MANUFACTURE (Introduction)

“produced in a large-scale industrial operation”

 Apa itu
manufaktur??
 Apa ini juga
termasuk
manufaktur??
 Finish/ unfinish
Manufacturing parts
Proses Process, using:
Machine
Manufaktur Raw material
Man/ labor
Tools
Methods Scrap/ waste
• Manufaktur adalah salah satu sumber Apa Pentingnya
pendapatan terpenting dalam perekonomian manufaktur
suatu negara.
• Produk Domestik Bruto Indonesia th 2010
adalah Rp. 1.375.233,7 miliar
• Profesi yang digeluti oleh Sarjana Teknik
Industri antara lain : Design Engineers, Product
Engineers, Research and Development,
Manufacturing Engineer, Planning, Safety,
Materials, etc.
 Manufacturing
Process
Kegiatan mengubah bahan mentah (raw
material) atau bahan setengah jadi (unfinished
material) menjadi bentuk lain yang memiliki
nilai tambah (added value) menggunakan
mesin, tools, methods, dan manusia.

Contoh: Milling, Turning, Casting, Welding, dll.

 CORPORATE STRATEGY
• Market pull:
inspirations come from market
• Technology push:
emphasize services and technology

Lebih banyak Company dengan produk market pull

14
 PROCESS DESIGN VS PRODUCT DESIGN
Process design
1. Batch vs continuous process
2. Inputs and Outputs
3. Recycles and reactors optimization
4. Separation and heat integrations Product design
1. Identify customer needs
2. Generate ideas to meet needs
3. Select most appropriate idea
4. Manufacture product

Manufacture product mencakup process design

15
 PRODUCT MANUFACTURE
• INTELECTUAL PROPERTY
• FINDING MISSING INFORMATION
• FINAL/DETAILED SPECIFICATION INTELECTUAL PROPERTY
• Patents
• Trade secrets
Produk baru perlu dipatentkan

Jenis patent di US:

1. Utility patent
2. Design patent
3. Living plant patent
16
 Supplying MISSING INFORMATION
Kompetensi seorang engineer:
“bekerja dengan data yang terbatas”

Tidak ada cara atau metode khusus untuk mencari data yang
kurang
Secara prinsip: minimize expenses!
• Mencari data/informasi dari literature, jurnal, dan sejenisnya
• Menghitung, merancang (desk calculation)
• Data penting yang belum ada dicari dari eksperimen

Yang sering dihadapi chemical engineer adalah mencari cara

sintesis: REACTION PATH STRATEGIES 17
 FINAL SPECIFICATION
Setting final specification can be aided by:
1. Product structure
+ Chemical composition
+ Physical geometry
+ Chemical properties: reactivity
+ Thermodynamic properties

2. Central product attributes

Most important characteristics that the product has advantages over other products

3. Chemical triggers
Identify any chemistry that makes the product become active
Effect of solvent, temperature, pH, pressure, etc. 18
 Example of reaction path strategies

Manufacture of sulfuric acid

• Proses kamar timbal
• Contact process
Manufacture of ethanol
1. Fermentation of glucose
carbohydrate → glucose (hydrolysis)
C6H12O6 → 2 C2H5OH + 2 CO2 (fermentation)

2. Hydration of ethylene
H2C=CH2 + H2O → CH3-CH2OH (gas phase)

Pengetahuan tentang kimia (umum, organik), proses

industri kimia sangat diperlukan! 19
 Solvent for CO2 removal (Acid gas removal)

Basic reaction:
2 RNH2 + CO2 → RNH3+ + RNHCOO-
One mol CO2 needs 2 mols amines

Guido Sartori (1974), Exxon chemist, found that by changing the (structure of) amines, reaction
could be changed.
RNH2 + CO2 + H2O → RNH3+ + HCO3-

Using hindered amine, such as diisopropylamine:

(CH3)2C-NH-C(CH3)2
• The side groups have a high electron repelling power
• To increase the solubility into water, -OH is attached
20
 Expected specification:
1. Solvent that can double the capacity of absorption column.
2. Rate of reaction must be at least as high as that for the conventional solvent.
3. Operating condition must be similar to the previous condition (absorption 40° – 80°C,
stripping 120°C).
4. The solvent must be stable in the presence of corrosion inhibitor (V+)

• Sartori: hindered amines can reduce reaction stoichiometry, from 2 mols amines to 1 mol amine
• However, R group can reduce the reactivity of amine. A lot of experiments were conducted to
choose the appropriate structure of R
• The amine must be tested its stability against temperature (thermal stability) and corrosion
inhibitor
21
 Example of setting FINAL SPECIFICATION
FREON FREE FOAM INSULATOR
• Refrigerators need polyurethane foam insulator.
• It is made by injecting Freon into molded polyurethane (95% volume of
bubbles, contains Freon)
• Freon is banned (destructing ozone layer)

0.08 T
kT  → kT(CO2) = 3.kT(Freon)
 2 M
Mol weight (M) Mol diameter (σ)
N2 28 3.8 Å
CO2 44 3.9 Å
Freon (CCl2F2) 121 5.3 Å
22
 STEPS OF STRATEGY
PRODUCT STRUCTURE
Must contain 95% gas bubbles (light weight)
THE KEY ATTRIBUTE
Insulator thickness must at least be similar to that of Freon (thermal conductivity!)
Monoatomic dilute gas:
kT = (1/3)(λ)(energy/volume)(molecular velocity)
For small bubble: diameter ~ mean free path (λ)

kB
kT  dp
2mT
kB : Boltzmann’s constant
p : pressure
m : mass of gass inside the bubble
23
To reduce thermal conductivity:
• Smaller diameter (less than 1μm, but very difficult)
• Reduce the pressure p
• Reduce mass of gas m

• CO2 is blown into molded polyurethane, as in the previous process

• Polyurethane is blown in a bag of metal foil (impermeable to all
gases)
• After foaming, NaOH is added into the bag, to attract CO2 from
bubbles

24