SANUSI, YASA (2026) RANCANG BANGUN SISTEM FOTOREDUKSI UV UNTUK PRODUKSI BESI OKSALAT DARI LIMBAH BAJA KARBON MENGGUNAKAN METODE VDI 2221. S2 thesis, Universitas Mercu Buana Jakarta.
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Abstract
The steel processing industry in Indonesia, particularly valve manufacturing companies in Banten generates ever increasing amounts of steel waste. Although this waste retains a high iron content, it remains underutilized due to limited processing systems and a scarcity of research focused on carbon steel waste. Through the application of an eco friendly photochemical extraction process, carbon steel waste can be converted into value-added products, such as raw material for iron oxalate synthesis, thereby supporting sustainable waste management. Consequently, further research is required to design and construct a photoreduction-based iron oxalate (FeC2O4) production system. The objectives of this study were to design and build an iron oxalate production system utilizing a UV photoreduction process, to test the equipment and process parameters, and to analyze the characteristics of the resulting iron oxalate product. The design phase employed the VDI 2221 methodology, adhering to principles of functional optimization and technical compatibility. Iron oxalate extraction involved leaching and UV photoreduction via mirror reflection, followed by analysis using PSA, SEM-EDS, XRD, and FTIR. Photoreduction trials were conducted with durations of 3, 6, and 9 hours, utilizing an array of four UV lamps. The results indicated that "Photoreduction System Variation 1" was the optimal design, achieving a stability level of 84%. The best operational parameters were achieved with the 9-hour duration, yielding a 109.90% increase in iron oxalate crystals (10.35 g). Particle testing revealed an optimal size distribution, characterized by a Span value of 1.51 and a mean diameter of 23.55 μm, while morphological analysis confirmed the formation of uniform, smooth, elongated block shaped iron oxalate crystals with an Fe content of 13.40% and a mass fraction of 52.25%. Furthermore, the iron oxalate crystals formed α-FeC2O4·2H2O and β-FeC2O4·2H2O, with the presence of O-H, H-O-, COO-, C-O, O-C-O, and Fe-O functional groups confirmed. Research into this UV photoreduction-based iron oxalate production system offers a potential technological alternative for the manufacturing industry to transform carbon steel waste into value-added products, thereby supporting waste reduction efforts within the framework of green manufacturing. Keywords: Iron Oxalate, Steel Waste, Leaching, Photoreduction, Reflection Industri manufaktur pengolahan baja di Indonesia, terutama perusahaan manufaktur katup di Banten menghasilkan limbah baja dalam jumlah yang terus meningkat. Meskipun masih memiliki kandungan besi yang cukup tinggi, limbah tersebut belum dimanfaatkan secara optimal akibat keterbatasan sistem pengolahan dan masih minimnya penelitian berbasis limbah baja karbon. Penerapan proses ekstraksi fotokimia ramah lingkungan, limbah baja karbon dapat diolah menjadi produk bernilai tambah sekaligus mendukung pengolahan limbah yang berkelanjutan, salah satunya sebagai bahan baku sintesis besi oksalat. Oleh karena itu, diperlukan penelitian lebih lanjut untuk merancang bangun sistem produksi besi oksalat (FeC2O4) berbasis fotoreduksi. Tujuan penelitian ini adalah merancang bangun sistem produksi besi oksalat dengan proses fotoreduksi UV, menguji alat dan parameter proses, serta menganalisis karakteristik produk besi oksalat. Metode perancangan menggunakan metode VDI 2221 dengan prinsip optimasi fungsi dan kompatibilitas teknik. Proses ekstraksi besi oksalat menggunakan metode pelindian dan fotoreduksi UV melalui refleksi cermin, serta pengujian PSA SEM-EDS, XRD dan FTIR. Proses fotoreduksi dilakukan dengan variasi 3 jam, 6 jam, dan 9 jam, serta 4 lampu UV menyala. Hasil penelitian menunjukkan Sistem Fotoreduksi Variasi 1 merupakan desain terbaik dengan tingkat stabilitas 84%. Parameter operasional terbaik dicapai pada variasi 9 jam, dengan penambahkan kristal besi oksalat sebesar 109,90% (10,35 g). Hasil pengujian pertikel besi oksalat menunjukkan distribusi ukuran partikel yang paling baik, dengan nilai Span 1,51 dan diameter rata-rata 23,55 μm, yang diperkuat pengujian morfologi menunjukkan kristal besi oksalat seragam berbentuk balok memanjang yang jelas dan halus, dengan kandungan Fe 13,40% dan berat 52,25%. Selain itu, pada kristal besi oksalat membentuk -FeC2O4.2H2O dan - FeC2O4.2H2O, danterkonfirmasi adanya gugus fungsi O-H, H-O-, COO-, C-O, O-C-O, dan Fe-O. Penelitian sistem produksi besi oksalat melalui proses fotoreduksi UV ini berpotensi menjadi solusi, alternatif teknologi bagi industri manufaktur dalam pemanfaatan limbah limbah baja karbon menjadi produk bernilai tambah, dan mendukung pengurangan limbah pada implementasi green manufacture. Kata kunci: Besi Oksalat, Limbah Baja, Lindi, Fotoreduksi, Refleksi
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