Pra Rancangan Pabrik Calcium Nitrate Dari Batu Kapur dan Asam Nitrat Dengan Proses Kristalisasi Kapasitas 60.000 Ton/Tahun

Ningrum, Dyah Ayu Nyata (2026) Pra Rancangan Pabrik Calcium Nitrate Dari Batu Kapur dan Asam Nitrat Dengan Proses Kristalisasi Kapasitas 60.000 Ton/Tahun. Undergraduate thesis, UPN Veteran Jawa Timur.

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Abstract

A calcium nitrate plant utilizing a crystallization process based on calcium carbonate and nitric acid is to be established in the Jenu District, Tuban Regency, East Java, Indonesia. The primary raw materials are calcium carbonate (CaCO3) and nitric acid (HNO3). The production process comprises three stages. The first stage is raw material pre-treatment, during which the nitric acid is diluted to a concentration of 58%. The second stage is the core reaction phase, where calcium carbonate and nitric acid react to form calcium nitrate, water, and carbon dioxide (CO2) gas. The carbon dioxide gas is immediately separated into a storage tank for subsequent sale to third parties; the reaction proceeds with a 90% conversion rate. The third stage is purification, where the calcium nitrate solution is concentrated using an evaporator; product crystals are subsequently formed in a crystallizer and separated from the mother liquor via a centrifuge. The centrifuge output is dried in a rotary dryer and cooled on a cooling conveyor to stabilize the product temperature. Once the temperature is stabilized, the product undergoes size standardization in a ball mill. Finally, the calcium nitrate is packaged using a rotary packing system and stored in the calcium nitrate (Ca(NO3)2) product warehouse. Electricity for the plant is supplied by PLN and generator sets (sourced from PT PLN Nusantara Power – Tanjung Awar-awar Generation Unit). Water is obtained from the nearest rivers: the Kerek River and the Bengawan Solo River. The plant operates under a Limited Liability Company (PT) structure, utilizing a line-and-staff organizational model. The plant is designed for continuous operation, with a production schedule of 330 days per year. Based on the calculations and analysis performed, the following conclusions can be drawn: 1. Production Capacity : 60,000 tons/year 2. Company Structure : Limited Liability Company (PT) 3. Organizational System : Line and Staff 4. Plant Location : Industrial Estate, Jenu District, Tuban Regency, East Java, Indonesia 5. Land Area : 21,333 m² 6. Operating System : Continuous 7. Operating Schedule : 330 days/year, 24 hours/day 8. Number of Employees : 178 people 9. Raw Materials : a. Calcium Carbonate (CaCO3) : 5,804.5259 kg/hour b. Nitric Acid (HNO₃) : 16,374.2692 kg/hour c. Ammonia (NH3) : 792.7488 kg/hour 10. Products : a. Calcium Nitrate (Ca(NO3)2) : 7,757.7576 kg/hour b. Carbon Dioxide (CO2) : 2,048.7352 kg/hour 11. Utility Requirements : a. Electricity : 30,509.6771 kWh/day b. Water : 27,607.7049 m³/day c. Fuel : 3,017.4645 liters/year 12. Economic Analysis : a. Construction Period : 3 years b. Fixed Capital Investment (FCI) : Rp 663,083,093,688 c. Working Capital Investment (WCI) : Rp 303,549,208,968.91 d. Total Capital Investment (TCI) : Rp 966,632,302,657 e. Annual Raw Material Cost : Rp 423,267,388,494 f. Annual Utility Cost : Rp 36,105,704,303 g. Total Production Cost (TPC) : Rp 1,214,196,835,875.64 h. Sales Revenue : Rp 1,485,233,391,527.42 i. Bank Interest : 8% j. Return on Investment Before Tax : 33.23% k. Return on Investment After Tax : 24.93% l. Internal Rate of Return (IRR) : 19.05% m. Payback Period (PBP) : 3 years 5 months n. Break-Even Point (BEP) : 31.09%

Item Type: Thesis (Undergraduate)
Contributors:
ContributionContributorsNIDN/NIDKEmail
Thesis advisorEdahwati, LulukNIDN0011039403luluk.tm@upnjatim.ac.id
Thesis advisorPuspitawati, Ika NawangNIDN0025028806ika_nawang.tk@upnjatim.ac.id
Subjects: T Technology > TP Chemical technology > TP155 Chemical engineering
Divisions: Faculty of Engineering > Departement of Chemical Engineering
Depositing User: DYAH AYU DYAH Dyah
Date Deposited: 13 Oct 2026 02:29
Last Modified: 13 Oct 2026 02:29
URI: https://repository.upnjatim.ac.id/id/eprint/60592

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