2
Institut Semen dan Beton Indonesia
Process Engineering, 2010
Combustion
Molar Alkali/Sulfur Ratio dan Volatilitas
Indikasi sebuah perbandingan antara alkali dan molekul sulfur dikoreksi
oleh chlorine dalam total inputs (fuel dand raw materials) dari kiln feed
system (Target: 0.8 sampai 1.2)
Persamaan:
(Total Input SO
3
>1.25% akan menimbulkan built up)
Volatilitas: tingkat kemudahan atau kecepatan suatu bahan kimia akan
menguap dalam kondisi suhu dan tekanan tertentu ( limit < 0.7)
80
71 62 94
0
3
2 2
3
SO
Cl O Na K
SO
Alk
% berat
dengan:
C
clinker
= konsentrasi bahan di clinker
C
hotmeal
= konsentrasi bahan di hot meal
hotmeal
clinker
C
C
1
Institut Semen dan Beton Indonesia
Process Engineering, 2010
Moduli kiln Feed
Burnability menyatakan kemudahan terbentuknya mineral-mineral clinker
dari raw mix pada suatu kondisi tertentu dalam kiln system (tergantung
moduli dan kehalusan)
Burnability (by: FLS)
FCaO
(1400oC )
= + 0.33(LSF-(105.7-5.4SM))
+ 0.56 (CaCO3 >125)
+ 0.93 (SiO2 > 45)
Liquid phase: menentukan granulometri clinker dalam kiln (dusty or
balling)
% Liquid (1340 oC) = 6.10 (Fe2O3) + MgO + (Na2O + K2O) <----- AM > 1.38
= 8.5(Al2O3) - 5.22(Fe2O3) + MgO + (K2O + Na2O) <----- AM < 1.38
% Liquid (1400 oC) = 2.95(Al2O3) + 2.2 (Fe2O3) + MgO + (Na2O + K2O) <----- MgO max 2%
% Liquid (1450 oC) = 3.0(Al2O3) + 2.25(Fe2O3) + MgO + (Na2O + K2O) <----- MgO max 2%
Institut Semen dan Beton Indonesia
Process Engineering, 2010
AR SR Sifat Coating / clinker
< 1.6 < 2.5 Coating tipis, brick attack, liquid melt >>>
> 1.6 < 2.5 Coating tebal / ring, clinker ball, viscous melt >>>
< 1.6 > 2.5 Coating tipis, liquid melt <<<
> 1.6 > 2.5 Coating sangat tipis, viscous melt <<<
1.3 ~ 1.9 2.2 ~ 2.8 Normal coating - clinker
Granulasi Clinker dan pembentukan coating dipengaruhi kuantitas
(SR) dan viscositas (AR) liquid phase.
Granulasi clinker & pembentukan coating
Institut Semen dan Beton Indonesia
Process Engineering, 2010
Clinker Cooler
Layout Cooler
(distribusi clinker distribution, sistem grate plate, inklinasi grate,
drive, clinker crusher, clinker fall through handling)
Grate speed dan clinker bed (fluktuasi speed dan clinker bed,
drive system)
Distribusi udara, cooling fan (limit kapasitas fan)
Gap management (grate alignment, compartment sealing, grate
support, hopper discharge control)
Control loops and interlocks
Institut Semen dan Beton Indonesia
Process Engineering, 2010
Clinker Cooler
Grate speed:
Cooling Residence Time
Distribusi udara dan kapasitas cooling fan
SPM =
L * H * Lst *
cl
*
cl
P
P = Kapasitas
L = Lebar grate
H = Tinggi clinker bed
cooling =
P = Kapasitas
Lgr = panjang grate
L = Lebar grate
H = Tinggi clinker bed
Lgr * L * H
P /
cl
Institut Semen dan Beton Indonesia
Process Engineering, 2010
Fan Pressure & Air Distribution
Pressure fan:
dP
exp
= f(T) p
1
> p
2
> p
3
> ..p
n
(recuperation zone)
untuk cooling zone p
n
> p
n+1
Air distribution:
Recuperation zone = Cooling zone
(air beam + sealing) (air chamber/compartemen)
0
100
200
300
400
500
600
700
800
900
1000
1100
1200
1300
1400
1 2 3 4 5 6 7 8 9 10
T-cl
P-ug
dP Cl-bed
Ideal air distribution
air - clinker
Institut Semen dan Beton Indonesia
Process Engineering, 2010
STUDI KASUS - DISKUSI
Institut Semen dan Beton Indonesia
Process Engineering, 2010
BZT
1350 C
BET
1190 C
Oxygen at KI =
1.5%
CO=0.15%
Fuel rate Kiln speed Feed rate
Kiln draft
and PC draft
Oxygen after PC
1 - 1.5 %
Fuel rate PC
Studi Kasus Kiln System
T-cl 190
o
C
1
st
, 2
nd
, 3
rd
=23 spm 1
st
chamb. = 35 mbar
2
nd
air 680
o
C
Hotmeal:
2.85% SO3,
0.14% cl
91% calc
: 326 tph
Speed 100% RPM
Damper 100%
410
o
C, 65mbar, 4.0 %O
2
: 60 %
5 mbar
Plant A data 2009 sbb:
Kapasitas terpasang: 5000 TPD (CF=1.65)
Specific heat consumption : 3400 MJ/t
Kiln: availabilty 85.1%, rate index 95%
Primary air :
Rad. 4600Nm3/h 130mbar
Ax. 5000Nm3/h 200mbar
Kiln ID: 4.7m L=75m
Cooler W: 3.3m L:27m
Institut Semen dan Beton Indonesia
Process Engineering, 2010
Analisis Material 2009 (data lab.)
Kiln Feed
LOI = 35.9%
SM = 2.35
LSF = 99
SiO2 >45 = 0.35%
CaCO3 > 125 = 2.8%
Clinker
SO3 = 0.35
FCaO = 0.55 %
AM = 1.7
LSF = 96
Fuel (coal)
NCV = 52100 kcal/kg
Ash = 10%
VM = 41%
R90 = 25%
S = 1.35%
Institut Semen dan Beton Indonesia
Process Engineering, 2010
Target Produksi 2010:
Menaikkan produksi clinker 1.710.000 T/A (budget 2009: 1.660.000 T/A)
Kiln availability 90% (Overhaul tahunan 15 hari)
Menurunkan spesific thermal energy 5%
Lakukan analisis data operasi 2009
Botleneck proses, dampak masalah dan improvement apa yang dapat
saudara lakukan (optimalisai proses atau proposal CAPEX
(modifikasi)?). Isi tabel (p.16-17).
Langkah-langkah:
Hitung OEE & Production rate 2009 dan evaluasi gap terhadap design
capacity
Task 2009
Institut Semen dan Beton Indonesia
Process Engineering, 2010
Solusi Tahun 20
Bottlenecks 2009
Analisa Indikator proses
dan moduli
Bottleneck Impact terhadap
proses
Deskripsi
Improvement
proposal
Benefit terhadap
performance
(volume, cost,
energy consumption)
CAPEX dan
estimasi kiln
downtime
Institut Semen dan Beton Indonesia
Process Engineering, 2010
BZT
1450 C
BET
1050 C
Oxygen at KI =
0.9%
CO=0.25%
Fuel rate Kiln speed Feed rate
Kiln draft
and PC draft
Oxygen after PC
1.5 2.0 %
Fuel rate PC
Kondisi Kiln System 2010
T-cl 90
o
C
1
st
, 2
nd
, 3
rd
=15 spm 1
st
chamb. = 65 mbar
2
nd
air 910
o
C
Hotmeal:
3.26% SO3,
0.31% cl
94% calc
: 337 tph
Speed 100% RPM
Damper 100%
410
o
C, 65mbar, 4.7 %O
2
: 60 %
3 mbar
Kapasitas terpasang: 5000 TPD (CF=1.65)
Specific heat consumption : 3300 MJ/t
Kiln: availabilty 90%, rate index 98%
Primary air :
Rad. 4800Nm3/h 140mbar
Ax. 5000Nm3/h 200mbar
Kiln ID: 4.7m L=75m
Cooler W: 3.3m L:27m
Institut Semen dan Beton Indonesia
Process Engineering, 2010
Target Produksi 2010:
Menaikkan produksi clinker 1.710.000 T/A (budget 2009: 1.660.000 T/A)
Kiln availability 90%, Prod. Rate 98%
Menurunkan spesific thermal energy 5%
Data down time 2010:
Task
Trouble data 2010
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Institut Semen dan Beton Indonesia
Process Engineering, 2010
Target Produksi 2011:
Menaikkan produksi clinker 1.750.000 T/A (budget 2009: 1.710.000 T/A)
Kiln availability 90% (Overhaul tahunan 15 hari)
Menurunkan spesific thermal energy 5%
Lakukan analisis data operasi 2010
Botleneck proses, dampak masalah dan improvement apa yang dapat
saudara lakukan (optimalisai proses atau proposal CAPEX
(modifikasi)?). Isi tabel (p.16-17).
Langkah-langkah:
Hitung OEE & Production rate 2010 dan evaluasi gap terhadap full
design capacity
Task 2010