Desain Pabrik Garam Industri Dari Rejected Brine Pltu Suralaya Dengan Teknologi Mechanical Vapor Recompression (mvr) Dengan Kapasitas 35.167 Ton/tahun

Sucipto, Syefi Salima and Siringo-Ringo, Stevany Vionalia (2026) Desain Pabrik Garam Industri Dari Rejected Brine Pltu Suralaya Dengan Teknologi Mechanical Vapor Recompression (mvr) Dengan Kapasitas 35.167 Ton/tahun. Other thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

Perancangan pabrik garam industri dilakukan dengan memanfaatkan rejected brine dari PLTU Suralaya sebagai bahan baku utama, dengan kapasitas produksi 35.167 ton/tahun. Rejected brine dipilih karena memiliki salinitas tinggi, yaitu sekitar 1,5 – 2 kali salinitas air laut, serta tersedia secara berlimpah dan berkelanjutan sebagai hasil samping proses desalinasi air laut pada PLTU. Proses produksi diawali dengan pemurnian brine menggunakan Na₂CO₃, NaOH, dan BaCl₂ untuk menghilangkan ion Ca²⁺, Mg²⁺, dan SO₄²⁻, kemudian dilanjutkan dengan netralisasi menggunakan HCl. Brine hasil pemurnian selanjutnya dievaporasi menggunakan sistem Multiple-Effect Evaporation–Steam Vapor Recompression (MEE-SVR), dengan uap hasil evaporasi dikompresi dan dimanfaatkan kembali sebagai sumber panas untuk meningkatkan efisiensi energi. Proses dilanjutkan dengan kristalisasi dan sentrifugasi untuk memisahkan kristal garam, kemudian pengeringan menggunakan udara panas dan dingin, serta size reduction dan screening untuk memperoleh ukuran produk yang seragam. Tugas akhir desain pabrik ini bertujuan merancang pabrik garam industri berkapasitas 35.167 ton/tahun yang mencakup pemilihan proses, penyusunan Process Flow Diagram (PFD), perhitungan neraca massa dan energi, analisis Hazard and Operability Study (HAZOP) dan Piping and Instrumentation Diagram (P&ID), estimasi biaya, serta analisis kelayakan ekonomi dan dampak lingkungan. Hasil perancangan menunjukkan bahwa produk garam industri memenuhi spesifikasi SNI 0303:2012 dengan kadar NaCl ≥96%. Estimasi biaya menunjukkan Capital Expenditure (CAPEX) sebesar Rp95.476.469.502 dan Operating Expenditure (OPEX) sebesar Rp108.762.089.474 per tahun. Analisis ekonomi menghasilkan Net Present Value (NPV) sebesar Rp48.999.750.910, Internal Rate of Return (IRR) sebesar 17,12% yang melebihi Weighted Average Cost of Capital (WACC) sebesar 7,74%, Pay Out Time (POT) selama 5 tahun 2 bulan, serta Break Even Point (BEP) sebesar 15,14% dari kapasitas produksi. Analisis sensitivitas menunjukkan bahwa nilai IRR lebih sensitif terhadap penurunan harga jual dibandingkan terhadap kenaikan Fixed Capital Investment (FCI). Berdasarkan hasil analisis teknis, ekonomi, dan lingkungan, pabrik garam industri dari rejected brine PLTU Suralaya dinyatakan layak untuk didirikan.
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An industrial salt plant was designed using rejected brine from the Suralaya Power Plant desalination unit as the primary feedstock, with a production capacity of 35,167 tons/year. Rejected brine was selected due to its high salinity, approximately 1.6–2 times that of seawater, and its abundant and sustainable availability as a by-product of the seawater desalination process. The production process begins with brine purification using Na₂CO₃, NaOH, and BaCl₂ to remove Ca²⁺, Mg²⁺, and SO₄²⁻ ions, followed by neutralization with HCl. The purified brine is subsequently concentrated using a Multiple-Effect Evaporation–Steam Vapor Recompression (MEE-SVR) system, in which the generated vapor is compressed and reused as the heating medium to improve energy efficiency. The process is continued by crystallization and centrifugation to separate salt crystals, followed by drying using hot and cold air, and size reduction and screening to obtain a uniform product size. This Final Project aims to design an industrial salt plant with a production capacity of 35,167 tons/year, including process selection, development of the Process Flow Diagram (PFD), mass and energy balance calculations, Hazard and Operability Study (HAZOP) and Piping and Instrumentation Diagram (P&ID) analyses, cost estimation, and economic feasibility and environmental impact assessments. The design results indicate that the industrial salt product meets the requirements of SNI 0303:2012 with a NaCl content of at least 96%. The estimated Capital Expenditure (CAPEX) is Rp95,476,469,502, while the annual Operating Expenditure (OPEX) is Rp108,762,089,474. The economic evaluation yields a positive Net Present Value (NPV) of Rp48,999,750,910, an Internal Rate of Return (IRR) of 17.12%, exceeding the Weighted Average Cost of Capital (WACC) of 7.74%, a Pay Out Time (POT) of 5 years and 2 months, and a Break Even Point (BEP) of 15.14% of production capacity. Sensitivity analysis indicates that the IRR is more sensitive to a decrease in the selling price than to an increase in the Fixed Capital Investment (FCI). Based on the technical, economic, and environmental evaluations, the proposed industrial salt plant utilizing rejected brine from the Suralaya CFPP is considered feasible for implementation.

Item Type:	Thesis (Other)
Uncontrolled Keywords:	Industrial Salt, Rejected Brine, MEE-SVR, Suralaya Power Plant, Garam Industri, Rejected Brine, MEE-SVR, PLTU Suralaya
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:	Syefi Salima Sucipto
Date Deposited:	29 Jul 2026 03:09
Last Modified:	29 Jul 2026 03:09
URI:	http://repository.its.ac.id/id/eprint/139398

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