UNIVERSITAS INDONESIA

PRODUCTION OF ADVANCED AND LOW CARBON

CEMENT

Revised Assignment 2

GROUP 32

GROUP PERSONNEL:
ADITHA OKTARIANY (1406531662)
FITRIANI MEIZVIRA (1406565493)
IVA RAUDYATUZZAHRA (1406531795)
RICKY (1406570934)
YUGO WIDHI NUGROHO (1406563235)
ZHOFRAN BINTANG (1206250166)

CHEMICAL ENGINEERING DEPARTMENT

ENGINEERING FACULTY
DEPOK
SEPTEMBER 2017
 EXECUTIVE SUMMARY

In plant design, after deciding the manufacturing process, there is a need to

do optimization in the area of energy consumption. Energy consumption will affect
the capital and operational cost, and will eventually determine the economic
feasibility of the plant. Therefore, optimizing energy consumption is a very
important thing to do.
Heat integration is applied in chemical plant to achieve energy optimization.
Heat integration is commonly achieved by using heat exchanger network, where
streams with high energy gives its heat to a stream that needs temperature increase.
The give-and-take between streams in the plant will minimize the use of heat utility,
thus energy consumption will be diminished as well.
In cement plant, similar action can not be applied the same way, for the
stream is mainly solid, and no heat exchanger can be used to exchange heat. Instead
of using heat exchanger network, the manufacturing process in cement plant applies
the heat integration principal by utilizing the flue gas from rotary kiln, to give a pre-
heating for the raw meal. Another heat integration is also shown in the air cooler,
where the exhaust air that have high temperature after cooling the clinker is drawn
to the kiln as heating media.
Another utility is fuel, in which it will be used for calcination process in
rotary kiln. Fuel in this cement plant consists of 70% coal and 30% biomass. The
need of fuel is calculated from net heating value of each materials and the power
requirement from the involved equipment. Net heating value for coal is evaluated
from process simulation, while biomass is evaluated by referencing to existing data,
because of incompatibilities that occur upon using any process simulator. The
calculation shows that the fuel requirment for this advanced and low carbon cement
is about 19 ton/hour.
Electricity is the most essential utility in the plant. It empowers most of the
devices used for the main process and other uses such as office operation and
lightings. From the purposes, electricity needs are analyzed into two: for plant
operation and office needs. We calculate the plant operation electricity requirement
and office and lightings electricity requirement. The calculation shows that for plant

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operation electricity needed is 31,410.324 MWh, and for office and lighting is
214,985.00 kWh.

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 LIST OF CONTENT

EXECUTIVE SUMMARY ................................................................................... ii

LIST OF CONTENT ........................................................................................... iv
LIST OF FIGURES .............................................................................................. v
LIST OF TABLES ............................................................................................... vi
CHAPTER 1 ENERGY INTEGRATION ............. Error! Bookmark not defined.
1.1 Energy Integration and Heat Exchanger Network ................................ 1
1.2 Heat Recovery Pinch ............................................................................ 1
1.2.1 Composite Curve............................................................................... 1
1.2.2 Problem Table Cascade ..................................................................... 2
1.3 Energy Integration in Cement Plant...................................................... 2
CHAPTER 2 UTILITY ........................................................................................ 6
2.1 Fuel ....................................................................................................... 6
2.2 Electricity .............................................................................................. 7
2.2.1 Plant Operation Electricity Requirement .......................................... 7
2.2.2 Power Generation ....................................................................................... 8
CHAPTER 3 CONCLUSION ............................................................................ 11
REFERENCES .................................................................................................... 12

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 LIST OF FIGURES

Figure 1.1 Production Of Advanced And Low Carbon Cement . Error! Bookmark
not defined.
Figure 1.2 Flue Gas and Raw Meal Contact Inside Cyclone Preheater .................. 4

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 LIST OF TABLES

Table 2.2 Equipment Energy Requirement ............................................................. 7

Table 2.5 Caterpillar Power Generator Specification ............................................. 9

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 CHAPTER 1
ENERGY INTEGRATION

1.1 Energy Integration and Heat Exchanger Network

Nearly every equipment in a chemical plant relies on energy consumption
to do the work. For example: pumps, distillation column, compressor, heater, and
cooler. Because of this, energy and power consumption is an important thing in
designing a plant, since it will determine both the capital and operational cost of the
plant, and eventually the economic feasibility of the plant as well. To have the most
economic working plan, energy usage needs to be optimized through energy
integration.
To enter a certain process or equipment, a stream needs to reach a certain
temperature, and it can be achieved by installing heat utilities in the plant: hot
utilities that use steam or fuel; and cold utilities that use cooling water or refrigerant,
which means more energy usage to each utilities used. To make it more efficient,
chemical plants hold to energy integration principal. Instead of using utilities,
energy integration is a method of using energy that is owned by process stream to
give to another stream that needs a temperature change. By applying this method,
chemical plants can save up energy usage.
1.2 Heat Recovery Pinch
Generally, heat integration can be achieved through effective use of heat
exchangers. In heat exchange network, the streams arrangement, such as which
streams can exchange heat, can be determined from a method called heat recovery
pinch. The term pinch is introduced by Linnhoff and Vredeveld to present a new
set of thermodynamically based methods that guarantee minimum energy levels in
design of heat exchanger networks. There are two kind of methods which can be
used to determine the pinch from all heat exchangers in a plant: composite curve
and problem table cascade.
1.2.1 Composite Curve
Composite curve is also known as Temperature Enthalpy Plot. Composite
curve plots enthalpy and temperature profiles of heat availability for hot streams,
and heat demand for cold streams. A minimum temperature difference (Tmin), a

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temperature limit in which heat exchange can happen, is determined first. After
having hot stream profile and cold stream profile, both then will be compiled in
one graph to determine the total of heat recovery from the gap above and under the
line.
1.2.2 Problem Table Cascade
This method differs from the previous one because this method uses
numerical approach to solve the heat recovery amount, heat exchanger needed, and
utilities needed in a plant. Generally, problem table cascade is favored over
composite curve because of the better accuracy.
1.3 Energy Integration in Cement Plant
In this plant, whole materials processed are in the form of solids. There is
little amount of heat transfer found in the main process because most of the process
in the plant is mechanical.
Because the main stream is solid, it is impossible to use heat exchanger to
recover heat from stream. So, instead of applying HEN using mentioned method
above, the heat integration in the plant is applied in the overall process. Illustrated
by the process flow diagram, the heat integration is created through the flue gas
usage from the clinker that is transferred to the preheater cyclones. Hot gas that has
been used in calcination process still has much enthalpy in it, so instead of releasing
it right away, it is moved to the preheater cyclones to heat the raw meal. By having
the raw meal preheated, the kiln will have lighter work to do the calcination proces

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Figure 1.1. Advanced and Low Carbon Cemeent Process Flow Diagram

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This process also shows that the heat integration is just feasibly applied for
the utility, not the processed material. We can conclude from this description that
heat integration in the form of heat exchanger network cannot be applied for this
plant.
Below are the heat integration in the cyclone preheater process scheme. The
flue gas will enter the the cyclone and will contact with the raw meal materials,
there will be heat transfer between the flue gas and the material.

Figure 0.1 Flue Gas and Raw Meal Contact Inside Cyclone Preheater
(Source: FLSmidth, 2011)

The heat transfer between flue gas and material are calculated each stages.
By calculating each heat transferred by flue gas and received by raw meal we can
calculate the temperature of raw meal after leaving one stage of cyclone preheater.
Data of raw meal and flue gas are provided in Table 1.1. below.

Table 1.1. Raw Meal and Flue Gas Data

Mass (kg / 1 hr basis) Cp m.Cp
Raw Meal 82480.8 2166.32 178,678,073.6
Flue Gas 270905.4 605.4 164,006,189.7

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After calculating for each stages, we may know number of heat transferred
and output temperature of raw meal in each stages. The result is provided in table
below.

Table 1.2. Energy Integration Calculation

Flue Gas Raw Meal

Stage Q transferred
T in T out T in T out
1 33,055,764,231 478 293 27 228.552
2 30,732,926,745 650 478 228.552 415.94
3 26,623,291,192 799 650 415.94 578.271
4 16,259,862,406 890 799 578.271 677.413
5 19,654,778,732 1000 890 677.413 797.255

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 CHAPTER 2
UTILITY

2.1 Fuel
Fuel is the main utility in the plant that is needed for operating the rotary
kiln. The fuel will be processed into the grinding process due to the form of solids,
resulting the hot gas that will be used for the rotary kiln.
The fuel used in the plant are from coal and biomass (shell palm), with
composition of 70% and 30% respectively, determined by the common research
and practice conducted in cement plant, such as Lafarge. The calculation of fuel
requirement is done by dividing power requirement from involved equipment
(which in this case is rotary kiln) by net heating value from fuels. Power
requirement can be acquired from process simulation that has been done in Aspen
Plus V10. Net heating value from coal is acquired from the simulation as well,
meanwhile the value for biomass is taken from (Kavalek, 2013), considering the
incompatibilities and difficulties in simulation compared to coal.
Table 2.1. shows the calculation done to seek for fuel consumption for the
plant.

Table 2.1. Fuel Calculation

Net Heating % Fuel Duty
Value mass requirement (kJ/hr)
(kJ/kg) (kg/hr)
Coal 22950 0.7 13288.51582 422347000
Biomass 20610 0.3 5695.078209
Total mass 18983.59403
Target duty 422347000

Target Duty is the power requirement for rotary kiln. Total Mass is
substituted by any value at first, and then the Fuel Requirement will be calculated
by multiplying NHV and mass percentage. Duty column will be calculated by
multiplying NHV and Fuel Requirement. After that, by using Goal Seek feature in
Excel, the value in Duty is set to Target Duty, to acquire Total Mass from the fuel.

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By knowing the Total Mass, Fuel Requirement column will calculate mass needed
for each fuel.
By the calculation above, the plant needs fuel for 18.98 ton/hour, rounded
up to 19 ton/hour, with coal 13.29 ton/hour and biomass 5.7 ton/hour.
2.2 Electricity
Electricity is the most essential utility in the plant. It empowers most of the
devices used for the main process and other uses such as office operation and
lightings. From the purposes, electricity needs are analyzed into two: for plant
operation and office needs.
2.2.1 Plant Operation Electricity Requirement
Most of the devices operated in the plant use electricity as the power
resource. Electricity is used both for main process devices and utility ones. Whole
main process electricity requirement will be supplied by Perusahaan Listrik Negara
(PLN) this table below shows the calculations of electricity requirement in the main
process and utilities in the plant.

Table 2.1 Equipment Energy Requirement

Usage Energy
No Tag Power
Equipment Qty Time Required
. number (kW)
(h) (kWh)
1 Jaw crusher CR-101 1 24 110 2,640
2 Rod mill MI-101 1 24 2500 60,000
3 Ball mill MI-102 1 24 120 2,880
4 Blending machine BR-101 3 24 20 1,440
5 Electrostatic precipitator
EP-101 1 24 75 1,800
6 Cyclone for preheater CY-101 1 24 190 4,560
7 Rotary kiln RK-101 1 24 315 7,560
8 Grate cooler E-101 1 24 120 2,880
9 Air cooler E-102 1 24 120 2,880
10 Fuel crusher CR-102 1 24 55 1,320
11 Fuel mill MI-104 1 24 132 3,168
12 Flash dryer DR-101 1 24 22 528
(no tag
13 Screw conveyor 1 24 146.95 3526.8
number)
Overall Duty 95,182.8

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The electricity requirement above is calculated just for one-day operation.

The whole electricity requirement is supposed to be calculated for one-whole-year
operation, in this case, 330 days. Number of plant operation days is taken so because
of the consideration of shut down-maintenance-start up process which will take
around one month and needs less electricity. The plant is continuously operating
for about 24 hours a day. The calculation for the whole electricity requirement for
one year follows this equation:
Daily plant operation electricity requirement = energy requirement
energy generation (2.1)
Daily plant operation electricity requirement = (95,182.8 0) kWh
Daily plant operation electricity requirement = 95,182.8 kWh
Annual plant operation electricity req. = daily electricity requirement x
days of plant operation (2.2)
Annual electricity requirement = (88.776 MWh) (330 days)
Annual plant operation electricity requirement = 31.410 MWh
Electricity cost from Perusahaan Listrik Negara is about IDR 1,112.00 per
kWh for industrial category I-1/3500 VA-14 kVA. So, the total cost for electricity
need is:
Annual plant operation electricity cost = annual plant operation
electricity requirement x electricity cost (2.3)
Annual plant operation electricity cost = (31,410,324 kWh) (IDR
1,112.00/kWh)
Annual plant operation electricity cost = IDR 34,928,280,288.00
2.2.2 Power Generation
This cement plant operates for 24 hours with a continuous process, any
electricity failure would be fatale since all of the equipments works by the
electricity power. To prevent that, there should be built a power generator that might
be used if there is any disturbance and electricity failure from Perusahaan Gas
Negara. Diesel power generator is a common type of power generator that has been
used by many cement plant, since solar fuel has a higher calorific value and lower
carbon dioxide emission than the coal fuel.

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To count the total fuel and cost required, the SAIDI ( system average
interruption duration index) and SAIFI (system average interruption frequency)
should be known first, we can get it from data that surveyed and issued by BPPT in
2013, for West Java Province the SAIDI number is 1.22 and for the SAIFI number
is 1.89. This figure and table below shown the diesel power generator machine by
Caterpillar that will be used in this plant.

Figure 2. 1 Caterpillar Power Generator

(Source : Caterpillar Asia, 2017)

Table 2.2 Caterpillar Power Generator Specification

Specifications Value
Type 3612
Frequency 50 Hz
Minimum Rating 3550 kVA (2840 kW)
Maximum Rating 5375 kVA (4300 kW)
Speed 750 & 1000 rpm
Fuel Diesel
Fuel Consumption 100% Load 1200 L/h
(Source: Caterpillar Asia, 2017)

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The calculation of the fuel and cost for emergency diesel power generator
(one hour basis):
Electricity Requirement = 95,183 kWh / 24 h = 4000 kW
Fuel Requirement = (1200L / 4000 kW ) 4300 kW = 1290 L
Fuel Requirement Corrected = Fuel Requirement SAIDI SAIFI
= 1290 L 1.89 1.22 = 2975 L
Solar cost from Pertamina is about IDR 8,200.00 per Liter for industrial
category. So, the total cost for electricity need in this basis is:
Fuel (Solar) Cost = IDR 8,200/L 2975 L = IDR 24, 395, 000.00

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 CHAPTER 3
CONCLUSION

The main stream is solid, it is impossible to use heat exchanger to recover heat
from stream. So, instead of applying HEN, the heat integration in the plant is
applied in the overall process
The plant needs fuel for 18.98 ton/hour, rounded up to 19 ton/hour, with coal
13.29 ton/hour and biomass 5.7 ton/hour.
Total annual plant operation electricity requirement = 31,410.324 MWh and
annual plant operation electricity cost = IDR 34,928,280,288.00
Total annual office and lighting electricity requirement is 214,985.00 kWh and
annual office and lighting operation electricity cost is IDR 239,063,320.00

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 REFERENCES

Alsop, P.A. 1998. Cement Plant Operations Handbook for Dry Process Plants, 2nd
Edition. International Cement Review.
Chinyama, Moses P. M. 2011. Alternative Fuels in Cement Manufacturing. Intech
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Ikhwan Wahyudi. 2011. Indarung VI Harapan Baru Sumatera Barat. Online.
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Rubenstein, Madeleine. 2012. Emissions from the Cement Industry. Online.

Available at: http://blogs.ei.columbia.edu/2012/05/09/emissions-from-the-
cement-industry/
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Pulverized Coal Combustion in Cement Rotary Kiln. Hubei: Huazhong
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