Electronic Theses and Dissertation

Prarancangan pabrik Prarancangan Pabrik Portland Composite Cement
(PCC) Ramah Lingkungan dengan Pemanfaatan Fly Ash Sebagai Substitusi
Klinker Kapasitas 1.000.000 Ton/Tahun dan beroperasi 330 hari/tahun. Pabrik
berlokasi di Kecamatan Muara Jawa, Kabupaten Kutai Kartanegara, Provinsi
Kalimantan Timur dengan luas lahan 25.868m². Bentuk badan usaha yang dipilih
adalah Perseroan Terbatas (PT) dengan struktur organisasi garis dan staf serta
kebutuhan tenaga kerja sebanyak 224 orang.
Produk utama yang dihasilkan adalah Portland Composite Cement (PCC)
sebesar 1.000.000 ton/tahun. Kebutuhan air dari sumber air permukaan yaitu
Sungai Mahakam yang berada di Kalimantan Timur.sebesar 10.045,65 kg/jam,
sedangkan kebutuhan listrik sebesar 5.356,05 kW dipasok dari PLN dengan
generator sebagai cadangan. Kebutuhan bahan bakar solar untuk generator sebesar
603,65 L/jam. Hasil analisa ekonomi yang diperoleh adalah sebagai berikut:
1. Fixed Capital Investment = Rp 681.614.698.601,02
2. Working Capital Investment = Rp 75.734.966.511,22
3. Total Capital Investment = Rp 757.349.665.112,24.
4. Total Biaya Produksi = Rp 1.165.763.667.697,26 /tahun
5. Hasil Penjualan = Rp 1.556.105.801.703,48/tahun
6. Laba Bersih = Rp 273.239.493.804,35/tahun
7. Pay Out Time (POT) = 2,6 tahun
8. Internal Rate of Return (IRR) = 36,08%
9. Break-even Point (BEP) = 30,18%
Berdasarkan studi kelayakan teknis dan ekonomis yang telah dilakukan,
dapat disimpulkan bahwa prarancangan pabrik semen layak untuk dilanjutkan ke tahap
perancangan dan pembangunan pabrik. Selain itu, pabrik ini diharapkan dapat
memenuhi kebutuhan semen dalam negeri.

The preliminary design of an environmentally friendly Portland Composite Cement (PCC) plant utilizing fly ash as a clinker substitute is proposed with a production capacity of 1,000,000 tons/year operating for 330 days/year. The plant is to be located Kutai Kartanegara Regency, East Kalimantan Province, Indonesia, covering an area of 25,868 m². The selected business entity is a Limited Liability Company (Perseroan Terbatas/PT) with a line-and-staff organizational structure and a total workforce of 224 employees. The main product is Portland Composite Cement (PCC) with an annual production capacity of 1,000,000 tons/year. Process water requirement, amounting to 10,045.65 kg/h, is supplied from the Mahakam River in East Kalimantan. The total electrical power demand is 5,356.05 kW, which is supplied by the state electricity company (PLN) with an on-site generator as backup. Diesel fuel consumption for the generator is estimated at 603.65 L/h.The economic evaluation yielded the following key indicators: 1. Fixed Capital Investment (FCI) = IDR 681,614,698,601.02 2. Working Capital Investment (WCI) = IDR 75,734,966,511.22 3. Total Capital Investment (TCI) = IDR 757,349,665,112.24 4. Total Production Cost (TPC) = IDR 1,165,763,667,697.26/year 5. Annual Sales Revenue = IDR 1,556,105,801,703.48/year 6. Net Profit = IDR 273,239,493,804.35/year 7. Pay Out Time (POT) = 2.6 years 8. Internal Rate of Return (IRR) = 36.08% 9. Break-Even Point (BEP) = 30.18% Based on the technical and economic feasibility studies conducted, the preliminary design of the environmentally friendly Portland Composite Cement (PCC) plant utilizing fly ash as a clinker substitute is considered feasible for further engineering and construction development. In addition, the plant is expected to meet domestic demand for Portland Composite Cement while reducing clinker consumption and promoting the utilization of industrial waste in Indonesia.