PERANCANGAN

PRODUK DAN PROSES

KIMIA
Dr. Tutuk Joko Kusworo, ST, M.Eng
Hargono, MT,IR

ChE Undip for better life

REFERENSI
1.

Douglas, J. M. (1995). Chemical Process Design. McGraw-Hill Book

Co., Tokyo.

2.

Cussler, E. L and Moggridge, G. D. (2001). Chemical Product

Design. Cambridge University Press, Cambridge.

3.

Ulrich, K. T. and Eppinger, S. D. (2011). Product Design and

Development. 5rd edn. Mc Graw Hill, Boston.

4.

Seider, W. D., Seider, J. D., & Lewin, D. R. (2004). Product &

Process Design Principles: Synthesis, Analysis and Evaluation.
John Wiley & Sons, Inc., New York.

5. Smith, R. (2005). Chemical Processes: Design and Integration.

John Wiley & Sons, Inc., New York.

ChE Undip for better life

TUJUAN
PEMBELAJARAN
Setelah mengikuti mata kuliah ini, mahasiswa
diharapkan mampu mengembangkan
perencanaan produk kimia (chemical product
design) secara inovatif sebagai integrasi antara
kemampuan pengetahuan teknik kimia dengan
kemampuan managerial.

ChE Undip for better life

ChE Undip for better life

TUJUAN
PEMBELAJARAN
1. Perancangan produk kimia
2. Flowsheet proses
- pemilihan unit proses
- interkoneksi antar unit
- estimasi kondisi operasi optimum dan desain

ChE Undip for better life

POKOK BAHASAN
1. Konsep dasar perancangan produk (chemical product
design)
2. Konsep technology push dan market pull
3. Perancangan produk kimia dan life cycle analysis
4. Quality function deployment
5. Interaksi produk dan process design
6. Prinsip dasar dan tahap-tahap perancangan proses kimia;
7. Struktur dan sintesis process flow diagram;
ChE Undip for better life

SISTEM PENILAIAN
TUGAS
25
10
25
UTS
40
ChE Undip for better life

10
25 +
15

OUTLINE KULIAH HARI INI

Konsep dasar perancangan produk
(chemical product design)
1. Pengantar
2. Pengenalan produk kimia
3. Konsep dasar chemical product design

ChE Undip for better life

INTRODUCTION
Perubahan paradigma Chemical Engineer

engaged in all kinds of activities well beyond

traditional chemical engineering. (memadukan
segala kegiatan teknik kimia yang terlalu sulit, yang
bersifat tradisional)
primary metal manufacture, food, consumer goods,
electronics, medical devices, pharmaceuticals,
water, finance, etc.
Societal megatrends such as human health,
water, food, etc. will demand new technologies of
ChemEs
Products are no longer just another truck or rail car
of a solvent or plastic but can be a consumer good,
a system, a manufactured article, etc. this requires

ChE Undip for better life

CHEMICAL PRODUCT
write down one of chemical
product that pop out from
your mind

ChE Undip for better life

PENGENALAN PRODUK
KIMIA
Basic Chemical
Products

Industrial Products

Configured
Consumer Product:

ChE Undip for better life

PENGENALAN PRODUK
KIMIA
Basic Chemical Products:
1. Involve well-defined molecules and mixtures of
molecules
2. Not sold directly to the consumer.
3. Technological inventions (penemuan,rekaan) normally
associated (dihubungkan) with new materials and less
often with new process/ manufacturing and product
technologies.

ChE Undip for better life

PENGENALAN PRODUK
KIMIA

Basic
chemical
product

ChE Undip for better life

Primary

Secondary

PENGENALAN PRODUK
KIMIA

Primary
Contoh: Sulfuric acid,
ethylene, propylene,
phosphoric acid, ammonia

ChE Undip for better life

- Commodity or Bulk chemicals

- Manufactured in large-scale processes
(>1000 t/year) in continuous operation.
- Product that is sold without differentiation by all
suppliers (quality and composition are identical);
characterized by thermophysical and transport
properties.
- Sold into a global market: products differentiated
only by price (low selling prices + high sales V).
- Focus of the design is on the process to produce
them from various raw materials

PENGENALAN -PRODUK
Fine chemicals and Specialty
chemicals
KIMIA
- Manufactured in small quantities

Secondary
Contoh: Cosmetic
components, drugs.

ChE Undip for better life

(<100 t/year) in batch processing.

- Low sales volume with high selling
prices (10$/kg
cosmetic component 2000 /100
mg tPA drug)
- Focus of the design on identify the
chemicals or mixture
of chemicals that have the desired
properties to satisfy
consumer needs.
- Fine chemicals:
Defined by their chemical
structure and content
- Specialty chemicals:
Identified by their performance.
Trade marked names

PENGENALAN PRODUK
KIMIA
Industrial Products:
1. Properties in satisfying (memuaskan) customer needs
are dominant (microstructure, particle-size distribution,
functional, sensorial and physical properties).
2. Few industrial chemicals are purchased by the
consumer.
3. Are ingredients and building blocks of configured
consumer products.
4. Films, fibers, paper, creams, pastes

ChE Undip for better life

PENGENALAN PRODUK
KIMIA
Configured Consumer Products:
1. Normally sold to the consumer.
2. Characterized by properties similar to those of Industrial
chemicals; in same cases their three-dimensional
configurations are crucial to satisfying customer needs.
3. These include integrated circuits, dialysis devices, solar
desalination devices, drug delivery patches, fuel cells,
hand-warmers, Post-it notes, ink-jet cartridges,
detachable wall hangers, cosmetics, laundry detergents,
pharmaceuticals, transparencies for overhead
projectors, and many others.

ChE Undip for better life

THE AIMS OF CHEMICAL

PRODUCT AND PROCESS
DESIGN

1. To produce a purchased raw material

2. To convert a waste by-product to a valuable
product
3. To create (membuat) a completely new material
(syntethic fiber, food, bioprocessing)
4. To find a new way of producing an existing
product (new catalyst, bioprocessing alternative)
5. To exploit (memanfaatkan) new technology
6. To exploit a new material of construction (hightemp or high-press operation, speciality
polymer)
ChE Undip for better life

BASIC CHEMICAL PRODUCT

DESIGN
Needs
Ideas

Selection

Manufacture

ChE Undip for better life

What need should

the product fill?
What kind of
ideas could fill
this need?
Which ideas are
the most
promissing?
How can we make
the product and
test it critically?

BASIC CHEMICAL PRODUCT

DESIGN
Process Design vs. Product Design: Chemical Engineering
Design

Product Design

Process Design

Customer Need (Market PullTechnology Push)

Input/Output structure

Idea Generation

Batch vs. Continuous

Selection

Reaction and Recycle

Manufacture process

Separation system / heat

recovery

Adapted from Cussler, 2011.

Cussler, E., 2011, Education for the New Chemical Industry. XXXII National Meeting of AMIDIQ. Mexico,
May 4,2011

ChE Undip for better life

BASIC CHEMICAL PRODUCT

DESIGN
Design in its most simplistic viewpoint is composed of the
following steps:
1.
2.
3.
4.

Determine the problem and its constraints

Generate potential solutions
Develop sufficient detail that solutions can be
compared and eliminated
Implement the preferred solution

input

ChE Undip for better life

MODIFICATION
STEPS

output

ChE Undip for better life

ChE Undip for better life

NEEDS
1. Survey the customer needs
2. Convert the qualitative needs into design
specifications (quantitative with chemical detail)

ChE Undip for better life

ChE Undip for better life

ChE Undip for better life

IDEAS/ SOLUTIONS
1. Literature has widely ranging value.
2. Patents and trade information from competitors
3. Other methods for idea generation use schemes
for developing chemical synthesis.
4. pay special attention to customers who already
are using existing, similar products.

ChE Undip for better life

SELECTION
1. The decision will involve making estimates
based on chemistry and engineering
2. estimate how each will perform relative to the
specifications we have set
3. Quality function deployment

ChE Undip for better life

ChE Undip for better life

Successful product and process design are based

on a uniform set of engineering design
strategies.
1. The initial design analysis of a product design problem
identifies constraints on physical and chemical properties,
(e.g., the product must be an azeotrope, or must be
emulsified in water, or must retain its flexibility even after
years of UV exposure).
2. These constraints are used to generate design candidates
that may have different compositions and possibly different
forms.
3. The composition, form, and physical properties of each of
these product candidates determines the required
processing operations for its production, (e.g., the
product must be coated, the liquid components must be
mixed with emulsifier at high speed, or various additives
must
blended
ChE
Undipbe
for better
life into product).

 Group

PROJECT

1. Pilih Tema (Energi, Material, Pangan)

2. Pilih sub tema (New product or exsisting product)
3. Pilih produk yang akan digunakan dalam project
4. Analisis consumer needs
5. Konversi consumer needs spesifikasi desain produk
6. Kumpulkan ide/solusi (min. 10) untuk mencapai
spesifikasi desain produk
7. Analisis HOQ (Quality Function Deployment) untuk
seleksi ide
8. Sintetis proses, terjemahkan dalam bentuk BFD
9. BFD PFD detail dengan deskripsi proses

Individual membuat short communication mengenai bagian

yang dikerjakan dalam group project
ChE Undip for better life

ChE Undip for better life

ChE Undip for better life