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 (Sales Cost) 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.

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 Sales Cost 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.