Design of Steel Plant Based on Direct Reduced Iron with Hydrogen Reduction and Electric Arc Furnace Process

Bagaswira, Evantara Aldhi and Husodo, Muhammad Ramadhani (2026) Design of Steel Plant Based on Direct Reduced Iron with Hydrogen Reduction and Electric Arc Furnace Process. Other thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

Desain pabrik baja ini bertujuan untuk meningkatkan proses produksi baja hijau dengan menerapkan teknologi Besi Reduksi Langsung (DRI) berbasis reduksi hidrogen, yang kemudian dilebur menggunakan Tungku Busur Listrik (EAF). Teknologi ini dipilih sebagai proses alternatif dari Tungku Peleburan–Tungku Oksigen Dasar (BF–BOF) yang saat ini menghasilkan emisi karbon tinggi. Pabrik ini dirancang untuk memanfaatkan pasir besi lokal dari daerah Cilacap dan sekitarnya, yang memiliki kandungan Fe₂O₃ sekitar 66–70%. Bahan baku diproses melalui proses peletisasi dan pengeringan, yang kemudian direduksi menggunakan gas hidrogen murni (H₂ 99,99%) di dalam reaktor Tungku Poros untuk menghasilkan DRI. Produk DRI akan dilebur bersama dengan baja bekas dan fluks CaO di dalam EAF untuk menghasilkan baja karbon rendah. Komposisi baja cair yang dihasilkan akan mengandung 99,89% massa besi (Fe), 0,105% karbon (C), dan 0% fosfor (P) dan sulfur (S), sehingga memenuhi spesifikasi baja karbon rendah menurut SNI 53:2019, yang terdiri dari minimal 99,85% Fe, dan maksimal 0,25% C, serta 0,05% P dan S. Pabrik ini dirancang untuk beroperasi selama 24 jam per hari dan total 330 hari per tahun, dengan kapasitas produksi 1 juta ton per tahun, usia operasional 15 tahun, serta konstruksi selama 2 tahun. Pabrik akan berlokasi di Cilacap, Jawa Tengah dengan mempertimbangkan ketersediaan utilitas bahan baku, pelabuhan, dan pasar. Aspek ekonomi proyek ini menunjukkan bahwa investasi awal akan membutuhkan Rp 28,08 triliun, dengan biaya operasional 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, suku bunga bank adalah 8% dan tingkat inflasi adalah 2,3%. Hasil analisis kelayakan menunjukkan bahwa proyek ini memiliki Tingkat Pengembalian Internal (IRR) sebesar 12,00%, Nilai Sekarang Bersih (NPV) sebesar Rp 3,75 triliun, Waktu Pengembalian Modal (Pay Out Time) selama 8 tahun, dan Titik Impas (BEP) sebesar 39,59%. Selain layak secara teknis dan finansial, proses ini juga unggul secara lingkungan karena tidak menghasilkan emisi karbon dioksida, hanya uap air sebagai produk sampingan, sehingga mendukung target emisi nol bersih dan kebijakan dekarbonisasi nasional. Dengan mempertimbangkan semua aspek teknis, ekonomi, dan lingkungan dari proyek ini, proyek ini dianggap layak untuk direalisasikan dan berpotensi memberikan kontribusi besar terhadap kemandirian dan keberlanjutan industri baja nasional.
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This steel plant design is intended to improve the process of green steel production by applying Direct Reduced Iron (DRI) technology based on hydrogen reduction, which is then melted down using Electric Arc Furnace (EAF). This technology was chosen as an alternative process from the current Blast Furnace–Basic Oxygen Furnace (BF–BOF) which produces high carbon emissions. The plant is designed to utilize local iron sand from areas of Cilacap and its surroundings, which has an Fe₂O₃ content of around 66–70%. Raw materials are processed through pelletizing and drying process, which then reduced using pure hydrogen gas (H₂ 99.99%) in Shaft Furnace reactor to produce DRI. The DRI product would be melted together with scrap steels and flux CaO inside EAF to produce low carbon steel. The composition of the liquid steel produced would contain 99,89% iron mass (Fe), 0,105% carbon (C), and 0% phosphorus (P) and sulfur (S), hence fulfilling the specifications of low steel carbon according to SNI 53:2019, where it's made up of minimal 99,85% Fe, and maximal of 0,25% C, and 0,05% of P and S. This plant is designed to operate for 24 hours per day and a total of 330 days per year, with production capacity of 1 million tons per year, operating age of 15 years, as well as constructions for 2 years. The plant would be in Cilacap, Central Java with the consideration of the availability of raw material utilities, ports, and markets.
The economic aspect of this project shows that initial investment would require Rp 28,08 trillion, with operating costs of Rp 8,19 trillion per year. It is designed to gain sales income of Rp 15,10 trillion per year. By assuming the project age for 15 years, the bank interest rate is 8% and the inflation rate is 2.3%. The results of the feasibility analysis show that this project has an Internal Rate of Return (IRR) of 12.00%, a Net Present Value (NPV) of IDR 3.75 trillion, a Pay Out Time of 8 years, and a Break Even
Point (BEP) of 39.59%. Besides being technically and financially feasible, the process is also environmentally excelled as it does not emit carbon dioxide emissions, only water vapor as the side product, hence supporting the target of net zero emission and the national decarbonization policy. By considering all the technical, economic, and environmental aspects of this project, the project is deemed
worthy to be realized and has the potential to make major contributions to 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 > TP Chemical technology > TP155.5 Chemical plants--Design and construction
Divisions:	Faculty of Industrial Technology > Chemical Engineering > 24201-(S1) Undergraduate Thesis
Depositing User:	Evantara Aldhi Bagaswira
Date Deposited:	28 Jul 2026 07:04
Last Modified:	28 Jul 2026 07:04
URI:	http://repository.its.ac.id/id/eprint/138637

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