3.1.

1 Step preparation of raw materials

1. Destruction / Crushing
Limestone stored in a storage shed with 30C temperature and pressure of 1 atm. Limestone
crusher destroyed with the aim is to produce solids / powders limestone uniform size.
2. sieving / screening
After limestone crushed and then screened through a screen with a size of 200 mesh.
Materials that do not qualify returned to the screener crusher machine for reprocessing.
Limestone qualify screener using a conveyor belt and transported by bucket elevator and then
accommodated in the hopper. In the hopper, limestone inserted into the screw feeder that
serves as a feeder, then limestone introduced into the reactor for processing.
Sulfuric acid is stored in storage tanks at 30C and pressure conditions of 1 atm. The sulfuric
acid has a concentration of 98%. Sulfuric acid is then pumped to the mixer to be diluted with
water until it reaches the level of 50%. Are also added into the mixer recycle of the filter.

3.1.2 Step Formation of Product

This stage aims to form gypsum which is a reaction between limestone and sulfuric acid. The
reactor used is RATB (flow stirred tank reactor) takes place continuously equipped with
stirring to accelerate the reaction. Limestone into the reactor at a temperature of 30C and
sulfuric acid from the mixer at a temperature of 30C at a pressure of 1 atm. The reaction
occurs in the reactor takes place at a pressure of 1 atm and a temperature of 93C. The
reaction occurs in the reactor is an exothermic reaction, the reactor is equipped with cooller
(cooling jacket) so that the operating temperature is maintained. Water used as a cooling
medium with a temperature of 28 C masuh. The temperature of the product out of the
reactor at 93C.
Reaction in the reactor will occur as follows:
CaCO3 + H2SO4 + H2O CaSO4.2H2O + H2O + CO2
In addition to produce calcium sulfate dihydrate (CaSO4.2H2O) also produces carbon
dioxide gas (CO2). CO2 out of the reactor through the discharge pipe and directly discharged
into the environment. Slurry out of the reactor and then pumped to a filter press.
3.1.3 Step Separation and Purification Products
Separation step aims to separate gypsum with water and sulfuric acid. This separation process
using a type of filter press. Out of filter that operates at a temperature of 30C and 1 atm this
is gypsum products as cake and sulfuric acid solution as the filtrate.
Cake gypsum flowed out the filter using a screw feeder to the dryer operating at a
temperature of 30C and a pressure of 1 atm so menggalami purification process, namely the
process of spending the fluid content in the gypsum cake. Purification process gypsum cake
(CaSO4.2H2O) aims to raise the purity of gypsum cake (CaSO4.2H2O) resulting filter cake
produced because the purity is low and does not meet with anyone in the market. Purification
process using a rotary dryer which type of direct counter-current drying method using a blast
of hot air as the heating medium.
Product output rotary dryer CaSO4.2H2O who had levels of 97% was already on the market.
CaSO4.2H2O levels on the market is 91%. To homogenize the size of the product, gypsum
further filtered using a screener using a bucket elevator transported to the silo to
accommodate temporary gypsum products before heading to the packaging unit to be packed
and stored in the warehouse as the main product. The resulting filtrate from the filter in the
form of water and sulfuric acid which then direcycle to the mixer.

3.1.4 Packaging
Gypsum products packed or packed with tools Filling Machine (FM-01) into the plastic with
heavy equipment ranging between 10-50 kg depending packaging cement factory. Storage in
a protected location to prevent damage from weather and air to minimize contact premises
which can reduce absorption capability.