Pra Desain Pabrik Portland Composite Cement (PCC)

Saepulah, Ferdi and Mukmin, Filo Sofia Kamila (2021) Pra Desain Pabrik Portland Composite Cement (PCC). Undergraduate thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

Indonesia merupakan negara yang memiliki cadangan mineral yang besar, seperti batu kapur, tanah liat dan juga batu bara. Sehingga industri semen di Indonesia diminati para investor untuk menginvestasikan pada pembangunan plant dan pabrik baru. Lokasi pabrik akan didirikan di Kabupaten Agam, Sumatera Barat. Pemilihan lokasi pabrik dikarenakan ketersediaan bahan baku, tenaga kerja tersedia, jangkauan pemasaran luas, dan utilitas tersedia. Pabrik semen ini diperkirakan dapat memproduksi semen sebanyak 2.100.000 ton/tahun. Untuk memenuhi kapasitas tahunan, pabrik akan beroperasi secara kontinyu 24 jam per hari selama 330 hari. Dalam proses pembuatan semen dipilih proses kering (dry process) karena dinilai lebih efisien dalam energi yang dibutuhkan untuk membuat semen. Adapun tahapan dry process yang pertama adalah proses persiapan bahan baku menjadi raw meal. Kedua, proses pemanasan dan pembakaran terjadi disepanjang cyclone pre-heater dan kiln. Reaksi yang terjadi adalah reaksi kalsinasi dan klinkerisasi. Ketiga, proses finishing yaitu pencampuran akhir antara klinker dan filler. Keempat adalah proses persiapan bahan bakar untuk unit pembakaran. Dari perhitungan analisa ekonomi, dengan harga jual semen sebesar Rp 50.000 per sack, dimana 1 sack berisi 50 kg semen, diperoleh nilai Internal Rate of Return (IRR) sebesar 19,32%. Nilai IRR tersebut lebih besar dari bunga bank pinjaman 11,27% per tahun, sehingga dari perhitungan tersebut menunjukkan bahwa pabrik ini layak untuk didirikan. Waktu pengembalian modal (Pay Out Time) untuk pabrik PCC ini selama 4,69 tahun. Modal untuk pendirian pabrik menggunakan rasio 30% modal sendiri 70% modal pinjaman. Penaksiran Modal (CAPEX) yang dibutuhkan adalah Rp 1.518.620.096.298,83,- dan juga Biaya Operasional (OPEX) yang dibutuhkan adalah Rp 867.707.697.799,-.
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Indonesia is a country that has large mineral reserves, such as limestone, clay and coal. So that the cement industry in Indonesia attracts investors to invest in the construction of new plants and factories. The location of the factory will be established in Agam District, West Sumatra. The choice of its location is due to the availability of raw materials, available labor, wide marketing reach, and available utilities. This cement factory is estimated to be able to produce cement as much as 2,100,000 tons/year. To meet the annual capacity, the plant will operate continuously 24 hours per day for 330 days. In the cement manufacturing process, the dry process is chosen because it is considered more efficient in the energy needed to make cement. The first dry process stage is the process of preparing raw materials into raw meal. Second, the heating and combustion processes occur along the cyclone pre-heater and kiln. The reactions that occur are calcination and clinkerization reactions. Third, the finishing process is the final mixing between clinker and filler. Fourth is the process of preparing fuel for the combustion unit. From the calculation of economic analysis, with a cement selling price of IDR 50,000 per sack, where 1 sack contains 50 kg of cement, the Internal Rate of Return (IRR) value is 19.32%. The IRR value is greater than the bank loan interest rate of 11.27% per year, so from this calculation it shows that this factory is feasible to build. The payout time for this PCC factory is 4.69 years. The capital for the establishment of the factory uses a ratio of 30% own capital 70% borrowed capital. Estimated Capital (CAPEX) required is IDR 1,518,620,096,298.83,- and the required Operational Cost (OPEX) is IDR 867,707,697,799,-.

Item Type:	Thesis (Undergraduate)
Uncontrolled Keywords:	dry process, kabupaten agam, semen, dry process, kabupaten agam, cement
Subjects:	T Technology > TP Chemical technology > TP155.5 Chemical plants--Design and construction
Divisions:	Faculty of Industrial Technology and Systems Engineering (INDSYS) > Chemical Engineering > 24201-(S1) Undergraduate Thesis
Depositing User:	Ferdi Saepulah
Date Deposited:	22 Aug 2021 09:44
Last Modified:	22 Aug 2021 09:44
URI:	http://repository.its.ac.id/id/eprint/88451

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