Pra Rancangan Pabrik Pembuatan Smelter Grade Alumina dari Bauksit Menggunakan Proses Bayer Lime-Sintering dengan Kapasitas 700.000 Ton/Tahun dan Tugas Khusus Rancangan Keteknikan Rotary Kiln

Abstract

Alumina is the raw material for aluminum production, 90% of alumina worldwide is used in aluminum production and the remainder is used in the pharmaceutical industry. In the manufacture of aluminum, bauxite must first be furified into smelter grade alumina. Smelter grade alumina is the most stable type of alumina because it is alumina that has gone through the calcination stage with temperature above 1.000 oC.Prelimanary design of smelter grade alumina plant from bauxite is prepared using the Bayer Lime-Sintering process with a capacity of 700.000 tons/year which operates for 330 days a year. The sintering process is carried out to reduce the silica content in the product by adding calcium carbonate (CaCO3) at the red mud waste treatment stage. The plant location is planned to be built in Kijang District, Bintan Regency, Kepulauan Riau Province with a water source from the Pulai River and a land area of 47.320 m2. This plant is planned in the form of a limited liability company using a line and staff organizational structure. The number of workers needed to operationing this plant is 127 people. The results of economic analysis from this smelter grade alumina plant are as follows:  Capital Investment = IDR 9.788.771.198.689,79  Production Cost = IDR 1.475.248.573.743,90  Total Sales = IDR 3.526.476.399.319,50  Net Profit = IDR 1.647.440.851.019,69  Profit Margin = 56,42%  Break Even Point = 21,22%  Return on Investment = 14,23%  Pay Out Time = 7 years and 1 month  Return on Network = 23,71%  Internal Rate of Return = 15,92% From the results of economic analysis, it was found that “Manufactured Plant of Smelter Grade Alumina” is feasible to established.