Prarancangan Pabrik Pembuatan Calcined Clay dari Tanah Liat Kaolinit Menggunakan Flash Calciner dengan Kapasitas Produksi 1.200.000 Ton/Tahun

Abstract

Calcined clay is a partial clinker replacement material produced from the kaolinite clay calcination process to reduce CO2 emissions in the cement production process. This calcined clay plant proposal has a production capacity of 1.200.000 tons/year and operates for 330 days a year. The main process in this plant consists of three stages, namely the grinding and drying of raw materials, the dehydroxylation reaction and cooling stage, and the storage stage. In the dehydroxylation stage, a flash calciner unit operating at 450-800 °C for 30 minutes is used. The amount of kaolinite clay required to achieve the annual production capacity is 200.390,7897 kg/hour. The calcined clay manufacturing plant is planned to be established in Banjar Regency, South Kalimantan, with a total plant area of 15.000 m2. The water requirement of the plant is supplied from Rangas River as much as 2,382.9941 kg/hour. The planned form of company organization is a Limited Liability Company (PT) with a line and staff organizational structure, and a total of 160 employees. The investment capital for the establishment and operation of the plant is Rp1.846.085.146.713 and the production cost is Rp483.056.341.584. The results of the economic analysis of this factory design have a profit margin (PM) of 30,18%; Break Even Point (BEP) of 54,67%; Return on Investment (ROI) of 8,11%; Pay Out Time (POT) for 13 years; Return on Network (RON) of 25,14%; and Internal Rate of Return (IRR) of 25,97%. Based on the results of economic analysis, it can be concluded that the calcined clay manufacturing plant from kaolinite clay using flash calciner is feasible to be established.