Tk19 Revised Assignment3

UNIVERSITAS INDONESIA
ADSORBENT FOR CIGARETTE SMOKE ODOR
Revised Assignment 3
GROUP 19
GROUP PERSONNEL:
EVAN LIBRIANDY (1406607722)
IRFAN FAISAL PANE (1406564300)
OSEL SAKADEWA (1406604600)
SEKAR AYU CHADARWATI (1406531744)
YUGO WIDHI NUGROHO (1406563235)
CHEMICAL ENGINEERING DEPARTMENT

ENGINEERING FACULTY
UNIVERSITAS INDONESIA
APRIL, 2017
EXECUTIVE SUMMARY
In the beginning of this assignment, we first reflect to the final specifications

with some modifications to start planning the manufacturing process. The final
specifications include product composition and performances and brief descriptions
on how the adsorbent works for adsorbing cigarette smoke odor. We also compare
again our own product with existing products. The first chapter also describes the
prototype of the product, including the sketch of the product and the packaging for
retail, the visual, and verbal branding such as brand, logo, and tagline. The main
content of the product is activated carbon (59.5%), water (14%), and the rest are
impurities. The packaging of the product is divided into two kind, the hard case
package which is made of hard-density polyethylene and the refill pack which is
made of low-density polyethylene and completed with seal. Both package have the
inner package made of tea bag.
The first thing to do is analyzing the market to predict our production
capacity. We start by doing market segmentation to break down the target market
into smaller groups for marketing efficiency purpose. Then we estimate our product
demand based on total of second hand smoker (SHS) in Indonesia and using that
demand data for prediction of our production capacity in the next 10 years that will
determine the whole manufacturing process. We only use demand because our
product is a new product in Indonesia’s market.
Palm shell is one of the most abundant waste in palm oil processing, with a
share of 12% from total weight of palm fruit. Palm oil production averaging at 5.6
million tons annually, which resulted 672,000 tons of palm shell produced. The
amount of palm shell will continue to rise as palm oil production projected to grow
in recent future. Palm shell contain 26.6% of cellulose and 27.7% of hemicelluloses,
which contributed to high absorptivity characteristic in an activated carbon. This
number is bigger than the other waste that contain the contributed in activated
carbon. The process to make palm shell to be cigarette odor adsorbent product is
divided into 4 steps: carbonization, activation, quality control and packaging.
i
Universitas Indonesia
In the next sub chapter, we explain about specification of some major
equipment that will be used in our manufacturing process. The first step is
carbonization (turning organic compound to charcoal), which need some batch
furnace, and a crusher to decrease the particle size. The next process is chemical
activation with ZnCl2 in a mixer. Then the wet carbon will be physically activated
by processing them in a fluidized bed reactor. The next step is to dip the carbon in
H2O solution so that the ZnCl2 will disintegrate and react with H2O and forming a
HCl solution. The remaining Zinc substances are adsorbed in activated carbon so it
causes instability in carbon structure. This instable carbon will yield a better
adsorption site. The next step is drying with a spin flash dryer to remove HCl from
previous process, and to remove excess aquades. The capacity of each product is
not the same. The required capacity of each equipment will be calculated in the
detailed mass balance in the next sub chapter. The calculation includes overall mass
balance and mass balance for each equipment. This calculation is useful for
determining the amount of raw material needed to reach production target. Apart
from mass balance, we also have to calculate energy requirement for our
manufacturing process to be successful. This will be done by predict the working
time for each equipment and multiply it by the power required of each product. The
total power required will be used to determine the power we need to supply from
PLN.
Our plant is product-oriented layout, which concern in efficiency of place.
We only have 1 line of production. The main building is 300 m2 in area and 9 m in
height. The plant occupied on 500-m2 land in Kampar Regency, Riau, Sumatra,
Indonesia. Abundant raw material around the area, direct energy sources,
accessibility to land transportation are our considerations to choose this spot.
Availability of laborer around the region that mainly involved in agricultural job
also add up the certainty.
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TABLE OF CONTENTS
EXECUTIVE SUMMARY ............................................................................................... i

TABLE OF CONTENTS ................................................................................................ iii
LIST OF FIGURES .......................................................................................................... v
LIST OF TABLES ........................................................................................................... vi
CHAPTER 1 PRODUCT DESCRIPTION..................................................................... 1
1.1 Product Final Specification ................................................................................. 1
1.2 Product Positioning ............................................................................................. 2
1.3 Product Description ............................................................................................ 5
1.4 Prototype of Product ........................................................................................... 8
1.4.1 Sketch of Product ........................................................................................ 8
1.4.2 Brand, Logo, and Tagline ........................................................................... 8
1.4.3 Packaging of the Product ............................................................................ 9
CHAPTER 2 PRODUCT MANUFACTURING .......................................................... 13
2.1 Market Analysis ................................................................................................ 13
2.1.1 Market Segmentation ................................................................................ 13
2.1.2 Demand of Adsorbent for Cigarette Smoke Odor ..................................... 14
2.1.3 Supply of Adsorbent for Cigarette Smoke Odor ....................................... 15
2.1.4 Market Opportunity................................................................................... 15
2.1.5 Production Capacity of Adsorbent for Cigarette Smoke Odor ................. 15
2.2 Raw Materials ................................................................................................... 16
2.3 Block Flow Diagram ......................................................................................... 18
2.3.1 Material and Component Preparation ....................................................... 19
2.3.2 Carbonization ............................................................................................ 19
2.3.3 Chemical and Physical Activation ............................................................ 19
2.3.4 Product Quality Control ............................................................................ 20
2.3.5 Packaging Process ..................................................................................... 20
2.4 Equipment ......................................................................................................... 21
2.4.1 Carbonization Furnace .............................................................................. 21
2.4.2 Crusher ...................................................................................................... 22
2.4.3 Mixer ......................................................................................................... 23
2.4.4 Furnace ...................................................................................................... 24
2.4.5 Spin Flash Dryer ....................................................................................... 25
2.4.6 Packaging Machine ................................................................................... 27
2.4.7 Conveyor belt ............................................................................................ 29
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2.5 Mass and Energy Balance ................................................................................. 30
2.5.1 Mass Balance ............................................................................................ 30
2.5.2 Energy Balance ......................................................................................... 35
2.6 Plant Layout & Scheduling ............................................................................... 37
2.7 Detail of Plant Factory ...................................................................................... 40
CHAPTER 3 CONCLUSION ........................................................................................ 47
REFERENCES ................................................................................................................ 48
iv
LIST OF FIGURES
Figure 1. 1 Product comparison diagram, comparing own-concept adsorbent to existing

product ................................................................................................................................ 2
Figure 1. 2 Schematic representation of the pore network of a carbon adsorbent ............. 5
Figure 1. 3 Effect of temperature on adsorption capacity of TMP on Carbon C ............... 7
Figure 1. 4 Granular activated carbon ................................................................................ 8
Figure 1. 5 Logo of “SEMBAKO” .................................................................................... 9
Figure 1. 6 Hard case front view of SEMBAKO ............................................................. 10
Figure 1. 7 Hard case back and upper view of SEMBAKO ............................................ 11
Figure 1. 8 Inner package of SEMBAKO ........................................................................ 11
Figure 1. 9 SEMBAKO refill package – front view ........................................................ 12
Figure 1. 10 SEMBAKO refill package – back view ....................................................... 12
Figure 2. 1 Smoking prevalence in Indonesia .................................................................. 13
Figure 2. 2 Cigarettes Production in Indonesia ................................................................ 14
Figure 2. 3 Palm shell ...................................................................................................... 17
Figure 2. 4 Competition of ash after burning process ...................................................... 18
Figure 2. 5 Block flow diagram of activated carbon manufacturing................................ 19
Figure 2. 6 Block Flow Diagram of Carbonization .......................................................... 19
Figure 2. 7 Block flow diagram of activated carbon chemical and physical activation ... 20
Figure 2. 8 Carbonization Furnace ................................................................................... 21
Figure 2. 9 Charcoal Crushing Machine .......................................................................... 22
Figure 2. 10 Solid - Liquid Mixer .................................................................................... 23
Figure 2. 11 (a) Schematic of Physical Activation of Carbon and (b) Fluidized Bed
Reactor for carbon activation ............................................................................................ 25
Figure 2. 12 Spin Flash Dryer .......................................................................................... 26
Figure 2. 13 Inner Bag Packaging Machine ..................................................................... 27
Figure 2. 14 Plastic Bag Sealing Machine ....................................................................... 28
Figure 2. 15 Conveyor Belt .............................................................................................. 29
Figure 2. 16 Overview of Mass Balance .......................................................................... 34
Figure 2. 17 Overview of Energy Balance ....................................................................... 36
Figure 2. 18 Plant layout for activated carbon manufacturing ......................................... 37
Figure 2. 19 Map Location Kampar, Riau Province ........................................................ 42
Figure 2. 20 Palm oil mill locations around the plant ...................................................... 42
Figure 2. 21 Oil palm plantation development in Sumatra Island by province ............... 43
Figure 2. 22 Oil palm plantation and economic performance in Riau, by regency .......... 44
Figure 2. 23 Regional minimum labor wage 2017 comparison with 2016 in Riau ......... 45
v
LIST OF TABLES
Table 1. 1 Final Specification of Product ........................................................................... 1

Table 2. 1 Production Capacity ........................................................................................ 16
Table 2. 2 Palm Shell Composition .................................................................................. 17
Table 2. 3 Specification of Carbonization Furnace .......................................................... 21
Table 2. 4 Specification of charcoal crushing machine .................................................... 22
Table 2. 5 Specification of mixer ..................................................................................... 24
Table 2. 6 Specification of activation reactor ................................................................... 25
Table 2. 7 Specification of spin flash drier ...................................................................... 26
Table 2. 8 Specification of packaging machine................................................................ 27
Table 2. 9 Specification of packaging machine................................................................ 28
Table 2. 10 Specification of conveyor belt ....................................................................... 29
Table 2. 11 Composition of product component .............................................................. 30
Table 2. 12 Overall mass balance..................................................................................... 30
Table 2. 13 Mass balance in dryer .................................................................................... 31
Table 2. 14 Mass balance in washing tank ....................................................................... 31
Table 2. 15 Mass balance in reactor ................................................................................. 32
Table 2. 16 Mass balance in mixer ................................................................................... 32
Table 2. 17 Mass balance in crusher ................................................................................ 32
Table 2. 18 Mass balance in furnace ................................................................................ 33
Table 2. 19 Overall energy balance .................................................................................. 35
Table 2. 20 Plant scheduling ............................................................................................ 38
vi
1
CHAPTER 1
PRODUCT DESCRIPTION
1.1 Product Final Specification
This section will describe the final concept of the product. The final concept
consists of adjustment from the concept that is created in previous assignments in
which some aspects will be eliminated and adjusted with some specifications that
meet consumers’ needs. This final concept will also lead to direct the manufacturing
process to be right. The metric of final specifications is stated below.
Table 1. 1 Final Specification of Product

Score
Specification Unit
Own
Product Performance
Working Time hours 1-2
Usage of Lifetime months 6
Rate of Adsorption ml/g adsorbent 80 - 100
Temperature Range oC 20 - 35
Product Perception
Saturation Indicator yes/no yes
Emits Good Smell yes/no no
Ability to Kill Mosquitos yes/no no
Regeneration Time hours 1-2
Regeneration Temperature oC 100oC
Product Properties
Surface Area m2/g 1000 - 1100
Pore Diameter nm 0.65 - 0.70
Pore Volume ml/g 0.35 - 0.45
Density g/cm3 0.5
Product Retailing
2
Table 1.1 Final Specification of Product (cont’d)

Package Diameter cm 10
Package Height cm 4
Gross Weight g 2000 - 2500
Regulation
Acute inhalation mg/l 64.4
Acute Oral Toxicity g/kg 10
Eco Friendly
Market
Rp 40,000 -
Price IDR/unit
60,000 / unit
1.2 Product Positioning
After making the final specification of our product, the next thing that has
to be done is positioning the similar products that have been marketed through
comparisons via radar graph. This graph helps us if the specification of our product
is either better or worse than other products in quality. Here is the radar diagram for
comparing our own product with others.
Own Product Airpura T600

Tub O' Carbon Odor Buster Ambipur After Tobacco
Fast to adsorb odor

5
4
3 Large adsorbing
Easy to manufacture
2 capacity
1
0
Safe and eco-friendly Low cost
Work specifically for

smoke odor
Figure 1. 1 Product comparison diagram, comparing own-concept adsorbent to existing product
3
Here are brief descriptions on how we gave the score to own product and
others.
- Fast in adsorbing odor
We give own-concept product the score 4 because the rate of volatile
organic compound adsorption for activated carbon is considered high.
Airpura T600 gets the score 5 because of its ability is supported by both
electricity and additional filter. Tub O’ Carbon Odor Buster gets the score
4 because it can adsorb the cigarette odor pretty fast. Ambipur gets the score
3 due to its work; it works on car and car has another circulation system so
that the work of this product is considered not so effective if the circulation
system dominates.
- Large adsorbing capacity
We give own-concept product the score 4 due to our concept is adsorbent
for indoor use and focus on volatile organic compound so that the adsorbing
capacity is supposed to be large. We give Airpura T600 the score 5 for this
aspect because of the electricity-supported mechanism and the product size
that makes the capacity is large. Tub O’ Carbon Odor Buster is given the
score 4 because it is used indoor which is supposed to have large adsorbing
capacity. Ambipur After Tobacco gets the score 2 due to its limited use for
car which has smaller area than common room.
- Low cost
Own-concept product is given score 5 because of big number of raw
materials found in nature and the manufacturing involves a few number of
process so the production cost is forecasted low. The selling price is
forecasted from Rp 50.000,00 to Rp 75.000,00 for own-concept product.
Airpura T600 gets the score 2 because it involves complex manufacturing
from the raw material, packaging, and the electricity support so that those
devices will make the production cost and the selling price are expensive,
around $849.98. Tub O’ Carbon Odor Buster is given score 4 because the
selling price is low ($12).
- Work specifically for smoke odor
4
Three out of four compared products (own-concept product, Tub O’ Carbon

Odor Buster, and Ambipur After Tobacco) get the score 4 because they are
already designed for cigarette odor removal. Meanwhile, Airpura T600 gets
the score 5 due to its extra-work; adsorbing ability, filter addition, and
electricity support make the work specific and efficient.
- Safe and eco-friendly
The same score (5) is found in own-concept product and Tub O’ Carbon
Odor Buster because of the eco-friendly raw material (entirely carbon).
Airpura T600 is given score 4 because it is very safe to use but it still uses
polymers for the packaging which is hardly bio-degraded. Ambipur After
Tobacco uses more chemicals that is hardly bio-degraded yet it is still safe
to use so that it gets the score 3.
- Easy to manufacture
We give the score 4 for own-concept product because making adsorbent
from activated carbon is considered easy from the ease of collecting raw
material, creating the carbon, and the activation step. Airpura T600 is given
the score 2 due to machinery design so that creating the machine needs high-
technology manufacture and this is not considered simple. Tub O’ Carbon
Odor Buster is given the score 4 because the manufacturing process is not
hard; it has to do thermal activation and the packaging is considered simple.
Ambipur After Tobacco gets the score 3 because it involves chemicals and
extracts so that the manufacturing is considered complex and the packaging
is supposed to be appropriate to be installed into car blower.
From the radar graph and each performance description, we can conclude
some advantages of own-concept product. They are;
- It has high rate of adsorption so that it is fast to adsorb odor;

- It has large adsorbing capacity;
- The production cost is low so that the price of it is cheap;
- It works specifically for cigarette smoke odor removal;
- It is safe to use and environmentally-friendly when it is exposed, and;
- It is easy to manufacture due to minimal technological use.
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1.3 Product Description
Activated carbon is a solid, porous, carbonaceous material prepared by

carbonizing and activating organic substances. The raw materials, which include
sawdust, peat, lignite, coal, cellulose residues, coconut shells, petroleum coke, etc.,
may be carbonized and activated at high temperature with or without the addition
if inorganic salts in a stream of activating gases such as steam or carbon dioxide.
Alternatively, carbonaceous matter may be treated with a chemical activating agent
such as phosphoric acid or zinc chloride and the mixture carbonized at an elevated
temperature, followed by removal of the chemical activating agent by water
washing. The main formula of activated carbon is C so the entire body of activated
carbon is made by carbon only.
Structurally, activated carbon has a porous carbon structure, which contains

small amounts of different heteroatoms such as oxygen and hydrogen. Some
activated carbons also contain carriable amounts of mineral matter (ash content)
depending on the nature of the raw material used as precursor. The porous structure
is perhaps the main physical property that characterizes activated carbons.
Activated carbon can be classified into 3 categories based on their size of pore.
They are micropores (pore width smaller than 2 nm), mesopores (pore width from
2-50 nm), and macropores (pore width larger than 50 nm).
Figure 1. 2 Schematic representation of the pore network of a carbon adsorbent

(Source: Menéndez-Díaz & Martín-Gullón, 2006)
6
Activated carbon that we are going to use as adsorbent is in the form of

granules, in other word, Granular Activated Carbon (GAC). GAC has a mean
particle size between 1-5 mm which is large. GAC is widely applied as fixed-bed
adsorbent in continuous processes and with low pressure drops, in both liquid and
gas phase applications. Most of the gas phase applications, such as gas purification,
air filtering, and gas masks, use GAC. This indicates that GAC is appropriate for
indoor cigarette odor removal since odor removal can be mentioned as gas
purification by adsorbing volatile organic compound that is toxic and is able to harm
human’s health. GAC, as mentioned before, offers a lower pressure drop along with
the fact that it can be regenerated or reactivated and therefore reused more than
once.
Activated carbon is safe to use and eco-friendly. This aspect can be seen
from its raw material. Types of raw material for making activated carbon are many;
since an activated carbon is structurally a non-graphitic carbonaceous material,
almost any carbonaceous solid material can be converted into activated carbon.
There are enormous number of possible raw materials such as wood, lignocellulosic
biomass, peat, lignite, and coals that can be used to make activated carbon. Organic
waste, such as coffee-bean grout, crops waste, and coconut shell, is also possible to
process. Those raw materials, practically, are all inexpensive materials with a high
carbon content and a low inorganic content, and consequently, are suitable for use
as activated carbon precursor. Activated carbon, which is almost entirely organic,
is biodegradable when it is exposed to the environment so there is no meaningful
risk if it is properly thrown away, in other words, it is eco-friendly. Referred to
activated carbon material safety data sheet (MSDS), the health point is given the
score 1 which means activated carbon doesn’t make serious health problem unless
there is sufficient exposure to human’s body such as skin irritation, eye contact,
ingestion, and inhalation, meanwhile it has no carcinogenic, mutagenic, teratogenic,
and developmental toxicity. Activated carbon is automatically ignited on 452°C yet
highly flammable n presence of open flames, sparks, and high heat and non-
flammable in presence of shocks. Since this product won’t be used in high heat and
fire-exposure area, this material is considered safe to use.
7
Activated carbon is considered effective for adsorbing volatile organic

compound performed in ambient temperature. There are some types of volatile
organic compounds (VOC) found in cigarette smoke that cause odor, including
styrene and acetaldehyde. An experiment was conducted for 2,2,4-trimethylpentane
to be adsorbed by activated carbon at elevating temperatures (30°C, 50°C, and
75°C) over the concentration range of 25-100 ppm using gravimetric methods. The
activated carbon that was used for this experiment had a total BET surface area of
1530 m2/gram and a total pore volume of 0.704 ml/gr. Andrew et al. (2004), through
this experiment, stated that the adsorption capacity decreased approximately 5%
and 11% by weight for the temperature intervals of 20°C and 45°C, respectively.
This indicates that for room temperature (25°C/77°F), when the graphic below is
extrapolated, activated carbon still has large capacity for adsorbing volatile organic
compound that exists in the air especially inside the room.
Figure 1. 3: Effect of temperature on adsorption capacity of TMP on Carbon C

(Source: Dallas, et al., 2004)
8
1.4 Prototype of Product
This section will discuss about the prototype of the product in the market
from its physical appearance, the visual and verbal branding of the product which
includes brand, logo, and tagline, and the sketch of the packaging which includes
the physical appearance and dimension detail of the product packaging.
1.4.1 Sketch of Product
Our product is in the form of granular activated carbon. The net mass is 160
grams. The color of the adsorbent is black due to the cooking process of raw
material that will be discussed on the next chapter. The activated carbon is
processed by chemical-physical activation which will involve some chemicals for
activating the carbon so there will be chemicals inside the pore of the activated
carbon that will disturb the equilibrium of the surface and trigger the adsorption
phenomena for some VOCs in the air that are produced by cigarettes.
Figure 1. 4 Granular activated carbon

(Reproduced)
1.4.2 Brand, Logo, and Tagline
To create the strong market, we need branding for our product. This is
essential since the existing products have already had their iconic brand. Branding
characterizes our product to others which must be catchy, memorable, and on-point
(not going anywhere from the essence of the product). Costumers and/or consumers
9
will be much attracted with the physical appearance of the product on the first place
before reading the detail of the product’s performance.
The very first step of branding strategy is putting the product’s name, logo,
and the tagline. We name our product “SEMBAKO” which is derived from Bahasa
Indonesia, describing our main goal to eliminate VOCs from the air. “SEMBAKO”
is considered attractive for Indonesian people since it’s commonly used in wide
conversation about people’s need of living (the original word, ‘sembako,’ is an
acronym of ‘sembilan bahan pokok,’ translated as ‘nine main ingredients.’).
The logo of “SEMBAKO” is given below.
Figure 1. 5 Logo of “SEMBAKO”
The logo describes the brand’s identity and main goal. The cigarette which
is trapped inside the square means that the product will adsorb the cigarette odor
that is created inside the room (the square). The thing in the corner is palm fruit
which the shell is used as the raw material of activated carbon.
The tagline is in Bahasa Indonesia below the product’s name, “Serap
Maksimal Bau Rokok,” (English: maximally adsorbing cigarette odor). Basically,
the product name “SEMBAKO” is derived from the tagline which is on point to the
main goal of the product. The tagline has already described that the product
performs odor elimination, especially for cigarette odor.
1.4.3 Packaging of the Product
Packaging of the product will be created into two forms: small paper bag
and high-density polyethylene (HDPE). HDPE is the most widely used type of
10
plastic. It’s used to make many types of bottles and containers. Unpigmented
bottles are translucent, have good barrier properties and stiffness, and are well
suited to packaging products with a short shelf life such as milk. Because HDPE
has good chemical resistance, it is used for packaging many household and
industrial chemicals such as detergents and bleach. Pigmented HDPE bottles have
better stress crack resistance than unpigmented HDPE.
 Excellent resistance to most solvents
 Higher tensile strength compared to other forms of polyethylene
 Relatively stiff material with useful temperature capabilities
The dimension of HDPE packaging is 10 cm in diameter and 4 cm in height, in the
form of cylinder. The HDPE packaging will include inner package in the form of
paper bags to avoid the less performance due to unwanted adsorption phenomena
when the product has already stocked to the wholesaler/retailer.
Figure 1. 6 Hard case front view of SEMBAKO
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Figure 1. 7 Hard case back and upper view of SEMBAKO
Figure 1. 8 Inner package of SEMBAKO
12
Figure 1. 9 SEMBAKO refill package – front view
Figure 1. 10 SEMBAKO refill package – back view
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CHAPTER 2
PRODUCT MANUFACTURING
2.1 Market Analysis
Market analysis is a quantitative and qualitative assessment of a market. In

this part, the objective of market analysis is to predict the production capacity based
on the product demand.
2.1.1 Market Segmentation
In this part, we try to break down a larger market target into smaller, more
homogeneous groups of customers to increase marketing efficiency. We are using
demographic market segmentation dividing our target market into two groups.
Those two groups are active smoker and second hand smoker in Indonesia.
Below is a table showing the population of active smoker and second hand
smoker (SHS) in Indonesia. Looking from the trend in the last 3 years, the growth
of active smoker and second hand smoker is 1.05% and 1.07% respectively.
120000000
100000000 Active
Smoker
80000000
POPULATION
60000000 Second
Hand
40000000
Smoker
20000000
0
2001 2006 2011 2016
YEAR
Figure 2. 1 Smoking prevalence in Indonesia

(Source: reproduced from many sources)
Second hand smoker become our primary target market because nearly all
SHS state that they are disturbed by smoke odor. Active smoker become our
secondary target because only some of them disturbed by smoke odor.
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2.1.2 Demand of Adsorbent for Cigarette Smoke Odor
Demand of cigarettes in Indonesia is very high. In 2015, cigarettes were the

second largest household expense after rice. Indonesian households spend three to
five times more on cigarettes than on education. Below is a table showing demand
of cigarettes in Indonesia from 2010 to 2015. We estimate there will be total 380
billion cigarettes produced in 2018.
360
350
Cigarettes Produce (billion)
340
330 Cigarettes
Production
320
310
300
290
2010 2011 2012 2013 2014 2015
Year
Figure 2. 2 Cigarettes Production in Indonesia

(Source: Gabungan Perserikatan Pabrik Rokok Indonesia (GAPPRI))
The total of active smoker and second hand smoker (SHS) are also increase
each year. We estimate the demand of our product from total of second hand smoker
in 2018 that disturbed by smoke odor and have interest in our product base on
questionnaires in the last assignment. We estimate that there will be 120,000,000
million second hand smoker in 2018. We assume that every one of our product
represent 10 persons. Then we can calculate the demand prediction of our product
in 2018.
120,000,000
= 12,000,000
10 /
From the last assignment, we know that the density of granule activated
carbon is 0.5 g/cm3. After knowing volume of each of our product, we can calculate
the mass of each activated carbon in our product.
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0.5 × ×5 ×5 ×4 = 160
Demand prediction of our product in 2018

120,000,000
= 12,000,000
10 /
Estimation of GAC in 2018
1
12,000,000 × 160 × = 1920
1,000,000
2.1.3 Supply of Adsorbent for Cigarette Smoke Odor
There is no any adsorbent that specifically for removal of smoke odor in

Indonesia. People are usually using alternative method to remove smoke odor such
as using baking powder or vinegar. The only existing product in the market for
smoke odor is ambipur after tobacco. However, this product is only use for car and
have relatively low usage of time. The supply in Indonesia is dominated by general
removal odor product that made from zeolit such as Bagus and Fumakilla.
2.1.4 Market Opportunity
Our product is a better than existing product because it has ability to remove
both smoke odor specifically and general odor, smaller size and higher capacity.
Moreover, there is no company in Indonesia that produce product for smoke odor
removal and there are more than 110 million people in Indonesia who disturbed by
smoke odor. By these advantages of our product quality and market condition, we
are optimistic to get into the competition and win the market from similar existing
product producer. As new producer, we will try to product 20% of total demand.
2.1.5 Production Capacity of Adsorbent for Cigarette Smoke Odor
The estimation of demand of our product in 2018 by targeting 20% of

demand, our production capacity will be
20% × 12,000,000 = 2,400,000
We assume that in 2018 there will be 278 working days, so the production
capacity is
2,400,000
≈ 8,633 /
278
16
384
= 1.38 /
278
The working time for labour is 8 hours/day based on the government
regulation. The average growth of active smoker, second hand smoker, and
production of cigarettes is 1.05%. Below is table of estimation production capacity
for the next 10 years. Considering our product is new, we should see the market
response in the future to evaluate our production capacity prediction in the next 10
years.
Table 2. 1 Production Capacity

Production Production
Year Capacity (ton Capacity
GAC/year) (product/year)
2018 384.00 2,400,000
2019 403.20 2,520,000
2020 423.36 2,646,000
2021 444.53 2,778,300
2022 466.75 2,917,215
2023 490.09 3,063,076
2024 514.60 3,216,230
2025 540.33 3,377,041
2026 567.34 3,545,893
2027 595.71 3,723,188
2.2 Raw Materials
The raw materials selection is the important step to fulfill a specific product
criteria. We need to obtain material in manufacturing process to make the cigarette
odor adsorbent. The adsorbent is activated carbon. Many substance can be the
activated carbon, especially the waste that is earned easily and cheaper than pure
substance. Not only that, we can solve the environment problem by recycling the
waste. Adsorbent surface area is the factor that decide capability of adsorbent to
adsorb many odor in same time. Activated carbon from palm shell has large surface
area and also eco-friendly to use.
17
Figure 2. 3 Palm shell

(Source: en.wikipedia.org, 2017)
Palm shell contain 26.6% of cellulose and 27.7% of hemicelluloses, which

contributed to high absorptivity characteristic in an activated carbon. Palm shell is
one of the most abundant waste in palm oil processing, with a share of 12% from
total weight of palm fruit. Palm oil production averaging at 5.6 million tons
annually, which resulted 672,000 tons of palm shell produced. The amount of palm
shell will continue to rise as palm oil production projected to grow in recent future.
Hence, with palm shell waste is in abundance, advanced process to convert palm
shell waste to a product with higher economically value is needed.
Table 2. 2 Palm Shell Composition

Component Percentage
Cellulose 26.6%
Hemicellulose 27.7%
Lignin 29.4%
Ash 0.6%
Extractive component 4.2%
Nitrogen 0.1%
Water 8%
18
Figure 2. 4 Competition of ash after burning process

Activation treatment for palm shell to be activated carbon needs the

activating agents by adding several chemicals such as KOH, H3PO4, and ZnCl2.
H3PO4 treatment has been used to produce activated carbon with surface area of
438.9 m2/g. KOH usage as an activating agent produced larger surface area of 3000
m2/g. Furthermore, ZnCl2 application will produce activated carbon with the
surface area of 1100 m2/g. KOH and ZnCl2 is a proven activating agent in activated
carbon synthesis to produce the product with large surface area. Therefore, in our
product used ZnCl2 as an activating agent in activated carbon synthesis from palm
shell because the surface area is in range of needs in specification product and more
economical than KOH.
2.3 Block Flow Diagram
Block flow diagram show the process manufacture of cigarette odor

adsorbent by using activated carbon from palm shell as a main raw material. There
are some steps to manufacture this product. The step is following, material
preparation, carbonization, physical and chemical activation, quality control, and
packaging process. The raw material is only palm shell but the activation treatment
needs several chemicals such as KOH, ZnCl2 and nitrogen gas. Block flow diagram
and process flow diagram of the manufacture the cigarette odor adsorbent product
is shown in figure below.
19
Figure 2. 5 Block flow diagram of activated carbon manufacturing
2.3.1 Material and Component Preparation
Prepare the palm shell about 1965.825 kg to earn 520 kg activated carbon
that can convert to 3237 products of cigarette odor smoke adsorbent from activated
carbon. This number means that to makes one product of cigarette odor smoke
adsorbent, we need 0.607 kg palm shell. Palm shell can earn from many palm
producer. Not only can use the waste to reduce environment problem and more
economically, palm shell has many availability of stock in Indonesia. Before
carbonization process, distribute the palm shell to the plant.
2.3.2 Carbonization
Palm shell is used as feedstock in activated carbon synthesis. The step after
preparing material is conducting carbonization at 400oC for two hours.
Carbonization process resulted the palm shell content no water and volatile
substance. Palm shell ash then crushed with a mortar and sieved by a mesh
equipment to produced small particle sized 1-2 mm. This small particle will create
larger surface area and more activated pores to adsorb the chemicals in cigarette
odor.
Figure 2. 6 Block Flow Diagram of Carbonization
2.3.3 Chemical and Physical Activation
Activated the carbon which sized 1-2 mm by using ZnCl2 as an activating

agent. Composition ratio between carbon and activating agent is 1:4. Activation
process done in mixing speed at 100 rpm and 85oC temperature for two hours. After
the chemical process, activated carbon will be produced with physical activation by
20
using Nitrogen gas at 850oC for an hour. Nitrogen gas flow at 100 cc/minute rate.
After an hour, physical activation resumed by flowing CO2 gas in an hour at 850°C
temperature.
Subsequently, activated carbon cooled by flowing CO2 into the reactor, to
remove free oxygen in the reactor. Removing free oxygen is done to prevent
damage to product pores which can result losses in the end activated carbon product.
Later, activated carbon will be washed by aquades to remove the remaining of
chlorides. Activated carbon then resized to a smaller size such as 212-150μm, 150-
106μm, 106-50μm, 50-37μm and <37μm. After that, dry at an oven with
temperature at 100°C for 24 hours.
Activated carbon will be characterized based on Indonesia’s industrial
standard. Characterization amount of activated carbon yield, iod numbers, water
content, ash content, and volatile matter which was removed in heating process.
Figure 2. 7 Block flow diagram of activated carbon chemical and physical activation
2.3.4 Product Quality Control
The finished product will be tested to ensure that our products are of good
at quality and performance. This process is called quality control. Quality control
in this product is contain, water and ash content at final product, and surface area
calculation and particle size. Water content on the activated carbon must measure
under 15% which meet the SII standard and ash content is under 25%. Surface area
of activated carbon is at least 1100 m2/g.
2.3.5 Packaging Process
Our product is divided into two kind of packaging, the first one is product
with casing and weight indicator to detect how many cigarette smoke odor was
adsorbed in our product. The other one is the refill package that only deliver the
activated carbon with tea bag as a primary package and vacuum plastic as a
secondary package to protect the activated carbon from air contact. This different
of packaging is useful to consumer that can save money with buy the refill one.
21
2.4 Equipment
2.4.1 Carbonization Furnace
Carbonization is a process of converting organic substance into carbon.

Palm shell will enter the furnace and then carbonized at 400oC for 2 hours. To
satisfy the production target, raw material entering the furnace is 5217 kg/day, with
38% yield. The furnace will be operating in batch condition.
Figure 2. 8 Carbonization Furnace

(Source: Anonymous, 2016)
Specification of the furnace we use is displayed in table 2.3 below:
Table 2. 3 Specification of Carbonization Furnace
Type Two furnace connected
Capacity 5000 - 6000 kg
Weight 6800 kg
Power 0,22 kW
1600*1800 mm each
Dimension (D*H)
3500*1800 mm total
Type Air flow
FOB Price $8000
22
The palm shell entering the furnace is 5217 kg, and then the output will be
1774 kg charcoal, 209 kg, and evaporated amount of volatile compound reaches
3235 kg.
The set of equipment consists of 2 furnace, with 5000 kg capacity each. The
advantage of using this kind of furnace is that when one furnace is finished and
being cooled, the other one is still running, means time efficiency.
2.4.2 Crusher
Crushing is needed for optimizing surface area of activated carbon. Small

size carbon particle will result in larger adsorption surface area. The required
capacity of crusher needed for our manufacturing process is 1982,5 kg/day. The
crushing process will be operating on flow (continuous) operation.
Figure 2. 9 Charcoal Crushing Machine

Specification of the crusher we use is displayed in table 2.4 below:
Table 2. 4 Specification of charcoal crushing machine
Capacity 5000 kg/h
Feeding in mouth size 400*120 mm
Output material size < 3 mm
Weight 700 kg
Power 7,5 kW
Dimension (L*W*H) 2700*100*1500 mm
FOB Price $3000
Crusher capacity is 5000 kg/h, but we only need crushing of 1982,5 kg, so
the approximate operating time is 24 minutes.
23
2.4.3 Mixer
Mixer is used for chemical activation process. In our manufacturing process,

granular carbon is activated chemically and physically. ZnCl 2 will be used as
activating agent. The type of mixer we used is mixer for solid - liquid. With 1 to 4
carbon to activating agent ratio (Yuliusman et.al, 2017), total capacity needed for
mixing process is 9912,3 kg/day (1982,5 kg carbon and 7929,8 kg ZnCl 2 solution).
By knowing density of each component, some simple calculation can be done to
determine each volume. Activated carbon (density of 2000 kg/m3) and ash (density
of 2650 kg/m3), along with ZnCl2 (density of 2910 kg/m3) yield the requirement
volume for the mixer of 3690 L at the very least. The operating condition is 85oC
for 2 hours (Yuliusman et.al, 2017).
We used 2 mixers, one is for chemical activation of ZnCl2 and carbon.
Another mixer is used for washing (contacting solid and H2O) to remove the
remaining chloride. The mixer for washing will be at least 5622 L. Time to wash is
approximately 1 hour.
Figure 2. 10 Solid - Liquid Mixer

(Source: Inoxpa, 2015)
24
Specification of the mixer we will use is displayed in table 2.5 below:

Table 2. 5 Specification of mixer
Amount 2
Capacity 10000 L
Blending Speed 100 rpm
Power 5,5 kW
Dimension of Tank 2300*2440 mm
Total Height 4500 mm
Inlet & outlet diameter 51 mm
FOB Price $10000
Source: (Anonymous, 2014)
With the requirement of 9912,3 L, the mixing process is only one batch per
day which takes about 2 hours.
2.4.4 Furnace
After contacting carbon with activating agent, carbon then will undergo
physical activation. Physical activation can be done by putting carbon in a vessel,
then gradually heated to desired temperature with constant flow of N2 (to repress
oxygen in the vessel) for one hour, and with CO2 flow for the next one hour. We
use rotary kiln furnace for this purpose because of its large capacity.
25
Figure 2. 11 (a) Schematic of Physical Activation of Carbon and (b) Fluidized Bed Reactor for
carbon activation
Specification of the reactor we will use is displayed in table 2.6 below:
Table 2. 6 Specification of activation reactor
Capacity 500 – 20000 L
Power 110 Kw
Dimension (D*H) 1500*2000 mm
Rotation Speed 0 – 300 rpm
FOB Price $100000

(Source: Anonymous. 2016)
The requirement capacity of the reactor is about 9917 kg. So, the activation
process takes approximately 2 hours (1 hour for each gas flow)
2.4.5 Spin Flash Dryer
Spin flash dryer is needed because when activated carbon is washed with
H2O, subconsciously many H2O is adsorbed to the pore of activated carbon.
Therefore, we need to dry the activated carbon in order to make it functional before
packaging.
26
Figure 2. 12 Spin Flash Dryer

(Source: SPX FLOW, 2016)
Specification of the drier we will use is displayed in table 2.7 below:
Table 2. 7 Specification of spin flash drier
Amount 2
Evaporation Capacity 1000 kg H2O/h
Power 75 Kw
Dimension (D*H) 1700*600 mm
Area Covering 160 m2
FOB Price $100000
The amount of water that will be evaporated is approximately 1600 kg. So,
with this machine specification of 1000 kg H2O per hour evaporation rate, it takes
1,6 hour for drying.
27
2.4.6 Packaging Machine
Inner Packaging Machine
Figure 2. 13 Inner Bag Packaging Machine

(Source: Betterpack, 2015)
Specification of the packaging machine we will use is displayed in table 2.8 below:
Table 2. 8 Specification of packaging machine
Bag size (L*W*H) 80*10*100 mm
Packing Speed 50 – 80 bags/min
Weight 300 kg
Power 2 Kw
FOB Price $2000
With target of 8633 products per day, it takes about 2 hours.
After the product is already packed in inner package, the stream will be split
into 2 streams, one stream goes to sealing machine, the other stream goes to hard
case packaging. The ratio of hard case product and refill product is 9:1
28
Plastic Bag Sealing Machine

This sealing machine is used for packaging of the refill pack. The capacity
of sealing machine is 10% of production. So it should be 864 bags per day
Figure 2. 14 Plastic Bag Sealing Machine

Table 2. 9 Specification of packaging machine
Bag Type Pillow bag, gusseted bag, block bottom bag
Max. Packing Size 200*140 mm
Packing Speed 20 - 50 bags/min (adjustable)
Weight 600 kg
Power 3 Kw
FOB Price $3200
With 864 bags/ day and capacity of 50 bags/min, the sealing process will
take approximately 18 minutes
For the hard case product (main product, with cylindrical plastic tube),
packaging to the tube will be done manually. There will be 2 conveyor belt, with
29
one conveyor above the other. Products which have been packaged in tea bag will
be on the upper conveyor belt, and empty cylindrical tube will be in the lower
conveyor belt. The product will fall into the cylindrical tube, and then the cap will
be put manually by some workers.
2.4.7 Conveyor belt
Conveyor belt is used for transportation of product in tea bag (1 conveyor)

and empty cylindrical tube (another conveyor) for final packaging.
Figure 2. 15 Conveyor Belt

(Source: Automated Conveyor System, 2017)
Table 2. 10 Specification of conveyor belt
Amount 2
Type Electric
Power 0,75 kW
Belt Width 400 mm
Dimension (L*W*H) 5000*500*1400 (upper conveyor)
5000*500*1200 (lower conveyor)
Conveying Capacity 45 kg.min
Conveying Speed 30 m/min
FOB Price $300
30
2.5 Mass and Energy Balance
2.5.1 Mass Balance
Final Product:
Table 2. 11 Composition of product component
Komposisi % Weight (kg)
GAC 0.595 520.0
Unactivated carbon 0.170 148.4
Water 0.145 126.7
Ash 0.090 78.6
TOTAL 873.7
(Source: Yuliusman et.al. 2017)
According to Yuliusman (2017), the water and ash in final product is 14,5%
and 9% respectively. The remaining 76,5% consist of 77,8% activated carbon and
22,2% of unactivated carbon. 77,8% is the activated carbon yield from chemical
activation with ZnCl2 and physical activation.
Overall mass balance
Table 2. 12 Overall mass balance
INPUT OUTPUT
Stream Composition % Weight Stream Component % Weight
Organic Evaporated volatile
1 Compound 1 5217.0 2A compound 1 3234.5
Water remaining
GAC
2 from Aquades 1 336.2 17 0.595 1380.0
Water 0.145 336.2
Ash 0.090 208.7
Unactivated Carbon 0.170 393.8
TOTAL 5553.2 TOTAL 5553.2
Equipment mass balance

To determine the mass flow for each stream, we do some mass balance
calculation. This mass can be converted into volume if we know the density of each
component, therefore we get to know what capacity our equipment would be. This
31
calculation also beneficial for determining raw material needed for manufacturing
process of activated carbon. To do this, we will use reverse calculation method,
which means the calculation will be done from final product, then the last
equipment in the process, and so on until the calculation reach the first equipment.
a) Dryer
Table 2. 13 Mass balance in dryer
INPUT OUTPUT
Stream Composition % Weight Stream Composition % Weight
Aquades +
Aquades 0.163 1931.3 14 ZnCl2 1 9524.9
GAC 0.117 1380.0 GAC 0.595 1380.0
Ash 0.018 208.7 Water 0.145 336.2
12
Unactivated
Carbon 0.033 393.8 15 Ash 0.090 208.7
Unactivated
ZnCl2 0.670 7929.8 Carbon 0.170 393.8
2318.7
b) Washing Tank
Table 2. 14 Mass balance in washing tank
INPUT OUTPUT
Stream Composition % Weight Stream Composition % Weight
11 Aquades 1 1931.3 Aquades 0.163 1931.3
GAC 0.139 1380.0 GAC 0.117 1380.0
Ash 0.021 208.7 Ash 0.018 208.7
Unactivated 12 Unactivated
10
Carbon 0.040 393.8 Carbon 0.033 393.8
ZnCl2 7929.8 ZnCl2 0.670 7929.8
9912.3 11843.6
32
c) Reactor
Table 2. 15 Mass balance in reactor
INPUT OUTPUT
7 N2 1 1.8 8 N2 1 1.8
6 CO2 1 2.9 9 CO2 1 2.9
Granular Carbon 0.179 1773.8 GAC 0.139 1380.0
Ash 0.021 208.7 Ash 0.021 208.7
5 Unactivated
10
ZnCl2 0.8 7929.8 Carbon 0.040 393.8
9912.3 ZnCl2 0.8 7929.8
9912.3
d) Mixer
Table 2. 16 Mass balance in mixer
INPUT OUTPUT
4 ZnCl2 1 7929.8 ZnCl2 0.8 7929.8
Granular Carbon 0.895 1773.8 Granular Carbon 0.179 1773.8
5
3 Ash 0.105 208.7 Ash 0.021 208.7
1982.5 9912.3
e) Crusher
Table 2. 17 Mass balance in crusher
INPUT OUTPUT
Granular Carbon 0.895 1773.8 Granular Carbon 0.895 1773.8
2 Ash 0.105 208.7 3 Ash 0.105 208.7
1982.5 1982.5
33
f) Furnace
Table 2. 18 Mass balance in furnace
INPUT OUTPUT
Organic
1 Compound 1 5217.0 2 Granular Carbon 0.895 1773.8
Ash 0.105 208.7
Evaporated
2A volatile
compound 1 3234.5
34
Figure 2. 16 Overview of Mass Balance
35
2.5.2 Energy Balance
Energy balance calculation is needed to determine how many power we

need for electricity supply from PLN.
Table 2. 19 Overall energy balance
Working
Total
Power per hour Time per
Equipment Quantity Energy
(kW) Equipment
(kW)
(hour)
Furnace 1 0.22 2 0.44
Crusher 1 7.5 0.4 3
Mixer 1 5.5 2 11
Rotary Kiln Furnace 1 55 2 110
Mixer 2 1 5.5 1 5.5
Spin Flash Dryer 1 75 2 150
Inner Packaging
1 2 0.5 1
Machine
Plastic Bag Sealing
1 3 0.33 1
Machine
Conveyor belt 2 0.75 2 3
279.94
36
Figure 2. 17 Overview of Energy Balance
37
2.6 Plant Layout & Process Scheduling
Here is given the brief plant layout of the activated carbon manufacturing and the
process scheduling that is divided into 3 pages. The process scheduling is in the
range of 24-hour-working cycle.
Figure 2. 18 Plant layout for activated carbon manufacturing
38
Table 2. 20 Process scheduling

Duration
Process 8:00 9:00 10:00 11:00 12:00
(minutes)
Loading to furnace 30
Carbonization (batch furnace) 120
Unloading from furnace 30
Loading to Crusher 30
Crushing (continous crusher) 30
Unloading from crusher 30
Loading to Mixer 30
Chemical Activation with
120
Zinc Chloride (Mixer)
Break 60
Number of Workers 35 20
39
Table 2. 20 Process scheduling (cont’d. 1)
Duration
Process 13:00 14:00 15:00 16:00 17:00
(minutes)
Chemical Activation with

120
Zinc Chloride (Mixer)
Unloading from Mixer 30
Loading to Furnace 30
Physical Activation with

60
Nitrogen (Batch Furnace)
Physical Activation with
Carbon dioxide (Batch 60
Furnace)
Unloading from furnace 30
Loading to dryer 30
Drying with water (batch

100
dryer)
Number of Workers 30 30
40
Table 2. 20 Process scheduling (cont’d. 2)

Duration
Process 18:00 19:00 20:00 21:00
(minutes)
Drying with water (batch
100
dryer)
Break 60
Unloading from dryer 30

Loading to inner packaging
30
machine
Packaging (inner packaging) 120
Sealing Plastic (sealing
20
plastic machine)
Packaging hard case product
120
(belt conveyor)
Storage 60
Number of Workers 30 20 20
2.7 Detail of Plant Factory
The plant site is arranged according to product-oriented layout. According

to the demand that is sufficiently high and sustainable over a long period of time, it
is usually cost effective to rearrange resources from a process layout to a product
layout as defined by the sequence of steps required to make the product. The process
involved only by relatively small equipments so it does not fit to process-oriented
layout where the sustainable of the transporting chain from site to site is very
highlighted.
The factory building has 3 doors located on the front. One main door leads
directly to the office as the administrative center, two on the right and left side
respectively for the entry of raw materials and outgoing finished products. The
length and width each 20 m and 15 m, which means it has an area of 300 m2. The
single-storey building has a height of 9 m, high enough to cover all parts of the
building including the equipment used in operation. With this height, it is expected
the hot ambient generated from the equipment does not accumulate and increase
41
the temperature of the building. Hot air will be lighter so it rises to the top, with
adequate ventilation to keep the ambient temperature remains comfortable.
The factory stood on the land area of 500 m2 to 250 m2 land area parking.
To facilitate large vehicle out for transportation, road barrier fence or wall is less
than helpful. To view the visual details of the layout of the plant can be seen in the
following figure.
In the interior of the building, there is a room deposit of raw materials that
are useful to ascertain the condition of the goods received within specification
purchased as weighed. Crude goods are then stored in open space in the middle part
of manufacturing space to simplify the production process. Cost-saving treatment
the place, where the terms of physics do not give a bad influence on the quality of
oil palm shell itself.
On the left there is a point laboratory for quality testing of raw materials. To
maintain the quality of the product, the feasibility of the raw material is taken into
account. A series of production process carried out in one straight line. This is
because if the product-oriented layout, so this way you can save on costs due to
space and efficiency.
After the finished product, then put into storage sheds like material, the
finished product will also need to undergo a series of laboratory testing which is
located right next to the warehouse. This building is equipped with toilets for male
and female deodorant. For security reasons, there is security post in front of the
main building. In addition, we have an assembly point in the middle of the parking
area in case of emergency.
The location determination is one aspect that is important in the
establishment of a factory. Location plant will affect the condition of the plant of
technical and economic perspective. Plant existence at a particular location will also
affect society and the environment around it.
The plant of manufacturing activated carbon from oil palm shell are planned
to be built in Kampar, Riau province, Sumatra.
42
Figure 2. 19 Map Location Kampar, Riau Province

Since the early 1980s, Riau Province has been the primary target for oil
palm plantation development as part of Indonesia’s agricultural development
policy. The statistical graph below shows that year after year, the growth of oil palm
plantation is greatly increasing. Riau is geographically strategic, since the weather
and landscape specification is suitable for the growth of palm trees.
At this location, we can see that very many palm oil mills in the vicinity.
That is, access to raw materials is guaranteed, especially using a landline. Indeed,
the target market is the main island of Java, but for some reason the volume of raw
material which is much larger than the finished product, then transport will be easier
and cheaper if established closer to the source of raw materials.
Figure 2. 20 Palm oil mill locations around the plant

(Source: maps.google.com, 2017)
43
Figure 2. 21 Oil palm plantation development in Sumatra Island by province (1989-2010)

(Source: GAPKI, 2010)
The east coast of Sumatra became the site of one of the most intensive and
successful pursuits of foreign agricultural enterprise or plantation. Bio-physically,
the area is quite suitable for oil palm growing, with high rainfall (minimum 1600
mm/year) and a tropical climate within 10° of the equator.
44
Figure 2. 22 Oil palm plantation and economic performance in Riau, by regency

(Sources: Regencies’ statistics, 2011)
1. Availability of Raw Materials
Based on data from the Central Bureau of Statistics, Riau is a province with
the largest area of oil palm plantations in Indonesia, namely 1,300,000
hectares. Riau is also the highest TKKS producing provinces, namely
128,000 tons.
In Riau province, districts that produce fresh fruit bunches (FFB) is the most
Kampar, which resulted in TBS as much as 7,680,797 tons / year. Kampar
Regency also the largest CPO producer in Riau, namely 1,273,944 tons of
CPO. Then Kampar also TKKS largest producer in Riau Province.
A large number of raw materials and an easy reach, then Kampar, Riau
Province have been selected as the location of the activated carbon plant to
be established.
2. Utilities and accessibility
The operation of a plant depends on the availability of water for the factory
production process there are stages for washing that requires enough water
supply. In the vicinity of the plant site should also be available so that
45
sufficient electric power to facilitate the drainage of the machines that work
at this plant. This major river located in Kampar regency is partly still
functioning well as a means of clean water sources as well as a source of
electrical energy (hydropower Koto Panjang). As one of the largest area in
the province of Riau, Kampar ongoing basis to improve the facilities and
infrastructure such as road network (1856.56 km), electricity (72.082
KWH) with 5 units of diesel power plant Hydroelectric Power Plant (HEPP)
in Koto length that produces energy with a capacity of 114.240 KWh
connected. Other facilities also include telecommunications services (fixed
line, mobile phone and internet networks) and water network with a
production capacity of 1,532,284 m³.
3. Employment and Labor
Human resources are also one of the factors critical to the ongoing
production at the factory. It also needs to be considered on a regional
minimum wage rates in the establishment of the factory, in order to ensure
the fulfillment of the rights of employees to earn an adequate income. The
table below show that regional minimum labor wage of Kampar Regency
relatively lower than other regencies.
Figure 2. 23 Regional minimum labor wage 2017 comparison with 2016 in Riau
(Source: http://www.biaya.net, 2017)
46
Most workers in this district work in the plantation sector, agriculture and
forestry. With the existence of this plant will increase the level of
employment for the community around the factory.
47
CHAPTER 3
CONCLUSION
Reaching to the end of this assignment, we have got some conclusions

through the discussion along the paper.
- The cigarette odor adsorbent is packaged into two forms: hard case
packaging and refill package.
- Based on demand and market opportunity calculation, our production
capacity will be 384 ton GAC/year or 2,400,000 product/year with growth
rate of 1.05%/year.
- Palm shell is used as raw material to make cigarette odor adsorbent because
contain 26.6% of cellulose and 27.7% of hemicelluloses, which contributed
to high absorptivity characteristic in an activated carbon and can utilize the
waste form palm oil processing in Indonesia.
- The activating process use ZnCl2 as activating agent in chemical activation
and N2 in physical activation.
- There are various equipment that will be used in our manufacturing process,
those are batch furnaces, continuous charcoal crusher, granular carbon –
ZnCl2 mixer, fluidized bed reactor, another mixer, and spin flash dryer.
- Overall mass balance is useful for determining amount of raw material
needed, which is 5217 kg of palm shell.
- Energy balance is used for determining power that will be supplied, which
is 280 Kw per day.
- The plant occupied on 500-m2 land in Kampar Regency, Riau, Sumatra,
Indonesia. Availability of raw materials, accessibility to land transportation,
direct energy source supply, and the availability of labor is our consideration
to choose this place.
- The plant site is arranged according to product-oriented layout since we only
have 1 line of production and the consideration of space efficiency.
48
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Tk19 Revised Assignment3

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UNIVERSITAS INDONESIA

ADSORBENT FOR CIGARETTE SMOKE ODOR

CHEMICAL ENGINEERING DEPARTMENT

In the beginning of this assignment, we first reflect to the final specifications

EXECUTIVE SUMMARY ............................................................................................... i

Figure 1. 1 Product comparison diagram, comparing own-concept adsorbent to existing

Table 1. 1 Final Specification of Product ........................................................................... 1

1.1 Product Final Specification

Table 1. 1 Final Specification of Product

Table 1.1 Final Specification of Product (cont’d)

1.2 Product Positioning

Own Product Airpura T600

Fast to adsorb odor

Safe and eco-friendly Low cost

Work specifically for

Figure 1. 1 Product comparison diagram, comparing own-concept adsorbent to existing product

Three out of four compared products (own-concept product, Tub O’ Carbon

- It has high rate of adsorption so that it is fast to adsorb odor;

1.3 Product Description

Activated carbon is a solid, porous, carbonaceous material prepared by

Structurally, activated carbon has a porous carbon structure, which contains

Figure 1. 2 Schematic representation of the pore network of a carbon adsorbent

Activated carbon that we are going to use as adsorbent is in the form of

Activated carbon is considered effective for adsorbing volatile organic

Figure 1. 3: Effect of temperature on adsorption capacity of TMP on Carbon C

1.4 Prototype of Product

1.4.1 Sketch of Product

Figure 1. 4 Granular activated carbon

1.4.2 Brand, Logo, and Tagline

Figure 1. 5 Logo of “SEMBAKO”

Figure 1. 6 Hard case front view of SEMBAKO

Figure 1. 7 Hard case back and upper view of SEMBAKO

Figure 1. 8 Inner package of SEMBAKO

Figure 1. 9 SEMBAKO refill package – front view

Figure 1. 10 SEMBAKO refill package – back view

2.1 Market Analysis

Market analysis is a quantitative and qualitative assessment of a market. In

Figure 2. 1 Smoking prevalence in Indonesia

2.1.2 Demand of Adsorbent for Cigarette Smoke Odor

Demand of cigarettes in Indonesia is very high. In 2015, cigarettes were the

Figure 2. 2 Cigarettes Production in Indonesia

Demand prediction of our product in 2018

There is no any adsorbent that specifically for removal of smoke odor in

The estimation of demand of our product in 2018 by targeting 20% of

Table 2. 1 Production Capacity

2.2 Raw Materials

Figure 2. 3 Palm shell

Palm shell contain 26.6% of cellulose and 27.7% of hemicelluloses, which

Table 2. 2 Palm Shell Composition

Figure 2. 4 Competition of ash after burning process

Activation treatment for palm shell to be activated carbon needs the

Block flow diagram show the process manufacture of cigarette odor

Figure 2. 5 Block flow diagram of activated carbon manufacturing

2.3.1 Material and Component Preparation

Figure 2. 6 Block Flow Diagram of Carbonization

2.3.3 Chemical and Physical Activation

Activated the carbon which sized 1-2 mm by using ZnCl2 as an activating

2.3.4 Product Quality Control

2.3.5 Packaging Process

2.4.1 Carbonization Furnace

Carbonization is a process of converting organic substance into carbon.

Figure 2. 8 Carbonization Furnace

Crushing is needed for optimizing surface area of activated carbon. Small

Figure 2. 9 Charcoal Crushing Machine

Dimension (DH) 15002000 mm