Desain Pabrik Baja Berbasis Direct Reduced Iron dengan Reduksi Hidrogen dan Proses Electric Arc Furnace

Indra Novanto, Mudfi and Hanafi, Yusuf (2025) Desain Pabrik Baja Berbasis Direct Reduced Iron dengan Reduksi Hidrogen dan Proses Electric Arc Furnace. Other thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

Desain pabrik baja ini bertujuan untuk mengembangkan proses produksi baja yang ramah lingkungan dengan menerapkan teknologi Direct Reduced Iron (DRI) berbasis reduksi hidrogen, yang kemudian dilebur menggunakan Electric Arc Furnace (EAF). Teknologi ini dipilih sebagai alternatif dari proses Blast Furnace–Basic Oxygen Furnace (BF–BOF) yang menghasilkan emisi karbon tinggi. Pabrik dirancang untuk memanfaatkan pasir besi lokal dari wilayah Cilacap dan sekitarnya, yang memiliki kandungan Fe₂O₃ sekitar 66–70%. Bahan baku tersebut diolah melalui proses pelletizing dan pengeringan, lalu direduksi menggunakan gas hidrogen murni (H₂ 99,99%) dalam reaktor shaft furnace untuk menghasilkan DRI. Produk DRI kemudian dilebur bersama scrap baja dan flux CaO dalam EAF untuk menghasilkan baja karbon rendah. Komposisi baja cair yang dihasilkan menunjukkan fraksi massa besi (Fe) sebesar 99,895%, karbon (C) sebesar 0,105%, fosfor (P) dan sulfur (S) masing-masing 0%, sehingga seluruhnya telah memenuhi spesifikasi baja karbon rendah menurut SNI 53:2019, yaitu Fe minimal 98,5%, C maksimal 0,25%, dan P serta S masing-masing maksimal 0,05%. Pabrik ini dirancang untuk beroperasi selama 24 jam per hari dan 330 hari per tahun, dengan kapasitas produksi 1 juta ton baja per tahun, umur operasional 15 tahun, serta masa konstruksi selama 2 tahun. Lokasi pembangunan dipilih di Cilacap Jawa Tengah dengan pertimbangan ketersediaan pelabuhan utilitas bahan baku dan pasar. Aspek ekonomi proyek menunjukkan kebutuhan investasi awal sebesar Rp 28,08 triliun dengan biaya operasional sebesar Rp 8,19 triliun per tahun. Proyek ini dirancang untuk menghasilkan pendapatan penjualan sebesar Rp 15,10 triliun per tahun. Dengan asumsi umur proyek selama 15 tahun tingkat suku bunga bank sebesar 8% dan laju inflasi 2,3% hasil analisis kelayakan menunjukkan bahwa proyek ini memiliki Internal Rate of Return (IRR) sebesar 12,00% Net Present Value (NPV) sebesar Rp 3,75 triliun waktu pengembalian modal (Pay Out Time) selama 8 tahun dan Break Even Point (BEP) sebesar 39,59%. Selain layak secara teknis dan finansial proses ini juga unggul secara lingkungan karena tidak menghasilkan emisi karbon dioksida melainkan hanya menghasilkan uap air sebagai produk samping sehingga mendukung target net zero emission dan kebijakan dekarbonisasi nasional. Dengan mempertimbangkan seluruh aspek teknis ekonomis dan lingkungan proyek ini dinilai layak untuk direalisasikan dan berpotensi memberikan kontribusi besar terhadap kemandirian dan keberlanjutan industri baja nasional.
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This steel plant design aims to develop an environmentally friendly steel production process by implementing hydrogen-based Direct Reduced Iron (DRI) technology, followed by
melting in an Electric Arc Furnace (EAF). This technology is selected as an alternative to the conventional Blast Furnace–Basic Oxygen Furnace (BF–BOF) route, which produces high carbon emissions. The plant is designed to utilize local iron sand from the Cilacap region and surrounding areas, containing approximately 66–70% Fe₂O₃. The raw material is processed through pelletizing and drying stages, then reduced using high-purity hydrogen gas (H₂ 99.99%) in a shaft furnace to produce DRI. The DRI is subsequently melted with steel scrap and CaO flux in the EAF to produce low-carbon steel. The resulting molten steel composition meets the Indonesian National Standard (SNI 53:2019) for low-carbon steel, with a mass fraction of iron (Fe) at 99.895%, carbon (C) at 0.105%, and both phosphorus (P) and sulfur (S) at 0%. These values satisfy the standard limits of Fe ≥ 98.5%, C ≤ 0.25%, and P, S ≤ 0.05%. The plant is designed to operate 24 hours per day for 330 days per year, with a production capacity of 1 million tons of steel annually, a 15-year operational life, and a 2-year construction period. Cilacap, Central Java, is selected as the plant location based on proximity to ports, utilities, raw materials, and markets. The economic aspects of the project show an initial investment requirement of IDR 28.08 trillion, with annual operational costs of IDR 8.19 trillion. The plant is expected to generate annual sales revenue of IDR 15.10 trillion. Based on a 15-year project lifetime, with a bank interest rate of 8% and an inflation rate of 2.3%, the profitability analysis indicates an Internal Rate of Return (IRR) of 12.00%, a Net Present Value (NPV) of IDR 3.75 trillion, a Pay Out Time (POT) of 8 years, and a Break Even Point (BEP) of 39.59%. In addition to being technically and financially feasible, this process is also environmentally advantageous, as it produces only water vapor instead of carbon dioxide emissions, thus supporting national net-zero emission targets and green industrialization policies. Considering all technical, economic, and environmental aspects, this steel plant project is deemed feasible and has the potential to strengthen the independence and sustainability of the national steel industry.

Item Type:	Thesis (Other)
Uncontrolled Keywords:	Baja, Direct Reduced Iron, Electric Arc Furnace, Steel, Direct Reduced Iron, Electric Arc Furnace
Subjects:	T Technology > TN Mining engineering. Metallurgy > TN408.N56 Sand, Iron T Technology > TN Mining engineering. Metallurgy > TN687 Electric furnaces. T Technology > TP Chemical technology > TP155.5 Chemical plants--Design and construction T Technology > TP Chemical technology > TP155.7 Chemical processes.
Divisions:	Faculty of Industrial Technology and Systems Engineering (INDSYS) > Chemical Engineering > 24201-(S1) Undergraduate Thesis
Depositing User:	Mudfi Indra Novanto
Date Deposited:	29 Jul 2025 08:50
Last Modified:	29 Jul 2025 08:50
URI:	http://repository.its.ac.id/id/eprint/122834

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