Perancangan Pabrik Natrium Karbonat Berbasis Biogas Melalui Proses Karbonasi Terintegrasi Siklus Medium Pressure Steam Untuk Utilitas Internal

Fathurrohman, Andhika and Devi, I Gusti Ayu Agung Istri Dwi Jovanca (2026) Perancangan Pabrik Natrium Karbonat Berbasis Biogas Melalui Proses Karbonasi Terintegrasi Siklus Medium Pressure Steam Untuk Utilitas Internal. Other thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

Bahasa Indonesia

Peningkatan emisi CO₂ akibat dominasi energi fosil di Indonesia menimbulkan kebutuhan akan teknologi pemanfaatan CO₂ (carbon utilization) untuk mendukung transisi energi dan target net-zero emission. Natrium karbonat (Na₂CO₃) merupakan bahan kimia strategis yang banyak digunakan dalam industri kaca, kertas, dan deterjen. Namun, Indonesia masih bergantung sepenuhnya pada impor Na₂CO₃ dalam jumlah besar. Di sisi lain, potensi biogas dari limbah industri dan peternakan di Indonesia sangat melimpah serta mengandung CO₂ dan CH₄ yang belum dimanfaatkan secara optimal. Oleh karena itu, dirancang pabrik Na₂CO₃ berbasis biogas melalui proses karbonasi yang terintegrasi dengan siklus medium-pressure steam sebagai utilitas internal. CO₂ dari biogas diserap oleh larutan NaOH untuk menghasilkan Na₂CO₃ di dalam reaktor bubble column. Sementara itu, CH₄ hasil pemisahan biogas digunakan sebagai bahan bakar untuk pembangkitan medium-pressure steam (5 bar). Flue gas hasil pembakaran yang masih mengandung CO₂ dialirkan kembali ke tahap karbonasi kedua untuk meningkatkan efisiensi penyerapan karbon. Steam yang dihasilkan digunakan sebagai sumber panas utama pada sistem evaporasi triple-effect untuk mengonsentrasikan larutan, kemudian diikuti proses kristalisasi, pengeringan, pengecilan ukuran partikel, dan pengemasan hingga diperoleh produk Na₂CO₃ padat berkemurnian tinggi (±99% berat) dengan ukuran partikel 250–500 µm. Sistem utilitas dirancang secara tertutup melalui pemanfaatan kembali kondensat steam dan udara panas untuk meminimalkan konsumsi energi eksternal. Perancangan ini mencakup pemilihan proses dan reaktor, penyusunan Process Flow Diagram (PFD), integrasi energi melalui siklus steam internal, studi awal HAZOP, spesifikasi peralatan, serta analisis ekonomi. Integrasi pemanfaatan CO₂ dan CH₄ dari biogas serta sistem utilitas berbasis medium-pressure steam menjadikan pabrik ini tidak hanya mampu menurunkan emisi karbon, tetapi juga meningkatkan kemandirian industri kimia nasional melalui substitusi impor Na₂CO₃. Hasil analisis ekonomi menunjukkan bahwa proyek ini layak secara finansial dengan Net Present Value (NPV) sebesar Rp587.591.099.908,00, Internal Rate of Return (IRR) sebesar 19,35% yang lebih tinggi daripada Weighted Average Cost of Capital (WACC) sebesar 14,01%, serta Payback Period selama 5,12 tahun. Analisis Break-Even Point (BEP) menunjukkan bahwa titik impas dicapai pada sekitar 36,42% kapasitas penjualan. Pabrik dirancang beroperasi dengan kapasitas produksi 29.950 ton per tahun dan umur ekonomis selama 20 tahun. Berdasarkan hasil analisis tersebut, proyek dinyatakan layak secara finansial sehingga pabrik layak dibangun mulai tahun 2029, dengan potensi pengembalian modal yang relatif cepat serta keuntungan yang signifikan dalam jangka panjang.
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The increasing CO₂ emissions resulting from the dominance of fossil energy in Indonesia have created an urgent need for carbon utilization technologies to support the national energy transition and net-zero emission targets. Sodium carbonate (Na₂CO₃) is a strategic chemical widely used in the glass, paper, and detergent industries. However, Indonesia remains fully dependent on large-scale imports of Na₂CO₃. Meanwhile, the country has abundant biogas potential from industrial and livestock waste containing CO₂ and CH₄ that have not yet been optimally utilized. Therefore, a biogas-based Na₂CO₃ plant is designed using a carbonation process integrated with a medium-pressure steam cycle as an internal utility system. In this process, CO₂ from biogas is absorbed by a NaOH solution to produce Na₂CO₃ in a bubble column reactor. Meanwhile, the CH₄ separated from biogas is used as fuel for generating medium-pressure steam (5 bar). The flue gas from combustion, which still contains CO₂, is recycled to a secondary carbonation stage to enhance carbon absorption efficiency. The generated steam serves as the primary heat source for a triple-effect evaporation system to concentrate the solution, followed by crystallization, drying, particle size reduction, and packaging to produce high-purity (approximately 99 wt%) solid Na₂CO₃ with particle sizes ranging from 250 to 500 µm. The utility system is designed as a closed loop through condensate and hot-air recovery to minimize external energy consumption. The plant design includes process and reactor selection, development of the Process Flow Diagram (PFD), energy integration through an internal steam cycle, a preliminary HAZOP study, equipment specification, and economic analysis. The integration of CO₂ and CH₄ utilization from biogas, together with a medium-pressure steam-based utility system, enables the plant not only to reduce carbon emissions but also to strengthen the self-sufficiency of Indonesia’s chemical industry by replacing imported Na₂CO₃. The economic analysis demonstrates that the project is financially feasible, yielding a Net Present Value (NPV) of IDR 587,591,099,908.00, an Internal Rate of Return (IRR) of 19.35%, which exceeds the Weighted Average Cost of Capital (WACC) of 14.01%, and a Payback Period of 5.12 years. The Break-Even Point (BEP) analysis indicates that the break-even condition is achieved at approximately 36.42% of sales capacity. The plant is designed with a production capacity of 29,950 tons per year and an economic lifetime of 20 years. Based on these results, the project is considered financially feasible, and the plant is therefore suitable for construction beginning in 2029, offering relatively rapid capital recovery and substantial long-term profitability.

Item Type:	Thesis (Other)
Uncontrolled Keywords:	Biogas, Integrasi Energi, Karbonasi, Medium Pressure Steam, Natrium Karbonat, Biogas, Carbonation, Energy Integration, Medium Pressure Steam, Sodium Carbonate
Subjects:	T Technology > TP Chemical technology > TP248.25.B55 Bioreactors--Fluid dynamics.
Divisions:	Faculty of Industrial Technology and Systems Engineering (INDSYS) > Chemical Engineering > 24201-(S1) Undergraduate Thesis
Depositing User:	Andhika Fathurrohman
Date Deposited:	21 Jul 2026 09:54
Last Modified:	21 Jul 2026 09:54
URI:	http://repository.its.ac.id/id/eprint/136069

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