DAFTAR ISI

KATA PENGANTAR ................................................................................

DAFTAR ISI ............................................................................................... iii
DAFTAR GAMBAR .................................................................................. viii
DAFTAR TABEL ....................................................................................... xi
DAFTAR LAMPIRAN ............................................................................... xii
BAB I PENDAHULUAN .................................................................... 1
1.1. Latar Belakang .................................................................. 2
1.2. Tujuan ............................................................................... 2
1.3. Tempat dan Waktu Pelaksanaan ....................................... 2
1.4. Metode Kerja Praktek ...................................................... 2
BAB II TINJAUAN UMUM PERUSAHAAN .................................... 4
2.1. Sejarah dan Perkembangan Perusahaan ............................ 4
2.2. Letak Geografi................................................................... 4
2.3. Tata Letak Pabrik .............................................................. 5
2.4. Struktur Organisasi ............................................................ 5
2.4.1. Manajer Unit ........................................................... 5
2.4.2. Kepala Dinas Teknik dan Pengolahan (KDTP) ...... 6
2.4.3. Kepala Dinas Tanaman ........................................... 7
2.4.4. Kepala Dinas Tata Usaha (KDTU) ......................... 8
2.4.5. Asisten Pengolahan ................................................ 8
2.4.6. Asisten Teknik atau Sipil ........................................ 9
2.4.7. Asisten Afdeling ..................................................... 10
2.4.8. Asisten SDM/Umum ............................................... 10
2.4.9. Asisten Tata Usaha.................................................. 11
2.4.10. Perwira Pengaman (Pa. Pam) ................................ 11
2.5. Ketenagakerjaan ................................................................ 12
2.6. Sistem Manajemen Keselamatan dan Kesehatan Kerja
(SMK3) ............................................................................. 13
2.7. Sistem Manajemen Mutu (ISO-9001-200) dan Sistem
Manajemen Lingkungan (ISO 14001-2004) ..................... 14
 2.8. Jam Kerja........................................................................... 14
2.9. Sistem Pengupahan ........................................................... 15
BAB III TINJAUAN PUSTAKA ........................................................... 17
3.1. Kelapa Sawit ..................................................................... 17
3.2. Minyak Kelapa Sawit atau CPO (Crude Palm Oil) ........... 19
3.2.1. Komposisi Kimia Minyak Kelapa Sawit/CPO ........ 20
3.2.1.1. Trigliserida Pada Minyak Kelapa Sawit .... 20
3.2.1.2. Senyawa Non Trigeliserida Pada Minyak
Kelapa Sawit .............................................. 21
3.2.1.3. Mono dan Digliserida Serta Asam Lemak
Bebas ......................................................... 22
3.2. Kualitas Minyak Kelapa Sawit.................................. 22
BAB IV PROSES PRODUKSI .............................................................. 26
4.1. Stasiun Penerimaan Buah (Fruit Reception) ..................... 27
4.1.1. Jembatan Timbang (Weight Bridge) ....................... 27
4.1.2. Sortasi ................................................................... 29
4.1.3. Penampungan Buah (loading ramp) ........................ 30
4.1.4. Lori ................................................................... 32
4.2. Stasiun Perebusan (Steriliser)............................................ 33
4.3. Stasiun Penebahan (Thresher) ........................................... 35
4.3.1. Hositing Crane ........................................................ 35
4.3.2. Auto Feeder ............................................................. 36
4.3.3. Threser ................................................................... 36
4.3.4. Fruit Conveyor dan Fruit Elevator .......................... 38
4.3.5. Empty Bunch Conveyor .......................................... 38
4.3.6. Hopper (Janjang kosong) ........................................ 39
4.4. Stasiun Pencacahan dan Kempa (Digester and Pressing
Station) ................................................................... 39
4.4.1. Digester ................................................................... 40
4.4.2. Screw Press/Kempa ................................................. 42
4.5. Stasiun Pemurnian Minyak /Clarifier ................................ 44
4.5.1. Proses Pemurnian minyak ....................................... 44
 4.5.1.1. Sand Trap Tarik .......................................... 45
4.5.1.2. Vibre Separator ........................................... 46
4.5.1.3. Bak Raw Oil (RO) ...................................... 47
4.5.1.4. Balance Tank .............................................. 48
4.5.1.5 Continous Setting Tank (CST) .................... 48
4.5.1.6. Oil Tank ...................................................... 49
4.5.1.7. Oil Purifier ................................................. 50
4.5.1.8. Vacum Driver ............................................. 51
4.5.1.9. Storage Tank ............................................... 52
4.5.2. Proses Pengambilan Minyak dari Sludge ................ 53
4.5.2.1. Sludge Tank ................................................ 53
4.5.2.2. Brush Cleaning Strainer .............................. 54
4.5.2.3. Sand Cyclone/Pre Cleane ........................ 54
4.5.2.4. Buffer Tank ................................................. 55
4.5.2.5. Sludge Separator ......................................... 55
4.5.2.6. Bak Penampang Minyak (Basin) ................ 56
4.5.2.7. Kolam Limbah ............................................ 57
4.5.2.8. Bak Penampung Sludge (Fat Pit) ................ 57
4.5.2.9. Deoiling Pond ............................................. 58
4.6. Stasiun Pabrik Biji atau Kernel ......................................... 59
4.6.1. Cake Breaker Conveyor .......................................... 59
4.6.2. Depricarper .............................................................. 60
4.6.3. Nut Conveyor .......................................................... 60
4.6.4. Destroner dan Nut Silo ............................................ 61
4.6.5. Ripple Mill .............................................................. 61
4.6.6. Light Tenera Dusi Separator (LTDS I-II) ............... 62
4.6.7. Hydrocyclone / Clay Bath ....................................... 62
4.6.8. Silo Inti (Kernel Drier) ............................................ 63
4.6.9. Kernel Bunker ......................................................... 63
BAB V SPESIFIKASI ALAT ............................................................... 64
5.1. Stasiun penerimaan ........................................................... 64
5.2. Stasiun perebusan .............................................................. 66
 5.3. Stasiun Penebah (Threser) ................................................. 67
5.4. Stasiun Pencacahan dan Kemap (Digester and Pressing
Station) ................................................................... 69
5.5. Stasiun Pemurnian Minyak (Clarification Station) ........... 71
5.6. Proses Pengambilan Minyak dari Sludge .......................... 75
5.7. Stasiun Pengolahan Biji (Kernel Station).......................... 79
5.8. Stasiun Pendukung Pengolahan ........................................ 85
BAB VI UTILITAS ................................................................... 91
6.1. Water Treatment (Pengoalahn Air) .................................. 91
6.1.1. Parameter Mutu Air................................................. 91
6.1.2. Sistem Pengolahan Air ............................................ 93
6.1.2.1. Pengolahan Luar (External Treatment) ...... 93
6.1.2.2. Pengolahan Dalam (Internal Treatment) .... 102
6.2. Boiler (Ketel Uap) ............................................................. 104
6.3. Power Plant ................................................................... 108
6.3.1. Turbin Uap .............................................................. 108
6.3.2. Back Pressure Vessels (BPV) ................................. 109
6.3.3. Diesel Genset .......................................................... 110
6.3.4. Kontrol Panel .......................................................... 110
6.3.5. Perusahaan Listrik Negara (PLN) ........................... 111
6.4. Limbah dan Penanganannya.............................................. 111
6.4.1. Limbah Padat .......................................................... 111
6.4.2. Limbah Cair ............................................................ 112
6.4.2.1. Cooling Pond .............................................. 112
6.4.2.2. Seding pond ................................................ 113
6.4.2.3. Primary Pond .............................................. 113
6.4.2.4. Secondary Pond .......................................... 113
6.4.2.5. Sand Bath .................................................... 114
6.4.2.6. Aerobic Pond .............................................. 114
6.4.2.7. Final Pond ................................................... 114
6.4.3. Limbah Gas ............................................................. 115
6.4.4. Limbah Bahan Berbahaya dan Beracun (B3).......... 117
BAB VII PENGAWASAN MUTU ......................................................... 118
7.1. Standar Mutu ................................................................... 118
7.1.1. Bahan Baku ............................................................. 118
7.1.2. Produk Akhir ........................................................... 119
7.1.3. Air Umpan Boiler dan Air Boiler ........................... 119
7.2. Analisa Mutu ................................................................... 120
7.2.1. Analisa Kadar Asam lemak Bebas .......................... 120
7.2.2. Analisa Kadar Air Pada Minyak ............................. 121
7.2.3. Analisa Kadar Kotoran ............................................ 121
7.2.4. Analisa Losis Minyak ............................................. 122
7.2.5. Analisa Losis Inti .................................................... 122
7.2.6. Analisis pH .............................................................. 123
7.2.7. Analisis Total Disolved Solid (TDS) ..................... 123
7.2.8. Analisis Silika ......................................................... 124
7.2.9. Analisis Kesadahan (Hardness) .............................. 124
BAB VIII PENUTUP ................................................................... 126
8.1. Kesimpulan ................................................................... 126
8.2. Saran ................................................................... 127
DAFTAR PUSTAKA ................................................................... 128
 DAFTAR GAMBAR

Gambar 4.1. (a) Jembatan Timbang dan (b) konstruksi Load Cell ........ 28
Gambar 4.2. Loading Ramp ................................................................... 30
Gambar 4.3. (a) Lori dan (b) Konstruksi Lori........................................ 32
Gambar 4.4. Grafik Sistem Perebusan Tiga Puncak (Tripple Peak) ...... 34
Gambar 4.5. (a) Sterilizer dan (b) Konstruksi Sterilizer ........................ 34
Gambar 4.6. Hoisting Crane .................................................................. 35
Gambar 4.7. Auto Feeder ....................................................................... 36
Gambar 4.8. Thresher............................................................................. 37
Gambar 4.9. Fruit Elevator .................................................................... 38
Gambar 4.10. Empty Bunch Conveyor .................................................... 38
Gambar 4.11. Diagram Alir Proses di Stasiun Penebah .......................... 39
Gambar 4.12. Digester ............................................................................. 40
Gambar 4.13. (a) Screw Press dan (b) Konstruksi Screw Press .............. 43
Gambar 4.14. Balance Tank ..................................................................... 48
Gambar 4.15. (a) Continious Settling Tank dan (b) Konstruksi Continiou
Settling Tank ..................................................................... 50
Gambar 4.16. Oil purifier......................................................................... 51
Gambar 4.17. (a) Vacuum Drier dan (b) konstruksi Vacuum Drier ........ 52
Gambar 4.18. (a) Sludge Tank dan (b) Konstruksi Sludge Tank ............. 53
Gmbar 4. 19. Sand Cyclone .................................................................... 54
Gambar 4.20. Sludge Separator ............................................................... 56
Gambar 4.21. Bak Basin .......................................................................... 56
Gambar 4.22. kolam limba Kecil ............................................................. 57
Gambar 4.23. Bak Penampang Sludge (Bak Fat Fit) ............................... 59
Gambar 4.24. Deoling pond ..................................................................... 59
Gambar 4.25. Depericarper ...................................................................... 60
Gambar 4.26. Kernel Bunker ................................................................... 63
Gambar 6.1. Menara Air (Water Tower) ............................................... 96
Gambar 6.2. Demin Plant....................................................................... 97
Gambar 6.3. Cation Tank ....................................................................... 97
Gambar 6.4. Dearator tank ..................................................................... 98
Gambar 6.5. Anion Tank ....................................................................... 98
 DAFTAAR TABEL

Tabel 2.1. Jumlah Penyebaran tenaga kerja di PT. Perkebunan Nusantara IV

Unit Usaha Pabatu 2012 ........................................................... 12
Tabel 2.2. Jumlah Pekerja dalam Satu Shift di PKS Unit Usaha Pabatu .. 15
Tabel 3.1. Kriteria Kematangan Buah ....................................................... 19
Tabel 3.2. Komposisi yang Tak Tersabunkan dalam Minyak Kelapa Sawit 20
Tabel 3.3. Komposisi Asam lemak Minyak Kelapa Sawit dan Minyak
Inti Kelapa Sawit ...................................................................... 21
Tabel 3.4. Syarat Mutu Minyak Kelapa Sawit Mentah/CPO .................... 23
Tabel 3.5. Standar Mutu Minyak Sawit / CPO yang dihasilakn oleh
PT. Perkebunan Nusanta IV (persero) Unit Usaha Pabatu....... 25
Tabel 6.1. Satuan Kesadahan .................................................................... 92
Tabel 6.2. Parameter Kontrol Regenerasi ................................................ 100
Tabel 6.3. Bahan Kimia Internal Boiler .................................................... 103
Tabel 6.4. Parameter Kontrol Air Umpan Boiler dan Air Boiler .............. 104
Tabel 6.5. Data Analsisi Limbah Cair Untuk Aplikasi Lahan .................. 115
Tabel 6.6. Hasil pengujian Emisi Boiler ................................................... 116
Tabel 7.1. Standar Mutu Bahan Baku Tndan Buah Segar......................... 118
Tabel 7.2. Standat Mutu CPO dan Inti Sawit yang Ditetapkan Perusahan 119
Tabel 7.3. Standar Mutu Air Umpan Boiler dan Air Boiler ...................... 119