Wibowo, Chiervy Brby Minarti and Putri, Benecdita Evangelin Arindani (2026) Desain Pabrik Precipitated Calcium Carbonate (PCC) Berbasis Batu Kapur Melalui Proses Karbonasi. Other thesis, Institut Teknologi Sepuluh Nopember.
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Abstract
Precipitated calcium carbonate (PCC) merupakan bahan kimia anorganik bernilai tambah yang banyak digunakan pada industri kertas, plastik, karet, cat, farmasi, dan konstruksi. Pertumbuhan industri pengguna di Indonesia mendorong peningkatan konsumsi PCC yang belum sepenuhnya diimbangi oleh kapasitas produksi domestik sehingga ketergantungan terhadap impor masih tinggi. Pra-desain pabrik ini bertujuan merancang pabrik PCC yang layak secara
teknis dan ekonomis melalui analisis pasar, seleksi teknologi proses, evaluasi ketersediaan bahan baku, penentuan kapasitas produksi, serta pemilihan lokasi. Hasil kajian menunjukkan bahwa proses karbonasi dipilih sebagai metode produksi. Bahan baku utama berupa Batu Kapur (CaCO3) dipasok dari produsen domestik seperti CV TerraLime Indonesia di Gresik, karbon dioksida (CO2) diperoleh dari hasil kalsinasi, Air proses (H2O) diperoleh dari PT. Kalam
Leverage Mulia, sedangkan kebutuhan air sebagai utilitas peralatan berasal dari utilitas kawasan industri dan sumber air permukaan seperti Sungai Bengawan Solo. Produk yang dirancang adalah yang umum digunakan sebagai filler pada industri kertas dan industri farmasi. Penetapan kapasitas produksi dilakukan berdasarkan analisis supply-demand dan pendekatan substitusi impor sehingga diperoleh kapasitas rancangan sebesar 30.000 ton/tahun. Penentuan lokasi menggunakan metode Analytical Hierarchy Process dengan mempertimbangkan aspek lahan dan bahan baku, pasar, utilitas, tenaga kerja, transportasi, regulasi, serta iklim dan topografi. Hasil analisis menunjukkan Kawasan Industri Java Integrated Industrial and Ports Estate (JIIPE) Manyar, Gresik, Jawa Timur sebagai lokasi paling optimal. Pendirian pabrik ini dengan waktu operasi 330 hari. Untuk mendirikan pabrik PCC ini dibutuhkan modal investasi sebesar Rp1,518,795,970,835.92. Berdasarkan analisis ekonomi, diperoleh estimasi modal (CAPEX) sebesar Rp1,786,818,789,218.73 dan biaya operasional (OPEX) sebesar
Rp555,846,051,678.75. Hasil penjualan produk per tahun diperkirakan mencapai Rp933.468.345.122 dengan Internal Rate of Return (IRR) sebesar 21.04%, Pay Out Time (POT) selama 4.99 tahun, Net Present Value (NPV) sebesar Rp3,808,052,250,540.08 (bernilai positif), dan Weighted Average Cost of Capital (WACC) sebesar 5.45%. Berdasarkan hasil analisis tersebut, dapat disimpulkan bahwa pabrik ini layak untuk didirikan karena nilai WACC lebih kecil daripada IRR (WACC < IRR).
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Precipitated Calcium Carbonate (PCC) is a value-added inorganic chemical widely used in the paper, plastic, rubber, paint, pharmaceutical, and construction industries. The growth of these downstream industries in Indonesia has increased PCC consumption, which has not been fully supported by domestic production capacity, resulting in a continued reliance on imports. This pre-design study aims to design a PCC plant that is technically and economically feasible through market analysis, process technology selection, raw material availability evaluation, production capacity determination, and site selection. The study results indicate that the carbonation process was selected as the production method. The main raw material, limestone (CaCO3), is supplied by domestic producers such as CV TerraLime Indonesia in Gresik, while carbon dioxide (CO2) is obtained from the calcination process. Process water (H2O) is supplied by PT Kalam Leverage Mulia, whereas utility water requirements are fulfilled through industrial estate utilities and surface water sources, such as the Bengawan Solo River. The proposed products are PCC grades commonly used as fillers in the paper and pharmaceutical industries. The production capacity was determined based on supply-demand analysis and an import substitution approach, resulting in a design capacity of 30,000 tons/year. Site selection was conducted using the Analytical Hierarchy Process (AHP) by considering factors such as land and raw material availability, market accessibility, utilities, labor, transportation, regulations, climate, and topography. The analysis identified the Java Integrated Industrial and Ports Estate (JIIPE) in Manyar, Gresik, East Java, as the most suitable location. The plant is designed to operate for 330 days per year. The establishment of the PCC plant requires a total investment cost of IDR 1,518,795,970,835.92. Economic analysis estimated a capital expenditure (CAPEX) of IDR Rp1,786,818,789,218.73 and an operational expenditure (OPEX) of IDR 555,846,051,678.75. Annual product sales are projected to reach IDR 933,468,345,122, with an Internal Rate of Return (IRR) of 21.04%, a Pay Out Time (POT) of 4.99 years, a positive Net Present Value (NPV) of IDR 3,808,052,250,540.08, and a Weighted Average Cost of Capital (WACC) of 5.45%. Based on these economic indicators, the proposed plant is considered economically feasible since the WACC is lower than the IRR (WACC < IRR).
| Item Type: | Thesis (Other) |
|---|---|
| Uncontrolled Keywords: | Precipitated Calcium Carbonate (PCC), Proses Karbonasi, Analisis Pasar, Kapasitas Produksi, Bahan Baku, Pemilihan Lokasi, Precipitated Calcium Carbonate (PCC), Carbonation Process, Market Analysis, Production Capacity, Raw Materials, Site Selection |
| Subjects: | T Technology > TD Environmental technology. Sanitary engineering > TD455 Chemical precipitation. Coagulation. Flocculation. Water--Purification--Flocculation. 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 and Systems Engineering (INDSYS) > Chemical Engineering > 24201-(S1) Undergraduate Thesis |
| Depositing User: | Chiervy Brby Minarti Wibowo |
| Date Deposited: | 28 Jul 2026 04:03 |
| Last Modified: | 28 Jul 2026 04:03 |
| URI: | http://repository.its.ac.id/id/eprint/138540 |
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