Desain Pabrik Iron powder Dengan Material Biji Besi Hematit (Fe2O3) Menggunakan Proses Electrowinning Berbasis Low Emission

Nayondra, Adzka Farizky and Abdurrahman, Ahmad Muhammad Umar (2026) Desain Pabrik Iron powder Dengan Material Biji Besi Hematit (Fe2O3) Menggunakan Proses Electrowinning Berbasis Low Emission. Other thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

Pabrik Iron Powder berbahan baku bijih besi hematit (Fe₂O₃) dirancang dengan kapasitas produksi sebesar 5.000 ton/tahun menggunakan proses electrowinning berbasis low emission, berlokasi di Padang Industrial Park (PIP), Kabupaten Padang Pariaman, Sumatera Barat, dengan rencana operasi mulai tahun 2030. Bahan baku utama berupa bijih besi mengandung Fe₂O₃ sebesar 62,901% yang diperoleh dari Kabupaten Solok Selatan, Sumatera Barat, sedangkan bahan penunjang berupa larutan NaOH 50%wt diperoleh dari pemasok komersial. Proses produksi meliputi tahapan pre-treatment untuk mereduksi ukuran bijih besi hingga 10 mikron, dilanjutkan proses leaching menggunakan larutan NaOH 4 mol/L pada suhu 180°C dan tekanan 10 bar selama 4 jam sehingga mengekstrak kandungan SiO₂ sebesar 90,16%, kemudian filtrasi untuk memisahkan cake bijih besi dari filtrat Na₂SiO₃, mixing bijih besi hasil filtrasi dengan elektrolit NaOH 50%wt pada suhu 110°C, proses electrowinning secara elektrokimia menggunakan arus listrik 6.775 A dan tegangan 2,30 V yang menghasilkan iron powder dengan current efficiency di atas 90% dan kemurnian Fe ≥99%, serta tahapan rinsing dan drying hingga moisture content ≤0,1%wt. Produk iron powder yang dihasilkan memiliki kemurnian Fe ≥99%wt dengan ukuran partikel 15–20 mikron, sesuai standar industri untuk aplikasi powder metallurgy dan komponen otomotif. Hasil analisis ekonomi menunjukkan kelayakan finansial dengan Net Present Value (NPV) sebesar Rp 155,992,333,069.32, Internal Rate of Return (IRR) sebesar 23%, dan Payback Period selama 7.41 tahun, dengan CAPEX sebesar Rp 394,700,110,144.07 dan OPEX sebesar Rp216,856,623,280.35 per tahun. Ditinjau dari aspek lingkungan, penggunaan proses electrowinning secara signifikan menurunkan emisi CO₂ hingga 0,1–0,4ton CO₂/ton Fe dibandingkan proses konvensional blast furnace yang menghasilkan 1,8–2,2ton CO₂/ton Fe, sehingga mendukung komitmen industri terhadap produksi rendah emisi karbon.
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An iron powder plant using hematite iron ore (Fe₂O₃) as the primary feedstock has been designed with a production capacity of 5,000 tonnes per year employing a low-emission electrowinning process, situated at Padang Industrial Park (PIP), Padang Pariaman Regency, West Sumatra, with planned operations commencing in 2030. The primary raw material consists of iron ore containing 62.901% Fe₂O₃ sourced from South Solok Regency, West Sumatra, while the auxiliary material, a 50 wt% NaOH solution, is procured from commercial suppliers. The production process encompasses several stages: pre-treatment to reduce iron ore particle size to 10 microns; leaching using a 4 mol/L NaOH solution at 180°C and 10 bar for 4 hours, achieving a SiO₂ extraction efficiency of 90.16%; filtration to separate the iron ore cake from the Na₂SiO₃ filtrate; mixing of the filtered iron ore with 50 wt% NaOH electrolyte at 110°C; electrowinning via electrochemical reduction at 6,775 A and 2.30 V, yielding iron powder with a current efficiency exceeding 90% and Fe purity ≥99%; followed by rinsing and drying to achieve a moisture content of ≤0.1 wt%. The resulting iron powder meets industrial specifications with Fe purity ≥99 wt% and a particle size of 15–20 microns, suitable for powder metallurgy and automotive component applications. Economic analysis confirms the project’s financial viability with a Net Present Value (NPV) of IDR 155,992,333,069.32, an Internal Rate of Return (IRR) of 23%, and a Payback Period of 7.41 years, supported by a CAPEX of IDR 394,700,110,144.07 and an annual OPEX of IDR Rp216,856,623,280.35 From an environmental perspective, the electrowinning process substantially reduces CO₂ emissions to 0.1–0.4 tonnes CO₂/tonne Fe compared to conventional blast furnace operations generating 1.8–2.2 tonnes CO₂/tonne Fe, thereby affirming the plant’s commitment to low-carbon production.

Item Type:	Thesis (Other)
Uncontrolled Keywords:	Iron powder, Bijih Besi, Electrowinning, Alkaline Leaching, Rendah Emisi. Iron powder, Iron Ore, Electrowinning, Alkaline Leaching, Low Emission
Subjects:	T Technology > TP Chemical technology > TP155.5 Chemical plants--Design and construction
Divisions:	Faculty of Industrial Technology > Chemical Engineering > 24201-(S1) Undergraduate Thesis
Depositing User:	Adzka Farizky Nayondra
Date Deposited:	28 Jul 2026 08:11
Last Modified:	28 Jul 2026 08:11
URI:	http://repository.its.ac.id/id/eprint/138823

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