KATA PENGANTAR

Puji dan syukur kami ucapkan kepada Tuhan Yang Maha Esa, karena atas
berkat dan rahmat-Nya, Laporan Kerja Praktek di PT Semen Padang dapat
diselesaikan. Laporan Kerja Praktek ini memmiliki tugas khusus yang berjudul
“Menghitung Neraca Massa dan Energi Pada Unit Kilndi Pabrik Indarung II/III PT
Semen Padang”. Laporan Kerja Praktek ini ditulis untuk memenuhi persyaratan mata
kuliah Kerja Praktek di Jurusan Teknik Kimia, Fakultas Teknik, Universitas
Sumatera Utara. Kerja Praktek dimulai pada tanggal 22 Januari 2018 s.d. 09 Maret
2018 di Biro Produksi II/III PT. Semen Padang.
Selama penyusunan Laporan Kerja Praktek ini, penulis banyak menerima
bantuan dan dorongan dari berbagai pihak. Oleh karena itu, pada kesempatan ini
penulis mengucapkan terima kasih sebesar-besarnya kepada:
1) Kedua orang tua, saudara, dan keluarga besar yang selalu mendukung dan
mendoakan sehingga Kerja Praktek ini berjalan lancar
2) Ibu Maya Sarah, S.T., M.T., Ph.D., IPM. Selaku Ketua jurusan Teknik Kimia
Universitas Sumatera Utara.
3) Ibu Dr. Maulida, S.T., M.Sc. selaku dosen pembimbing Kerja Praktek Teknik
Kimia Universitas Sumatera Utara
4) PT. Semen Padang yang telah memberikan kesempatan kerja praktek kepada
penulis sehingga laporan ini dapat disusun dengan baik.
5) Bapak Ujang Friatna, S.T. selaku Kepala Bagian Biro Produksi Indarung II/III
PT. Semen Padang.
6) Bapak Sumarno selaku pembimbing di Biro Produksi Indarung II/III PT. Semen
Padang.
7) Bapak Syafriwel, Bapak Wismaldi, Bang Dani, Bang Hendrik, Bang Adi, Bang
Heru, Bang Andri, Bang Andi dan Seluruh staff karyawan dan karyawati PT.
Semen Padang yang telah memberikan banyak bimbingan dan pengetahuan.

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8) Febrina Iskandar, Azwin Harfansah Nst, Ilham Fujian Junaidi, Danil Maha Putra,
Hamzah Arifin Sinambela, Michael Dillo Rizki Ginting, Agus Ari Setiawansyah,
Ridho Kurniadi, Alfhan Kurnia, M. Reza yang telah banyak membantu selama
pelaksanaan kerja praktek di PT. Semen Padang.
Penulis meyakini bahwa laporan ini jauh dari kesempurnaan dan semoga
laporan ini dapat memberikan masukan bagi yang membaca.

Padang, Maret 2018

Penulis

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 DAFTAR ISI

KATA PENGANTAR .......................................................................................... ..i

DAFTAR ISI ........................................................................................................ ..iii
DAFTAR GAMBAR ........................................................................................... vii
DAFTAR TABEL .............................................................................................. ... x
BAB I PENDAHULUAN ..................................................................................... 1
1.1 Latar Belakang .......................................................................................... 1
1.2 Tujuan Kerja Praktek ................................................................................ 2
1.3 Manfaat Kerja Praktek .............................................................................. 2
1.3.1 Bagi Mahasiswa ............................................................................... 2
1.3.2 Bagi Universitas ............................................................................... 2
1.3.3 Bagi Perusahaan ............................................................................... 2
1.4 Waktu Pelaksanaan Kerja Praktek ............................................................ 3
BAB II GAMBARAN UMUM PERUSAHAAN ................................................. 4
2.1 Sejarah PT Semen Padang ........................................................................ 4
2.2 Lokasi Perusahaan ..................................................................................... 8
2.3 Struktur Organisasi Perusahaan ............................................................... 10
BAB III TINJAUAN PUSTAKA ........................................................................ 12
3.1 Semen ....................................................................................................... 12
3.2 Jenis-jenis Semen ..................................................................................... 14
3.2.1 Portland Cement ............................................................................. 14
3.2.2 Non-Portland Cement ..................................................................... 16
3.3 Bahan Baku Pembuatan Semen................................................................ 16
3.3.1 Bahan Baku Utama ......................................................................... 16
3.3.2 Bahan Tambahan (Aditif) ............................................................... 24
3.3.3 Bahan Korektif ................................................................................ 27
3.4 Sifat Fisika dan Sifat Kimia Semen ......................................................... 28
3.4.1 Sifat Fisika Semen .......................................................................... 28
3.4.2 Sifat Kimia Semen .......................................................................... 32
3.5 Faktor Kualitas Semen ............................................................................. 35
3.6 Standar Nasional Indonesia (SNI) ............................................................ 36

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BAB IV PROSES PRODUKSI............................................................................ 39
4.1 Tahapan Proses Pembuatan Semen .......................................................... 39
4.1.1 Tahap Penyediaan dan Persiapan Bahan Baku ............................... 40
4.1.1.1 Quarry (Penambangan) ....................................................... 40
4.1.1.2 Pengadaan dan Penyimpanan Bahan Baku ......................... 40
4.1.2 Tahap Penggilingan Bahan Baku (Pembentukan Raw Mix) ........... 47
4.1.3 Tahap Pembentukan Klinker (Pembakaran Raw Mix) .................... 56
4.1.3.1 Persiapan Batu Bara (Fine Coal) ........................................ 56
4.1.3.2 Proses Pemanasan Awal (Preheater) .................................. 63
4.1.3.3 Proses Pembuatan Klinker (Pembakaran Raw Mix) ............ 64
4.1.3.4 Tahap Penyimpanan Klinker di Dalam Silo ........................ 70
4.1.4 Tahap Penggilingan Klinker (Pembuatan Semen) .......................... 71
4.1.4.1 Tahap Pengumpanan Material ............................................ 71
4.1.4.2 Tahap Penggilingan Awal di Vertical Roller Mill .............. 72
4.1.4.3 Tahap Penggilingan di Cement Mill.................................... 77
4.1.4.4 Tahap Pengiriman Semen ke Silo Semen ........................... 81
4.1.5 Tahap Pengantongan Semen ........................................................... 82
BAB V SPESIFIKASI ALAT .............................................................................. 83
5.1 Spesifikasi Alat Utama ............................................................................. 83
5.1.1 Raw Mill .......................................................................................... 83
5.1.2 Coal Mill ......................................................................................... 83
5.1.3 Unit Kiln ......................................................................................... 84
5.1.4 Planetary Cooler............................................................................. 85
5.1.5 Cement Mill..................................................................................... 85
5.2 Alat Pendukung Operasi........................................................................... 86
5.2.1 Cyclone ........................................................................................... 86
5.2.2 Gas Conditioning Tower (GCT) ..................................................... 87
5.2.3 Electrostatic Precipitator (EP) ....................................................... 88
5.2.4 Cerobong (Stack) ............................................................................ 89
5.2.5 Jet Pulse Filter (JPF) ...................................................................... 89
5.2.6 Bag House Filter (BHF) ................................................................. 90
5.2.7 Hopper ............................................................................................ 91

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 5.2.8 Ducting............................................................................................ 91
5.3 Alat Penarikan Material ........................................................................... 92
5.3.1 Bridge Scrapper .............................................................................. 92
5.3.2 Side Reclaimer ................................................................................ 93
5.3.3 Bucket Chain Excavator ................................................................. 94
5.4 Alat Transportasi ...................................................................................... 95
5.4.1 Belt Conveyor ................................................................................. 95
5.4.2 Bucket Elevator ............................................................................... 95
5.4.3 Appron Conveyor ............................................................................ 96
5.4.4 Air Slide/Fluxo Slide ....................................................................... 97
5.4.5 Screw Conveyor .............................................................................. 98
5.4.6 Drag Chain ..................................................................................... 98
5.5 Alat Sensor ............................................................................................... 99
5.5.1 Sensor Proximity Switch ................................................................. 99
5.5.2 Sensor Temperatur .......................................................................... 99
5.5.3 Sensor Pressure .............................................................................100
5.5.4 Sensor Level ..................................................................................100
5.5.5 Sensor Vibrasi ................................................................................100
5.5.6 Flame Detector ..............................................................................100
BAB VI UTILITAS ............................................................................................101
6.1 Utilitas ................................................................................................... ..101
6.1.1 Penyiapan Air .............................................................................. ..101
6.1.2 Penyediaan Tenaga Listrik........................................................... ..101
6.1.2.1 Pembangkit Tenaga Listrik Sendiri.................................. ..101
6.1.2.2 Sumber Tenaga Listrik PLN ............................................ ..102
6.1.3 Bahan Bakar ................................................................................. ..102
BAB VII PENGOLAHAN LIMBAH ............................................................... ..103
BAB VIII PROSEDUR ANALISA ................................................................. ...105
BAB IX KESIMPULAN DAN SARAN ............................................................ 109
9.1 Kesimpulan.............................................................................................. 109
9.2 Saran ........................................................................................................ 109
DAFTAR PUSTAKA ......................................................................................... 111

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LAMPIRAN A TUGAS KHUSUS................................................................ ….LA-1
A.1 Pendahuluan ....................................................................................... .....LA-1
A.1.1 Judul Tugas Khusus ........................................................................LA-1
A.1.2 Latar Belakang ..........................................................................…..LA-1
A.1.3 Rumusan Masalah .....................................................................…..LA-2
A.1.4 Tujuan Tugas Khusus ...............................................................…..LA-2
A.1.5 Manfaat Tugas Khusus .............................................................…..LA-2
A.2 Dasar Teori .........................................................................................…..LA-2
A.2.1 Suspension Preheater ................................................................…..LA-2
A.2.2 Rotary Kiln ................................................................................…..LA-3
A.2.3 Reaksi yang Terjadi Pada Rotary Kiln ......................................…..LA-4
A.2.4 Faktor-Faktor Komposisi Kiln Feed yang Mempengaruhi
Pembakaran Pada Kiln ................................................................. ..LA-5
A.2.5 Neraca Massa ............................................................................... ..LA-6
A.2.6 Neraca Panas ................................................................................ ..LA-7
A.3 Metode Pelaksanaan Tugas Khusus ...................................................... ..LA-7
A.4 Analisa Perhitungan Pada Rotary Kiln .................................................. ..LA-8
A.4.1 Data Untuk Perhitungan............................................................... ..LA-8
A.4.1.1 Data dari Laboratorium Proses Indarung II/III .............. ..LA-8
A.4.1.2 Data dari Ruang Otomasi............................................... ..LA-9
A.4.1.3 Asumsi Excess O2 .......................................................... ..LA-9
A.4.1.4 Asumsi False Air ........................................................... ..LA-9
A.4.1.5 Asumsi Udara Primer .................................................... ..LA-9
A.4.2 Perhitungan Neraca Massa........................................................... LA-10
A.4.3 Perhitungan Neraca Energi .......................................................... LA-19
A.5 Kesimpulan Tugas Khusus .................................................................... LA-28

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 DAFTAR GAMBAR

Gambar 2.1 PT Semen Padang pada Tahun 1910 ................................................. 5

Gambar 2.2 PT Semen Padang pada Tahun 1995 ................................................. 7
Gambar 2.3 Perubahan Logo PT Semen Padang .................................................. 7
Gambar 2.4 PT Semen Padang, Indarung ............................................................. 8
Gambar 2.5 Packing Plant PT Semen Padang di Teluk Bayur & Dumai ........... 9
Gambar 2.6 Struktur Organisasi PT Semen Padang ............................................ 11
Gambar 3.1 Semen ............................................................................................... 12
Gambar 3.2 Batu Kapur (Lime Stone) .................................................................. 17
Gambar 3.3 Batu Silika (Silica Stone) ................................................................. 18
Gambar 3.4 Pasir Besi (Iron Sand) ...................................................................... 20
Gambar 3.5 Tanah Liat (Clay) ............................................................................. 22
Gambar 3.6 Gypsum ............................................................................................. 24
Gambar 3.7 Pozzolan ........................................................................................... 26
Gambar 4.1 Flowsheet Pembuatan Semen .......................................................... 39
Gambar 4.2 Belt Conveyor ................................................................................... 41
Gambar 4.3 Metode Conical Shell Stacking ........................................................ 41
Gambar 4.4 Alat Penarikan Side Reclaimer ......................................................... 42
Gambar 4.5 Alat Penarikan Portal Reclaimer ..................................................... 43
Gambar 4.6 Metode Windrow Stacking ............................................................... 44
Gambar 4.7 Alat Penarikan Bucket Chain Excavator .......................................... 45
Gambar 4.8 Hopper .............................................................................................. 48
Gambar 4.9 Dosimat Feeder ................................................................................ 49
Gambar 4.10 Raw Mill Tipe Duodan Mill ........................................................... 50
Gambar 4.11 Open Diaphragm ............................................................................ 50
Gambar 4.12 Shell Liner Pada Kompartmen I (a) dan Kompartmen II (b) ......... 51
Gambar 4.13 Diaphragm untuk Keluaran Kompartmen I (a)
dan Kompartmen II (b) ................................................................... 51
Gambar 4.14 Rima Screen (a) dan Saringan di Bawah Tube Mill (b).................. 52
Gambar 4.15 Grinding Media di Kompartmen I (a) dan Kompartmen II (b) ...... 52
Gambar 4.16 Cara Kerja Cyclone ........................................................................ 54

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Gambar 4.17 Sistem Pengisian dan Pengeluaran pada Homogenizing Silo ......... 55
Gambar 4.18 Sistem Penarikan Raw Mix dalam Homogenizing Silo .................. 55
Gambar 4.19 Storage Raw Coal........................................................................... 56
Gambar 4.20 Rotary Table Feeder....................................................................... 57
Gambar 4.21 Feed Arrangement dari Coal Mill .................................................. 58
Gambar 4.22 Drying Chamber yang Dilengkapi dengan Lifter ........................... 58
Gambar 4.23 Discharge Arrangement yang Dihubungkan Langsung
dengan Separator............................................................................. 59
Gambar 4.24 Bag House Filter pada Coal Mill ................................................... 60
Gambar 4.25 Pengumpanan Fine Coal Indarung II yaitu Pfister ........................ 61
Gambar 4.26 Pengumpanan Fine Coal Indarung III yaitu
Screw Conveyor (a) dan Weighting Belt (b) .................................. 61
Gambar 4.27 Bucket Elevator H1/H2U02-03 (a) dan
Schenck Feeder W1/W2A01 (b) ..................................................... 62
Gambar 4.28 Bucket Elevator W1/W2A21 (a) dan Air Slide W1/W2A22 (b) .... 63
Gambar 4.29 Siklon Suspension Preheater (a) dan Gas Outlet
dari A51 - A61 ............................................................................... 64
Gambar 4.30 Rotary Kiln (a) dan Planetary Cooler (b) ...................................... 64
Gambar 4.31 Reaksi dan Pembentukan Senyawa Pada Berbagai
Zona dan Temperatur ..................................................................... 66
Gambar 4.32 Hammer Crusher ............................................................................ 69
Gambar 4.33 Prinsip Kerja Elektroda EP (a) dan Komponen-
komponen EP (b) ........................................................................... 70
Gambar 4.34 Bucket Conveyor W1U06/U07 (a) dan Silo Klinker (b) ................ 71
Gambar 4.35 Dosimat Feeder .............................................................................. 72
Gambar 4.36 Pregrinder di Indarung III (a) dan Belt Untuk Transport
Umpan (b) ...................................................................................... 73
Gambar 4.37 Roller dan Grinding Tabe (a) dan Drag Chain Z2M22 (b) ........... 73
Gambar 4.38 Vibrating Screen Tampak Luar (a) dan Saringan
di dalamnya (b) .............................................................................. 74
Gambar 4.39 Cara Kerja Roller Mill .................................................................... 75
Gambar 4.40 Sirkulasi Internal di dalam Roller Mill........................................... 76

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Gambar 4.41 Diaphragma pada Cement Mill ...................................................... 77
Gambar 4.42 Cement Mill .................................................................................... 78
Gambar 4.43 Liner (a) dan Grinding Media yang Digunakan di
Dalam Cement Mill (b) ................................................................... 79
Gambar 4.44 Water Injection Pada (a) Inlet Mill dan (b) Outlet Mill.................. 79
Gambar 4.45 Silo Semen Indarung 2, 3, dan 4..................................................... 81
Gambar 5.1 Cara Kerja Cyclone ........................................................................ 86
Gambar 5.2 Gas Conditioning Tower dan Spray Lance .................................... 87
Gambar 5.3 Nozzle pada Gas Conditioning Tower ............................................ 88
Gambar 5.4 Electrostatic Precipitator dan Bagian-bagiannya .......................... 88
Gambar 5.5 Cerobong ........................................................................................ 89
Gambar 5.6 Bagian-bagian Jet Pulse Filter ....................................................... 90
Gambar 5.7 Bagian-bagianBag House Filter ..................................................... 90
Gambar 5.8 Hopper ............................................................................................ 91
Gambar 5.9 Ducting ........................................................................................... 92
Gambar 5.10 Bridge Scrapper ............................................................................. 92
Gambar 5.11 Side Reclaimer ............................................................................... 93
Gambar 5.12 Bucket Chain Excavator ................................................................. 94
Gambar 5.13 Belt Conveyor dan Bagian-bagiannya ............................................ 95
Gambar 5.14 Bagian-bagian Bucket Elevator ...................................................... 96
Gambar 5.15 Appron Conveyor dan Bagian-bagiannya ...................................... 97
Gambar 5.16 Bagian-bagian Air Slide ................................................................. 98
Gambar 5.17 Screw Conveyor dan Bagian-bagiannya ......................................... 98
Gambar A.1 Blok Diagram Unit Kiln ......................................................... ..LA-9
Gambar A.2 Blok Diagram Overall Unit Kiln ............................................ .LA-10

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 DAFTAR TABEL

Tabel 3.1 Sifat Fisika Batu Kapur ...................................................................... 17

Tabel 3.2 Komposisi Kimia Batu Kapur ............................................................ 18
Tabel 3.3 Sifat Fisika Batu Silika ...................................................................... 19
Tabel 3.4 Komposisi Kimia Batu Silika ............................................................ 19
Tabel 3.5 Sifat Fisika Pasir Besi ........................................................................ 20
Tabel 3.6 Komposisi Kimia Pasir Besi .............................................................. 21
Tabel 3.7 Sifat Fisika Copper Slag .................................................................... 21
Tabel 3.8 Komposisi Kimia Copper Slag .......................................................... 22
Tabel 3.9 Sifat Fisika Tanah Liat ....................................................................... 23
Tabel 3.10 Komposisi Kimia Tanah Liat ............................................................. 23
Tabel 3.11 Sifat Fisika Gypsum ........................................................................... 25
Tabel 3.12 Komposisi Kimia Gypsum ................................................................. 25
Tabel 3.13 Komposisi Kimia Pozzolan................................................................ 26
Tabel 3.14 Parameter dan Persyaratan Kandungan Fly Ash ................................ 27
Tabel 3.15 Standar Pembuatan Semen Portland Tipe I-V ................................... 37
Tabel 3.16 Standar Pembuatan Super Masonry Cement ...................................... 37
Tabel 3.17 Standar Pembuatan Portland Composite Cement .............................. 38
Tabel 3.18 Standar Pembuatan Portland Pozzolan Cement................................. 38
Tabel 4.1 Jenis Storage, Metode Stacking, dan Penarikan Bahan Baku ............ 46
Tabel 4.2 Kapasitas Hopper Unit Raw Mill ....................................................... 48
Tabel 4.3 Tahapan Reaksi pada Suhu Tertentu .................................................. 65
Tabel 5.1 Spesifikasi Alat Raw Mill .................................................................. 83
Tabel 5.2 Spesifikasi Alat Coal Mill .................................................................. 83
Tabel 5.3 Spesifikasi Alat Rotary Kiln .............................................................. 84
Tabel 5.4 Spesifikasi Alat Cyclone Preheater ................................................... 85
Tabel A.1 Komposisi Bahan Baku .............................................................. ..LA-8
Tabel A.2 Komposisi Batu Bara ................................................................. ..LA-8
Tabel A.3 Komposisi Ash Batu Bara .......................................................... ..LA-8
Tabel A.4 Massa Umpan Rotary Kiln ......................................................... .LA-11
Tabel A.5 Massa Batubara Masuk Kiln ...................................................... .LA-13

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Tabel A.6 Massa Ash Batubara Masuk Kiln ............................................... .LA-13
Tabel A.7 Massa Komponen Gas Hasil Reaksi .......................................... .LA-16
Tabel A.8 Neraca Massa pada Rotary Kiln ................................................. .LA-18
Tabel A.9 Perhitungan Panas Umpan Kiln .................................................. .LA-19
Tabel A.10 Perhitungan Panas Sensibel Batubara ....................................... .LA-20
Tabel A.11 Perhitungan Panas Pembakaran Batubara ................................. .LA-21
Tabel A.12 Perhitungan Panas Disosiasi (Kalsinasi) ................................... .LA-22
Tabel A.13 Perhitungan Panas Udara Sekunder .......................................... .LA-22
Tabel A.14 Perhitungan Panas Udara Primer .............................................. .LA-22
Tabel A.15 Perhitungan Panas H2O dalam Batubara ................................... .LA-23
Tabel A.16 Perhitungan Panas Hot Klinker Keluar Kiln ............................. .LA-23
Tabel A.17 Perhitungan Panas CO2 Hasil Kalsinasi .................................... .LA-24
Tabel A.18 Perhitungan Panas Gas Hasil Pembakaran ................................ .LA-24
Tabel A.19 Perhitungan Panas Penguapan H2O dalam Batubara ................ .LA-25
Tabel A.20 Neraca Energi (Panas) pada Rotary Kiln .................................. .LA-27

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