Laporan Kerja Praktek

PT Semen Padang
12 November - 21 Desember 2018

KATA PENGANTAR

Alhamdulillah, segala puji dan syukur kepada Allah SWT yang telah memberi
rahmat, karunia, lindungan, dan bimbingan-Nya sehingga penulis dapat
menyelesaikan Laporan Kerja Praktek di PT Semen Padang. Laporan Kerja Praktek
ini ditulis untuk memenuhi persyaratan mata kuliah Kerja Praktek di Jurusan Teknik
Kimia, Universitas Sumatera Utara. Kerja Praktek dimulai pada tanggal 12 November
s.d. 21 Desember 2018 di Biro Produksi V PT Semen Padang.
Selama penyusunan Laporan Kerja Praktek ini, penulis banyak menerima
bantuan dan dorongan dari berbagai pihak. Oleh karena itu, pada kesempatan ini
penulis mengucapkan terima kasih sebesar-besarnya kepada:
1) Kedua orang tua, saudara, dan keluarga besar yang selalu mendukung dan
mendoakan sehingga Kerja Praktek ini berjalan lancar.
2) Ibu Maya Sarah, ST, MT, Ph.D, IPM selaku Ketua jurusan Teknik Kimia,
Universitas Sumatera Utara.
3) Bapak Prof. Ir. Indra Surya, M.Sc., Ph.D selaku koordinator Kerja Praktek
Teknik Kimia, Universitas Sumatera Utara.
4) Ibu Prof. Dr. Ir. Hamidah Harahap, M.Sc. selaku dosen pembimbing Kerja
Praktek.
5) PT Semen Padang yang telah memberikan kesempatan kerja praktek kepada
penulis sehingga laporan ini dapat disusun dengan baik.
6) Bapak Titut Eryanto selaku Kepala Biro Produksi V yang telah memberikan
bantuan selama melaksanakan kerja praktek.
7) Bapak Peter Sazli selaku pembimbing khusus dan Bapak Indra selaku
pembimbing lapangan yang telah memberikan arahan dan bimbingan selama
penyusunan laporan ini.
8) Bapak Mulfaroza, Bapak Dodi, Bapak Zul, Bapak Erwin, Bapak Rahmad,
Bapak Devy Sulasta, Bapak Leader, Bang Danu, Bapak Irwandi, Bapak
Ridwan, Bapak Nuardi, Bapak Ifran, Bapak Hermanda, Bapak Satria, Bapak
Armaini, Bapak Abdul Hadi, Bang Jhovi, Bapak Bram, Bapak Delfi, Bapak
Randi, Bapak Akmar, Bapak Hengki, Bapak Orix Bery, Bang Niko, Bang Dedi,
Bapak Dodoi, Bapak Halvika, Bang Aulia, Bapak Ferys, Bapak Ilham, Bapak

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 Laporan Kerja Praktek
PT Semen Padang
12 November - 21 Desember 2018

Derry, Amak Eva, Buk Dewi, Kak Ayu, Kak Rini serta semua pihak terkhusus
karyawan Dept. Produksi V yang telah memberikan banyak bantuan selama
pelaksanaan kerja praktek.
9) Rekan-rekan satu tim kerja praktek, Tri Rafika Aisyah, Habbyyu Muhammad,
Riri Adolina Siregar, Athir Muhammad Fakhar, dan terkhusus rekan satu
kelompok yaitu Dinda Meilani Jambak yang telah bekerja sama dengan baik
dan sudah banyak direpotkan dari awal sampai selesai kerja praktek.
10) Rekan-rekan satu angkatan Teknik Kimia Universitas Sumatera Utara tahun
2015 yang telah ikut serta memberi dukungan kepada penulis untuk tetap
semangat dalam mengikuti kegiatan kerja praktek.
Penulis meyakini bahwa laporan ini jauh dari kesempurnaan dan semoga
laporan ini dapat memberikan masukan bagi yang membaca.

Padang, Desember 2018

Penulis

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 Laporan Kerja Praktek
PT Semen Padang
12 November - 21 Desember 2018

DAFTAR ISI

KATA PENGANTAR ........................................................................................... i

DAFTAR ISI ......................................................................................................... iii
DAFTAR GAMBAR ........................................................................................... viii
DAFTAR TABEL ................................................................................................. xi
BAB I PENDAHULUAN ................................................................................ 1
1.1. Latar Belakang............................................................................... 1
1.2. Tujuan Kerja Praktek ..................................................................... 2
1.3. Ruang Lingkup Pelaksanaan ......................................................... 2
1.4. Manfaat Kerja Praktek ................................................................... 3
1.5. Waktu Pelaksanaan Kerja Praktek ................................................. 3
1.6. Metodologi Pengumpulan Data ..................................................... 3
BAB II GAMBARAN UMUM PERUSAHAAN ............................................. 4
2.1. Informasi Umum ........................................................................... 4
2.2. Sejarah PT Semen Padang ............................................................. 4
2.3. Lokasi Perusahaan ......................................................................... 9
2.4. Visi dan Misi serta Budaya Perusahaan ...................................... 11
2.4.1. Visi Perusahaan ................................................................. 11
2.4.2. Misi Perusahaan................................................................. 11
2.4.3. Budaya Perusahaan ............................................................ 11
2.4.4. Perkembangan Aktivitas Usaha PT Semen Padang .......... 12
2.5. Struktur Organisasi Perusahaan ................................................... 13
2.5.1. Struktur Organisasi PT Semen Padang.............................. 13
2.5.2. Struktur Organisasi Departemen Produksi V PT
Semen Padang .................................................................... 16
BAB III TINJAUAN PUSTAKA ..................................................................... 17
3.1. Sejarah Semen ............................................................................ 17
3.2. Pengertian Semen ....................................................................... 18
3.3. Jenis-jenis Semen ....................................................................... 20
3.3.1. Portland Cement ............................................................... 20
3.2.2. Non-Portland Cement ....................................................... 24

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3.4. Bahan Baku Pembuatan Semen .................................................... 25

3.4.1. Bahan Baku Utama ............................................................. 25
3.4.2. Bahan Tambahan (Aditif) ................................................... 30
3.4.3. Bahan Korektif ................................................................... 33
3.5. Sifat Fisika dan Sifat Kimia Semen.............................................. 34
3.5.1. Sifat Fisika Semen .............................................................. 34
3.5.2. Sifat Kimia Semen .............................................................. 39
3.6. Faktor Kualitas Semen.................................................................. 43
BAB IV DESKRIPSI PROSES ......................................................................... 45
4.1. Tahapan Proses Pembuatan Semen .............................................. 45
4.2. Tahap Penyediaan dan Persiapan Bahan Baku ............................. 46
4.2.1. Quarry (Penmabangan) ...................................................... 46
4.2.2. Pengadaan dan Penyimpanan Bahan Baku......................... 46
4.2.3. Tahap Penggilingan Bahan Baku (Pembentukan Raw
Mix) ..................................................................................... 53
4.2.4. Penyimpanan Raw Mix ....................................................... 58
4.2.5. Tahap Pembentukan Klinker (Pembakaran Raw Mix) ....... 59
4.2.5.1 Persiapan Batubara (Fine Coal) .............................. 59
4.2.5.2 Proses Pemanasan Awal (Preheater) ...................... 61
4.2.5.3 Proses Pembakaran (Rotary Kiln) ........................... 64
4.2.5.4 Proses Pendinginan (Grate Cooler) ........................ 69
4.2.5.5 Penyimpanan Klinker didalam Silo ........................ 72
4.2.6. Tahap Penggilingan Klinker (Pembuatan Semen) ............. 73
4.2.6.1 Proses Pengumpanan Material ................................ 73
4.2.6.2 Proses Penggilingan Awal di Roller Press ............. 74
4.2.6.3 Proses Penggilingan di Cement Mill ....................... 75
4.2.6.4 Proses Pemisahan pada Sepax Separator ................ 81
4.2.6.5 Penyimpanan Semen ............................................... 82
4.2.7. Tahap Pengantongan Semen............................................... 83
BAB V SPESIFIKASI ALAT .......................................................................... 84
5.1. Spesifikasi Alat Utama ................................................................. 84
5.1.1. Raw Mill ............................................................................. 84

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5.1.2. Coal Mill............................................................................. 85

5.1.3. Unit Kiln ............................................................................. 85
5.1.4. Grate Cooler ....................................................................... 86
5.1.5. Cement Mill ........................................................................ 86
5.2. Alat Pendukung Operasi ............................................................... 87
5.2.1. Cyclone ............................................................................... 87
5.2.2. Gas Conditioning Tower (GCT)......................................... 88
5.2.3. Electrostatic Precipitator (EP) ........................................... 89
5.2.4. Cerobong (Stack) ................................................................ 90
5.2.5. Jet Pulse Filter (JPF) .......................................................... 90
5.2.6. Bag House Filter (BHF) ..................................................... 91
5.2.7. Hopper ............................................................................... 92
5.2.8. Ducting .............................................................................. 92
5.3. Alat Penarikan Material ................................................................ 92
5.3.1. Bridge Scrapper.................................................................. 92
5.3.2. Side Reclaimer .................................................................... 93
5.3.3. Bucket Chain Excavator ..................................................... 94
5.4. Alat Transportasi .......................................................................... 94
5.4.1. Belt Conveyor ..................................................................... 95
5.4.2. Bucket Elevator .................................................................. 95
5.4.3. Appron Conveyor................................................................ 96
5.4.4. Air Slide/Fluxo Slide........................................................... 96
5.4.5. Screw Conveyor .................................................................. 97
5.4.6. Drag Chain ......................................................................... 98
5.5. Alat Sensor ................................................................................... 98
5.5.1. Sensor Proximity Switch ..................................................... 98
5.5.2. Sensor Temperatur.............................................................. 99
5.5.3. Sensor Pressure .................................................................. 99
5.5.4. Sensor Level ....................................................................... 99
5.5.5. Sensor Vibrasi ................................................................... 100
5.5.6. Flame Detector .................................................................. 100
BAB VI UNIT DAN PENGOLAHAN LIMBAH ............................................ 101

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6.1. Utilitas ......................................................................................... 101

6.1.1. Penyediaan Air .................................................................. 101
6.1.2. Penyediaan Energi Listrik ................................................. 102
6.1.3. Penyediaan Bahan Bakar ................................................... 103
6.2. Pengolahan Limbah ..................................................................... 104
6.3. Laboratorium ............................................................................... 104
BAB VII KESIMPULAN DAN SARAN .......................................................... 106
7.1. Kesimpulan .................................................................................. 106
7.2. Saran ............................................................................................ 106
DAFTAR PUSTAKA ........................................................................................... 108
LAMPIRAN A TUGAS KHUSUS ...................................................................... 110
A.1. Latar Belakang ..................................................................... 110
A.2. Tujuan .................................................................................. 111
A.3. Manfaat ................................................................................ 111
A.4. Ruang Lingkup .................................................................... 111
A.5. Dasar Teori .......................................................................... 112
A.5.1. Electrostatic Precipitator (EP) .................................. 112
A.5.2. Jenis-Jenis Electrostatic Precipitator (EP) ............... 113
A.5.3. Prinsip Kerja Electrostatic Precipitator (EP)............ 113
A.5.4 Komponen Utama Electrostatic Precipitator (EP) ... 114
A.5.5 Faktor yang Mempengaruhi Kinerja Electrostatic
Precipitator (EP) ....................................................... 116
A.5.6 Persamaan Deutsch-Anderson ................................... 118
A.6. Emisi .................................................................................... 118
A.7. Data dan Pembahasan Analisa Kinerja Electrostatic
Precipitator (EP) terhadap Penurunan Emisi ....................... 119
A.7.1 Nilai Opacity pada Bulan November ........................ 121
A.7.2 Emisi pada Bulan November ..................................... 122
A.7.3 Pengaruh Tegangan terhadap Efesiensi EP ............... 123
A.7.4 Pengaruh Efesiensi EP terhadap Emisi...................... 124
LAMPIRAN B FLOWSHEET PABRIK INDARUNG V PT SEMEN
PADANG .................................................................................... 123

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PT Semen Padang
12 November - 21 Desember 2018

DAFTAR GAMBAR

Gambar 2.1. Sejarah PT Semen Padang ............................................................. 4

Gambar 2.2. PT Semen Padang........................................................................... 7
Gambar 2.3. Sejarah Logo PT Semen Padang .................................................... 8
Gambar 2.4. PT Semen Padang, Indarung .......................................................... 9
Gambar 2.5. Packing Plant PT Semen Padang, Teluk Bayur (a) dan
Dumai (b)..................................................................................... 10
Gambar 2.6. Struktur Organisasi PT Semen Padang ......................................... 15
Gambar 2.7. Struktur Organisasi Departemen Produksi V PT Semen Padang .. 16
Gambar 3.1. Semen ............................................................................................ 18
Gambar 3.2. Semen Portland Tipe I ................................................................... 20
Gambar 3.3. Semen Portland Tipe II ................................................................. 21
Gambar 3.4. Semen Portland Tipe III ................................................................ 21
Gambar 3.5. Semen Portland Tipe V ................................................................. 22
Gambar 3.6. Super Mansonry Cement ............................................................... 22
Gambar 3.7 Oil Well Cement ............................................................................ 23
Gambar 3.8 Portland Composite Cement ......................................................... 23
Gambar 3.9 Semen Portland Pozzoland............................................................ 24
Gambar 3.10. Batu Kapur (Lime Stone) ............................................................... 25
Gambar 3.11. Batu Silika (Silica Stone) .............................................................. 26
Gambar 3.12. Pasir Besi (Iron Sand) ................................................................... 28
Gambar 3.13. Tanah Liat (Clay) .......................................................................... 30
Gambar 3.14. Gypsum .......................................................................................... 31
Gambar 3.15. Pozzolan ........................................................................................ 32
Gambar 4.1. Flowsheet Proses Pembuatan Semen ............................................ 45
Gambar 4.2. Belt Conveyor ................................................................................ 47
Gambar 4.3. Metode Chevron Stacking .............................................................. 47
Gambar 4.4. Alat Penarikan Bridge Scrapper .................................................... 48
Gambar 4.5. Metode Conical Shell Stacking ...................................................... 49
Gambar 4.6. Alat Penarikan Side Reclaimer ....................................................... 49
Gambar 4.7. Metode Windrow Stacking ............................................................. 50

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Gambar 4.8. Alat Penarikan Bucket Chain Excavator ........................................ 50

Gambar 4.9. Hopper ............................................................................................ 53
Gambar 4.10. Dosimat Feeder ............................................................................. 54
Gambar 4.11. Vertical Mill dan Bagian-Bagiannya ............................................. 55
Gambar 4.12. Proses dalam Vertical Mill ............................................................ 56
Gambar 4.13. Control Flow Silo (CF Silo) dan Bagian-Bagiannya .................... 58
Gambar 4.14. Sistem Penarikan Raw Mix dalam CF Silo.................................... 58
Gambar 4.15. Storage Raw Coal.......................................................................... 59
Gambar 4.16. Coal Mill ....................................................................................... 60
Gambar 4.17. Coriolis .......................................................................................... 61
Gambar 4.18. Suspension Preheater .................................................................... 62
Gambar 4.19. Proses pada Cyclone Preheater ..................................................... 63
Gambar 4.20. Rotary Kiln .................................................................................... 65
Gambar 4.21. Bagian-Bagian Rotary Kiln ........................................................... 69
Gambar 4.22. Grate Cooler ................................................................................. 69
Gambar 4.23. Roller Breaker di dalam Grate Cooler .......................................... 70
Gambar 4.24. Bagian Grate pada Grate Cooler .................................................. 71
Gambar 4.25. Proses pada Grate Cooler ............................................................. 71
Gambar 4.26. Dome Silo (Panah Biru) &Unburn Silo (Panah Hijau) ................. 73
Gambar 4.27. Appron Conveyor .......................................................................... 74
Gambar 4.28. Roller Press dan Bagian-Bagiannya ............................................. 75
Gambar 4.29. Cement Mill (Tube Mill)................................................................ 76
Gambar 4.30. Bagian-Bagian Cement Mill .......................................................... 77
Gambar 4.31. Bagian dalam Kompartemen I Cement Mill.................................. 77
Gambar 4.32. Grinding Media di Kompartemen I (a) dan II (b) ......................... 78
Gambar 4.33. Pergerakan Grinding Media di Kompartemen I (a) dan II (b) ...... 78
Gambar 4.34. Center Diaphragm dan Proses Perpindahan Material ................... 79
Gambar 4.35. Water Injection pada Cement Mill ................................................ 79
Gambar 4.36. Bagian-Bagian Sepax Separator ................................................... 81
Gambar 4.37. Cement Silo (Panah Biru) .............................................................. 82
Gambar 5.1. Cyclone .......................................................................................... 87

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Gambar 5.2. Gas Conditioning Tower dan Spray Lance ................................... 88

Gambar 5.3. Nozzle pada Gas Conditioning Tower ........................................... 89
Gambar 5.4. Electrostatic Precipitator dan Bagian-Bagiannya ........................ 89
Gambar 5.5. Cerobong ....................................................................................... 90
Gambar 5.6. Bagian-Bagian Jet Pulse Filter ..................................................... 91
Gambar 5.7. Bagian-bagian Bag House Filter ................................................... 91
Gambar 5.8. Hopper ........................................................................................... 92
Gambar 5.9. Ducting .......................................................................................... 92
Gambar 5.10. Bridge Scrapper ............................................................................ 92
Gambar 5.11. Side Reclaimer............................................................................... 93
Gambar 5.12. Bucket Chain Excavator ................................................................ 94
Gambar 5.13. Belt Conveyor dan Bagian-Bagiannya .......................................... 95
Gambar 5.14. Bagian-Bagian Bucket Elevator .................................................... 96
Gambar 5.15. Appron Conveyor dan Bagian-Bagiannya ..................................... 96
Gambar 5.16. Bagian-bagian Air Slide ............................................................... 97
Gambar 5.17. Screw Conveyor dan Bagian-Bagiannya ...................................... 98
Gambar A.1. Gambar Electrostatic Precipitator dan Bagian-Bagiannya.......... 112
Gambar A.2. Proses Pemberian Muatan pada Partikel ...................................... 114
Gambar A.3. Proses Pengumpulan Partikel ....................................................... 114
Gambar A.4. (a) Collecting Electrode dan Discharge Electrode (b) Collecting
Plate ............................................................................................. 115
Gambar A.5. Discharge Electrode ..................................................................... 116
Gambar A.6. Grafik Opacity pada Bulan November ......................................... 121
Gambar A.7. Grafik Emisi pada Bulan November ............................................ 122
Gambar A.8. Grafik Pengaruh Tegangan terhadap Efesiensi EP....................... 123
Gambar A.9. Grafik Pengaruh Efesiensi EP terhadap Emisi ............................. 124

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 Laporan Kerja Praktek
PT Semen Padang
12 November - 21 Desember 2018

DAFTAR TABEL

Tabel 3.1. Sifat Fisika Batu Kapur .................................................................... 26

Tabel 3.2. Komposisi Kimia Batu Kapur .......................................................... 26
Tabel 3.3. Sifat Fisika Batu Silika .................................................................... 27
Tabel 3.4. Komposisi Kimia Batu Silika .......................................................... 27
Tabel 3.5. Sifat Fisika Pasir Besi ...................................................................... 28
Tabel 3.6. Komposisi Kimia Pasir Besi ............................................................ 28
Tabel 3.7. Sifat Fisika Cooper Slag .................................................................. 29
Tabel 3.8. Komposisi Kimia Cooper Slag ........................................................ 29
Tabel 3.9. Sifat Fisika Tanah Liat .................................................................... 30
Tabel 3.10. Komposisi Kimia Tanah Liat ........................................................... 30
Tabel 3.11. Sifat Fisika Gypsum ......................................................................... 31
Tabel 3.12. Komposisi Kimia Gypsum ............................................................... 31
Tabel 3.13. Komposisi Kimia Pozzolan.............................................................. 32
Tabel 3.14. Parameter dan Persyaratan Kandungan Fly Ash .............................. 33
Tabel 3.15. Syarat Minimum Blaine untuk Semen Tanpa Fly Ash ..................... 43
Tabel 3.16. Syarat Minimum Blaine untuk Semen dengan Fly Ash ................... 43
Tabel 4.1. Jenis Storage, Metode Stacking, dan Penarikan Bahan Baku .......... 52
Tabel 4.2. Kapasitas Hopper Unit Raw Mill ..................................................... 53
Tabel 4.3. Suhu Material Tiap Stage di Suspension Preheater......................... 62
Tabel 4.4. Tahap Klinkerisasi ........................................................................... 67
Tabel A.1. Data Nilai Tegangan dan Kuat Medan Magnet.............................. 119
Tabel A.2. Data Hasil Analisa Kinerja Electrostatic Precipitator (EP) .......... 120

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