LAMPIRAN D

NERACA MASSA PENGOLAHAN

Kapasitas pengolahan : 45 ton/jam

Basis perhitungan : 1 jam operasi

Satuan massa : Kilogram

1. Sterilizer

Tandan Buah Segar (TBS) dari lori dimasukkan kedalam rebusan atau
sterilizer. TBS direbus dalam sterilizer untuk proses sterilisasi sebelum diproses
menjadi minyak. Temperatur perebusan 125oC-130oC, lama perebusan 110 menit
dan tekanan 2,8 - 3,0 Kg/cm2. Kebutuhan steam inlet adalah 45% (20.250 kg uap/
TBS). Exhaust steam 35% dan kondensat yang dibuang sebanyak 11%, sedangkan
TBS yang masak 89 % dari jumlah umpan yang direbus.

Evaporasi

10%

Inlet Steam Exhaust Steam

45%
10%

Sterilizer Tandan Rebus

TBS 100%
TBS 89%

45.000 kg/jam
Kondensat

11 %
A. Neraca massa bahan masuk :

1. TBS = 100% x 45.000 kg/jam = 45.000 kg/jam

2. Inlet Steam = 45% x 45.000 kg/jam = 20.250 kg/jam

B. Neraca massa bahan keluar :

1. Kondensat = 11% x 45.000 kg/jam = 4.950 kg/jam

2. Evaporasi = 10% x 45.000 kg/jam = 4.500 kg/jam

3. TBS Rebusan = 89% x 45.000 kg/jam = 40.050 kg/jam

4. Exhaust Steam = 35% x 45.000 kg/jam = 15.750 kg/jam

Komposisi Masuk (kg/jam) Keluar (kg/jam)

TBS 45.000 -
Inlet Steam 20.250 -
Exhaust Steam - 15.750
Kondensat - 4.950
Evaporasi - 4.500
TBS Rebusan - 40.050
Total 65.250 65.250

2. Thresher

TBS yang sudah masak diumpankan ke unit thresher melalui tippler dan
bunch hopper untuk memisahkan brondolan dari janjangannya dengan cara
mengangkat dan membanting. Persentase brondolan 70,2% dari 89% tandan rebus
yang telah disterilisasi. Hasil dari proses thresher berupa oil losses EFB, EFB,
brondolan, oil losses USB, dan USB dengan persentase 0,3%, 22,97%, 70,2%,
0,03%, dan 6,5%.
 Oil Losses
EFB 22,97%
EFB 0,3%

Brondolan
70,2%
Thresher

Tandan Rebus

89%

USB 6,5% Oil Losses USB

0,03%

A. Neraca massa bahan masuk :

1. Tandan Rebus = 89% x 45.000 kg/jam = 40.050 kg/jam

B. Neraca massa bahan keluar :

1. Oil Losses EFB = 0,3% x 40.050 kg/jam = 120,15 kg/jam

2. EFB = 22,97% x 40.050 kg/jam = 9.199,485 kg/jam

3. Brondolan = 70,2% x 40.050 kg/jam = 28.115,1 kg/jam

4. Oil Losses USB = 0,03% x 40.050 kg/jam = 12,015 kg/jam

5. USB = 6,5% x 40.050 kg/jam = 2.603,25 kg/jam

Komposisi Masuk (kg/jam) Keluar (kg/jam)

Tandan Rebus 40.050 -
Oil Losses EFB - 120,15
EFB - 9.199,485
Brondolan - 28.115,1
Oil Losses USB - 12,015
USB - 2.603,25
Total 40.050 40.050
3. Digester

Brondolan dari unit thresher kemudian diumpankan ke unit digester.

Brondolan tersebut diumpankan melalui fruit conveyor, fruit elevator dan
distributing conveyor. Brondolan tersebut akan dilumat dengan pisau-pisau
pengaduk yang berputar pada as sehingga daging buah pecah dan terlepas dari
biji. Proses pelumatan dilakukan dengan suhu 95oC dan tetap dipertahankan. Hasil
dari proses digester berupa daging buah yang sudah terlepas dari bijinya.

Brondolan Digester
70,2% Daging buah terpisah dari
biji 100%

- mesocarp 46,49%

- nut 32,23%

- bagian abnormal 3,34%

- bagian normal 3,69%

- calix leave 10,83%

- kekotoran 3,42%

A. Neraca massa bahan masuk :

1. Brondolan = 70,2% x 40.050 kg/jam = 28.115,1 kg/jam

B. Neraca massa bahan keluar :

 1.Daging buah terpisah dari biji = 100% x 28.115,1 kg/jam = 28.115,1
kg/jam

- Mesocarp = 46,49% x 28.115,1 kg/jam = 13.070,71 kg/jam

- Nut = 32,23% x 28.115,1 kg/jam = 9.061,4967 kg/jam

- Abnormal = 3,34% x 28.115,1 kg/jam = 939,04 kg/jam

- Normal = 2,5% x 28.115,1 kg/jam = 1.037,45 kg/jam

- Calix Leave = 10,83% x 28.115,1 kg/jam = 3.044,865 kg/jam

- Kekotoran = 3,42% x 28.115 kg/jam = 961,54 kg/jam

Komposisi Masuk (kg/jam) Keluar (kg/jam)

Brondolan 28.115,1 -
Mesocarp - 13.070,71
Nut - 9.061,4967
Abnormal - 939,04
Normal - 1.037,45
Calix Leave - 3.044,865
Dirt - 961,54
Total 28.115,1 28.115,1

4. Screw Press

Daging buah dan biji yang telah terpisah kemudian diumpankan menuju
screw press. Screw press akan mengekstraksi crude oil yang terdiri dari double
worm screw sebagai pendorong, press cage sebagai penyaring minyak keluar, dan
cone sebagai penekan. Hasil dari screw press berupa nut, crude oil, dan fiber
dengan persentase 13,11%, 75,49%, dan 11,4%.

Nut 13,11%

Daging buah Screw Press Crude Oil

terpisah dari
biji 100% 75,49%
 Fiber 11,4%

A. Neraca massa bahan masuk :

1.Daging buah terpisah dari biji = 100% x 28.115,1 kg/jam = 28.115,1

kg/jam

- Mesocarp = 46,49% x 28.115,1 kg/jam = 13.070,71 kg/jam

- Nut = 32,23% x 28.115,1 kg/jam = 9.061,4967 kg/jam

- Abnormal = 3,34% x 28.115,1 kg/jam = 939,04 kg/jam

- Normal = 2,5% x 28.115,1 kg/jam = 1.037,45 kg/jam

- Calix Leave = 10,83% x 28.115,1 kg/jam = 3.044,865 kg/jam

- Kekotoran = 3,42% x 28.115 kg/jam = 961,54 kg/jam

B. Neraca massa bahan keluar :

1. Nut = 13,11% x 28.115,1 kg/jam = 3.685,89

kg/jam

2. Crude Oil = 75,49% x 28.115,1 kg/jam = 21.224,089

kg/jam

3. Fiber = 11,4% x 28.115,1 kg/jam = 3.205,12

kg/jam

Komposisi Masuk (kg/jam) Keluar (kg/jam)

Mesocarp 13.070,71 -
Nut 9.061,4967 -
Abnormal 939,04 -
Normal 1.037,45 -
Calix Leave 3.044,865 -
Dirt 961,54 -
Nut - 3.685,89
Crude Oil - 21.224,089
 Fiber - 3.205,12
Total 28.115,1 28.115,1

5. Screen Vibrating

Crude Oil
Screen Crude Oil 96 %
75,49% Vibrating
- Oil 50%

- Moisture 20%

- Sludge 30%
Kotoran

4%

A. Neraca massa bahan masuk :

1. Crude Oil = 75% x 28.115,1/jam = 21.224,089 kg/jam

B. Neraca massa bahan keluar :

1. Crude Oil = 96% x 21.224,089/jam = 20.375,125 kg/jam

- Oil = 50% x 20.375,125 = 10.187,563 kg/jam

- Moisture = 20% x 20.375,125 = 4.075,025 kg/jam

- Sludge = 30% x 20.375,125 = 6.112,5375 kg/jam

2. Kotoran = 4% x 21.224,089 kg/jam = 848,96 kg/jam

Komposisi Masuk (kg/jam) Keluar (kg/jam)

Crude Oil 21.224,089 -
Crude Oil - 20.375,125
Kotoran - 848,96
 Total 21.224,089 21.224,089

4. CST

Crude oil hasil olahan dari screen vibrating kemudian diumpankan

menuju CST (Continuous Setling Tank) melalui crude oil tank. Crude oil tersebut
diendapkan dengan waktu retensi 4 s/d 5 jam untuk memisahkan antara oil dan
sludge. Persentase oil yang dihasilkan adalah 67% dan persentase sludge yang
dihasilkan adalah 33%. Sludge yang dihasilkan kemudian diumpankan menuju
decanter.

Crude Oil 96% CST Oil 67%

Sludge 33%

A. Neraca massa bahan masuk :

1. Oil = 96% x 21.224,089 kg/jam = 20.375,125 kg/jam

B. Neraca massa bahan keluar :

1. Crude Oil = 67% x 20.375,125 kg/jam = 13.651,334 kg/jam

2. Sludge = 33% x 20.375,125 kg/jam = 6.723,7913 kg/jam

Komposisi Masuk (kg/jam) Keluar (kg/jam)

Oil 20.375,125 -
Crude Oil - 13.651,334
Sludge - 6.723,7913
Total 20.375,125 20.375,125
5. Vacuum Dryer

Oil hasil pengendapan pada CST kemudian diumpankan menuju vacuum

dryer melalui oil tank. Oil hasil vacuum dryer terdiri dari CPO (crude palm oil),
zat pengotor dan jumlah air. Persentase untuk CPO, kotoran, dan air adalah
99,76%, 0,019%, dan 0,22%. CPO hasil olahan vacuum dryer kemudian
diumpankan menuju storage tank untuk disimpan sementara.

Vacuum CPO
Oil 96%
Dryer
99,76%

Kotoran Air

0,019% 0,22%

A. Neraca massa bahan masuk :

1. Oil = 96% x 20.375,125 kg/jam = 13.651,334 kg/jam

B. Neraca massa bahan keluar :

1. CPO = 99,77% x 13.651,334 kg/jam = 13.618,571 kg/jam

2. Air = 0,22% x 13.651,334 kg/jam = 30,033 kg/jam

3. Kotoran = 0,019% x 13.651,334 kg/jam = 2,6 kg/jam

 Komponen Masuk (kg/jam) Keluar (kg/jam)
Oil 13.651,334 -
CPO - 13.618,571
Air - 30,033
Kotoran - 2,6
Total 13.651,334 13.651,334

6. Decanter

Sludge hasil proses pada CST diumpankan menuju decanter melalui sludge tank
dan sludge buffer tank. Hasil olahan decanter adalah heavy phase, light phase,
dan solid dengan persentase 65%, 32%, dan 3%. Solid hasil pemisahan dialirkan
menuju lapangan untuk land application dan light phase akan dialirkan kembali
menuju CST untuk diproses kembali.

Light Phase 65%

- Oil 60%

- Moisture 15%

-Sludge 35 %

Decanter
Sludge 33% Heavy Phase 32%

Solid 3 %
A. Neraca massa bahan masuk :

1. Sludge = 33% x 20.375,125 kg/jam = 13.651,334 kg/jam

B. Neraca massa bahan keluar :

1. Light Phase = 65% x 13.651,334 kg/jam = 8.873,3671

kg/jam
 - Oil = 60% x 8.873,3671 kg/jam = 5.324,0203 kg/jam

- Moisture = 15% x 8.873,3671 kg/jam = 1.331,0051 kg/jam

- Sludge = 35% x 8.873,3671 kg/jam = 3.105,6785 kg/jam

2. Heavy Phase = 32% x 13.651,334 kg/jam = 4.368,4269 kg/jam

3. Solid = 3% x13.651,334 kg/jam = 409,54 kg/jam

Komponen Masuk (ton/jam) Keluar (ton/jam)

Sludge 13.651,334 -
Light Phase - 8.873,3671
Solid - 409,54
Heavy Phase - 4.368,4269
Total 13.651,334 13.651,334

7. BST

BST = 10,67 ton

Total CPO = 10,58
OER = 23,51%

CPO = 96% x 21.224,089 kg/jam = 20.375,125 kg/jam

CPO Light Phase = 60% x 8.873,3671 kg/jam = 5.324,0203 kg/jam

Total CPO = (20.375,125 + 5.324,0203) kg/jam = 25.699,145 kg/jam

OER (Oil Extraction Rate) = 10,58 ton/jam : 45 ton/jam = 23,51 %

MATERIAL BALANCE OF FFB PROCESS/HOUR

UNIT KERJA PMKS PERANAP

FRESH FRUIT
BUNCH
45,000 Kg (100%)

Condensate