III-1

III. NERACA MASSA

Pra rancangan pabrik Triple superphosphate dari Phosphate rock dan

Phosphoric acid dengan proses granulasi kapasitas 66.000 ton/tahun menggunakan
alur sebagai berikut:
Kapasitas produksi : 66.000 ton/tahun
Jumlah hari kerja : 330 hari
Jumlah kerja per hari : 24 jam
66.000 𝑡𝑜𝑛 1000 𝑘𝑔 1 𝑡𝑎ℎ𝑢𝑛 1 ℎ𝑎𝑟𝑖
Massa kapasitas produksi : × × 330 ℎ𝑎𝑟𝑖 × 24 𝑗𝑎𝑚
𝑡𝑎ℎ𝑢𝑛 𝑡𝑜𝑛

: 8.333,3333 kg/jam
Basis : 1.000 kg/jam
Konversi : 96%
3.1 Crusher

Fungsi :Menghancurkan batuan fosfatmenjadi lebih kecil

3Recycle

Batuan fosfat 2
Crusher
1 Batuan fosfat

Tabel 3.1 Neraca Massa Crusher

Input (kg/jam) Output (kg/jam)

Komponen
1 3 2
Ca3(PO4)2 1.731,4927 34,6299 1.766,1225
H2O 161,6060 3,2321 164,8381
MgO 184,6926 3,6939 188,3864
SiO2 69,2597 1,3852 70,6449
Al2O3 92,3463 1,8469 94,1932
Fe2O3 23,0866 0,4617 23,5483
TiO2 46,1731 0,9235 47,0966
2.308,6569 46,1731
Total 2.354,8300
2.354,8300

III-1
 III-2

3.2 Screener-1

Fungsi : Menyaring batuan fosfat dengan ukuran 200 mesh

Batuan Fosfat Batuan Fosfat

Screen
2 4

3
Recycle

Tabel 3.2 Neraca Massa Screener-1

Input
Output (kg/jam)
Komponen (kg/jam)
2 3 4
Ca3(PO4)2 1.766,1225 34,6299 1.731,4927
H2O 164,8381 3,2321 161,6060
MgO 188,3864 3,6939 184,6926
SiO2 70,6449 1,3852 69,2597
Al2O3 94,1932 1,8469 92,3463
Fe2O3 23,5483 0,4617 23,0866
TiO2 47,0966 0,9235 46,1731
2.354,8300 46,1731 2.308,6569
Total
2.354,8300 2.354,8300

3.3 Mixer

Fungsi : Menghomogenkan H3PO4 segar dengan H3PO4 hasi Recycle

6 12 Recycle
H2O H3PO4
H2O

5 7
Mixer
H3PO4 H3PO4
 III-3

Tabel 3.3 Neraca Massa Mixer

Input (kg/jam) Output (kg/jam)

Komponen
5 12 6 7
H2O 4.050,0000 7.177,2782 8.100,0000 19.327,2782
H3PO4 12.150,0000 9.063,1682 - 21.213,1682
16.200,0000 16.240,4463 8.100,0000 40.540,4463
Total
40.540,4463 40.540,4463

3.4 Reaktor

Fungsi :Sebagai tempat untuk mereaksikan batuan fosfat dan asam fosfat
membentuk Triple superphosphate
Ca3(PO4)2 4
8 3Ca(H2PO4)2.H2O
Reaktor
7
H3PO4
H2 O
Tabel 3.4 Neraca Massa Reaktor

Input (kg/jam) Output (kg/jam)

Komponen
4 7 8
3Ca(H2PO4)2.H2O - - 4.011,5834
Ca3(PO4)2 1.731,4927 - 86,5746
H2O 161,6060 8.100,0000 7.974,7535
H3PO4 - 12.150,0000 10.070,1869
MgO 184,6926 - 184,6926
SiO2 69,2597 - 69,2597
Al2O3 92,3463 - 92,3463
Fe2O3 23,0866 - 23,0866
TiO2 46,1731 - 46,1731
2.308,6569 20.250,0000 22.558,6567
Total
22.558,6567 22.558,6567
 III-4

Tabel 3.5 Neraca Massa Recycle Reaktor

Input (kg/jam) Output (kg/jam)

Komponen
4 7 8
3Ca(H2PO4)2.H2O - - 4.011,5834
Ca3(PO4)2 1.731,4927 - 86,5746
H2O 161,6060 19.327,2782 19.202,0317
H3PO4 21.213,1682 19.133,3551
MgO 184,6926 - 184,6926
SiO2 69,2597 - 69,2597
Al2O3 92,3463 - 92,3463
Fe2O3 23,0866 - 23,0866
TiO2 46,1731 - 46,1731
Total 2.308,6569 40.540,4463 42.849,1030
42.849,1030 42.849,1030

3.5 Rotary Drayer

Fungsi : Menguapkan air dan memadatkan granul

3Ca(H2PO4)2.H2O
Udara 9 10 Ca3(PO4)2
panas 8 8
H3PO4
H2 O
3Ca(H2PO4)2.H2O Udara panas
Ca3(PO4)2 10
Rotary Dryer
H3PO4 8

8
H2 O
3Ca(H2PO4)2.H2O
11 Ca3(PO4)2
8
H3PO4
H2 O
 III-5

Tabel 3.6 Neraca Massa Rotary Dryer

Input (kg/jam) Output (kg/jam)

Komponen
8 9 11 10
3Ca(H2PO4)2.H2O 4.011,5834 - 3.610,4251 401,1583
Ca3(PO4)2 86,5746 - 8,6575 77,9172
H2O 7.974,7535 - 12.024,7535 7.177,2782
H3PO4 10.070,1869 - 10.070,1869 9.063,1682
MgO 184,6926 - 18,4693 166,2233
SiO2 69,2597 - 6,9260 62,3337
Al2O3 92,3463 - 9,2346 83,1116
Fe2O3 23,0866 - 2,3087 20,7779
TiO2 46,1731 - 4,6173 41,5558
Udara Panas - 24.802,1813 - 4.5111,7313
Total 22.558,6567 24.802,1813 25.775,5788 21.605,2556
47.360,8380 47.360,8380

Tabel 3.7 Neraca Massa Recycle Rotary Dryer

Input (kg/jam) Output (kg/jam)

Komponen
8 9 11 10
3Ca(H2PO4)2.H2O 4.011,5834 - 3.610,4251 401,1583
Ca3(PO4)2 86,5746 - 8,6575 77,9172
H3PO4 19.133,3551 - 1.913,3355 17.220,1096
H2O 19.202,0317 - 1.920,2032 17.281,8285
MgO 184,6926 - 18,4693 166,2233
SiO2 69,2597 - 6,9260 62,3337
Al2O3 92,3463 - 9,2346 83,1116
Fe2O3 23,0866 - 2,3087 20,7779
TiO2 46,1731 - 4,6173 41,5558
Udara Panas - 8.569,8206 - 8.569,8206
42.849,1030 8.569,8206 7.494,1770 43.924,7466
Total
51.418,9236 51.418,9236
 III-6

3.6 Centrifuge

Fungsi : Memisahkan Asam Fosfat dan Air

H3PO4
H2O
3Ca(H2PO4)2.H2O 12 3Ca(H2PO4)2.H2O
Ca3(PO4)2 Ca3(PO4)2
H3PO4 10 13 H3PO4
H2O Centrifuge H2O
MgO MgO
SiO2 SiO2
Al2O3 Al2O3
Fe2O3 Fe2O3
TiO2 TiO2

Tabel 3.8 Neraca Massa Centrifuge

Input (kg/jam) Output (kg/jam)

Komponen
10 12 13
3Ca(H2PO4)2.H2O 401,1583 - 401,1583
Ca3(PO4)2 77,9172 - 77,9172
H3PO4 9063,1682 9063,1682 -
H2O 7177,2782 7177,2782 -
MgO 166,2233 - 166,2233
SiO2 62,3337 - 62,3337
Al2O3 83,1116 - 83,1116
Fe2O3 20,7779 - 20,7779
TiO2 41,5558 - 41,5558
16240,4463 853,0779
Total 17093,5243
17093,5243
 III-7

3.7 Crusher-2
Fungsi : Menghancurkan granul hingga ukuran 6 mesh
14
3Ca(H2PO4)2.H2O 3Ca(H2PO4)2.H2O
Recycle Ca3(PO4)2
Ca3(PO4)2
H3PO4 H3PO4
11 15 H2O
H2O Crusher-2
MgO MgO
SiO2 SiO2
Al2O3 Al2O3
Fe2O3 Fe2O3
TiO2 TiO2

Tabel 3.9 Neraca Massa Crusher-2

Input (kg/jam) Output (kg/jam)

Komponen
11 14 15
3610,4251 72,2085 3682,6336
3Ca(H2PO4)2.H2O
8,6575 0,1731 8,8306
Ca3(PO4)2
1913,3355 38,2667 1951,6022
H3PO4
1920,2032 38,4041 1958,6072
H2O
18,4693 0,3694 18,8386
MgO
6,9260 0,1385 7,0645
SiO2
9,2346 0,1847 9,4193
Al2O3
2,3087 0,0462 2,3548
Fe2O3
4,6173 0,0923 4,7097
TiO2
Subtotal 7.494,1770 149,8835 7.644,0606
Total 7.644,0606 7.644,0606
 III-8

3.8 Screener

Fungsi : Menyaring kembali ukuran granul yang >6 mesh

13

3Ca(H2PO4)2.H2O
Ca3(PO4)2 3Ca(H2PO4)2.H2O
14
H3PO4 Screener Ca3(PO4)2
H2O 15 H3PO4
H2O
16 3Ca(H2PO4)2.H2O
Ca3(PO4)2
H3PO4
H2O

Tabel 3.10 Neraca Massa Screener

Komponen Input (kg/jam) Output (kg/jam)

15 13 16 14
3Ca(H2PO4)2.H2O 3682,6336 401,1583 4002,1161 81,6758
Ca3(PO4)2(s) 8,8306 77,9172 85,0128 1,7350
H3PO4 1951,6022 - 1912,5702 39,0320
H2O 1958,6072 - 1919,4351 39,1721
MgO 18,8386 166,2233 181,3607 3,7012
SiO2 7,0645 62,3337 68,0103 1,3880
Al2O3 9,4193 83,1116 90,6803 1,8506
Fe2O3 2,3548 20,7779 22,6701 0,4627
TiO2 4,7097 41,5558 45,3402 0,9253

7.644,0606 853,0779 8.333,3333 163,6667

Total
8.497,1385 8.497,1385