Kata pengantar dan daftar isi (2)
LAPORAN KERJA PRAKTEK
PT. INDOCEMENT TUNGGAL PRAKARSA, Tbk. Plant 7-8
KATA PENGANTAR
Puji syukur kepada Allah SWT, atas berkat rahmat dan hidayah-Nya
sehingga kami dapat menyelesaikan laporan kerja praktek yang berjudul “Analisa
Perhitungan Neraca Massa dan Neraca Panas pada Unit Raw Mill di Plant 8”
dengan baik. Laporan ini ditujukkan untuk memenuhi salah satu syarat kelulusan
jurusan Teknik Kimia program studi S1 di Sekolah Tinggi Teknologi Indocement.
Selain
itu
pelaksanaan
praktik
kerja
lapangan
menjadi
sarana
untuk
mengaplikasikan ilmu pengetahuan yang didapatkan di Sekolah Tinggi Teknologi
Indocement. Penulis mengucapkan terima kasih kepada semua pihak yang telah
membantu selama proses pelaksanaan praktik kerja lapangan dan pengerjaan
laporan praktik kerja lapangan ini, diantaranya kepada:
1.
Kepada Allah Swt, atas rahmat dan karunia-Nya sehingga penulis dapat
2.
menyelesaikan laporan ini,
Kedua orang tua dan keluarga yang penulis cintai, yang selalu memberi
motivasi dan mendoakan kelancaran serta kesuksesan pelaksanaan praktik
3.
kerja lapangan,
PT Indocement Tunggal Prakarsa Tbk. Citeureup - Bogor yang telah
4.
mengijinkan kami untuk melaksanakan PKL disana,
Bapak Dedi A. Dasuki di bagian CPDD (Corporate People Dev. Department)
yang telah membantu mengurus perizinan berlangsungnya kerja praktek di
5.
PT. Indocement Tunggal Prakarsa, Tbk.,
Bapak Nurcholis selaku pembimbing lapangan selama PKL di PT Indocement
Tunggal Prakarsa, Tbk Citeureup - Bogor yang telah mengarahkan,
6.
membimbing serta memberikan pengetahuan tentang industri semen,
Bapak Tommy, Bapak Sulistyo, Bapak Samsudin, Bapak Okta, Bapak Irman
serta seluruh staff P7-8. Terima kasih telah membantu, meluangkan waktu
7.
dan memberi informasi kepada penulis,
Bapak Hamzah dan Bapak H. Sanusi selaku foreman dan Bapak Eko selaku
patroller di Unit Raw Mill, yang telah membantu penulis dalam pengambilan
sampel di lapangan,
LAPORAN KERJA PRAKTEK
PT. INDOCEMENT TUNGGAL PRAKARSA, Tbk. Plant 7-8
8.
Rekan- rekan PKL yang turut serta berperan penting dalam pelaksanaan PKL,
juga teman-teman Prodi S1 Teknik Kimia Sekolah Tinggi Teknologi
Indocement 2012 yang senantiasa turut memberikan dukungan terhadap
penulis.
Mohon maaf penulis sampaikan bila ada salah kata dalam penulisan
laporan kerja praktek ini. Penulis sadar laporan ini masih memiliki banyak
kekurangan. Oleh karena itu, penulis harapkan pembaca dapat memberikan
masukan-masukan yang bersifat membangun untuk kesempurnaan laporan ini.
Harapan penulis, semoga laporan ini bisa bermanfaat, menjadi sumber informasi
dan menambah pengetahuan pembaca tentang proses produksi pembuatan semen.
Bogor, Maret 2016
Tim Penulis
DAFTAR ISI
LAPORAN KERJA PRAKTEK
PT. INDOCEMENT TUNGGAL PRAKARSA, Tbk. Plant 7-8
COVER..................................................................................................................i
LEMBAR PENGESAHAN...................................................................................ii
KATA PENGANTAR...........................................................................................iii
DAFTAR ISI..........................................................................................................v
DAFTAR TABEL..................................................................................................xi
DAFTAR GAMBAR............................................................................................xiii
BAB I
PENDAHULUAN
1.1 Latar Belakang...........................................................................................1
1.2 Tujuan Kerja Praktek.................................................................................2
1.3 Ruang Lingkup Laporan Kerja Praktek.....................................................2
1.4 Waktu dan Tempat Pelaksanaan Kerja Praktek.........................................2
BAB II
PROFIL PERUSAHAAN
2.1 Sejarah dan Perkembangan Pabrik............................................................3
2.1.1 Sejarah Pendirian PT. Indocement Tunggal Prakarsa, Tbk.............3
2.1.2 Perkembangan PT. Indocement Tunggal Prakarsa, Tbk..................5
2.1.3 Lokasi Pabrik...................................................................................8
2.2 Visi, Misi dan Moto Perusahaan..............................................................10
2.2.1 Visi Perseroan.................................................................................10
2.2.2 Misi Perseroan................................................................................10
2.2.3 Motto Perseroan.............................................................................10
2.3 Struktur Organisasi Perusahaan..............................................................11
2.4 Struktur Organisasi Plant 7-8.................................................................13
2.5 Sumber Daya Manusia............................................................................14
LAPORAN KERJA PRAKTEK
PT. INDOCEMENT TUNGGAL PRAKARSA, Tbk. Plant 7-8
2.5.1 Tenaga Kerja.................................................................................14
2.5.2 Waktu Kerja..................................................................................15
2.5.3 Fasilitas Karyawan........................................................................16
BAB III
PEMILIHAN PROSES
3.1 Jenis-jenis Proses.....................................................................................18
3.1.1 Proses Basah..................................................................................18
3.1.2 Proses Kering.................................................................................18
3.2 Perbandingan Proses................................................................................18
3.3 Pemilihan Proses......................................................................................19
3.3.1 Proses Basah..................................................................................19
3.3.2 Proses Kering.................................................................................19
BAB IV
BAHAN BAKU DAN HASIL PRODUKSI
4.1 Bahan Baku..............................................................................................20
4.1.1 Bahan Baku Utama........................................................................20
4.1.2 Bahan Baku Pendukung ................................................................24
4.1.3 Bahan Korektif...............................................................................27
4.2 Produk yang Dihasilkan............................................................................28
4.2.1 Semen Portland (Portland Cement)................................................28
4.2.2 Portland Composite Cement (PCC)...............................................30
4.2.3 White Cement (WC)........................................................................31
4.2.4 Oil Well Cement (OWC).................................................................32
4.2.5 White Mortar TR30..........................................................................33
BAB V
DESKRIPSI PROSES
LAPORAN KERJA PRAKTEK
PT. INDOCEMENT TUNGGAL PRAKARSA, Tbk. Plant 7-8
5.1 Konsep Proses............................................................................................34
5.1.1 Mekanisme Proses.........................................................................34
5.2 Deskripsi Proses........................................................................................35
5.2.1 Persiapan Bahan............................................................................36
5.2.1.1 Penambangan Batu Kapur.................................................38
5.2.1.2 Penambangan Sandyclay...................................................44
5.2.1.3 Penanganan Masalah Penambangan..................................47
5.2.1.4 Reklamasi..........................................................................48
5.2.2 Pengadaan Dust EAF, Pasir Silika, dan Gypsum.........................49
5.3 Unit Pengeringan dan Penggilingan Bahan Baku (Raw Mill Unit).........51
5.4 Suspension Pre-Heater.............................................................................55
5.5 Kiln...........................................................................................................60
5.6 Cooler.......................................................................................................63
5.7 Unit Penggilingan Akhir (Cement Mill Unit)...........................................65
5.8 Unit Pengantongan Semen (Packing Unit)...............................................68
5.9 Coal Mill...................................................................................................69
BAB VI
PERALATAN PROSES
6.1 Alat Utama.................................................................................................71
6.1.1 Raw Grinding Mill............................................................................71
6.1.2 Raw Meal Silo..................................................................................73
6.1.3 Coal Mill..........................................................................................74
6.1.4 Suspension Pre-heater......................................................................77
6.1.5 Rotary Kiln.......................................................................................78
6.1.6 Dust Collector...................................................................................79
6.1.7 Grate Cooler.....................................................................................82
6.1.8 Clinker Silo (Semi-prefabricated steel material)..............................83
6.1.9 Finish Grinding Mill.........................................................................83
6.1.10 Separator.........................................................................................86
LAPORAN KERJA PRAKTEK
PT. INDOCEMENT TUNGGAL PRAKARSA, Tbk. Plant 7-8
6.2 Alat Pendukung..........................................................................................88
6.2.1 Alat Transportasi...............................................................................88
6.2.2 Alat Timbang Weighing Feeder.......................................................92
6.2.3 Alat Pengeruk (Reclaimer)................................................................92
BAB VII
UTILITAS
7.1 Unit Penyediaan dan Pengolahan Air (Water Supply Section).................94
7.1.1 Pasokan Air Baku............................................................................95
7.1.2 Pengolahan Air Baku.......................................................................97
7.2 Unit Energi Listrik..................................................................................100
7.3 Unit Penyediaan Udara...........................................................................100
7.3.1 Udara Tekan...................................................................................101
7.3.2 Udara Bebas...................................................................................101
7.4 Unit Penyediaan Bahan Bakar.................................................................102
7.5 Unit Pembuatan Kantong Semen.............................................................103
7.6 Unit Peralatan Berat.................................................................................106
7.7 Unit Fabrikasi dan Perbaikan Mesin........................................................106
7.8 Unit Pengolahan Limbah..........................................................................107
BAB VIII
LABORATORIUM
8.1
8.2
8.3
8.4
Laboratorium X-ray................................................................................112
Laboratorium Kimia...............................................................................112
Laboratorium Fisika................................................................................113
Prosedur Analisa.....................................................................................114
8.4.1 Analisa Bahan Baku, Bahan Pembantu, dan Bahan Aditif..........114
8.4.1.1 Analisa Bahan Baku dan Bahan Pembantu
Pada Laboratorium X-Ray..............................................114
8.4.1.2 Analisa Batu Kapur Pada Laboratorium Kimia..............115
8.4.1.3 Analisa Tanah Liat (Clay) dan Pasir Silika (Silica Sand)
Pada Laboratorium Kimia...............................................117
8.4.1.4 Analisa Dust EAF Pada Laboratorium Kimia................120
8.4.1.5 Analisa Bagan Aditif (Gypsum)
dalam Laboratorium Kimia.............................................122
8.4.2 Analisa Raw Meal..........................................................................123
8.4.2.1 Analisa Raw Meal Pada Laboratorium X-Ray................123
LAPORAN KERJA PRAKTEK
PT. INDOCEMENT TUNGGAL PRAKARSA, Tbk. Plant 7-8
8.4.2.2 Analisa Raw Meal Pada Laboratorium Kimia.................124
8.4.3 Analisa Klinker...............................................................................124
8.4.3.1 Analisa Klinker Pada Laboratorium X-Ray.....................124
8.4.3.2 Analisa Klinker Pada Laboratorium Kimia......................125
8.4.4 Analisa Semen................................................................................128
8.4.4.1 Analisa Semen Pada Laboratorium Kimia.......................128
8.4.4.2 Analisa Semen Pada Laboratorium Fisika........................132
8.4.4.2.1 Pengujian Kehalusan................................132
DAFTAR PUSTAKA..........................................................................................136
LAMPIRAN.........................................................................................................137
LAMPIRAN A.1..................................................................................................138
LAMPIRAN A.2..................................................................................................139
LAMPIRAN A.3..................................................................................................140
LAMPIRAN A.4..................................................................................................141
LAMPIRAN A.5..................................................................................................142
LAMPIRAN A.6..................................................................................................143
LAPORAN KERJA PRAKTEK
PT. INDOCEMENT TUNGGAL PRAKARSA, Tbk. Plant 7-8
DAFTAR TABEL
Tabel 2.1 Plant-plant yang Dioperasikan Oleh
PT. Indocement Tunggal Prakarsa, Tbk............................................7
Tabel 2.2 Jumlah Tenaga Kerja Berdasarkan Wilayah Kerja...........................14
Tabel 2.3 Jumlah Tenaga Kerja Berdasarkan Usia...........................................14
Tabel 2.4 Jumlah Tenaga Kerja Berdasarkan Jenjang Pendidikan...................15
Tabel 2.5 Waktu Kerja Normal.........................................................................15
Tabel 2.6 Waktu Kerja Shift.............................................................................15
Tabel 2.7 Waktu Kerja Shift Untuk Bagian Delivery dan Packing..................16
Tabel 3.1 Perbandingan Proses Basah dan Kering...........................................18
Tabel 5.1 Mekanisme Reaksi Pembentukan Kristal Semen.............................34
Tabel 5.2 Komposisi Batu Kapur.....................................................................38
Tabel 5.3 Type Crusher yang Dipakai di Quarry D.........................................43
Tabel 5.4 Komposisi Tanah Liat......................................................................44
Tabel 5.5 Type Crusher yang Dipakai di Hambalang......................................46
Tabel 5.6 Permasalahan dan Tindakan dalam Kegiatan
Operasional Penambangan...............................................................48
LAPORAN KERJA PRAKTEK
PT. INDOCEMENT TUNGGAL PRAKARSA, Tbk. Plant 7-8
Tabel 5.7 Komposisi Senyawa pada Pasir Silika.............................................49
Tabel 5.8 Komposisi Senyawa pada Dust EAF...............................................50
Tabel 5.9 Komposisi Senyawa pada Gypsum..................................................50
Tabel 5.10 Reaksi yang Terjadi dalam Suspension Pre-Heater.......................56
Tabel 5.11 Reaksi yang Terjadi dalam Kiln......................................................60
Tabel 7.1 Karakteristik Air Bersih....................................................................95
Tabel 7.2 Karakteristik Air Sungai Cileungsi...................................................97
Tabel 7.3 Syarat Baku Mutu Air Pendingin.....................................................97
Tabel 7.4 Karakteristik Air Hasil Pengolahan.................................................99
Tabel 7.5 Kapasitas Pembangkit Listrik
PT. Indocement Tunggal Prakarsa, Tbk........................................100
Tabel 7.6 Pedoman Penetapan Baku Udara Ambien Nasional......................109
Tabel 7.7 Pedoman Batas Tingkat Kebisingan..............................................110
Tabel 8.1 Analisa Laboratorium X-Ray.......................................................112
LAPORAN KERJA PRAKTEK
PT. INDOCEMENT TUNGGAL PRAKARSA, Tbk. Plant 7-8
DAFTAR GAMBAR
Gambar 2.1 Tata Letak PT. Indocement Tunggal Prakarsa, Tbk.
Citeureup-Bogor.........................................................................8
Gambar 2.2 Struktur Organisasi Perusahaan...................................................11
Gambar 2.3 Struktur Organisasi Plant 7-8.......................................................13
Gambar 4.1 Storage Limestone........................................................................21
Gambar 4.2 Storage Clay.................................................................................23
Gambar 4.3 Storage Pasir Besi (Pyrite Cynder)...............................................24
Gambar 4.4 Ordinary Portland Cement (Tipe I).............................................29
Gambar 4.5 Moderate Sulfate Resistance Cement (Tipe II)............................29
Gambar 4.6 High Sulfate Resistance Cement (Tipe V)....................................30
Gambar 4.7 Portland Composite Cement (PCC).............................................31
Gambar 4.8 White Cement...............................................................................32
Gambar 4.9 Oil Well Cement (OWC)..............................................................32
Gambar 4.10 White Mortar TR30...................................................................33
Gambar 5.1 Alur Proses Pembuatan Semen...................................................36
Gambar 5.2 Struktur Organisasi Mining Division..........................................37
Gambar 5.3 Proses Drilling.............................................................................40
LAPORAN KERJA PRAKTEK
PT. INDOCEMENT TUNGGAL PRAKARSA, Tbk. Plant 7-8
Gambar 5.4 Proses Blasting............................................................................41
Gambar 5.5 Proses Loading dan Hauling.......................................................42
Gambar 5.6 Proses Crushing..........................................................................43
Gambar 5.7 Proses Penambangan Batu Kapur di PT. Indocement Tunggal
Prakarsa, Tbk............................................................................44
Gambar 5.8 Proses Penambangan Tanah Liat di PT. Indocement Tunggal Prakarsa,
Tbk............................................................................47
Gambar 5.9 Tahapan Pembuatan Semen Secara Keseluruhan......................51
Gambar 6.1 Raw Grinding Mill.....................................................................71
Gambar 6.2 Raw Meal Silo............................................................................73
Gambar 6.3 Coal Mill.....................................................................................74
Gambar 6.4 Suspension Preheater..................................................................77
Gambar 6.5 Rotary Kiln..................................................................................78
Gambar 6.6 Electrostatic Precipitator............................................................79
Gambar 6.7 Bag Filter....................................................................................81
Gambar 6.8 Grate Cooler...............................................................................82
Gambar 6.10 Finish Grinding Mill.................................................................83
Gambar 6.11 Grit Separator...........................................................................86
Gambar 6.12 Turbo Separator..................................................................................86
Gambar 6.13 Bucket Elevator.........................................................................88
Gambar 6.14 Appron Conveyor......................................................................89
LAPORAN KERJA PRAKTEK
PT. INDOCEMENT TUNGGAL PRAKARSA, Tbk. Plant 7-8
Gambar 6.15 Belt Conveyor............................................................................90
Gambar 6.16 Screw Conveyor.........................................................................91
Gambar 6.17 Air Slide.....................................................................................91
Gambar 6.18 Weight Feeder...........................................................................92
Gambar 6. 19 Reclaimer.................................................................................92
PT. INDOCEMENT TUNGGAL PRAKARSA, Tbk. Plant 7-8
KATA PENGANTAR
Puji syukur kepada Allah SWT, atas berkat rahmat dan hidayah-Nya
sehingga kami dapat menyelesaikan laporan kerja praktek yang berjudul “Analisa
Perhitungan Neraca Massa dan Neraca Panas pada Unit Raw Mill di Plant 8”
dengan baik. Laporan ini ditujukkan untuk memenuhi salah satu syarat kelulusan
jurusan Teknik Kimia program studi S1 di Sekolah Tinggi Teknologi Indocement.
Selain
itu
pelaksanaan
praktik
kerja
lapangan
menjadi
sarana
untuk
mengaplikasikan ilmu pengetahuan yang didapatkan di Sekolah Tinggi Teknologi
Indocement. Penulis mengucapkan terima kasih kepada semua pihak yang telah
membantu selama proses pelaksanaan praktik kerja lapangan dan pengerjaan
laporan praktik kerja lapangan ini, diantaranya kepada:
1.
Kepada Allah Swt, atas rahmat dan karunia-Nya sehingga penulis dapat
2.
menyelesaikan laporan ini,
Kedua orang tua dan keluarga yang penulis cintai, yang selalu memberi
motivasi dan mendoakan kelancaran serta kesuksesan pelaksanaan praktik
3.
kerja lapangan,
PT Indocement Tunggal Prakarsa Tbk. Citeureup - Bogor yang telah
4.
mengijinkan kami untuk melaksanakan PKL disana,
Bapak Dedi A. Dasuki di bagian CPDD (Corporate People Dev. Department)
yang telah membantu mengurus perizinan berlangsungnya kerja praktek di
5.
PT. Indocement Tunggal Prakarsa, Tbk.,
Bapak Nurcholis selaku pembimbing lapangan selama PKL di PT Indocement
Tunggal Prakarsa, Tbk Citeureup - Bogor yang telah mengarahkan,
6.
membimbing serta memberikan pengetahuan tentang industri semen,
Bapak Tommy, Bapak Sulistyo, Bapak Samsudin, Bapak Okta, Bapak Irman
serta seluruh staff P7-8. Terima kasih telah membantu, meluangkan waktu
7.
dan memberi informasi kepada penulis,
Bapak Hamzah dan Bapak H. Sanusi selaku foreman dan Bapak Eko selaku
patroller di Unit Raw Mill, yang telah membantu penulis dalam pengambilan
sampel di lapangan,
LAPORAN KERJA PRAKTEK
PT. INDOCEMENT TUNGGAL PRAKARSA, Tbk. Plant 7-8
8.
Rekan- rekan PKL yang turut serta berperan penting dalam pelaksanaan PKL,
juga teman-teman Prodi S1 Teknik Kimia Sekolah Tinggi Teknologi
Indocement 2012 yang senantiasa turut memberikan dukungan terhadap
penulis.
Mohon maaf penulis sampaikan bila ada salah kata dalam penulisan
laporan kerja praktek ini. Penulis sadar laporan ini masih memiliki banyak
kekurangan. Oleh karena itu, penulis harapkan pembaca dapat memberikan
masukan-masukan yang bersifat membangun untuk kesempurnaan laporan ini.
Harapan penulis, semoga laporan ini bisa bermanfaat, menjadi sumber informasi
dan menambah pengetahuan pembaca tentang proses produksi pembuatan semen.
Bogor, Maret 2016
Tim Penulis
DAFTAR ISI
LAPORAN KERJA PRAKTEK
PT. INDOCEMENT TUNGGAL PRAKARSA, Tbk. Plant 7-8
COVER..................................................................................................................i
LEMBAR PENGESAHAN...................................................................................ii
KATA PENGANTAR...........................................................................................iii
DAFTAR ISI..........................................................................................................v
DAFTAR TABEL..................................................................................................xi
DAFTAR GAMBAR............................................................................................xiii
BAB I
PENDAHULUAN
1.1 Latar Belakang...........................................................................................1
1.2 Tujuan Kerja Praktek.................................................................................2
1.3 Ruang Lingkup Laporan Kerja Praktek.....................................................2
1.4 Waktu dan Tempat Pelaksanaan Kerja Praktek.........................................2
BAB II
PROFIL PERUSAHAAN
2.1 Sejarah dan Perkembangan Pabrik............................................................3
2.1.1 Sejarah Pendirian PT. Indocement Tunggal Prakarsa, Tbk.............3
2.1.2 Perkembangan PT. Indocement Tunggal Prakarsa, Tbk..................5
2.1.3 Lokasi Pabrik...................................................................................8
2.2 Visi, Misi dan Moto Perusahaan..............................................................10
2.2.1 Visi Perseroan.................................................................................10
2.2.2 Misi Perseroan................................................................................10
2.2.3 Motto Perseroan.............................................................................10
2.3 Struktur Organisasi Perusahaan..............................................................11
2.4 Struktur Organisasi Plant 7-8.................................................................13
2.5 Sumber Daya Manusia............................................................................14
LAPORAN KERJA PRAKTEK
PT. INDOCEMENT TUNGGAL PRAKARSA, Tbk. Plant 7-8
2.5.1 Tenaga Kerja.................................................................................14
2.5.2 Waktu Kerja..................................................................................15
2.5.3 Fasilitas Karyawan........................................................................16
BAB III
PEMILIHAN PROSES
3.1 Jenis-jenis Proses.....................................................................................18
3.1.1 Proses Basah..................................................................................18
3.1.2 Proses Kering.................................................................................18
3.2 Perbandingan Proses................................................................................18
3.3 Pemilihan Proses......................................................................................19
3.3.1 Proses Basah..................................................................................19
3.3.2 Proses Kering.................................................................................19
BAB IV
BAHAN BAKU DAN HASIL PRODUKSI
4.1 Bahan Baku..............................................................................................20
4.1.1 Bahan Baku Utama........................................................................20
4.1.2 Bahan Baku Pendukung ................................................................24
4.1.3 Bahan Korektif...............................................................................27
4.2 Produk yang Dihasilkan............................................................................28
4.2.1 Semen Portland (Portland Cement)................................................28
4.2.2 Portland Composite Cement (PCC)...............................................30
4.2.3 White Cement (WC)........................................................................31
4.2.4 Oil Well Cement (OWC).................................................................32
4.2.5 White Mortar TR30..........................................................................33
BAB V
DESKRIPSI PROSES
LAPORAN KERJA PRAKTEK
PT. INDOCEMENT TUNGGAL PRAKARSA, Tbk. Plant 7-8
5.1 Konsep Proses............................................................................................34
5.1.1 Mekanisme Proses.........................................................................34
5.2 Deskripsi Proses........................................................................................35
5.2.1 Persiapan Bahan............................................................................36
5.2.1.1 Penambangan Batu Kapur.................................................38
5.2.1.2 Penambangan Sandyclay...................................................44
5.2.1.3 Penanganan Masalah Penambangan..................................47
5.2.1.4 Reklamasi..........................................................................48
5.2.2 Pengadaan Dust EAF, Pasir Silika, dan Gypsum.........................49
5.3 Unit Pengeringan dan Penggilingan Bahan Baku (Raw Mill Unit).........51
5.4 Suspension Pre-Heater.............................................................................55
5.5 Kiln...........................................................................................................60
5.6 Cooler.......................................................................................................63
5.7 Unit Penggilingan Akhir (Cement Mill Unit)...........................................65
5.8 Unit Pengantongan Semen (Packing Unit)...............................................68
5.9 Coal Mill...................................................................................................69
BAB VI
PERALATAN PROSES
6.1 Alat Utama.................................................................................................71
6.1.1 Raw Grinding Mill............................................................................71
6.1.2 Raw Meal Silo..................................................................................73
6.1.3 Coal Mill..........................................................................................74
6.1.4 Suspension Pre-heater......................................................................77
6.1.5 Rotary Kiln.......................................................................................78
6.1.6 Dust Collector...................................................................................79
6.1.7 Grate Cooler.....................................................................................82
6.1.8 Clinker Silo (Semi-prefabricated steel material)..............................83
6.1.9 Finish Grinding Mill.........................................................................83
6.1.10 Separator.........................................................................................86
LAPORAN KERJA PRAKTEK
PT. INDOCEMENT TUNGGAL PRAKARSA, Tbk. Plant 7-8
6.2 Alat Pendukung..........................................................................................88
6.2.1 Alat Transportasi...............................................................................88
6.2.2 Alat Timbang Weighing Feeder.......................................................92
6.2.3 Alat Pengeruk (Reclaimer)................................................................92
BAB VII
UTILITAS
7.1 Unit Penyediaan dan Pengolahan Air (Water Supply Section).................94
7.1.1 Pasokan Air Baku............................................................................95
7.1.2 Pengolahan Air Baku.......................................................................97
7.2 Unit Energi Listrik..................................................................................100
7.3 Unit Penyediaan Udara...........................................................................100
7.3.1 Udara Tekan...................................................................................101
7.3.2 Udara Bebas...................................................................................101
7.4 Unit Penyediaan Bahan Bakar.................................................................102
7.5 Unit Pembuatan Kantong Semen.............................................................103
7.6 Unit Peralatan Berat.................................................................................106
7.7 Unit Fabrikasi dan Perbaikan Mesin........................................................106
7.8 Unit Pengolahan Limbah..........................................................................107
BAB VIII
LABORATORIUM
8.1
8.2
8.3
8.4
Laboratorium X-ray................................................................................112
Laboratorium Kimia...............................................................................112
Laboratorium Fisika................................................................................113
Prosedur Analisa.....................................................................................114
8.4.1 Analisa Bahan Baku, Bahan Pembantu, dan Bahan Aditif..........114
8.4.1.1 Analisa Bahan Baku dan Bahan Pembantu
Pada Laboratorium X-Ray..............................................114
8.4.1.2 Analisa Batu Kapur Pada Laboratorium Kimia..............115
8.4.1.3 Analisa Tanah Liat (Clay) dan Pasir Silika (Silica Sand)
Pada Laboratorium Kimia...............................................117
8.4.1.4 Analisa Dust EAF Pada Laboratorium Kimia................120
8.4.1.5 Analisa Bagan Aditif (Gypsum)
dalam Laboratorium Kimia.............................................122
8.4.2 Analisa Raw Meal..........................................................................123
8.4.2.1 Analisa Raw Meal Pada Laboratorium X-Ray................123
LAPORAN KERJA PRAKTEK
PT. INDOCEMENT TUNGGAL PRAKARSA, Tbk. Plant 7-8
8.4.2.2 Analisa Raw Meal Pada Laboratorium Kimia.................124
8.4.3 Analisa Klinker...............................................................................124
8.4.3.1 Analisa Klinker Pada Laboratorium X-Ray.....................124
8.4.3.2 Analisa Klinker Pada Laboratorium Kimia......................125
8.4.4 Analisa Semen................................................................................128
8.4.4.1 Analisa Semen Pada Laboratorium Kimia.......................128
8.4.4.2 Analisa Semen Pada Laboratorium Fisika........................132
8.4.4.2.1 Pengujian Kehalusan................................132
DAFTAR PUSTAKA..........................................................................................136
LAMPIRAN.........................................................................................................137
LAMPIRAN A.1..................................................................................................138
LAMPIRAN A.2..................................................................................................139
LAMPIRAN A.3..................................................................................................140
LAMPIRAN A.4..................................................................................................141
LAMPIRAN A.5..................................................................................................142
LAMPIRAN A.6..................................................................................................143
LAPORAN KERJA PRAKTEK
PT. INDOCEMENT TUNGGAL PRAKARSA, Tbk. Plant 7-8
DAFTAR TABEL
Tabel 2.1 Plant-plant yang Dioperasikan Oleh
PT. Indocement Tunggal Prakarsa, Tbk............................................7
Tabel 2.2 Jumlah Tenaga Kerja Berdasarkan Wilayah Kerja...........................14
Tabel 2.3 Jumlah Tenaga Kerja Berdasarkan Usia...........................................14
Tabel 2.4 Jumlah Tenaga Kerja Berdasarkan Jenjang Pendidikan...................15
Tabel 2.5 Waktu Kerja Normal.........................................................................15
Tabel 2.6 Waktu Kerja Shift.............................................................................15
Tabel 2.7 Waktu Kerja Shift Untuk Bagian Delivery dan Packing..................16
Tabel 3.1 Perbandingan Proses Basah dan Kering...........................................18
Tabel 5.1 Mekanisme Reaksi Pembentukan Kristal Semen.............................34
Tabel 5.2 Komposisi Batu Kapur.....................................................................38
Tabel 5.3 Type Crusher yang Dipakai di Quarry D.........................................43
Tabel 5.4 Komposisi Tanah Liat......................................................................44
Tabel 5.5 Type Crusher yang Dipakai di Hambalang......................................46
Tabel 5.6 Permasalahan dan Tindakan dalam Kegiatan
Operasional Penambangan...............................................................48
LAPORAN KERJA PRAKTEK
PT. INDOCEMENT TUNGGAL PRAKARSA, Tbk. Plant 7-8
Tabel 5.7 Komposisi Senyawa pada Pasir Silika.............................................49
Tabel 5.8 Komposisi Senyawa pada Dust EAF...............................................50
Tabel 5.9 Komposisi Senyawa pada Gypsum..................................................50
Tabel 5.10 Reaksi yang Terjadi dalam Suspension Pre-Heater.......................56
Tabel 5.11 Reaksi yang Terjadi dalam Kiln......................................................60
Tabel 7.1 Karakteristik Air Bersih....................................................................95
Tabel 7.2 Karakteristik Air Sungai Cileungsi...................................................97
Tabel 7.3 Syarat Baku Mutu Air Pendingin.....................................................97
Tabel 7.4 Karakteristik Air Hasil Pengolahan.................................................99
Tabel 7.5 Kapasitas Pembangkit Listrik
PT. Indocement Tunggal Prakarsa, Tbk........................................100
Tabel 7.6 Pedoman Penetapan Baku Udara Ambien Nasional......................109
Tabel 7.7 Pedoman Batas Tingkat Kebisingan..............................................110
Tabel 8.1 Analisa Laboratorium X-Ray.......................................................112
LAPORAN KERJA PRAKTEK
PT. INDOCEMENT TUNGGAL PRAKARSA, Tbk. Plant 7-8
DAFTAR GAMBAR
Gambar 2.1 Tata Letak PT. Indocement Tunggal Prakarsa, Tbk.
Citeureup-Bogor.........................................................................8
Gambar 2.2 Struktur Organisasi Perusahaan...................................................11
Gambar 2.3 Struktur Organisasi Plant 7-8.......................................................13
Gambar 4.1 Storage Limestone........................................................................21
Gambar 4.2 Storage Clay.................................................................................23
Gambar 4.3 Storage Pasir Besi (Pyrite Cynder)...............................................24
Gambar 4.4 Ordinary Portland Cement (Tipe I).............................................29
Gambar 4.5 Moderate Sulfate Resistance Cement (Tipe II)............................29
Gambar 4.6 High Sulfate Resistance Cement (Tipe V)....................................30
Gambar 4.7 Portland Composite Cement (PCC).............................................31
Gambar 4.8 White Cement...............................................................................32
Gambar 4.9 Oil Well Cement (OWC)..............................................................32
Gambar 4.10 White Mortar TR30...................................................................33
Gambar 5.1 Alur Proses Pembuatan Semen...................................................36
Gambar 5.2 Struktur Organisasi Mining Division..........................................37
Gambar 5.3 Proses Drilling.............................................................................40
LAPORAN KERJA PRAKTEK
PT. INDOCEMENT TUNGGAL PRAKARSA, Tbk. Plant 7-8
Gambar 5.4 Proses Blasting............................................................................41
Gambar 5.5 Proses Loading dan Hauling.......................................................42
Gambar 5.6 Proses Crushing..........................................................................43
Gambar 5.7 Proses Penambangan Batu Kapur di PT. Indocement Tunggal
Prakarsa, Tbk............................................................................44
Gambar 5.8 Proses Penambangan Tanah Liat di PT. Indocement Tunggal Prakarsa,
Tbk............................................................................47
Gambar 5.9 Tahapan Pembuatan Semen Secara Keseluruhan......................51
Gambar 6.1 Raw Grinding Mill.....................................................................71
Gambar 6.2 Raw Meal Silo............................................................................73
Gambar 6.3 Coal Mill.....................................................................................74
Gambar 6.4 Suspension Preheater..................................................................77
Gambar 6.5 Rotary Kiln..................................................................................78
Gambar 6.6 Electrostatic Precipitator............................................................79
Gambar 6.7 Bag Filter....................................................................................81
Gambar 6.8 Grate Cooler...............................................................................82
Gambar 6.10 Finish Grinding Mill.................................................................83
Gambar 6.11 Grit Separator...........................................................................86
Gambar 6.12 Turbo Separator..................................................................................86
Gambar 6.13 Bucket Elevator.........................................................................88
Gambar 6.14 Appron Conveyor......................................................................89
LAPORAN KERJA PRAKTEK
PT. INDOCEMENT TUNGGAL PRAKARSA, Tbk. Plant 7-8
Gambar 6.15 Belt Conveyor............................................................................90
Gambar 6.16 Screw Conveyor.........................................................................91
Gambar 6.17 Air Slide.....................................................................................91
Gambar 6.18 Weight Feeder...........................................................................92
Gambar 6. 19 Reclaimer.................................................................................92