PABRIK SEMEN PORTLAND POZZOLAN (PPC) DENGAN BAHAN ADITIF FLY ASH MENGGUNAKAN DRY PROCESS

Rosalya, Andhara and Sugianto, Nailun Nabila (2021) PABRIK SEMEN PORTLAND POZZOLAN (PPC) DENGAN BAHAN ADITIF FLY ASH MENGGUNAKAN DRY PROCESS. Undergraduate thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

Perkembangan industri semen meningkat sejalan dengan program pembangunan infrastruktur. Hal ini dikatakan oleh Kementrian PUPR yang melakukan perencanaan untuk mengejar ketertinggalan infrastruktur dari negara lain dan memenuhi target sesuai Rencana Pembangunan Jangka Menengah Nasional (RPJMN) 2020-2024. Semen merupakan salah satu komoditas strategis sebagai penunjang perekonomian nasional melalui program-program pembangunan infrastruktur, gedung, perumahan, dan fasilitas umum lainnya. Kondisi tersebut mempengaruhi permintaan semen dalam negeri dan meningkatkan kapasitas produksi yang dihasilkan oleh industri semen. Pertambahan kapasitas produksi juga akan berdampak pada bahan baku semen yaitu batu kapur (limestone), tanah liat (clay), pasir besi (iron sand), dan pasir silika (silika sand). Dukungan ketersediaan baku utama dan bahan baku penunjang baik dari segi jumlah maupun kualitas merupakan hal yang penting agar aktivitas produksi semen berjalan sesuai rencana. Dalam hal ini, Kalimantan Selatan memiliki sumber batu kapur (limestone) 19.087.343.687 ton dan pasir besi (laterite) yang terdapat di Kotabaru. Sedangkan fly ash didapatkan dari limbah Pembangkit Listrik Asam Asam yang berada di Tanah Laut, Kalimantan Selatan. Lokasi yang dipilih untuk pendirian Pabrik Semen Portland Pozzoland (PPC) ini adalah Kotabaru, Kalimantan Selatan. Kapasitas produksi pabrik Semen Portland Pozzoland (PPC) yang akan didirikan yaitu 2.400.000 ton/tahun akan beroperasi secara continuous selama 300 hari/tahun. Proses pembuatan semen yang terpilih adalah proses kering. Pada proses penyiapan bahan baku batu kapur dan tanah liat, di cruher batu kapur di pacah oleh hammer dan tanah lia melewati clay cutter sehingga terjadi size reduction. Material yang berupa pasir silika, pasir besi dan mix pile keluar dari binnya dan diumpankan ke raw mill. Produk dari raw mill kemudian dialirkan ke preheater, lalu di umpankan ke proses pembakaran di kiln dengan suku 855°C. Di dalam kiln akan mengalami proses pembakaran dengan suhu 1250 - 1450°C, sehingga menghasilkan senyawa clinker yang kemudian didinginkan di dalam clinker cooler. Proses penggilingan akhir dimulai dari proses penyiapan bahan tambahan yaitu gypsum dan fly ash yang akan diumpankan ke dalam ball mill menjadi semen yang berukuran 325 mesh. Sehingga menghasilkan produk Semen Portland Pozzoland (PPC) sebanyak 48.000.000 sak/tahun. Optimasi dan efisiensi dilakukan dengan melakukan subtitusi bahan bakar biomasa pada bahan bakar batubara pada proses pembakaran di kiln dengan menggunakan metode LCA (Life Cycle Assesment). Analisa ekonomi diperoleh total biaya bahan baku pertahun sebesar Rp. 787.161.257.384 dengan harga semen Rp. 35.600 per/50 kg, dengan nilai Internal Rate of Return (IRR) sebesar 23% pertahun, Pay Out Time (POT) sebesar 4,433 tahun, Break Even Point (BEP) sebesar 43,18% dan Net Present Value (NPV) sebesar Rp. 1.108.861.951.211.
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The development of the cement industry is increasing in line with the infrastructure development program. This was said by the Ministry of PUPR, which is planning to catch up with infrastructure from other countries and meet targets according to the 2020-2024 National Medium- Term Development Plan (RPJMN). Cement is one of the strategic commodities to support the national economy through infrastructure, buildings, housing and other public facilities development programs. This condition affects domestic cement demand and increases the production capacity of the cement industry. The increase in production capacity will also have an impact on cement raw materials, namely limestone, clay, iron sand, and silica sand. (silica sand). Support for the availability of main raw materials and supporting raw materials, both in terms of quantity and quality, is important so that cement production activities run according to plan. In this case, South Kalimantan has a source of 19,087,343,687 tons of limestone (limestone) and iron sand (laterite) found in Kotabaru. While fly ash is obtained from the waste of the Asam Asam Power Plant located in Tanah Laut, South Kalimantan. The location chosen for the establishment of the Portland Pozzoland Cement Plant (PPC) is Kotabaru, South Kalimantan. The production capacity of the Portland Pozzoland Cement (PPC) plant to be established is 2,400,000 tons/year and will operate continuously for 300 days/year. The selected cement manufacturing process is a dry process. In the process of preparing limestone and clay raw materials, the limestone crusher is crushed by a hammer and the clay passes through the clay cutter so that size reduction occurs. The material in the form of silica sand, iron sand and mix pile comes out of the bin and is fed to the raw mill. The product from the raw mill is then flowed into the preheater, then fed to the combustion process in the kiln at a rate of 855°C. In the kiln it will undergo a combustion process with a temperature of 1250 - 1450°C, resulting in a clinker compound which is then cooled in the clinker cooler. The final milling process starts from the process of preparing additional materials, namely gypsum and fly ash which will be fed into the ball mill into cement with a size of 325 mesh. This results in the production of Portland Pozzoland Cement (PPC) as much as 48,000,000 sacks/year. Optimization and efficiency are carried out by substituting biomass fuel for coal fuel in the combustion process in the kiln using the LCA (Life Cycle Assessment) method. Economic analysis obtained the total cost of raw materials per year is Rp. 787,161,257,384 with a cement price of Rp. 35,600 per/50 kg, with an Internal Rate of Return (IRR) of 23% per year, Pay Out Time (POT) of 4,433 years, Break Even Point (BEP) of 43.18% and Net Present Value (NPV) of Rp. 1,108,861,951,211.

Item Type:	Thesis (Undergraduate)
Uncontrolled Keywords:	semen portland pozzolan (PPC), batu kapur, fly ash, rotary Kiln, portland pozzolan cement (PPC), limestone, fly ash, rotary kiln
Subjects:	T Technology > TP Chemical technology > TP883 Portland cement.
Divisions:	Faculty of Vocational > 24305-Industrial Chemical Engineering Technology
Depositing User:	Andhara Rosalya
Date Deposited:	23 Aug 2021 05:20
Last Modified:	23 Aug 2021 05:20
URI:	http://repository.its.ac.id/id/eprint/89909

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