Location: South Jakarta

RMIT Academic Supervisor: TBA

Project Background

To respond to increasing market demand, Sampangan plans to gradually scale its production capacity from approximately 20 tons per day to up to 275 tons per day through a phased and controlled expansion.

At present, the production system operates primarily in batch or semi-batch mode and does not yet achieve fully continuous-flow operation. While individual unit operations are technically scalable, cycle-time mismatches across critical processing stages—including carbonization, chemical activation, washing, drying, and material handling—limit overall system throughput. This misalignment creates bottlenecks, idle capacity, and compounding inefficiencies that become increasingly significant as production volume increases.

In parallel, the current quality control (QC) approach is primarily focused on final product verification and has not yet been formalized into a standardized system. Variability in raw materials, operating conditions, and production cycles introduces measurable risks to product consistency, adsorption performance, and compliance with customer specifications. Without a clearly defined QC framework, increasing production capacity would elevate quality risk and complicate downstream industrial applications.

Furthermore, the existing production setup lacks an integrated equipment and material design framework that links process requirements with realistic timelines and budget assumptions. Effective scale-up therefore requires not only technical process redesign, but also engineering-based planning that aligns equipment selection, material flow, operational timing, and cost considerations within a coherent system.

This project addresses these challenges through a chemical engineering–driven system design approach, focusing on production flow synchronization, establishment of a scale-appropriate QC system, and development of scale-up–ready operational planning tools. Designed as a hybrid program—predominantly remote with a two-week on-site period—the project prioritizes analytical, design, and documentation outputs that can be developed without continuous physical manufacturing activities. On-site activities are focused on data validation, process observation, and alignment with operational realities.

Project Objectives

The expected outcomes of this project emphasize operational readiness, quality assurance, and informed decision-making, including:

• – A system-level strategy for scaling activated carbon production from 20 to 275 tons per day through phased expansion
• – Improved alignment of cycle times and material flow across unit operations to reduce bottlenecks and idle capacity
• – Establishment of a structured QC framework focused on final product consistency as production capacity increases
• – Reduced risk of quality deviation, rework, and operational inefficiency during scale-up
• – Clear technical inputs to support equipment procurement, timeline planning, and high-level budget estimation
• – Enhanced internal capability to manage production growth in a controlled, data-driven manner

Relevant Engineering Fields

Chemical Engineering, Environmental Engineering

Project Outcomes

To support the hybrid program structure and limited on-site duration, the project will deliver the following system-level, design-focused outputs:

• Process and Flow Design
  • – Cycle-time and bottleneck analysis for all major unit operations
  • – Process flow diagrams reflecting current operations and proposed scale-up configurations
  • – Mass and energy balance models for phased capacity increases

• Quality Control (QC) System Design
  • – Key quality parameters and test methods for final activated carbon products, defined to meet customer and application specification.
  • – Final product sampling plans and acceptance criteria, including testing frequency, pass/fail thresholds, and batch release logic
  • – Documentation and traceability framework linking final product test results to production batches and raw material sources
  • – Identification of critical in-process parameters for future QC integration, including recommended control points and indicative monitoring methods to support later scale-up and continuous operation

• QC Laboratory Support Planning
  • – Identification of reagents, solvents, and reference standards required for each QC test method
  • – Estimated laboratory chemical consumption rates based on testing frequency and sampling volume
  • – QC testing schedules linked to production cycles and scale-up phases
  • – Minimum inventory levels and replenishment timing to prevent interruptions in QC activities

• Operational and Scale-Up Planning

• • Standard Operating Procedure (SOP) frameworks suitable for scaled operations
  • A scale-up roadmap integrating technical milestones and QC readiness checkpoints
  • A consolidated technical recommendation report summarizing system design, QC strategy, and scale-up priorities

These outputs are intentionally designed to be achievable through remote analytical work, with on-site engagement focused on data validation, process observation, and alignment with operational realities rather than physical modification or installation.

Relevant Skills

• – Process modelling and system analysis
• – Mass and/or energy balance calculations
• – Definition of engineering assumptions and parameters
• – Sustainability and environmental impact awareness
• – Technical reporting for preliminary engineering studies
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Note: This project is being revised by the RMIT academic supervisor and the scope may change. Further details on the project and its outcomes will be provided closer to the start date.