Desain Pabrik Precipitated Calcium Carbonate (PCC) Dari Limbah Kapur (Lime Mud) Industri Pulp Dan Kertas Menggunakan Proses Karbonasi

Kamila, Zahra Eza and Aribah, Zalfa Alya Nur (2026) Desain Pabrik Precipitated Calcium Carbonate (PCC) Dari Limbah Kapur (Lime Mud) Industri Pulp Dan Kertas Menggunakan Proses Karbonasi. Other thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

Precipitated Calcium Carbonate (PCC) merupakan bahan pengisi penting pada industri kertas karena mampu meningkatkan kecerahan, opasitas, dan kualitas permukaan produk. Pembahasan mengenai desain pabrik PCC dari limbah kapur (lime mud) industri pulp dan kertas menggunakan proses karbonasi sebagai upaya pemanfaatan limbah menjadi produk bernilai tambah. Bahan baku utama berupa lime mud dengan kandungan dominan CaCO3 diproses melalui tahapan pre-treatment, kalsinasi, slaking, karbonasi, dewatering, pengeringan, size reduction, classification, dan pengemasan. Proses karbonasi dipilih berdasarkan pertimbangan teknis, lingkungan, dan ekonomi karena menggunakan CO2 sebagai reaktan utama serta mendukung konsep carbon capture utilization. Reaktor karbonasi yang digunakan adalah bubble column karena sesuai untuk sistem gas-cair-padat, memiliki konstruksi sederhana, risiko penyumbatan lebih rendah, dan konsumsi energi relatif lebih efisien. Produk akhir ditargetkan memenuhi spesifikasi PCC filler grade untuk industri kertas, terutama kadar CaCO3, brightness, ukuran partikel, residu kasar, dan moisture. Pabrik dirancang beroperasi secara kontinu selama 24 jam per hari dan 330 hari per tahun dengan kapasitas produksi 75.000 ton PCC per tahun. Lokasi pabrik ditetapkan di Perawang, Kabupaten Siak, Riau, karena dekat dengan sumber lime mud, pasar industri kertas, serta didukung akses utilitas dan transportasi. Berdasarkan hasil perhitungan, kebutuhan process water sebesar 110.455,53 kg/jam, cooling water sebesar 96.573,44 kg/jam, dan kebutuhan daya sebesar 1.182,1 hp. Analisis ekonomi menunjukkan Total Capital Investment sebesar Rp309.658.201.643,67, Total Production Cost sebesar Rp103.751.795.313,86 per tahun, NPV sebesar Rp291.001.137.478,58, IRR sebesar 17,47%, dan Pay Out Time 5,5 tahun. Dengan demikian, pabrik PCC ini layak dikembangkan secara teknis, ekonomi, dan lingkungan, serta mendukung prinsip industri berkelanjutan berbasis ekonomi sirkular.
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Precipitated Calcium Carbonate (PCC) is an important filler material in the paper industry because it improves brightness, opacity, surface quality, and production efficiency. This report presents the design of a PCC plant from lime mud waste generated by the pulp and paper industry using the carbonation process. Lime mud, which contains calcium carbonate as the dominant component, is processed through pre-treatment, calcination, slaking, carbonation, dewatering, drying, size reduction, classification, and packaging. The carbonation process was selected based on technical, environmental, and economic considerations because it uses carbon dioxide as the main reactant and supports carbon capture utilization. The selected carbonation reactor is a bubble column reactor due to its suitability for gas-liquid-solid systems, simple construction, lower plugging risk, and efficient energy consumption. The final product is designed to meet PCC filler grade requirements for paper applications, including calcium carbonate content, brightness, particle size distribution, residue, pH, abrasion level, and moisture content. The plant operates continuously for 24 hours per day and 330 days per year with a production capacity of 75,000 tons PCC per year. The selected location is Perawang, Siak Regency, Riau, because it is close to lime mud sources, paper industry markets, utilities, and transportation access. The process water requirement is 110,455.53 kg/hour, the cooling water requirement is 96,573.44 kg/hour, and the total power requirement is 1,182.1 hp. Economic analysis gives a Total Capital Investment of IDR 309,658,201,643.67, Total Production Cost of IDR 103,751,795,313.86 per year, NPV of IDR 291.001.137.478,58, IRR of 17.47%, and Pay Out Time of 5.5 years. Therefore, this PCC plant is technically, economically, and environmentally feasible and supports sustainable industry through a circular economy approach.

Item Type:	Thesis (Other)
Uncontrolled Keywords:	Bubble column, Karbonasi, Lime Mud, Precipitated Calcium Carbonate, Pabrik PCC
Subjects:	T Technology > TP Chemical technology > TP155.5 Chemical plants--Design and construction T Technology > TP Chemical technology > TP155.7 Chemical processes. T Technology > TP Chemical technology > TP245.C3 Calcium carbonate.
Divisions:	Faculty of Industrial Technology > Chemical Engineering > 24201-(S1) Undergraduate Thesis
Depositing User:	Zahra Eza Kamila
Date Deposited:	21 Jul 2026 03:38
Last Modified:	21 Jul 2026 03:38
URI:	http://repository.its.ac.id/id/eprint/135979

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