Pra Rancangan Pabrik Pembuatan Precipitated Calcium Carbonate (PCC) dari Limbah Marmer dengan Kapasitas 50.000 Ton/Tahun dan Tugas Khusus Rancangan Keteknikan Detail Rotary Kiln

Abstract

Pre-Design of Precipitated Calcium Carbonate (PCC) Manufacturing Plant from Marble Waste using the Caustic Soda (Lime-Soda) Process has 50.000 tons/year of plant capacity and it operates for 330 days in a year. The main process in this pre-design plant consists of four stages, first is the raw material pre-treatment, then the nitration reaction, the lime-soda reaction, and the last is product purification stage. A by-product purification process is also carried out which consists of four stages, they are the evaporation, crystallization, separation and product drying stage. In both reaction, which is nitration and lime-soda reaction, will be used continious stirred tank reactors that operates at temperature 30°C and pressure 1 atm for an hour of each reaction. The total amount of marble waste required to reach annual production capacity of plant is 8.887,7746 kg/hour. The spesific task completed is to detail the engineering design of rotary kiln. The kiln that has been designed has the following spesifications: • Inner diameter (ID) = 2,4446 m • Outer diameter (OD) = 3,2 m • Length = 65,4279 m • Power = 74 hp • Thickness = 5/9 in • Material of construction = Carbon Steel SA-299, refractory brick inside roll • Number of flights = 20 flights per circle • Gear diameter = 132 in • Pinion diameter = 1,2943 m • Number of piers = 4 • Number of roller supports = 8 (each pier has 2 roller support) • Number of axis = 8 (each roller has an axis) The PCC manufacturing plant from marble waste using caustic soda process is planned to be established in Besuki subdistrict, Tulungagung, East Java with land areal required about 25.695 m2. The water needs of plant are supplied from Brantas River about 27.531,6135 kg/hour. The form of business entity is a Limited Liability Company (LLC) and the form of organization is ‘line and staff’ with number of employees is 200 people. The results of economic analysis of this pra-design of PCC manufacturing plant from marble waste are as follows: • Sales revenue = Rp 2.853.733.337.475 • Net profit = Rp 692.939.539.206 • Profit Margin (PM) = 30,34% • Break Even Point (BEP) = 27,76% • Return on Investment (ROI) = 27,92% • Pay Out Time (POT) = 3,58 Years • Return on Network (RON) = 55,84% • Internal Rate of Return (IRR) = 17,04% Based on the results of plant economic analysis, can be concluded that the Precipitated Calcium Carbonate (PCC) manufacturing plant from marble waste using caustic soda process is worth establishing