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DATA PENGAMATAN Data aktual pengamatan yang dilakukan pada hari Kamis tanggal 29 januari 2014 Berdasarkan pada tekanan Tekanan Atmosfer = Temperatur Lingkungan = Kelembaban udara = 1 Kiln Feed = String A = String B =
2 Clinker Out = Faktor Clinker
260,000 kg/jam 135,200 kg/jam (52%) 124,800 kg/jam (48%) Komponen Komposisi(%) SiO2 Al2O3 Fe2O3 CaO MgO LOI H2O
13.39 3.10 1.93 43.45 0.58 34.80 0.71
145,251.397 kg/jam 1.790 Komponen Komposisi(%) SiO2 Al2O3 Fe2O3 CaO MgO
22.12 5.01 2.88 66.70 0.67
3 Bahan Bakar (Coal) NHV Heat of Consumption Total Heat of Consumption Fine Coal Ke Kiln Ke Kalsiner Komponen C H O N S
= = = = = = Komposisi (%) 58.64 4.25 27.62 0.79 3.82
H2O Ash 4 Persen Ash Raw Coal Raw Coal = Komposisi Ash SiO2 Al2O3 Fe2O3 CaO MgO 5 Bahan Baku Batu Kapur Tanah liat Pasir Besi Pasir Silika Total Komposisi SiO2 Al2O3 Fe2O3 CaO MgO H2O
6 Cooler Fan (12 Buah) Fan Fan K21 Fan K20 Fan K12 Fan K13 Fan K15 Fan K16 Fan K18 Fan K17 Fan K14 Fan K11 Fan K10 Fan K22
10.06 13.50 =
Fine Coal
Batu Kapur
Raw Coal 28.65 12.57 4.29 28.23 0.78
48.58 23.28 5.74 5.40 0.92
359 ton/jam 36.4 ton/jam 5.8 ton/jam 0 ton/jam 401.2 ton/jam Tanah Liat 7.12 1.57 0.74 48.19 0.62 8.00
58.37 17.38 7.54 1.97 0.97 29.25
Tekanan (mbar)
Volume(m3/jam) 94 63 50 17 18 5 10 4 18 19 50 54
19,000 32,000 35,000 25,261 53,000 9,500 8,700 9,500 31,000 35,000 30,000 31,000
7 Primary Air Fan Kapasitas Tekanan Suhu Bukaan
2,897 m3/jam 1.055 atm 30 oC 94 %
8 Coal Conveying Air Volume Tekanan Suhu
5,456 m3/jam 1.045 atm 303 K
9 Stack Fan Volume Tekanan Suhu 10 Udara Excess Kiln Line Calsiner
76,000.000 m3 1.052 atm 183 oC
20.000 % 20.000 %
11 Raw Material Grinding Temperatur Input Gas Panas Temperatur Input Bahan Mentah Temperatur Output Kandungan H2O pada Raw Meal Output 12 Raw Mill Motor Power Efisiensi Motor
340 32 67 =
3,100 85
760 mmHg 30 oC 72.5 %
5,100 kcal/kg batubara 810 kcal/kg clinker 117,653,631.285 kcal/jam 19,700.000 kg/jam 7,880.000 kg/jam (40%) 11,820.000 kg/jam (60%)
8.000 % 30,900 kg/h % % % % %
Pasir Besi
359,000 kg/jam 36,400 kg/jam 5,800 kg/jam 0 kg/jam 401,200 kg/jam Pasir Silika 64.15 15.16 36.06 1.61 1.05 14.50
Suhu(oK) 303 303 303 303 303 303 303 303 303 303 303 303
0.00 0.00 0.00 0.00 0.00 0.00
456 K
oC oC oC 0.009
kWh %
PERHITUNGAN NERACA MASSA A.
Menghitung Jumlah dan Komposisi Gas Panas 1 Clinker dari ash Batubara Ash Clinker (Ash FC) =
%Ash x Total Fine Coal ……………(1) = 13.50 = 2,659.50
Ash Raw Coal = %Ash x Raw Coal = =
8.00 2,472.00
(Sumber : Maniso Budiawan,2001) 2 Clinker dari Kiln Feed KF Klinker =
Clinker Out - Ash Coal ……………(2) = 145,251.40 = 142,591.90
(Sumber : Maniso Budiawan,2001) Komponen A SiO2 Al2O3 Fe2O3 CaO MgO
Komposisi Clinker B 22.12 5.01 2.88 66.70 0.67
Berat (kg) C 32,129.61 7,277.09 4,183.24 96,882.68 973.18
C = B/100 x Clinker Out E = D/100 x Ash Clinker F=C-E 3 Kiln Feed Tersaring KF Tersaring = KF Klinker/[1-(%LOI/100)] ………(3) = 142,591.90 (1- 34,8/100) = 218,699.23 kg String A = 113,723.60 kg (52%) String B = 104,975.63 kg (48%) (sumber : Prihadi Setyo, 2001)
4 Total Dust Total Dust = (KF - KF Tersaring)(1-H2O) = =
( 41,007.54 kg
260,000.00
5 Dust ke Coal Mill Dust ke Coal Mill = Ash Fine Coal - Ash Raw Coal …………………………..(4) Dust = (%Ash x Fine Coal)-(%Ashx Raw Coal) ( 13.50 % x = 2,659.50 Dust = 0.92 Dust = Dust =
187.50 203.80
(Sumber : Maniso Budiawan,2001)
6 Dust ke Raw Mill Dust ke Raw Mill = Total Dust - Dust ke Coal Mill = 41,007.54 = 40,803.73 kg 7 Komposisi Dust Total Kiln Feed = KF Klinker = Komponen A SiO2 Al2O3 Fe2O3 CaO MgO
%Kiln Feed B 13.39 3.10 1.93 43.45 0.58
260,000.00 142,591.90 Berat (kg) C 34,814.00 8,060.00 5,018.00 112,970.00 1,508.00
C = B/100 x Kiln Feed F=C-D 8 Komposisi Dust ke Coal Mill Ash Fine Coal
2,659.50
Ash Raw Coal Komponen A SiO2 Al2O3 Fe2O3 CaO MgO
2,472.00 %Fine Coal B 28.65 12.57 4.29 28.23 0.78
Berat (kg) C 761.95 334.30 114.09 750.78 20.74
C = B/100 x Ash Fine Coal E = D/100 x Ash Raw Coal F=C-E 9 Komposisi Dust ke Raw Mill Komponen A SiO2 Al2O3 Fe2O3 CaO MgO
Dust Total B 3,446.34 1,117.20 948.85 16,838.10 555.56
Total 10 Menghitung Gas Hasil Pembakaran fine Coal a. Kiln Line Fine Coal Kiln Line Komponen A C H O N S H2O Ash C = B X Kiln Line E = C/D
Dust Coal Mill C 1,962.84 909.78 255.99 884.26 43.49 22,906.05 4,056.36
= = Komposisi(%) B 58.64 4.25 27.62 0.79 3.82 10.06 13.50
Reaksi Pembakaran C (s)+ O2 (g)
S(s) + O2(g)
2H(s) + 1/2 O2(g) Total O2 pembakaran O dari coal O2 Teoritis Udara teoritis N2 suplay O2 excess string A = string B = Udara excess = %Udara excess =
475.293/0.21 1,543.08 4.39 5.61 20.00 Udara suplay-Udara teoritis Udara Teoritis 0.20 = 100.00
Udara supplay = Udara excess =
2,343.92 2,343.92 390.65
= Dimana :
O2 N2
= =
(Sumber : Himmelblau, 1996) Gas Hasil Pembakaran Coal CO2 =CO2 yang dihasilkan = SO2
385.07
= SO2 yang dihasilkan =
H2O = H2O Coal + H2O yang dihasilkan =
9.41
44.04
= = O2 =
211.49 3,806.83
= O2 Excess 82.04
N2 = N2 Coal + N2 Udara supplay N Coal = N2 Coal = N2 =
b.
Calsiner Line Fine Coal Kalsiner Line Komponen A C H O N S H2O Ash C = B X Kalsiner Line E = C/D Reaksi Pembakaran C (s)+ O2 (g)
S(s) + O2(g)
2H(s) + 1/2 O2(g) Total O2 pembakaran O dari coal O2 Teoritis Udara teoritis
62.25 1.30 37,065.14
11,820.00 = = Komposisi(%) B 58.64 4.25 27.62 0.79 3.82 10.06 13.50
N2 suplay O2 excess
2,314.63
Udara excess = %Udara excess =
20.00 Udara suplay-Udara teoritis Udara Teoritis 0.20 =
Udara supplay = Udara excess =
3,515.89 3,515.89 585.98
= Dimana :
O2 N2
= =
(Sumber : Himmelblau, 1996) Gas Hasil Pembakaran Coal CO2 =CO2 yang dihasilkan = SO2
577.60
= SO2 yang dihasilkan =
14.11
H2O = H2O Coal + H2O yang dihasilkan = = = O2 =
14.11 265.29 4,775.13
= O2 Excess 123.06
N2 = N2 Coal + N2 Udara supplay N Coal = N2 Coal = N2 =
3,264.68 68.01 57,183.36
11 Total Gas Hasil Pembakaran Coal Komponen CO2
Kiln Line Jumlah Mol (kmol) 385.07
SO2 H2O O2 N2
9.41 211.49 82.04 1,323.75
12 Reaksi Kalsinasi (Kiln Feed Clinker) Clinker Out = Kiln Line = Kalsiner Line = Komponen A CaO MgO
145,251.40 58,100.56 87,150.84 % massa B 66.70 0.67
C = B/100 X Clinker out D = 0.4 C E = 0.6 C Komponen
Kiln Line (kg) A
CaO MgO
B 38,753.07 389.27
E=BXD F=CXD
Reaksi Kalsinasi CaCO3(s) MgCO3(s)
a
CaO =
96,882.68
MgO =
973.18
Kiln Line (String A) CaO =
692.02
MgO = Total CO2 yang dihasilkan = > 25% Calsinasi terjadi di siklon 1 sampai 3 CO2 yang dihasilkan =
14.60
> 60% Calsinasi terjadi di kalsiner CO2 yang dihasilkan = > 15% Calsinasi terjadi di Kiln CO2 yang dihasilkan = CO2 yang ke luar dari string A = CO2 yang ke luar dari string B = b
Calsiner Line (String B) CaO = MgO = Total CO2 yang dihasilkan = > 85% Calsinasi terjadi di siklon 1 sampai 3 CO2 yang dihasilkan =
1,038.03 14.60
> 15% Calsinasi terjadi di Kiln CO2 yang dihasilkan = CO2 yang ke luar dari string A = CO2 yang ke luar dari string B = > Total CO2 hasil kalsinasi yang ke luar dari String A = > Total CO2 hasil kalsinasi yang ke luar dari String B = 13 Vapour H2O dari Kiln Feed String A = %H2O x Kiln Feed ke string A ………………(7) = 0,52% x Kiln Feed ke string A = 703.04 kg String B = = =
%H2O x Kiln Feed ke string B ………………(8) 0,48% x Kiln Feed ke string B 599.04 kg
(Sumber : Maniso Budiawan, 2001)
14 Exhaust Gas yang ke luar dari String B O2 = O2 Hasil Pembakaran Coal = 3,937.79 kg N2 = N2 Hasil Pembakaran Coal = 57,183.36 kg CO2 = Co2 Hasil Pembakaran Coal + CO2 Hasil Kalsinasi = 83,437.49 kg SO2 = SO2 Hasil Pembakaran Coal = 903.05 kg H2O = H2O Hasil Pembakaran Coal + Vapour H2O = 5,374.17 kg Total = 150,835.87 kg 15 Menghitung Udara Pendingin Grate Cooler (12 Fan) Fan P abs(atm) V(m3/jam) Fan K21 1.0928 Fan K20 1.0622 Fan K12 1.0493 Fan K13 1.0168 Fan K15 1.0176 Fan K16 1.0051 Fan K18 1.0094 Fan K17 1.0036 Fan K14 1.0174 Fan K11 1.0188 Fan K10 1.0493 Fan K22 1.0533 Total Udara Masuk Grate Cooler Pabs (atm) = [P (mbar) x 0.0009869233]+1 Total Udara Masuk Grate Cooler = 16 Menghitung Udara Primer a Primary Air Fan Kapasitas Tekanan Suhu Bukaan Volume = 2.897 m3 x 0,94 = n = PV/RT =
19,000 32,000 35,000 25,261 53,000 9,500 8,700 9,500 31,000 35,000 30,000 31,000
2,897.00 1.06 30.00 94.00
115.55
b.
Coal Conveying Air Volume Tekanan Suhu n = PV/RT =
Total Udara Primer ke Kiln = =
5,456.00 1.05 303.00 229.31 Primary Air Fan + Coal Conveying Fan 344.87
17 Menghitung Udara Sekunder Secondary Air = Udara supplay ke kiln - udara Primer = 1,999.06 kmol 18 Menghitung Udara Tersier Tersier air = Udara Supply ke Calsiner -Coal Conveying Air = 3,286.57 kmol 19 Menghitung Udara yang dibuang ke stack Stack Fan Volume Tekanan Suhu n = PV/RT =
76,000.00 m3 1.05 atm 183.00 oC 2,136.73 kmol
20 Gas Panas dari Grate Cooler yang dialirkan ke Raw Mill = Total Udara Cooler - Secondary Air - Tersier Air - Udara ke Stack = 5,861.87 kmol = Dimana O2 = 1,230.99 N2 = 4,630.88 21 Total Gas Panas yang masuk ke Raw Mill = Exhaust Gas dari String B + Gas Panas dari Cooler = 338,415.78 kg Gas Panas Masuk Raw Mill > O2 = O2 Exhaust Calsiner + O2 gas Panas dari Grate Cooler = > N2 = N2 Exhaust Calsiner + N2 gas Panas dari Grate Cooler = > CO2 = CO2 Exhaust Calsiner = > SO2 = SO2 Exhaust Calsiner = > H2O = H2O Exhaust Calsiner =
B
INPUT RAW MILL Batu Kapur Tanah liat Pasir Besi Pasir Silika Komposisi SiO2 Al2O3 Fe2O3 CaO MgO H2O
359.00 ton/jam 36.40 ton/jam 5.80 ton/jam 0.00 ton/jam Tanah Liat 7.12 1.57 0.74 48.19 0.62 8.00
Batu Kapur
Total Fresh Feed Lime stone (LS) Clay (CL) Iron Sand (IS) Silica Sand (SS) Total 1 Batu Kapur /Lime Stone (LS) SiO2 = Al2O3 = Fe2O3 = CaO = MgO = H2O = 2 Tanah Liat /Clay (CL) SiO2 = Al2O3 = Fe2O3 = CaO = MgO = H2O = 3 Pasir Besi / Iron Sand (IS)
58.37 17.38 7.54 1.97 0.97 29.25
Massa (kg/jam) H2O 8.00 29.25 14.50 8.75
359,000.00 36,400.00 5,800.00 0.00 401,200.00
359,000 7.12 % 1.57 % 0.74 % 48.19 % 0.62 % 8.00 %
x x x x x x 36,400.00
58.37 % 17.38 % 7.54 % 1.97 % 0.97 % 29.25 %
x x x x x x 5,800.00
SiO2 = Al2O3 = Fe2O3 = CaO = MgO = H2O =
64.15 % 15.16 % 36.06 % 1.61 % 1.05 % 14.50 %
4 Pasir Silika / Silika Sand (SS) SiO2 = Al2O3 = Fe2O3 = CaO = MgO = H2O =
x x x x x x 0.00
0.00 % 0.00 % 0.00 % 0.00 % 0.00 % 0.00 %
x x x x x x
Komposisi Feed Mill Feed Mill Lime stone (LS) Clay (CL) Iron Sand (IS) Silica Sand (SS) Total
C
Senyawa SiO2 25,560.80 21,246.68 3,720.70 0.00 50,528.18
Al2O3 5,636.30 6,326.32 879.28 0.00 12,841.90
5 Dust SiO2 = Al2O3 = Fe2O3 = CaO = MgO =
18,849.69 kg 1,483.49 kg 207.42 kg 692.87 kg 15,953.83 kg 512.07 kg
6 Gas Panas O2 N2 CO2 SO2 H2O
338,415.78 kg 43,329.58 kg 205,371.49 kg 83,437.49 kg 903.05 kg 5,374.17 kg
Menghitung H2O yang diuapkan
Feed Mill Lime stone (LS) Clay (CL) Iron Sand (IS) Silica Sand (SS) Dust Total
Berat Kering(kg) 209,081.60 31,387.72 6,845.74 0.00 18,849.69 266,164.75
Raw Meal Output (dry) = Dust + Batu kapur (dry) + Tanah Liat (dry) + Pasir Besi (dry) + Pasir Silika (dry) = 266,164.75 kg H2O Raw Meal Input = 40,208.00 kg Kandungan H2O pada Raw Meal Output = 0.90 0.01 .= H2O pada Raw Meal 266,164.75 .+ H2O pada Raw Meal H2O Raw Meal = 2,417.24 kg H2O yang diuapkan = H2O Raw Meal Input - H2O Raw Meal Output = 37,790.76 kg Persen Pengeringan = D
.=
H2O yang diuapkan x 100% H2O Raw Meal Input 93.99 %
OUTPUT RAW MEAL 1 Raw Meal Raw Meal Output = Raw Meal Output Dry + H2O Raw Meal Output = 268,581.99 kg SiO2 = Al2O3 = Fe2O3 = CaO = MgO = H2O =
52,011.67 kg 13,049.32 kg 8,185.51 kg 189,766.39 kg 43,841.65 kg 2,417.24 kg
2 Gas Panas O2 N2 CO2 SO2
43,329.58 kg 205,371.49 kg 83,437.49 kg 903.05 kg
H2O Total
43,164.93 kg 376,206.55 kg INPUT
>Raw Mix SiO2 = Al2O3 = Fe2O3 = CaO = MgO = H2O = Total > Gas Panas O2 N2 CO2 SO2 H2O Total
50,528.18 kg 12,841.90 kg 7,492.64 kg 173,812.56 kg 2,639.78 kg 40,208.00 kg 287,523.06 kg 43,329.58 kg 205,371.49 kg 83,437.49 kg 903.05 kg 5,374.17 kg 338,415.78 kg
> Dust dari Kiln SiO2 = Al2O3 = Fe2O3 = CaO = MgO = Total Total
A.
1,483.49 kg 207.42 kg 692.87 kg 15,953.83 kg 512.07 kg 18,849.69 kg 644,788.53 kg
menghitung besar energi untuk grinding material theory bond's
E =��(1/(√��)+1/(√��)) ��=1,46∗�� �=�/� �/�=1,46 ×��(1/√��−1/√��)
�/�=1,46 ×��(1/√��−1/√��)
dengan, P= gross power required (hp) T=kapasitas umpan ( ton/menit)
=
Df= diameter rata2 umpan (ft)
=
Dp= diameter rata2 produk (ft) Ei = index kerja Ei limestone =
10.18
Ei clay =
7.1
Ei bijih besi =
15.44 32.72
Bahan Baku Batu Kapur Tanah liat Pasir Besi Pasir Silika Total
293 ton/jam 42.74 ton/jam 8.32 ton/jam 0 ton/jam 344.06 ton/jam
1. E untuk batu kapur
�/�=1,46×10,18(1/√0,00002952−1/√0,0328)
P/T= P=
2,653.47 2.653,47 * T
P= E=
15,215.88 hp P/T 2,653.47 hp.min/ton
2. E untuk tanah liat
�/�=1,46×7,1(1/√0,00002952−1/√0,0328)
�/�=22,54(1/0,1811077
P/T= P=
1,850.65 1.850,65 * T
P= E=
10,612.26 hp P/T 1,850.65 hp.min/ton
3. E untuk bijih besi
�/�=1,46×15,44(1/√0,00002952−1/√0,0328)
P/T= P=
4,024.52 4.024,52 * T
P= E=
23,077.92 hp P/T 4,024.52 hp.min/ton
B
menghitung besar energi yang digunakan untuk grinding raw meal (campuran) Bahan Baku Batu Kapur Tanah liat Pasir Besi Pasir Silika Total
293 ton/jam 42.74 ton/jam 8.32 ton/jam 0 ton/jam 344.06 ton/jam
1. batu kapur E=
85,16/100����������
E=
2,259.68 hp.min/ton
2. tanah liat 12,42/100×�����ℎ����
E=
12,42/100×�����ℎ����
E=
229.89 hp.min/ton
3. bijih besi E=
2,42/100×�����ℎ����
E= Eraw mill =
C.
97.32 hp.min/ton E batu kapur + E tanah liat + E bijih besi 2.259,68 + 229,89 + 97,32 2,586.90 hp.min/ton
energi consumption mill only E alat =
19 kW.h/ton
E=
D.
19.00 kW.h/ton
menghitung efektivitas alat size reduction efektivitas alat SR =
E teori Eaktual alat =
1,527.60 2,586.90
=
0.5905 59.05
otal Fine Coal ……………(1) % x kg %x kg
19,700.00 kg
30,900.00 kg
t - Ash Coal ……………(2) kg kg
Komposisi Ash D 28.65 12.57 4.29 28.23 0.78
2,659.50 kg
Berat (kg) E 761.95 334.30 114.09 750.78 20.74
Berat KF Klinker(kg) F 31,367.66 6,942.80 4,069.15 96,131.90 952.44
-
218,699.23
)( 1-
0.0071
……………..(4) 19,700.00 kg ) 2,472.00 +
(
kg kg
203.80 kg
kg/h kg/h Berat KF Klinker D 31,367.66 6,942.80 4,069.15 96,131.90 952.44
kg
Komposisi Dust total F 3,446.34 1,117.20 948.85 16,838.10 555.56
8.00 % 0.08
x ( Dust
kg %Raw Coal D
Berat (kg) E 48.58 23.28 5.74 5.40 0.92
Komposisi Dust Ke CM F 1,200.90 1,962.84 575.48 909.78 141.89 255.99 133.49 884.26 22.74 43.49
Dust Raw Mill D 1,483.49 207.42 692.87 15,953.83 512.07 18,849.69
19,700.00 kg/jam 7,880.00 kg/jam (40%) Kiln Line (kg) C
BM D 4,620.83 334.90 2,176.46 62.25 301.02 792.73 1,063.80
Jumlah mol (kmol) E 12.00 385.07 1.00 334.90 16.00 136.03 14.00 4.45 32.00 9.41 18.00 44.04
CO2(g)
O2(g) dibutuhkan CO2 dihasilkan
385.07 385.07
SO2(g)
O2(g) dibutuhkan SO2 dihasilkan
9.41 9.41
H2O(g)
O2(g) dibutuhkan H2O dihasilkan
83.73 167.45
478.20 kmol 136.03 kmol 410.19 1,953.27 kmol
%(analyzer) ay-Udara teoritis Udara Teoritis Udara supplay 1,953.27 kmol kmol
O2 dari coal (O2 Pembakaran-O2 coal) 56,644.85 kg 37,034.01 kg 5,452.00
…………….(6)
x 100% 1,953.27
1,953.27 kmol 82.04 kmol 308.62 kmol
kmol
=
16,943.05 kg
kmol =
602.03 kg
kmol +
167.45 kmol
68.01
kmol kg
kmol
2,625.20 kg
kg kmol kg
2.59 kmol 31.13 kg
kg 19,700.00 kg/jam 11,820.00 kg/jam (60%) Kiln Line (kg) BM C D 6,931.25 502.35 3,264.68 93.38 451.52 1,189.09 1,595.70
Jumlah mol (kmol) E 12.00 577.60 1.00 502.35 16.00 204.04 14.00 6.67 32.00 14.11 18.00 66.06
CO2(g)
O2(g) dibutuhkan CO2 dihasilkan
577.60 577.60
SO2(g)
O2(g) dibutuhkan SO2 dihasilkan
14.11 14.11
H2O(g)
O2(g) dibutuhkan H2O dihasilkan
125.59 251.18
717.30 kmol 204.04 kmol 615.28 kmol 2,929.91
O2 dari coal (O2 Pembakaran-O2 coal) 84,967.27 kg
102.02
kmol
55,551.02 kg 5,452.00
%(analyzer) ay-Udara teoritis Udara Teoritis Udara supplay 2,929.91 kmol kmol
…………….(6)
x 100% 2,929.91
2,929.91 kmol 123.06 kmol 462.93 kmol
kmol
=
25,414.58 kg
kmol =
903.05 kg
kmol + kmol kg
251.18 kmol
kmol
3,937.79 kg
kg kmol kg
136.03 kmol 1,632.34 kg
Kiln Line Berat (kg)
Kalsiner Line Jumlah Mol (kmol) Berat (kg) 16,943.05 577.60 25,414.58
602.03 3,806.83 2,625.20 37,065.14
kg/h kg/h kg/h Massa (kg/jam)
14.11 265.29 123.06 2,042.26 3,022.32
Kiln Line (kg) C
903.05 4,775.13 3,937.79 57,183.36
Kalsiner Line (kg)
D 38,753.07 389.27
96,882.68 973.18
Kalsiner Line (kg)
BM
C 58,129.61 583.91
E 58,129.61 583.91
Kiln Line (kmol) D
56.00 40.00
CaO(s) + MgO(s) + kg, String A = String B = kg, String A = String B =
kmol, CO2 yang dihasilkan =
Kalsiner Line (kmol) E F 692.02 1,038.03 9.73 14.60
CO2(g) CO2(s) 38,753.07 kg = 58,129.61 kg =
692.02 1,038.03
389.27 kg = 583.91 kg =
9.73 14.60
692.02 kmol
kmol, CO2 yang dihasilkan = 706.62 kmol
14.60 kmol
176.65 kmol
423.97 kmol
105.99 kmol 282.65 kmol 423.97 kmol
kmol, CO2 yang dihasilkan = kmol, CO2 yang dihasilkan = 1,052.63 kmol
1,038.03 kmol 14.60 kmol
894.73 kmol
157.89 kmol 157.89 kmol 894.73 kmol 440.54 kmol = 1,318.70 kmol =
19,383.79 58,022.92
Suhu(oK) 303 303 303 303 303 303 303 303 303 303 303 303
R(m3.atm/kmol.K) n = PV/RT (kmol) 0.08206 835.073 0.08206 1,367.062 0.08206 1,477.163 0.08206 1,033.043 0.08206 2,169.169 0.08206 384.051 0.08206 353.201 0.08206 383.477 0.08206 1,268.488 0.08206 1,434.095 0.08206 1,266.140 0.08206 1,313.267 13,284.230
13,284.23 kmol
m3/jam (Data Desain) atm oC = % 2,723.18 m3 kmol
303.00 K
m3/jam atm K kmol
r Fan + Coal Conveying Fan kmol
456.00 K
Air - Udara ke Stack kmol = kmol = Total =
39,391.78 kg 148,188.14 kg 187,579.92 kg
43,329.58 kg 205,371.49 kg 83,437.49 kg 903.05 kg 5,374.17 kg
Total
338,415.78 kg
Pasir Besi
359,000.00 kg/jam 36,400.00 kg/jam 5,800.00 kg/jam 0.00 kg/jam Pasir Silika 64.15 15.16 36.06 1.61 1.05 14.50
0.00 0.00 0.00 0.00 0.00 0.00
Komposisi feed mill (%) Al2O3 Fe2O3 1.57 0.74 17.38 7.54 15.16 36.06 5.57 0.69
SiO2 7.12 58.37 64.15 91.33
kg 359,000 kg 359,000 kg 359,000 kg 359,000 kg 359,000 kg 359,000 kg
= = = = = =
25,560.80 kg 5,636.30 kg 2,656.60 kg 173,002.10 kg 2,225.80 kg 28,720.00 kg
36,400 kg 36,400 kg 36,400 kg 36,400 kg 36,400 kg 36,400 kg
= = = = = =
21,246.68 kg 6,326.32 kg 2,744.56 kg 717.08 kg 353.08 kg 10,647.00 kg
kg
kg
CaO 48.19 1.97 1.61 0.83
5,800 kg 5,800 kg 5,800 kg 5,800 kg 5,800 kg 5,800 kg
= = = = = =
3,720.70 kg 879.28 kg 2,091.48 kg 93.38 kg 60.90 kg 841.00 kg
0 kg 0 kg 0 kg 0 kg 0 kg 0 kg
= = = = = =
0.00 kg 0.00 kg 0.00 kg 0.00 kg 0.00 kg 0.00 kg
kg
Senyawa Fe2O3 2,656.60 2,744.56 2,091.48 0.00 7,492.64
CaO 173,002.10 717.08 93.38 0.00 173,812.56
MgO 2,225.80 353.08 60.90 0.00 2,639.78
H2O 28,720.00 10,647.00 841.00 0.00 40,208.00
sir Besi (dry) + Pasir Silika (dry)
%
da Raw Meal
OUTPUT > Raw Meal SiO2 = Al2O3 = Fe2O3 = CaO = MgO = H2O = Total > Gas Panas O2 N2 CO2 SO2 H2O Total
Total
52,011.67 kg 13,049.32 kg 8,185.51 kg 189,766.39 kg 3,151.85 kg 2,417.24 kg 268,581.99 kg 43,329.58 kg 205,371.49 kg 83,437.49 kg 903.05 kg 43,164.93 kg 376,206.55 kg
644,788.53 kg
401.2 ton/jam = 10mm =
0,01m =
90micronmeter=
0,09mm=
6.6866666667 ton/menit 0.0328 ft 0.00002952 ft
8.6692437366 0.8819798872 0.3733674359 9.9245910597 60
4.8833333 ton/menit 0.7123333 ton/menit 0.1386667 ton/menit 0.0000000 ton/menit 5.7343333 ton/menit
10.37
�/�=22,54(1/0,181107703−1/0,005433)
22.54
60
4.8833333 ton/menit 0.7123333 ton/menit 0.1386667 ton/menit 0.0000000 ton/menit 5.7343333 ton/menit
85.16 % 12.42 % 2.42 % 0.00 % 100.00 %
25.46 hp.h/ton
1,527.60 hp.min/ton 1.34
hp.min/ton hp.min/ton 1.6934383262 %
)
30,900.00 _Dust) Dust
kmol kmol kmol kmol kmol kmol kmol
kmol kmol kmol kmol kmol kmol kmol
er Line (kmol)
kmol kmol kmol kmol
kg kg
MgO 0.62 0.97 1.05 0.15
H20 tak terikat
37,790.76
√0,0328 √0,00002952
0.181107703 0.005433
PERHITUNGAN NERACA ENERGI Data temperatur untuk perhitungan neraca panas Temperatur Referensi Temperatur Input Gas Panas Temperatur Input Raw Mix Temperatur Output A. Panas Input 1. Feed Raw Mix (Dry Material) Senyawa SiO2 Al2O3 Fe2O3 CaO MgO Total Senyawa SiO2 Al2O3 Fe2O3 CaO MgO Cpmix
A= B= C= T in T ref m=
Massa (kg) 50,528.18 12,841.90 7,492.64 173,812.56 2,639.78 247,315.06 XA 2.185E+00 6.645E-01 2.772E-01 7.419E+00 1.715E-01 1.072E+01
1.072E+01 5.811E-03 -1.524E+05 305.00 301.00 4,183.48
Cp mix = A + BT + CT-2 (cal/(kmol.K)) Q1 = m ∫Cpdt Q1 = m [A.(Tin - Tref) + B/2(Tin2 - Tref2) + C/-1(Tin-1 - Tref-1)
Q1
= =
181,029.76 760,324.97 760.32 0.76
= =
2. Air (Material Bonding) Total Air yang terkandung dalam material m = 40,208.00 = 2,233.78 = 2,233,777.78 T input 32.00 T ref 28.00 A B C D m=
33.46 6.880E-03 7.604E-06 -3.593E-09 2,233,777.78
Cp = A + BT + CT2 + DT3 (J/moloC) Q2 = m ∫Cpdt Q2 = m [A.(Tin - Tref) + B/2(Tin2 - Tref2) + C/3(Tin3 - Tref3) + D/4(Tin4 - Tref4) Q2 = 300,873,392.97 = 300,873.39 = 300.87
3. Dust dari Kiln Senyawa SiO2 Al2O3 Fe2O3 CaO MgO Total
Massa (kg)
Senyawa SiO2 Al2O3
XA
1,483.49 207.42 692.87 15,953.83 512.07 18,849.69
8.163E-01 1.366E-01
Fe2O3 CaO MgO Total
3.262E-01 8.666E+00 4.233E-01 1.037E+01
A= B= C= T input T ref m=
1.037E+01 5.162E-03 -1.287E+05 613.00 301.00 328.75
Cp mix = A + BT + CT-2 (cal/(kmol.K)) Q3 = m ∫Cpdt Q3 = m [A.(Tin - Tref) + B/2(Tin2 - Tref2) + C/-1(Tin-1 - Tref-1) Q3
= =
1,233,934.53 5,182,525.02 5,182.53 5.18
= = 4. Gas Panas dari Kiln Senyawa Massa (kg) O2 N2 CO2 SO2 H2O Total
Senyawa O2 N2 CO2 SO2 H2O Total
43,329.58 205,371.49 83,437.49 903.05 5,374.17 338,415.78
Mol(kmol) 1,354.05 7,334.70 1,896.31 14.11 298.57 10,897.73
Senyawa O2 N2 CO2 SO2 H2O Total
XA 3.616E+00 1.952E+01 6.283E+00 5.038E-02 9.167E-01 3.038E+01
A= B= C= D=
30.38 1.052E-02 -1.759E-06 -5.579E-10
Cp mix = A + BT + CT2 + DT3 (J/moloC) Q4 = m ∫Cpdt Q4 = m [A.(Tin - Tref) + B/2(Tin2 - Tref2) + C/3(Tin3 - Tref3) + D/4(Tin4 - Tref4) Tinput = 340.00 Tref = 28.00 m= 10,897.73 10,897,727.42 Q4 = = =
109,623,139,938.70 109,623,139.94 109,623.14
5. Grinding Heat Motor Power Efisiensi Motor Grinding Heat = Mill Power X Efisiensi Motor = 2,635.00 = 9,486,000.00 B. PANAS OUTPUT 1. Raw Meal (Dry Material) Senyawa SiO2
Massa (kg) 52,011.67
Al2O3 Fe2O3 CaO MgO Total Senyawa SiO2 Al2O3 Fe2O3 CaO MgO Total
13,049.32 8,185.51 189,766.39 3,151.85 266,164.75 XA 2.085E+00 6.260E-01 2.808E-01 7.510E+00 1.898E-01 1.069E+01
A= B= C= T output T ref m=
1.069E+01 5.763E-03 -1.506E+05 340.00 301.00 4,512.23
Cp mix = A + BT + CT-2 (cal/(kmol.K)) Q1 = m ∫Cpdt Q1 = m [A.(Tin - Tref) + B/2(Tin2 - Tref2) + C/-1(Tin-1 - Tref-1) Q1
= =
1,947,536.58 8,179,653.65 8,179.65 8.18
= = 2. Air (Material Water) Total Air yang terkandung dalam material m = = = T output T ref A
2,417.24 134.29 134,290.99 67.00
28.00 33.46
B C D m=
6.880E-03 7.604E-06 -3.593E-09 134,290.99
Cp = A + BT + CT2 + DT3 (J/moloC) Q2 = m ∫Cpdt Q2 = m [A.(Tout - Tref) + B/2(Tout2 - Tref2) + C/3(Tout3 - Tref3) + D/4(Tout4 - Tref4) Q2 = 177,045,799.46 = 177,045.80 = 177.05
3. Gas Panas dari Kiln Senyawa Massa (kg) O2 N2 CO2 SO2 H2O Total
Senyawa O2 N2 CO2 SO2 H2O Total Senyawa O2 N2 CO2 SO2 H2O Total A=
43,329.58 205,371.49 83,437.49 903.05 43,164.93 376,206.55
Mol(kmol) 1,488.99 7,081.78 2,310.65 23.21 1,290.05 12,194.67 XA 3.553E+00 1.684E+01 6.842E+00 7.405E-02 3.540E+00 3.085E+01 30.85
B= C= D=
1.151E-02 -2.143E-06 -4.566E-10
Cp mix = A + BT + CT2 + DT3 (J/moloC) Q3 = m ∫Cpdt Q3 = m [A.(Tout - Tref) + B/2(Tout2 - Tref2) + C/3(Tout3 - Tref3) + D/4(Tout4 - Tref4) Toutput = 67.00 Tref = 28.00 m= 12,194.67 12,194,666.89 Q3 = = =
14,929,702,266.09 14,929,702.27 14,929.70
4. Evaporasi H2O (l) Air Raw Mix = Air Raw Meal = Air yang diuapkan = Kandungan air Raw Mix - Kandungan air Raw Meal = 37,790.76 = 2,099.49 = 2,099,486.79 Q4 =
92,377,418.54
5. Heat Loss Heat Loss = Panas Masuk - Panas Keluar = 11,923,609.92
Efisiensi Pengeringan =
= Efisiensi Panas =
= =
INPUT > Raw Mix (Dry Material) Air(Material Bonding) Dust dari Kiln Gas Panas Grinding Heat Total
28.00 oC 340.00 oC 32.00 oC 67.00 oC
Mr
Mol(kmol) 60.09 102.00 159.70 56.00 40.00
XB 1.751E-03 2.700E-04 1.799E-04 3.591E-03 1.888E-05 5.811E-03
K K kmol (F.L.smidth) C/-1(Tin-1 - Tref-1)
Fraksi mol (X) 840.88 0.2009987811 125.90 0.0300947739 46.92 0.0112148101 3,103.80 0.7419166224 65.99 0.0157750126 4,183.48 1.00
XC -4.848E+04 -1.572E+04 -4.748E+03 -8.013E+04 -3.292E+03 -1.524E+05
A 10.87 22.08 24.72 10 10.87
cal Joule kJ MJ
kg kmol mol C C
mol
C/3(Tin3 - Tref3) + D/4(Tin4 - Tref4) Joule kJ MJ
Mr 60.09
Mol(kmol) 24.69 2.03 4.34 284.89 12.80 328.75
102.00 159.70 56.00 40.00
XB
XC 6.542E-04 5.549E-05
-1.811E+04 -3.232E+03
Fraksi mol (X) A 7.510E-02 6.186E-03 1.320E-02 8.666E-01 3.894E-02 1.00
1.087E+01 2.208E+01 2.472E+01 1.000E+01 1.087E+01
2.117E-04 4.194E-03 4.661E-05 5.162E-03
-5.588E+03 -9.359E+04 -8.127E+03 -1.287E+05
K K kmol
C/-1(Tin-1 - Tref-1) cal Joule kJ MJ
Mr
Mol(kmol)
Fraksi mol (X) 1,354.05 1.243E-01 7,334.70 6.730E-01 1,896.31 1.740E-01 14.11 1.295E-03 298.57 2.740E-02 10,897.73 1.00
32.00 28.00 44.00 64.00 18.00
Fraksi mol (X)
A 0.12 0.67 0.17 0.00 0.03 1.00
29.10 29.00 36.11 38.91 33.46
B 1.158E-02 2.199E-03 4.233E-02 3.904E-02 6.880E-03
C -6.076E-06 5.723E-06 -2.887E-05 -3.104E-05 7.604E-06
XB
XC -7.549E-07 3.852E-06 -5.024E-06 -4.019E-08 2.083E-07 -1.759E-06
1.439E-03 1.480E-03 7.366E-03 5.055E-05 1.885E-04 1.052E-02
XD 1.629E-10 -1.932E-09 1.299E-09 1.114E-11 -9.844E-11 -5.579E-10
C/3(Tin3 - Tref3) + D/4(Tin4 - Tref4)
kmol mol Joule kJ MJ
3,100.00 kWh 85.00 %
kWh kJ
Mr
Mol(kmol) 60.09
865.56
Fraksi mol (X) 1.918E-01
A 1.087E+01
102.00 159.70 56.00 40.00
XB 1.671E-03 2.544E-04 1.822E-04 3.635E-03 2.090E-05 5.763E-03
K K kmol
C/-1(Tin-1 - Tref-1) cal Joule kJ MJ
kg kmol mol C C
127.93 51.26 3,388.69 78.80 4,512.23 XC -4.627E+04 -1.481E+04 -4.809E+03 -8.111E+04 -3.644E+03 -1.506E+05
2.835E-02 1.136E-02 7.510E-01 1.746E-02 1.00
2.208E+01 2.472E+01 1.000E+01 1.087E+01
kmol
+ C/3(Tout3 - Tref3) + D/4(Tout4 - Tref4) Joule kJ MJ
Mr
Mol(kmol)
Fraksi mol (X) 1,488.99 1.221E-01 7,081.78 5.807E-01 2,310.65 1.895E-01 23.21 1.903E-03 1,290.05 1.058E-01 12,194.67 1.00
29.10 29.00 36.11 38.91 33.46
Fraksi mol (X)
A 1.221E-01 5.807E-01 1.895E-01 1.903E-03 1.058E-01 1.00 XB 1.414E-03 1.277E-03 8.021E-03 7.430E-05 7.278E-04 1.151E-02
29.10 29.00 36.11 38.91 33.46
XC -7.419E-07 3.324E-06 -5.470E-06 -5.907E-08 8.044E-07 -2.143E-06
B 1.158E-02 2.199E-03 4.233E-02 3.904E-02 6.880E-03
XD 1.601E-10 -1.667E-09 1.414E-09 1.638E-11 -3.801E-10 -4.566E-10
C -6.076E-06 5.723E-06 -2.887E-05 -3.104E-05 7.604E-06
+ C/3(Tout3 - Tref3) + D/4(Tout4 - Tref4)
kmol mol Joule kJ MJ
H2O (g) 40,208.00 kg 2,417.24 kg
x - Kandungan air Raw Meal kg kmol mol kJ
kJ
Panas Evaporasi x 100% Panas Input 77.36 % Panas Output
X 100%
H =
44.00
Panas Input 107,492,346.26 x 100% 119,415,956.18 90.02
INPUT
variabel
persen H2O pada raw meal H2O Raw Mix H2O Raw Meal Umpan Raw Mix (ton) Input (oC) Output (oC) Raw Mill Motor Power (kWh) Persen Pengeringan (%) Heat Loss (kJ) Efisiensi Pengeringan (%) Efisiensi Panas (%)
760.32 kJ 300,873.39 kJ 5,182.53 kJ 109,623,139.94 kJ 9,486,000.00 kJ
Raw Meal (Dry Material) Air (Material Water) Gas Panas Evaporasi Heat Loss
119,415,956.18 kJ
Total
Desain
0.90 37,707.85 2,183.32 300.00 30.00 65.00 2,162.00 94.21 27,816,310.59 63.15 76.74
Aktual
0.90 % 40,208.00 kg/jam 2,417.24 kg/jam 287,523.06 ton/jam 32.00 oC 67.00 oC 3,100.00 kW 93.99 % 11,923,609.92 kJ 77.36 90.02
B 0.008712 0.008971 0.01604 0.00484 0.001197
C -241200 -522500 -423400 -108000 -208700
B
C 8.712E-03 8.971E-03 1.604E-02 4.840E-03 1.197E-03
-2.412E+05 -5.225E+05 -4.234E+05 -1.080E+05 -2.087E+05
D 1.311E-09 -2.871E-09 7.464E-09 8.606E-09 -3.593E-09
B 8.712E-03
C -2.412E+05
8.971E-03 1.604E-02 4.840E-03 1.197E-03
-5.225E+05 -4.234E+05 -1.080E+05 -2.087E+05
D 1.311E-09 -2.871E-09 7.464E-09 8.606E-09 -3.593E-09
kJ/mol
Meal (Dry Material) Material Water)
OUTPUT 8,179.65 kJ 177,045.80 kJ 14,929,702.27 kJ 92,377,418.54 kJ 11,923,609.92 kJ 119,415,956.18 kJ
persen panas hilang
9.98
%
Neraca Energi komponen RM Gas Debu H20 T ref panas laten air 0 C Asumsi yang di ambil komponen Raw mix H2O (g) Udara Clinker Cp = A + B.10^-6.T + C.10^-9.T^2 Cp : komponen Raw Material H2O Gas Debu
Power motor efisiensi motor
1 kcal = 1 kj/s = 1 kcal/jam =1 kW *((1 kJ/s)/1kW)*(1kcal/ 4,2 kJ)*(3600 s/1 1 kW
Neraca panas IN 1. Raw Material (dry) 2. H2O tak terikat 3. Gas panas 4. Debu 5. Panas Grinding
OUT 1. Raw Material (dry) 2. H2O terikat 3. H2O teruapkan 4. All gas out
INPUT > Raw Mix (Dry Material) H2O tak terikat Dust dari Kiln Gas Panas Grinding Heat
240,592.52 33,572.95 1,201,862.11 25,849,497.16 2,258,571.43
Total
29,584,096.17
efisiensi panas =
Efisiensi pengeringan
Tempe ratur (C) masuk
= = : A
keluar 32
67
340
67
340
67
30
65 28.00 539 Cp gas = Cp udara
C kcal/kg C
B
C 101 39 23 54
0.206 0.443 0.237 0.186
Cp (kcal/kg C) masuk 0.209194112
keluar 0.212600907
0.4441952
0.445738692
0.24482
0.238541
0.20436
0.189618
3,100 85
kW %
4.2 kJ 1 kW W)*(1kcal/ 4,2 kJ)*(3600 s/1jam) 857.1429 kcal/jam
37 28 0 0
m.cp.∆T Q
m 287,523.06 37,790.76 338,415.78 18,849.69
240592.5249 33572.9503 25849497.1589 1201862.1097 2258571.4286 29584096.1723519
kcal/jam kcal/jam kcal/jam kcal/jam kcal/jam kcal/jam
268,581.99 2,417.24 37,790.76
2226930.1744 39865.8885 20369220.7887623
kcal/jam kcal/jam kcal/jam
376,206.55
3499886.75046193
kcal/jam
26135903.6021
kcal/jam
3448192.5702
kcal/jam
m
Q
Panas hilang ( Q loss ) = % Q loss =
11.6555616577 %
OUTPU kcal/jam kcal/jam kcal/jam kcal/jam kcal/jam kcal/jam kcal/jam
panas keluar panas masuk
Raw Meal (Dry Material) H2O terikat H2O teruapkan Gas Panas Heat Loss Total
* 100% =
Panas H20 Teruapkan/ panas evaporasi
88.3444383423
*100% =
panas masuk
124253203.923878
OUTPUT 2,226,930.17 39,865.89 20,369,220.79 3,499,886.75 3,448,192.57 29,584,096.17
%
68.8519286514 %
kcal/jam kcal/jam kcal/jam kcal/jam kcal/jam kcal/jam kcal/jam
