomi didasarkan pada beberapa parameter, antara lain Fixed Capital Investment sebesar Rp 333.271.752.787,56 dan U.S. $ 34.666.553,30; Working Capital sebesar U.S. $ 17.020.527,92 dan Rp. 17.506.343.950,33; Profit before tax sebesar Rp. 304.102.219.015,09; Profit after tax sebesar Rp 228.076.664.261,32; ROI before taxes = 40.59%, Return on Investment after taxes = 30.44%; POT before taxes = 2.005 tahun; POT after taxes = 2.517 tahun; BEP sebesar 51.42%; SDP sebesar 30.06%, Discounted Cash Flow Rate of Return (DCFRR) = 30.2%. Berdasarkan data dan pertimbangan diatas, Pabrik Eco-efficiency nanokitosan yang dikembangkan berdasarkan konsep “sustainable business for social responsibility†ini menarik untuk dikaji lebih lanjut.
The basic concept of this plant is originated with the idea of Blue Economy, which aims to optimally use the local resources to develop self-sufficiency and fair trades. The commodity to be processed is the crab shell wastes, as an important part of the potential marine-based business. The crab shell is converted into chitosan, which will be sold in two forms: 1) as the suspension of nano-chitosan for preservation agent (as \\\"society-oriented product \\\" sold at very low prices as the plant’s social outreach to the surrounding community), 2) as pharmaceutical grade chitosan powder (as a \\\"commercial product\\\" sold at high price to guarantee the plant profitability). The process takes ground shell crab ( 50 mesh ) as raw materials. Firstly, chitin is isolated from the shell crab. Chitin isolation process consists of deproteination (82.57 % conversion) and demineralization process (99.08 % conversion). Conversion of chitin into chitosan and nano-chitosan consists of deacetylation and the production of nano-chitosan suspension. The reactants used are NaOH solution (in the deproteination and deacetylation reactor) and HCl solution (in demineralization reactor). The plant scheduling is based on Gant Chart optimum system, where the total cycle time consisted of charging, processing, emptying, and cleaning. The time for deproteination, demineralization, and deacetylation reactor is 0.83 hours, 13.33 hours, and 6.67 hours respectively. The production of nano-chitosan is based on pH adjustment, whereby the pH of chitosan dissolved in 1.50% acetic acid solution is gradually raised upto very close to its isoelectric pH (6.5). The process is carried out by slowly adding the residual NaOH solution from deacetylation process. The plant is designed with the capacity of 31.868 tons/year for nanochitosan and 1.607 ton/tahun for chitosan powder. This plant also produce crude amino acid as side product with capacity 914 ton/year. All of products are produced from crab shell as much as 10.610,53 tons/year, CH3COOH 99% as much as 542,05 tons/year, NaOH solid as much as 5744,34 tons/year and HCl 33% as much as 18.286,24 tons/year. Utilities includes water as much as 76,22 tons/hour; steam as much as 1.065,81 kg/hour; and 708,163 kW electrical power. The plant is planned to be built in Wajo Disctrict, South Sulawesi in 2017, with total area about 8 hectares. Total employees are needed as much as 230 people. The economic analysis concludes the plant’s economic attractiveness. It is based on several parameters, consist of Fixed Capital Investment of Rp 333.271.752.787,56 and U.S. $ 34.666.553,30; Working Capital of U.S. $ 17.020.527,92 and Rp. 17.506.343.950,33; Profit before tax of Rp. 304.102.219.015,09; Profit after tax of Rp 228.076.664.261,32; ROI before taxes = 40.59%, ROI after taxes = 30.44%; POT before taxes = 2.005 years; Pay Out Time after taxes = 2.517 years; Break Even Point (BEP) = 51.42%; Shut Down Point (SDP) = 30.06%, Discounted Cash Flow Rate of Return (DCFRR) = 30.2%. Based on data above, Eco-efficiency nanochitosan plant is interisting for further studies. It has sustainable business for social responsibility.
Kata Kunci : Blue Economy, kitosan, sustainable, pengawet
