Desain Pabrik Portland Composite Cement (PCC) Dengan Subtitusi Abu Sekam Padi

Kusnadi, Theresia Intan Christianingtyas (2025) Desain Pabrik Portland Composite Cement (PCC) Dengan Subtitusi Abu Sekam Padi. Other thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

Permintaan akan semen di Indonesia terus meningkat seiring percepatan pembangunan infrastruktur nasional, yang turut mendorong naiknya emisi karbon dari sektor konstruksi. Industri semen menyumbang sekitar 8% dari total emisi CO₂ global, sehingga diperlukan inovasi yang mendukung produksi berkelanjutan. Tugas akhir ini merancang pabrik Portland Composite Cement (PCC) dengan substitusi abu sekam padi (Rice Husk Ash/RHA) sebesar 3% dari total massa produksi semen sebagai bahan pozolan alternatif. Substitusi RHA ini bertujuan untuk menurunkan konsumsi klinker, mengurangi emisi CO₂, dan memanfaatkan limbah biomassa lokal secara efisien. Pabrik dirancang dengan kapasitas 4 juta ton per tahun dan akan dibangun di Kabupaten Tana Toraja, Sulawesi Selatan, berdasarkan hasil evaluasi lokasi menggunakan metode Analytical Hierarchy Process (AHP). Bahan baku utama terdiri atas 3,74 miliar ton batu kapur dan 1,13 miliar ton tanah liat, sedangkan kebutuhan tahunan RHA sebesar 120.000 ton diperoleh dari produksi sekam padi di Sulawesi Selatan yang mencapai 1.072.805 ton sekam padi per tahun. Proses produksi menggunakan metode kering karena efisien dalam penggunaan energi dan air, serta cocok untuk produksi berskala besar. Komposisi semen PCC mencakup 65–79% klinker, 21–35% bahan tambahan (termasuk RHA), dan 0–5% bahan korektif. Studi ini mencakup rancangan alur proses (PFD), diagram perpipaan dan instrumentasi (P&ID), analisis HAZOP, serta evaluasi kelayakan teknis dan ekonomi. Hasil evaluasi menunjukkan proyek ini layak dilaksanakan dengan nilai NPV sebesar Rp 2,974 triliun, IRR sebesar 21,85%, POT 5,92 tahun, BEP 34,61%, CAPEX sebesar Rp 1,737 triliun, dan OPEX sebesar Rp 300 miliar. Pabrik ini diharapkan dapat menjadi percontohan pengembangan industri semen berkelanjutan di Indonesia.

Kata kunci: abu sekam padi, analisis ekonomi, proses kering, substitusi RHA 3%, Tana Toraja
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Cement demand in Indonesia continues to grow in line with national infrastructure development, consequently increasing CO₂ emissions from the construction sector. The cement industry contributes approximately 8% of total global CO₂ emissions, prompting the need for more sustainable production approaches. This final project presents the design of a Portland Composite Cement (PCC) plant using rice husk ash (RHA) as an alternative pozzolanic material with a substitution rate of 3% of total cement mass. This strategy aims to reduce clinker consumption, lower carbon emissions, and utilize local biomass waste efficiently. The plant is designed to produce 4 million tons per year and is to be constructed in Tana Toraja Regency, South Sulawesi, selected using the Analytical Hierarchy Process (AHP). The primary raw materials include 3.74 billion tons of limestone and 1.13 billion tons of clay, while the required 120,000 tons of RHA annually is sourced from 1,072,805 tons of rice husk produced regionally. The dry process was selected for its high energy and water efficiency and suitability for large-scale production. PCC cement consists of 65–79% clinker, 21–35% supplementary materials (including RHA), and 0–5% corrective materials. The study encompasses process flow design (PFD), piping and instrumentation diagrams (P&ID), HAZOP analysis, and technical-economic feasibility evaluation. The results show that the project is feasible, with a Net Present Value (NPV) of IDR 2.974 trillion, an Internal Rate of Return (IRR) of 21.85%, a Pay Out Time (POT) of 5.92 years, Break Even Point (BEP) of 34.61%, Capital Expenditure (CAPEX) of IDR 1.737 trillion, and Operating Expenditure (OPEX) of IDR 300 million. This plant is expected to serve as a model for sustainable cement industry development in Indonesia.

Keywords: dry process, economic analysis, rice husk ash,Tana Toraja, 3% RHA substitution

Item Type:	Thesis (Other)
Uncontrolled Keywords:	abu sekam padi, analisis ekonomi, proses kering, substitusi RHA 3%, Tana Toraja dry process, economic analysis, rice husk ash,Tana Toraja, 3% RHA substitution
Subjects:	T Technology > TP Chemical technology T Technology > TP Chemical technology > TP155.5 Chemical plants--Design and construction T Technology > TP Chemical technology > TP883 Portland cement.
Divisions:	Faculty of Industrial Technology and Systems Engineering (INDSYS) > Chemical Engineering > 24201-(S1) Undergraduate Thesis
Depositing User:	Theresia Intan Christianingtyas Kusnadi
Date Deposited:	28 Jul 2025 02:38
Last Modified:	28 Jul 2025 02:38
URI:	http://repository.its.ac.id/id/eprint/121904

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