Sasono, Sella Ramadhani Alya and Firdaus, Ghaly Muhammad Bahreisy (2021) Pra Desain Pabrik Alumina Dari Bauksit Dengan Proses Bayer. Undergraduate thesis, Institut Teknologi Sepuluh Nopember.
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Abstract
Alumina merupakan produk yang memiliki nilai manfaat tinggi khususnya di industri Aluminium (Smelter Grade Alumina) dan juga sebagai pendukung komponen pendukung elektronik (Chemical Grade Alumina). Ditambahnya permintaan dari industry pengguna akhir (Minyak & Gas, Pengolahan Air, Plastik, dan lainnya), dan pasar global (Asia-Pasifik, Amerika, Eropa) mengakibatkan pertumbuhan untuk pasar Alumina. Berkaca kebutuhan di Indonesia, data ekspor-impor Alumina megalami peningkatan khususnya di bagian ekspor dari tahun 2016-2020, dan untuk bagian impor di Indonesia mengalami penurunan di tahun 2016-2020, hal ini merupakan dampak secara tidak langsung dari penerapan Undang-Undang No. 4 Tahun 2009 tentang Peningkatan nilai tambah sumber daya mineral dan/atau batu bara dengan wajib melakukan pengolahan dan pemurnian hasil penambangan di dalam negeri. Pada tahun 2019, produksi alumina di Indonesia sebesar 1,1 juta ton dimana alumina diekspor sebesar 1,08 juta ton dan alumina yang digunakan untuk pemenuhan kebutuhan dalam negeri sebesar 46 ribu ton. Diharapkan dengan didukungnya pabrik smelter alumina, maka total produksi alumina di Indonesia bertambah serta dapat mengurangi ketergantungan impor untuk sumber bahan baku produksi seperti (Smelter Grade Alumina) dan (Chemical Grade Alumina). Pabrik Smelter Alumina yang didirikan menggunakan proses Bayer (Proses Basa) dengan pertimbangan kebutuhan bahan baku utama yaitu bauksit dan juga konsumsi energi yang lebih ekonomis apabila dibandingkan dengan proses asam. Proses Bayer terbagi menjadi empat bagian proses utama, yaitu:
1. Digestion, merupakan proses pelarutan bauksit dengan natrium hidroksida membentuk natrium aluminat yang bertujuan untuk memisahkan kandungan gibbsite (Al2O3.H2O) dengan pengotor agar dapat terhidrasi menjadi alumina.
2. Klarifikasi, tahap penanganan red mud yang terdiri dari pengendapan, pencucian dan filtrasi.
3. Presipitasi, proses kritalisasi aluminium hidroksida (Al(OH)3) dengan melakukan proses pengendapan.
4. Kalsinasi, produk hidrat yang terbentuk dipanaskan
dengan suhu tinggi sehingga air kristal yang terkandung
dalam padatan akan hilang dan menghasilkan alumina.
Rencana pendirian pabrik ini akan dilakukan selama 3 tahun
dengan umur pabrik selama 25 tahun, dengan kapasitas yang sudah ditentukan yaitu 350.000 ton/tahun. Untuk memproduksi 350.000 ton/tahun, diperlukan operating expenditures (OPEX) sebesar Rp. 4,857,215,993,368.9 dengan capital expenditures (CAPEX) sebesar Rp. 1,883,118,806,777.0. Sumber dana investasi berasal dari modal sendiri sebesar 40% dan modal pinjaman 60%. Berdasarkan analisa ekonomi, Internal Rate of Return (IRR) pabrik ini sebesar 24,71% dengan bunga sebesar 7,95% per tahun dan laju inflasi 1,33%. Sedangkan untuk Pay Out Time (POT) selama 8 tahun 6 bulan. Dan Net Present Value (NPV) sebesar Rp 3,957,382,508,575.7. Dengan melihat aspek penilaian analisis ekonomi tersebut, maka dapat dikatakan Pabrik Alumina dari Bauksit dengan Proses Bayer ini layak untuk didirikan.
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Alumina is a product that has a high benefit value, especially in the Aluminum industry (Smelter Grade Alumina) and also as a support for electronic supporting components (Chemical Grade Alumina). Added demand from end-user industries (Oil & Gas, Water Treatment, Plastics, and others), and global markets (Asia-Pacific, Americas, Europe) resulted in growth for the Alumina market. Reflecting the needs in Indonesia, the export-import data of Alumina has increased, especially in the export sector from 2016-2020, and for the import part in Indonesia, it has decreased in 2016-2020, this is an indirect impact of the implementation of Law no. 4 of 2009 concerning Increasing the added value of mineral and/or coal resources with the obligation to carry out processing and refining of mining products in the country. In 2019, alumina production in Indonesia was 1.1 million tons, of which 1.08 million tons of alumina was exported and 46 thousand tons of alumina used to meet domestic needs. It is hoped that with the support of the alumina smelter plant, the total alumina production in Indonesia will increase and reduce dependence on imports for production raw material sources such as (Smelter Grade Alumina) and (Chemical Grade Alumina). The Alumina Smelter Plant which was established uses the Bayer process (Base Process) with consideration of the need for the main raw material, namely bauxite and also energy consumption which is more economical when compared to the acid process. The Bayer process is divided into four main processes, namely:
1. Digestion, is the process of dissolving bauxite with sodium hydroxide to form sodium aluminate which aims to separate the content of gibbsite (Al2O3.H2O) from impurities so that it can be hydrated into alumina.
2. Clarification, the stage of handling red mud which consists of deposition, washing and filtration.
3. Precipitation, the process of crystallizing aluminum hydroxide (Al(OH)3) by performing a precipitation process.
4. Calcination, the hydrate product formed is heated at high temperature so that the crystal water contained in the solid will be lost and produce alumina.
The plan to establish this factory will be carried out for 3 years with a factory life of 25 years, with a predetermined capacity of 350,000 tons/year. To produce 350,000 tons/year, operating expenditures (OPEX) of Rp. 4,857,215,993,368.9 with capital expenditures (CAPEX) of Rp. 1,883,118,806,777.0. Sources of investment funds come from own capital of 40% and 60% of loan capital. Based on economic analysis, this factory's Internal Rate of Return (IRR) is 24.71% with an interest rate of 7.95% per year and an inflation rate of 1.33%. As for the Pay Out Time (POT) for 8 years 6 months. And the Net Present Value (NPV) is Rp. 3,957,382,508,575.7. By looking at the assessment aspect of the economic analysis, it can be said that the Alumina Plant from Bauxite with the Bayer Process is feasible to be established.
| Item Type: | Thesis (Undergraduate) |
|---|---|
| Uncontrolled Keywords: | Alumina, Digestion, Clarification, Precipitation, Calcination, Alumina, Digesti, Klarifikasi, Presipitasi, Kalsinasi |
| Subjects: | T Technology > TP Chemical technology > TP155.5 Chemical plants--Design and construction |
| Divisions: | Faculty of Industrial Technology and Systems Engineering (INDSYS) > Chemical Engineering > 24201-(S1) Undergraduate Thesis |
| Depositing User: | Ghaly Muhammad Bahreisy Firdaus |
| Date Deposited: | 24 Aug 2021 12:39 |
| Last Modified: | 24 Aug 2021 12:39 |
| URI: | http://repository.its.ac.id/id/eprint/89180 |
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