W, Muhammad Revansyah Ramadhani (2026) Pra Rancangan Pabrik Kalsium Fluorida Dari Asam Fluosilikat Dengan Proses Presipitasi Kapasitas 50.000 Ton/Tahun. Undergraduate thesis, UPN Veteran Jawa Timur.
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Abstract
Calcium fluoride is an inorganic compound that plays an important role in various industrial sectors, including the chemical, metallurgical, glass, ceramic, and aluminum industries. It is widely used as a raw material for hydrogen fluoride (HF) production, a flux in metal smelting processes, and an additive in glass manufacturing. The increasing growth of industrial activities in Indonesia has led to a continuous rise in the demand for calcium fluoride. However, the domestic demand is still fulfilled through imports, making the establishment of a domestic production facility necessary. Therefore, a calcium fluoride plant utilizing fluosilicic acid through a precipitation process is proposed as an alternative to satisfy national demand while reducing import dependence. The plant is designed to commence operation in 2030 with a production capacity of 50,000 tons/year and will be located in the Java Integrated Industrial and Ports Estate (JIIPE), Gresik, East Java, employing 218 workers. The production process uses fluosilicic acid (H₂SiF₆), calcium carbonate (CaCO₃), and ammonia (NH₃) as the main raw materials. A 23 wt% H₂SiF₆ solution is first heated to 85°C, while liquid ammonia is depressurized from 11.6 atm to 1 atm, causing partial vaporization before entering a Continuous Stirred-Tank Reactor (CSTR). In the reactor, H₂SiF₆ reacts with NH₃ at a molar ratio of 1:7.2 under operating conditions of 85°C, 1 atm, and pH 7, producing ammonium fluoride (NH₄F) dissolved in water and precipitated silica (SiO₂) with a conversion of 81.69%. The resulting slurry is separated using a Rotary Drum Vacuum Filter, where the silica solids are dried in a rotary dryer at 110°C and subsequently ground in a ball mill to obtain a product purity of 99.8% with a particle size of 100 mesh. The NH₄F filtrate is then cooled to 45°C and reacted with a calcium carbonate slurry in a CSTR precipitation reactor at an NH₄F-to-CaCO₃ weight ratio of 1:1.37 under operating conditions of 45°C, 1 atm, and pH 11.5, achieving a conversion of 96.70%. The resulting calcium fluoride (CaF₂) is separated using a Rotary Drum Vacuum Filter, washed, dried in a rotary dryer at 110°C, and ground in a ball mill to produce calcium fluoride with a purity of 93.48% and a particle size of 100 mesh. Economic evaluation indicates that the proposed plant is financially feasible with a Fixed Capital Investment (FCI) of IDR 1,192,522,555,939, a Working Capital Investment (WCI) of IDR 210,289,495,961, a Total Capital Investment (TCI) of IDR 1,402,812,051,900, an annual raw material cost of IDR 1,501,271,701,556, an annual utility cost of IDR 435,839,132,050, annual sales revenue of IDR 2,995,350,114,692, a bank loan interest rate of 8%, a Rate of Investment (ROI) of 27.85% before tax and 20.89% after tax, a Payback Period (PBP) of 4 years and 2 months, an Internal Rate of Return (IRR) of 17.307%, and a Break-Even Point (BEP) of 31.70%.
| Item Type: | Thesis (Undergraduate) | ||||||||||||
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| Subjects: | T Technology > TP Chemical technology > TP155 Chemical engineering | ||||||||||||
| Divisions: | Faculty of Economic and Business > Department of Entrepreneurship | ||||||||||||
| Depositing User: | Muhammad Revansyah Ramadhani W | ||||||||||||
| Date Deposited: | 22 Jul 2026 07:38 | ||||||||||||
| Last Modified: | 22 Jul 2026 08:25 | ||||||||||||
| URI: | https://repository.upnjatim.ac.id/id/eprint/57040 |
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