Semen PCC Dengan Pemanfaatan Pasir Besi

Prasetya, Daniel Wiradanu and Junianto, Budi Rizky (2019) Semen PCC Dengan Pemanfaatan Pasir Besi. Undergraduate thesis, Intitut Teknologi Sepuluh Nopember.

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Abstract

Pembangunan proyek fisik strategis terus berlanjut bahkan terjadi percepatan meskipun perekonomian Indonesia sedang melambat. Semen merupakan elemen penting bagi perekonomian suatu Negara sebagai pengikat ini adalah bahan bangunan yang digunakan untuk infrastruktur dan pengembangan properti. Dengan demikian, penjualan semen memberikan informasi tentang kekuatan dan investasi di suatu negara.
Menurut catatan Asosiasi Semen Indonesia (ASI) pada tahun 2010 konsumsi semen di Indonesia tercatat sebesar 40.782.377 ton kemudian naik terus hingga mencapai 59.909.500 ton pada tahun 2014. Pada tahun 2015 diperkirakan akan naik menjadi 60.440.312 ton. Dari data tersebut terlihat bahwa kebutuhan semen PCC di Indonesia semakin meningkat.
Dalam proses pembuatan semen, terdapat dua teknologi, yaitu proses basah (Wet Process) dan proses kering (Dry Process). Proses basah yaitu dalam pembuatan semen menggunakan penambahan air saat penggilingan dan pencampuran bahan baku. Sedangkan pada proses kering, proses penggilinan dan pencampuran bahan baku dilakukan dalam keadaan kering. Dari kedua proses tersebut dipilihlah proses kering (Dry Process) karena dinilai lebih hemat. Adapun tahapannya yaitu (1) Proses persiapan bahan baku, meliputi penambangan dan pengeringan serta penggilingan bahan baku. Proses persiapan bahan baku dimulai dari penggalian limestone (batu kapur), clay (tanah liat), pasir besi dan pasir silika yang menggunakan alat berat kemudian diangkut oleh jenis kendaraan dump truck. Kemudian keempat bahan tersebut dimasukkan kedalam masing masing hopper, selanjutnya menuju crusher untuk dikecilkan ukruannya agar seragam sebelum memasuki tahap proses pembakaran pada kiln. (2) Proses pembakaran, proses pembakaran terdiri dari alat preheater dan kiln, alat-alat tersebut digunakan untuk proses pemanasan awal dan reaksi pembentukan kandungan utama semen, reaksinya : 4C + A + F → C4AF4, 3C + A → C3A, 2C + S → C2S dan C2S + C → C3S.
(3) Proses finishing, proses ini adalah untuk pencampuran dan penggilingan yang kedua agar kandungan semen lebih merata. Proses akhir pengepakan dan pengiriman ini dilakukan dengan kemasan 50 kg atau pengiriman dalam kapasitas besar sejenis truk dan distribusi kapal.
Adapun bahan baku yang dibutuhkan untuk menghasilkan produk PCC dengan kapasitas 315.657 kg/jam antara lain: (1) batu kapur (limestone) sebanyak 312.511 kg, (2) tanah liat sebanyak 65.107 kg, (3) pasir silica sebanyak 2.589 kg, (4) pasir besi sebanyak 1.668 kg, dan (5) fly ash sebanyak 42.614 kg. Dalam prosesnya, terdapat beberapa komponen yang hilang yaitu kandungan air dan beberapa bahan yang menjadi debu.
Bahan bakar yang digunakan untuk pemanasan di pabrik semen PCC adalah batubara. Karena batubara digunakan, sehingga dihasilkan flue gas dengan kandungan SO2, NO2 dan CO2. Sistem pemanasan yang dilakukan menggunakan udara hasil pembakaran dan aliran gas panas yang dihasilkan. Batubara digunakan sebagai pembakaran di kiln dan kalsiner, gas hasil pembakaran dari kiln digunakan kembali untuk pemanasan di preheater, kemudian diteruskan untuk pemanasan pada raw mill, sedangkan udara panas yang keluar dari cooler setelah proses pendinginan clinker digunakan pada kiln.
Peralatan yang digunakan dalam pembuatan Portland Composite Cement (PCC) antara lain crusher, raw mill, suspension preheater, rotary kiln dan finish mill. Kiln yang memiliki bahan konstruksi mild steel dan brick menggunakan high aloumina fire brick, dipilih karena tahan terhadap reaksi kimia. Pabrik Portland Composite Cement (PCC) ini rencananya akan didirikan di Kabupaten Kutai Timur di Provinsi Kalimantan TImur, Indonesia.
Dalam pendirian pabrik ini laju pengembalian modal (Internal Rate of Return /IRR ) didapatkan dari hasil perhitungan pada Appendiks D, harga i sebesar 20,86%. Harga i yang diperoleh lebih besar dari harga i untuk bunga pinjaman yaitu 10.50% per tahun. Dengan harga yang didapatkan dari perhitungan menunjukkan bahwa pabrik ini layak didirikan dengan kondisi tingkat bunga pinjaman 10.50% per tahun.
Dari perhitungan yang terlampir di appendiks D, didapatkan bahwa waktu pengembalian modal minimum adalah 4.5 tahun. Hal ini menunjukkan bahwa pabrik ini layak didirikan dengan kondisi tingkat bunga pinjaman 10.5% per tahun.
Titik impas dianalisa untuk mengetahui besarnya kapasitas produksi dimana biaya produksi total sama dengan hasil penjualan. Dengan memperhitungkan biaya tetap (FC), biaya variable (VC), biaya semi variabel (SVC) dan total penjualan didapatkan bahwa titik impas (BEP) =28.9%
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The development of strategic physical projects continues even accelerating even though the Indonesian economy is slowing down. Cement is an important element for a country's economy as a binder is a building material used for infrastructure and property development. Thus, cement sales provide information about the strength and investment in a country.
According to the records of the Indonesian Cement Association (ASI) in 2010 cement consumption in Indonesia was recorded at 40,782,377 tons and then continued to rise to reach 59,909,500 tons in 2014. In 2015 it is estimated to rise to 60,440,312 tons. From these data it can be seen that the PCC cement demand in Indonesia is increasing.
In the process of making cement, there are two technologies, namely Wet Process and Dry Process. The wet process is in the manufacture of cement using the addition of water during grinding and mixing of raw materials. While in the dry process, the process of milling and mixing of raw materials is carried out in a dry state. From the two processes, a dry process was chosen because it was considered more economical. The stages are (1) The process of preparing raw materials, including mining and drying and grinding of raw materials. The process of preparing raw materials starts from extracting limestone (clay), clay (clay), iron sand and silica sand that uses heavy equipment and then transported by type of dump truck vehicles. Then the four ingredients are inserted into each hopper, then towards the crusher to reduce the size to be uniform before entering the combustion process stage in the kiln. (2) The combustion process, the combustion process consists of a preheater and kiln, the tools are used for the preheating process and the reaction formation of the main content of cement, the reaction: 4C + A + F → C4AF4, 3C + A → C3A, 2C + S → C2S and C2S + C → C3S.
(3) The finishing process, this process is for mixing and second grinding so that the cement content is more evenly distributed. The final process of packing and shipping is carried out with 50 kg packaging or shipping in large capacity such as trucks and ship distribution.
The raw materials needed to produce PCC products with a capacity of 315,657 kg / hour include: (1) limestone as much as 312,511 kg, (2) clay as much as 65,107 kg, (3) silica sand as much as 2,589 kg, (4 ) iron sand as much as 1,668 kg, and (5) fly ash as much as 42,614 kg. In the process, there are several missing components, namely the water content and some materials that become dust.
The fuel used for heating in the PCC cement plant is coal. Because coal is used, resulting in flue gas with SO2, NO2 and CO2 content. The heating system is carried out using combustion air and the flow of hot gas produced. Coal is used as combustion in the kiln and calciner, the combustion gases from the kiln are reused for heating in the preheater, then continue to warm up in the raw mill, while the hot air that comes out of the cooler after the cooling clinker is used in the kiln.
The equipment used in making Portland Composite Cement (PCC) includes crushers, raw mill, suspension preheater, rotary kiln and mill finish. Kiln which has mild steel and brick construction materials uses high aloumina fire brick, chosen because it is resistant to chemical reactions. The Portland Composite Cement (PCC) plant is planned to be established in East Kutai Regency in East Kalimantan Province, Indonesia.
In the establishment of this factory the rate of return of capital (Internal Rate of Return / IRR) was obtained from the results of calculations in Appendix D, i price of 20.86%. The price i obtained is greater than the price i for the loan interest which is 10.50% per year. The price obtained from the calculation shows that this factory is feasible to be established under the condition that the loan interest rate is 10.50% per year.
From the calculations attached to appendix D, it was found that the minimum payback time was 4.5 years. This indicates that this plant is feasible to be established under the condition that the loan interest rate is 10.5% per year.
The break-even point is analyzed to determine the size of the production capacity where the total production costs are the same as the sales. Taking into account the fixed costs (FC), variable costs (VC), semi-variable costs (SVC) and total sales, it was found that the break-even point (BEP) = 28.9%

Item Type:	Thesis (Undergraduate)
Additional Information:	RSK 666.94 Jun s-1 2019
Uncontrolled Keywords:	PCC Cement, Pabrik Semen, Semen PCC
Subjects:	H Social Sciences > HD Industries. Land use. Labor > HD9622 Cement. Concrete. Cement and concrete additives T Technology > T Technology (General) T Technology > TA Engineering (General). Civil engineering (General) > TA418.9 Composite materials. Laminated materials.
Divisions:	Faculty of Industrial Technology and Systems Engineering (INDSYS) > Chemical Engineering > 24201-(S1) Undergraduate Thesis
Depositing User:	Budi Rizky Junianto
Date Deposited:	06 Dec 2021 08:26
Last Modified:	06 Dec 2021 08:26
URI:	http://repository.its.ac.id/id/eprint/61660

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