Electronic Theses and Dissertation

Industri semen merupakan salah satu sektor strategis yang menopang pertumbuhan pembangunan infrastruktur dan konstruksi nasional, khususnya di provinsi aceh yang memiliki potensi bahan baku batu kapur, tanah liat, dan pasir besi yang melimpah namun belum dimanfaatkan secara optimal. berdasarkan hal tersebut, dirancang sebuah pabrik portland composite cement (pcc) dengan kapasitas produksi 1.500.000 ton/tahun yang berlokasi di desa menasah bak u, kecamatan leupung, kabupaten aceh besar, provinsi aceh. penentuan kapasitas dilakukan berdasarkan analisis pertumbuhan industri semen nasional dengan metode compound annual growth rate (cagr) sebesar 2,35% per tahun serta penetapan target pangsa pasar sebesar 1,5% terhadap proyeksi kebutuhan semen pcc nasional pada tahun 2030. proses produksi yang dipilih adalah proses kering (dry process) dengan sistem suspension preheater–precalciner, yang dipilih berdasarkan penilaian kriteria terbobot karena unggul dari segi efisiensi energi (kebutuhan panas ±800 kkal/kg klinker), kapasitas produksi, serta dampak lingkungan dibandingkan proses basah. pabrik direncanakan dioperasikan oleh 249 orang karyawan dengan struktur organisasi berbentuk garis dan staf (line and staff). kebutuhan air pabrik seluruhnya dialokasikan untuk keperluan sanitasi karyawan, dengan pasokan listrik utama dari pln yang didukung oleh generator diesel cadangan berkapasitas 2.000 kw, serta bahan bakar batu bara untuk kebutuhan pembakaran rotary kiln. hasil analisis kelayakan ekonomi menunjukkan bahwa pabrik ini membutuhkan total capital investment (tci) sebesar rp1.240.498.517.074 dan total production cost (tpc) sebesar rp1.210.766.764.643 per tahun pada kapasitas produksi penuh, dengan hasil penjualan (sc) sebesar rp1.680.000.000.000 per tahun. evaluasi kelayakan investasi menghasilkan rate of return (ror) setelah pajak sebesar 26,48%, internal rate of return (irr) sebesar 25,61%, break even point (bep) sebesar 32,67% dari kapasitas produksi, serta payback period (pot) berkisar antara 2,68 hingga 4,19 tahun. berdasarkan seluruh indikator teknis dan ekonomi tersebut, pabrik portland composite cement berkapasitas 1.500.000 ton/tahun di leupung, aceh besar ini dinyatakan layak (feasible) untuk didirikan. kata kunci: portland composite cement, proses kering, suspension preheater- precalciner, prarancangan pabrik, kelayakan ekonomi, leupung aceh

The cement industry is a strategic sector supporting the growth of national infrastructure and construction development, particularly in Aceh Province, which possesses abundant limestone, clay, and iron sand reserves that have not yet been optimally utilized. Based on this potential, a Portland Composite Cement (PCC) plant with a production capacity of 1,500,000 tons/year was designed, to be located in Menasah Bak U Village, Leupung District, Aceh Besar Regency, Aceh Province. The production capacity was determined based on an analysis of national cement industry growth using the Compound Annual Growth Rate (CAGR) method of 2.35% per year, along with a target market share of 1.5% of the projected national PCC cement demand for 2030. The selected production process is the dry process with a Suspension Preheater–Precalciner system, chosen based on a weighted criteria assessment for its superior energy efficiency (heat requirement of ±800 kcal/kg clinker), production capacity, and environmental impact compared to the wet process. The plant is planned to be operated by 249 employees under a lineand-staff organizational structure. Water requirements are entirely allocated for employee sanitation purposes, with the main electricity supply from PLN backed by a 2,000 kW diesel generator, and coal as fuel for the rotary kiln combustion process. The economic feasibility analysis shows that the plant requires a Total Capital Investment (TCI) of Rp1,240,498,517,074 and a Total Production Cost (TPC) of Rp1,210,766,764,643 per year at full production capacity, with an annual (SC) of Rp1,680,000,000,000. The investment feasibility evaluation yields an after-tax Rate of Return (ROR) of 26.48%, an Internal Rate of Return (IRR) of 25.61%, a Break Even Point (BEP) of 32.67% of production capacity, and a Payback Period (POT) ranging from 2.68 to 4.19 years. Based on all technical and economic indicators, the 1,500,000 tons/year Portland Composite Cement plant in Leupung, Aceh Besar is declared feasible to be established. Keywords: Portland Composite Cement, dry process, Suspension PreheaterPrecalciner, plant pre-design, economic feasibility, Leupung Aceh