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)

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 =

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

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

/=1,4610,18(1/0,000029521/0,0328)

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

/=1,467,1(1/0,000029521/0,0328)

/=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

/=1,4615,44(1/0,000029521/0,0328)

P/T=
P=

4,024.52
4.024,52 * T

P=
E=

23,077.92 hp
P/T
4,024.52 hp.min/ton

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

E=

12,42/100

E=

229.89 hp.min/ton

3. bijih besi
E=

2,42/100

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(1/0,1811077031/0,005433)

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

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

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

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