NERACA MASSA

NERACA MASSA PRE-HEATER ILC

Pre-Heater
ILC Feed
Exhaust Gas
Pre-Heater

Hot Meal
PRE-HEATER ILC
Coal

Tertiary Air

Exhaust Gas Kiln

Gambar Neraca Massa di Pre-Heater

Komposisi Pre Heater pada tanggal 14 Februari tersaji pada table berikut:
Tabel A.1 Komposisi Pre-Heater ILC Feed

Komponen Persen Massa

SiO2 12,870
Al2O3 3,560
Fe2O3 2,300
CaO 43,720
MgO 0,700
K2O 0,220
Na2O 0,070
SO3 0,220
Cl 0,052
 H2O 1,166
Total 64,878

Sumber: PT Holcim Indonesia Cilacap Plant, 2018

CaO dan MgO dalam SP Feed berbentuk CaCO3 dan MgCO3

Reaksi yang terjadi:
1. CaCO3 → CaO + CO2
% CaO = 43,79 %
𝐵𝑀 𝐶𝑎𝐶𝑂3
% CaCO3 = × %𝐶𝑎𝑂
𝐵𝑀 𝐶𝑎𝑂
100𝑘𝑔/𝑘𝑔𝑚𝑜𝑙
= × 43,72%
56𝑘𝑔/𝑘𝑔𝑚𝑜𝑙

= 78,071%
2. MgCO3 → MgO + CO2
% MgO = 0,75 %
𝐵𝑀 𝑀𝑔𝐶𝑂3
% MgCO3 = × %𝑀𝑔𝑂
𝐵𝑀 𝑀𝑔𝑂
84𝑘𝑔/𝑘𝑔𝑚𝑜𝑙
= × 0,7%
40𝑘𝑔/𝑘𝑔𝑚𝑜𝑙

= 1,47%
Total feed yang masuk pada pre-heater ILC sebanyak = 203750 kg/jam
Massa SiO2 =12,87% × 203750 kg/jam =26222,625 kg/jam
Massa Al2O3 = 3,56% × 203750 kg/jam =7253,500 kg/jam
Massa Fe2O3 = 2,3% × 203750 kg/jam =4686,250 kg/jam
Massa CaO = 43,72% × 203750 kg/jam =159070,536 kg/jam
Massa MgO = 0,7% × 203750 kg/jam =2995,125 kg/jam
Massa K2O = 0,22% × 203750 kg/jam =448,250 kg/jam
Massa Na2O = 0,07% × 203750 kg/jam =142,625 kg/jam
Massa SO3 = 0,22% × 203750 kg/jam =448,250 kg/jam
Massa Cl = 0,052% × 203750 kg/jam =105,950 kg/jam
Massa H2O = 1,166% × 203750 kg/jam =2375,725 kg/jam
 Tabel A.2 Komposisi dan Massa Feed Pre-Heater ILC

Komponen Persen Massa (%) Massa (kg/jam)

SiO2 12,870 26222,625
Al2O3 3,560 7253,500
Fe2O3 2,300 4686,250
CaO 78,071 159070,536
MgO 1,470 2995,125
K2O 0,220 448,250
Na2O 0,070 142,625
SO3 0,220 448,250
Cl 0,052 105,950
H2O 1,166 2375,725
Total 100 203748,836

Tabel A.3 Komposisi dan Massa Feed Pre-Heater ILC Kering

Komponen Persen Massa (%) Massa (kg/jam)

SiO2 13,022 26222,625
Al2O3 3,602 7253,500
Fe2O3 2,327 4686,250
CaCO3 78,993 159070,536
MgCO3 1,487 2995,125
K2O 0,223 448,250
Na2O 0,071 142,625
SO3 0,223 448,250
Cl 0,053 105,950
Total 100,000 201373,111

Dust Lost (Debu terbuang dari Pre-Heater ILC feed bersama Exhaust Gas ILC)
Persen Dust Lost =7%
Massa Dust Lost = 14096,117 kg/jam
Massa Komponen = Massa komponen – (Massa komponen × Persen
Dust Lost)

Dust Lost adalah bagian dari Pre-Heater ILC feed yang terikut dalam gas buang SP
sehingga komposisinya sama dengan feed Pre-Heater ILC, Tabeldibawah ini menjelaskan massa
dan komposisi setelah pengurangan dust lost
 Tabel A.4 Komposisi dan Massa Feed Pre-Heater ILC Setelah Dust Lost

Komponen Persen Massa (%) Massa (kg/jam)

SiO2 13,022 24387,041
Al2O3 3,602 6745,755
Fe2O3 2,327 4358,213
CaCO3 78,993 147935,598
MgCO3 1,487 2785,466
K2O 0,223 416,873
Na2O 0,071 132,641
SO3 0,223 416,873
Cl 0,053 98,534
Total 100,000 187276,993

Reaksi Kalsinasi :
CaCO3  CaO + CO2
m 1479,356
r 1246,357 1246,357 1246,357
s 232,999 1246,357 1246,357

CaCO3 →CaO + CO2

Derajat Kalsinasi = 84,25%
𝑀𝑎𝑠𝑠𝑎 𝐶𝑎𝐶𝑂3
Mol CaCO3 mula-mula = 𝐵𝑀 𝐶𝑎𝐶𝑂3
147935,598 𝑘𝑔/𝑗𝑎𝑚
= 100 𝑘𝑔/𝑘𝑔𝑚𝑜𝑙

= 1479,3560 kgmol/jam
Mol CaCO3 terkalsinasi = 84,25% × Mol CaCO3 mula-mula
= 84,25% × 1479,3560 kgmol/jam
= 1246,3574 kgmol/jam
Massa CaCO3 terkalsinasi = Mol CaCO3 terkalsinasi × BM CaCO3
= 1246,3574 kgmol/jam × 100 kg/kgmol
= 124635,741 kg/jam
Massa CaO terbentuk = Mol CaO terbentuk × BM CaO
= 1246,357 kgmol/jam × 56 kg/kgmol
= 69796,015 kg/jam
Massa CO2 terbentuk = Mol CO2 terbentuk × BM CO2
= 1246,3574 kgmol/jam × 44 kg/kgmol
= 54839,726 kg/jam
Massa CaCO3 sisa = Mol CaCO3 sisa × BM CaO
= 232,999 kgmol/jam × 56 kg/kgmol
= 23299,857 kg/jam

MgCO3  MgO + CO2

m 33,160
r 27,938 27,938 27,938
s 5,223 27,938 27,938

MgCO3 →MgO + CO2

Derajat Kalsinasi = 84,25%
𝑀𝑎𝑠𝑠𝑎 𝑀𝑔𝐶𝑂3
Mol MgCO3 mula-mula = 𝐵𝑀 𝑀𝑔𝐶𝑂3
2785,466 𝑘𝑔/𝑗𝑎𝑚
= 84 𝑘𝑔/𝑘𝑔𝑚𝑜𝑙

= 33,160 kgmol/jam
Mol MgCO3 terkalsinasi = 84,25% × Mol MgCO3 mula-mula
= 84,25% × 33,160 kgmol/jam
= 27,938 kgmol/jam
Massa MgCO3 terkalsinasi = Mol MgCO3 terkalsinasi × BM MgCO3
= 27,938 kgmol/jam × 84 kg/kgmol
= 2346,755 kg/jam
Massa MgO terbentuk = Mol MgO terbentuk × BM MgO
= 27,938 kgmol/jam × 40 kg/kgmol
= 1117,503 kg/jam
Massa CO2 terbentuk = Mol CO2 terbentuk × BM CO2
 = 27,938 kgmol/jam × 44 kg/kgmol
= 1229,253 kg/jam
Massa MgCO3 sisa = Mol MgCO3 sisa × BM MgO
= 5,223 kgmol/jam × 40 kg/kgmol
= 438,711 kg/jam
Total CO2 terbentuk = 56068,979 kg/jam

Tabel A.5 Komposisi dan Massa Setelah Kalsinasi

Komponen Persen Massa (%) Massa (kg/jam)

SiO2 18,587 24387,041
Al2O3 5,141 6745,755
Fe2O3 3,322 4358,213
CaCO3 sisa 17,758 23299,857
MgCO3 sisa 0,334 438,711
CaO 53,195 69796,015
MgO 0,852 1117,503
K2O 0,318 416,873
Na2O 0,101 132,641
SO3 0,318 416,873
Cl 0,075 98,534
Total 100,000 131208,014

Bahan Bakar Pre-Heater ILC

Batu bara (Coal)
Feed batubara masuk SP = 11125 kg/jam
Tabel A.6 Komposisis Batu Bara

Komposisi Persen Massa

C 70,35
H2 5,3
N2 0,86
O2 19,27
S 0,12
Ash (abu) 4,1
 Total 100
Sumber :
Massa umpan batu bara SP = % massa × massa umpan batu bara kering, sehingga
didapatkan komposisi umpan batu bara,

Tabel A.7 Komposisi dan Massa Batu Bara Masuk Pre-Heater ILC

Komposisi Persen Massa (%) Massa (kg/jam)

C 70,35 7826,438
H2 5,30 589,625
N2 0,86 95,675
O2 19,27 2143,788
S 0,12 13,350
Ash (abu) 4,10 456,125
Total 100 11125,000

Tabel A.8 Komposisi Ash (debu) Pre-Heater ILC

Komponen Persen Massa (%)

SiO2 40,850
Al2O3 11,321
Fe2O3 14,860
CaO 18,299
MgO 7,621
TiO2 0,501
Na2O 0,852
K2O 0,812
P2O5 0,031
Mn3O4 0,219
SO3 4,633
Total 100
Sumber :

Massa Komponen=Persen Komponen × Massa Ash

 Tabel A.9 Komposisi Massa Abu Batubara SP Tanpa IL

Komponen Persen Massa (%) Massa (kg/jam)

SiO2 40,850 186,329
Al2O3 11,321 51,636
Fe2O3 14,860 67,781
CaO 18,299 83,468
MgO 7,621 34,759
TiO2 0,501 2,287
Na2O 0,852 3,888
K2O 0,812 3,705
P2O5 0,031 0,142
Mn3O4 0,219 0,997
SO3 4,633 21,130
Total 100 456,122

Reaksi pembakaran batubara di SP

C + O2  CO2
m 1479,356
r 1246,357 1246,357 1246,357
s 232,999 1246,357

𝑀𝑎𝑠𝑠𝑎 𝐶
Mol C mula-mula = 𝐵𝑀 𝐶
7826,438𝑘𝑔/𝑗𝑎𝑚
= 12 𝑘𝑔/𝑘𝑔𝑚𝑜𝑙

= 652,203 kgmol/jam
Massa CO2 terbentuk = Mol C terbentuk × BM C
= 652,203 kgmol/jam × 12 kg/kgmol
= 28696,938 kg/jam
Massa O2 diperlukan = Mol O2 diperlukan × BM O2
= 652,203 kgmol/jam × 32 kg/kgmol
= 20870,500 kg/jam
S + O2  SO2
m 0,417
r 0,417 0,417 0,417
 s 0,000 0,417

𝑀𝑎𝑠𝑠𝑎 𝑆
Mol S mula-mula = 𝐵𝑀 𝑆
13,350 𝑘𝑔/𝑗𝑎𝑚
= 32 𝑘𝑔/𝑘𝑔𝑚𝑜𝑙

= 0,417 kgmol/jam
Massa SO2 terbentuk = Mol S terbentuk × BM S
= 0,417 kgmol/jam × 32 kg/kgmol
= 26,700 kg/jam
Massa O2 diperlukan = Mol O2 diperlukan × BM O2
= 0,417 kgmol/jam × 32 kg/kgmol
= 13,350 kg/jam
H2 + 1/2O2  H2O
m 294,813 mol
r 294,813 mol 147,406 mol 294,813 mol
s 0,000 mol 294,813 mol

𝑀𝑎𝑠𝑠𝑎 𝐻2
Mol H2 mula-mula = 𝐵𝑀 𝐻2
589,625 𝑘𝑔/𝑗𝑎𝑚
= 2 𝑘𝑔/𝑘𝑔𝑚𝑜𝑙

= 294,813 0,417 kgmol/jam

Massa H2O terbentuk = Mol H2O terbentuk × BM H2O
= 294,813 kgmol/jam × 32 kg/kgmol
= 5306,625kg/jam
Massa O2 diperlukan = Mol O2 diperlukan × BM O2
= 147,406 kgmol/jam × 32 kg/kgmol
= 4717,000 kg/jam
Kebutuhan O2 total untuk reaksi pembakaran :
= (20870,500+ 13,350+ 147,406) kg/jam = 25600,850 kg/jam
Massa O2 di Batubara = 2143,788 kg/jam
Kebutuhan O2 Teoritis = Total O2 kebutuhan – O2 di batubara
= 25600,850 kg/jam - 2143,788 kg/jam
 = 23457,063 kg/jam
Excess Udara Pembakaran = 2%
Kebutuhan O2 Sesungguhnya = (100+2)% × Kebutuhan O2 Teoritis
= 102% × 23457,063 kg/jam
= 23926,203 kg/jam
Kebutuhan Udara Sesungguhnya:
100%
= × Kebutuhan O2 sesungguhnya
21%
100%
= × 23926,203 kg/jam
21%

= 113934,303 kg/jam
Udara Panas Masuk Pre-Heater ILC (Tertiary Air)
= 113934,304 kg/jam
79%
Massa N2 di Udara = 21% × Kebutuhan O2 sesungguhnya
79%
= 21% × 23926,203 kg/jam

Massa N2 Total
Massa O2 Sisa Pembakaran
Massa H2O terbentuk
= 90008,099 kg/jam
= Massa N2 di udara + Massa N2 di batubara
= 90008,099 kg/jam + 95,675 kg/jam
= 90103,77482 kg/jam
= Kebutuhan O2 Sesungguhnya – Kebutuhan O2 Teoritis
= 23926,203 kg/jam - 23457,063 kg/jam
= 469,14125 kg/jam
= Massa H2O Hasil Pembakaran
= 5306,625 kg/jam

Tabel A.10 Komposisi Gas Hasil Pembakaran

Komponen Massa (kg/jam)

CO2 28696,938
N2 90103,775
H2O 5306,625
O2 469,141
SO2 26,700
Total 124603,179
Total Massa Komponen = Massa Komponen di feed + Massa Komponen di
batubara

Tabel A.11 Komposisi Hot Meal ILC

Komponen Massa (kg/jam)

SiO2 24573,370
Al2O3 6797,391
Fe2O3 4425,993
CaCO3 sisa 23299,857
MgCO3 sisa 438,711
CaO 69879,484
MgO 1152,262
K2O 420,577
Na2O 136,529
SO3 438,003
Cl 98,534
Ash 1,139
Total 131661,849

Exhaust Gas Kiln Masuk Pre-Heater ILC

= 286478,7422 kg/jam
Exhaust Gas Pre-Heater ILC = GHP + Massa CO2 Terkalsinasi + Exhaust Gas Kiln+
H2O + Dust Lost
= 124603,179 + 56068,979 + 286478,742 + 2375,725
14096,118 kg/jam
= 483622,743 kg/jam
NERACA MASSA PRE-HEATER SLC

Pre-Heater
Exhaust Gas
SLC Feed
Pre-Heater

Hot Meal
PRE-HEATER SLC

Tertiary Air

GAMBAR NERACA MASSA SLC

Tabel A.12 Komposisi Feed Pre-Heater SLC

Komponen Persen Massa

SiO2 12,870
Al2O3 3,560
Fe2O3 2,300
CaO 43,720
MgO 0,700
K2O 0,220
Na2O 0,070
SO3 0,220
Cl 0,052
H2O 1,166
Total 64,878

Sumber : PT Holcim Indonesia Cilacap Plant

CaO dan MgO dalam SP Feed berbentuk CaCO3 dan MgCO3
Reaksi yang terjadi:
3. CaCO3 → CaO + CO2
% CaO = 43,79 %
𝐵𝑀 𝐶𝑎𝐶𝑂3
% CaCO3 = × %𝐶𝑎𝑂
𝐵𝑀 𝐶𝑎𝑂
100𝑘𝑔/𝑘𝑔𝑚𝑜𝑙
= × 43,72%
56𝑘𝑔/𝑘𝑔𝑚𝑜𝑙

= 78,071%
4. MgCO3 → MgO + CO2
% MgO = 0,75 %
𝐵𝑀 𝑀𝑔𝐶𝑂3
% MgCO3 = × %𝑀𝑔𝑂
𝐵𝑀 𝑀𝑔𝑂
84𝑘𝑔/𝑘𝑔𝑚𝑜𝑙
= 40𝑘𝑔/𝑘𝑔𝑚𝑜𝑙 × 0,7%

= 1,47%
Total feed yang masuk pada pre-heater SLC sebanyak = 315166,667 kg/jam

Massa SiO2 =12,87% × 315166,667 kg/jam = 40561,950 kg/jam

𝑀𝑎𝑠𝑠𝑎 𝐴𝑙2𝑂3 = 3,56% × 315166,667 kg/jam = 11219,9330 kg/jam
𝑀𝑎𝑠𝑠𝑎 𝐹𝑒2𝑂3 = 2,3% × 315166,667 kg/jam = 7248,833 kg/jam
𝑀𝑎𝑠𝑠𝑎 𝐶𝑎𝑂 = 43,72% × 315166,667 kg/jam = 246055,119 kg/jam
𝑀𝑎𝑠𝑠𝑎 𝑀𝑔𝑂 = 0,7% × 315166,667 kg/jam = 4632,950 kg/jam
𝑀𝑎𝑠𝑠𝑎 𝐾2𝑂 = 0,22% × 315166,667 kg/jam = 693,367 kg/jam
𝑀𝑎𝑠𝑠𝑎 𝑁𝑎2𝑂 = 0,07% × 315166,667 kg/jam = 220,617kg/jam
Massa SO3= 0,22% × 315166,667 kg/jam = 693,367 kg/jam
𝑀𝑎𝑠𝑠𝑎 𝐶𝑙 = 0,052% × 315166,667 kg/jam = 163,887kg/jam
𝑀𝑎𝑠𝑠𝑎 𝐻2𝑂 = 1,166% × 315166,667 kg/jam = 3674,843 kg/jam

Tabel A.13 Komposisi dan Massa Feed Pre-Heater SLC

Komponen Persen Massa (%) Massa (kg/jam)

SiO2 12,870 40561,950
Al2O3 3,560 11219,933
Fe2O3 2,300 7248,833
 CaO 78,071 246055,119
MgO 1,470 4632,950
K2O 0,220 693,367
Na2O 0,070 220,617
SO3 0,220 693,367
Cl 0,052 163,887
H2O 1,166 3674,843
Total 100 315164,866

Tabel A.14 Komposisi dan Massa Feed Pre-Heater SLC Kering

Komponen Persen Massa (%) Massa (kg/jam)

SiO2 13,022 40561,950
Al2O3 3,602 11219,933
Fe2O3 2,327 7248,833
CaCO3 78,993 246055,119
MgCO3 1,487 4632,950
K2O 0,223 693,367
Na2O 0,071 220,617
SO3 0,223 693,367
Cl 0,053 163,887
Total 100,000 311490,022

Dust Lost (Debu terbuang dari Pre-Heater SLC feed bersama Exhaust Gas SLC)
Persen Dust Lost =7%
Massa Dust Lost = 21804,30157 kg/jam
Massa Komponen = Massa komponen – (Massa komponen × Persen
Dust Lost)

Dust Lost adalah bagian dari Pre-Heater SLC feed yang terikut dalam gas buang SP
sehingga komposisinya sama dengan feed Pre-Heater SLC, Tabel dibawah ini menjelaskan massa
dan komposisi setelah pengurangan dust lost

Tabel A. 15

Komponen Persen Massa (%) Massa (kg/jam)

SiO2 13,022 37722,614
Al2O3 3,602 10434,538
 Fe2O3 2,327 6741,415
CaCO3 78,993 228831,261
MgCO3 1,487 4308,644
K2O 0,223 644,831
Na2O 0,071 205,174
SO3 0,223 644,831
Cl 0,053 152,415
Total 100,000 289685,721

Reaksi Kalsinasi :
CaCO3  CaO + CO2
m 2288,312607
r 2141,631769 2141,631769 2141,631769
s 146,6808381 2141,631769 2141,631769

CaCO3 →CaO + CO2

Derajat Kalsinasi = 93,59%
𝑀𝑎𝑠𝑠𝑎 𝐶𝑎𝐶𝑂3
Mol CaCO3 mula-mula = 𝐵𝑀 𝐶𝑎𝐶𝑂3
228831,261 𝑘𝑔/𝑗𝑎𝑚
= 100 𝑘𝑔/𝑘𝑔𝑚𝑜𝑙

= 2288,312607 kgmol/jam
Mol CaCO3 terkalsinasi = 93,59%× Mol CaCO3 mula-mula
= 84,25% × 2288,312607 kgmol/jam
= 2141,632kgmol/jam
Massa CaCO3 terkalsinasi = Mol CaCO3 terkalsinasi × BM CaCO3
= 2141,632 kgmol/jam × 100 kg/kgmol
= 214163,177 kg/jam
Massa CaO terbentuk = Mol CaO terbentuk × BM CaO
= 2141,632kgmol/jam × 56 kg/kgmol
= 119931,379kg/jam
Massa CO2 terbentuk = Mol CO2 terbentuk × BM CO2
= 2141,632 kgmol/jam × 44 kg/kgmol
 = 94231,798 kg/jam
Massa CaCO3 sisa = Mol CaCO3 sisa × BM CaO
= 146,681 kgmol/jam × 56 kg/kgmol
= 14668,084 kg/jam

MgCO3  MgO + CO2

m 51,293
r 48,005 48,005 48,005
s 3,288 48,005 48,005

MgCO3 →MgO + CO2

Derajat Kalsinasi = 93,59%
𝑀𝑎𝑠𝑠𝑎 𝑀𝑔𝐶𝑂3
Mol MgCO3 mula-mula = 𝐵𝑀 𝑀𝑔𝐶𝑂3
4632,950 𝑘𝑔/𝑗𝑎𝑚
= 84 𝑘𝑔/𝑘𝑔𝑚𝑜𝑙

= × 51,293 kgmol/jam
Mol MgCO3 terkalsinasi = 93,59% × Mol MgCO3 mula-mula
= 93,59% × 51,293 kgmol/jam
= 48,005 kgmol/jam
Massa MgCO3 terkalsinasi = Mol MgCO3 terkalsinasi × BM MgCO3
= 48,005 kgmol/jam × 84 kg/kgmol
= 4032,459 kg/jam
Massa MgO terbentuk = Mol MgO terbentuk × BM MgO
= 48,005 kgmol/jam × 40 kg/kgmol
= 1920,219 kg/jam
Massa CO2 terbentuk = Mol CO2 terbentuk × BM CO2
= 48,005 kgmol/jam × 44 kg/kgmol
= 2112,241 kg/jam
Massa MgCO3 sisa = Mol MgCO3 sisa × BM MgO
= 3,288 kgmol/jam × 40 kg/kgmol
 = 276,184 kg/jam
Total CO2 terbentuk = 96344,039 kg/jam

Komponen Persen Massa (%) Massa (kg/jam)

SiO2 19,511 37722,614
Al2O3 5,397 10434,538
Fe2O3 3,487 6741,415
CaCO3 sisa 7,587 14668,084
MgCO3 sisa 0,143 276,184
CaO 62,031 119931,379
MgO 0,993 1920,219
K2O 0,334 644,831
Na2O 0,106 205,174
SO3 0,334 644,831
Cl 0,079 152,415
Total 100,000 193341,682

Bahan Bakar Pre-Heater SLC

Batu bara (Coal)
Feed batubara masuk SP = 20695,833 kg/jam
Tabel Komposisi Umpan Batubara
Komposisi Persen Massa
C 70,35
H2 5,3
N2 0,86
O2 19,27
S 0,12
Ash (abu) 4,1
Total 100
Sumber :
Massa umpan batu bara SP = % massa × massa umpan batu bara kering, sehingga
didapatkan komposisi umpan batu bara,
Tabel Komposisi Massa Umpan Batubara SP
 Komposisi Persen Massa (%) Massa (kg/jam)
C 70,35 14559,519
H2 5,3 1096,879
N2 0,86 177,984
O2 19,27 3988,087
S 0,12 24,835
Ash (abu) 4,1 848,529
Total 100 20695,833

Tabel Komposisi Ash (debu)

Komponen Persen Massa (%)
SiO2 40,850
Al2O3 11,321
Fe2O3 14,860
CaO 18,299
MgO 7,621
TiO2 0,501
Na2O 0,852
K2O 0,812
P2O5 0,031
Mn3O4 0,219
SO3 4,633
Total 100
Sumber :
Massa Komponen=Persen Komponen × Massa Ash
Tabel Komposisi Massa Abu Batubara SP Tanpa IL
Komponen Persen Massa (%) Massa (kg/jam)
SiO2 40,850 346,628
Al2O3 11,321 96,059
Fe2O3 14,860 126,093
CaO 18,299 155,276
MgO 7,621 64,663
TiO2 0,501 4,254
Na2O 0,852 7,232
K2O 0,812 6,892
P 2 O5 0,031 0,264
 Mn3O4 0,219 1,855
SO3 4,633 39,308
Total 100 848,523

Reaksi pembakaran batubara di SP

C + O2  CO2
m 1213,293
r 1213,293 1213,293 1213,293
s 0,000 1213,293 1213,293

𝑀𝑎𝑠𝑠𝑎 𝐶
Mol C mula-mula = 𝐵𝑀 𝐶
14559,519 𝑘𝑔/𝑗𝑎𝑚
= 12 𝑘𝑔/𝑘𝑔𝑚𝑜𝑙

= 1213,293 kgmol/jam
Massa CO2 terbentuk = Mol C terbentuk × BM C
= 1213,293 kgmol/jam × 12 kg/kgmol
= 53384,902 kg/jam
Massa O2 diperlukan = Mol O2 diperlukan × BM O2
= 1213,293 kgmol/jam × 32 kg/kgmol
= 38825,383kg/jam
S + O2  SO2
m 0,776
r 0,776 0,776 0,776
s 0,000 0,776 0,776

𝑀𝑎𝑠𝑠𝑎 𝑆
Mol S mula-mula = 𝐵𝑀 𝑆
24,835 𝑘𝑔/𝑗𝑎𝑚
= 32 𝑘𝑔/𝑘𝑔𝑚𝑜𝑙

= 0,776 kgmol/jam
Massa SO2 terbentuk = Mol S terbentuk × BM S
= 0,776 kgmol/jam × 32 kg/kgmol
= 49,670 kg/jam
Massa O2 diperlukan = Mol O2 diperlukan × BM O2
= 0,776 kgmol/jam × 32 kg/kgmol
= 24,835 kg/jam
H2 + 1/2O2  H2O
m 548,440
r 548,440 274,220 548,440
s 0,000 274,220 548,440

𝑀𝑎𝑠𝑠𝑎 𝐻2
Mol H2 mula-mula = 𝐵𝑀 𝐻2
1096,879 𝑘𝑔/𝑗𝑎𝑚
=
2 𝑘𝑔/𝑘𝑔𝑚𝑜𝑙

= 548,440 kgmol/jam
Massa H2O terbentuk = Mol H2O terbentuk × BM H2O
= 548,440 kgmol/jam × 32 kg/kgmol
= 5306,625 kg/jam
Massa O2 diperlukan = Mol O2 diperlukan × BM O2
= 274,220kgmol/jam × 32 kg/kgmol
= 8775,033kg/jam
Kebutuhan O2 total untuk reaksi pembakaran :
= (38825,383+ 24,835+ 8775,033) kg/jam
= 47625,252 kg/jam
Massa O2 di Batubara = 3988,087kg/jam
Kebutuhan O2 Teoritis = Total O2 kebutuhan – O2 di batu bara
= 47625,252 kg/jam - 3988,087kg/jam
= 43637,165 kg/jam
Excess Udara Pembakaran = 2%
Kebutuhan O2 Sesungguhnya = (100+2)% × Kebutuhan O2 Teoritis
= 102% × 43637,165kg/jam
= 44509,908 kg/jam
Kebutuhan Udara Sesungguhnya:
100%
= × Kebutuhan O2 Sesungguhnya
21%
 100%
= × 44509,908 kg/jam
21%

= 211951,942 kg/jam
Udara Panas Masuk Pre-Heater SLC (Tertiary Air)
= 211951,942 kg/jam
79%
Massa N2 di Udara = 21% × Kebutuhan O2 Sesungguhnya
79%
= 21% × 44509,908 kg/jam

= 167442,034 kg/jam
Massa N2 Total = Massa N2 di udara + Massa N2 di batubara
= 167442,034 kg/jam + 177,984 kg/jam
= 167620,019 kg/jam
Massa O2 Sisa Pembakaran = Kebutuhan O2 Sesungguhnya – Kebutuhan O2 Teoritis
= 44509,908 kg/jam - 43637,165 kg/jam
= 872,743 kg/jam
Massa H2O terbentuk = Massa H2O Hasil Pembakaran
= 9871,913 kg/jam
GHP
Komponen Massa (kg/jam)
CO2 53384,902
N2 167620,019
H2O 9871,913
O2 872,743
SO2 49,670
Total 231799,246

Total Massa Komponen = Massa Komponen di feed + Massa Komponen di

batubara
Komposisi Hot Meal SLC
Komponen Massa (kg/jam)
SiO2 38069,241
Al2O3 10530,597
Fe2O3 6867,508
CaCO3 14668,084
MgCO3 276,184
 CaO 120086,655
MgO 1984,882
K2O 651,723
Na2O 212,406
SO3 684,139
Cl 152,415
Ash 2,119
Total 194185,951

Exhaust Gas Kiln Masuk Pre-Heater SLC

= 0 kg/jam
Exhaust Gas Pre-Heater SLC = GHP + Massa CO2 Terkalsinasi + Exhaust Gas Kiln+
H2O + Dust Lost
= 231799,246 + 96344,039 + 0 + 3674,843+
21804,302kg/jam
= 353622,430 kg/jam

Tabel Neraca Massa Pre-Heater (kg/jam)

ILC SLC
Stream
Input Output Input Output
PH Feed 203750,000 0,000 315166,667 0,000
Fuel 11125,000 0,000 20695,833 0,000
Exhaust Gas
286478,742 0,000 0,000 0,000
Kiln
Tertiary Air 113934,304 0,000 211951,942 0,000
Hot Meal 0,000 131661,849 0,000 194185,951
Exhaust Gas
0,000 483622,743 0,000 353622,430
PH
Total 615288,046 615284,591 547814,442 547808,381

NERACA MASSA ROTARY KILN

 Hot Meal ILC
Coal

Hot Mea SLC Primary Air

Exhaust Gas Kiln ROTARY KILN Secondary Air

Hot Clinker

Gambar Diagram Alir Massa di Rotary Kiln

Umpan Masuk Kiln = Hot Meal ILC + Hot Meal SLC
= (131661,849 + 194185,951) kg/jam
= 325847,800 kg/jam
Udara Masuk Kiln Primer
Laju Alir Udara Radial = 3760,000 Nm3/jam
Densitas = 1,293 kg/Nm3
Massa Udara Radial = 4861,680 kg/jam

Laju Alir Udara Axial = 10040,000 Nm3/jam

Densitas = 1,293 kg/Nm3
Massa Udara Axial = 12981,720 kg/jam

Laju Alir Udara Transport = 4930,000 Nm3/jam

Densitas = 1,293 kg/Nm3
Massa Udara Transport = 6374,490 kg/jam

Massa Udara Masuk Kiln = Massa Udara Radial + Massa Udara Axial + Massa Udara
Transport
= 4861,680 kg/jam + 12981,720 kg/jam + 6374,490 kg/jam
= 24217,890 kg/jam

Tabel Komposisi Massa Masuk Kiln

 Komponen Persen Massa Massa (kg/jam)
(%)
SiO2 19,225 62642,611
Al2O3 5,318 17327,988
Fe2O3 3,466 11293,501
CaCO3 11,652 37967,941
MgCO3 0,219 714,895
CaO 58,299 189966,139
MgO 0,963 3137,144
K2O 0,329 1072,300
Na2O 0,107 348,934
SO3 0,344 1122,142
Cl 0,077 250,948
Ash 0,001 3,257
Total 100,000 325847,800

Reaksi Kalsinasi :
CaCO3  CaO + CO2
m 379,679
r 379,679 379,679 379,679
s 0,000 379,679 379,679

CaCO3 →CaO + CO2

Derajat Kalsinasi = 100%
𝑀𝑎𝑠𝑠𝑎 𝐶𝑎𝐶𝑂3
Mol CaCO3 mula-mula = 𝐵𝑀 𝐶𝑎𝐶𝑂3
228831,261 𝑘𝑔/𝑗𝑎𝑚
= 100 𝑘𝑔/𝑘𝑔𝑚𝑜𝑙

Mol CaCO3 terkalsinasi
Massa CaCO3 terkalsinasi
Massa CaO terbentuk
= 379,679 kgmol/jam
= 100%× Mol CaCO3 mula-mula
= 100% × 379,679 kgmol/jam
= 379,679 kgmol/jam
= Mol CaCO3 terkalsinasi × BM CaCO3
= 379,679 kgmol/jam × 100 kg/kgmol
= 37967,941 kg/jam
= Mol CaO terbentuk × BM CaO
 = 379,679 kgmol/jam × 56 kg/kgmol
= 21262,047 kg/jam
Massa CO2 terbentuk = Mol CO2 terbentuk × BM CO2
= 379,679 kgmol/jam × 44 kg/kgmol
= 16705,894 kg/jam
Massa CaCO3 sisa = Mol CaCO3 sisa × BM CaO
= 0,000 kgmol/jam × 56 kg/kgmol
= 0,000 kg/jam
MgCO3  MgO + CO2
m 8,511
r 8,511 8,511 8,511
s 0,000 8,511 8,511

MgCO3 →MgO + CO2

Derajat Kalsinasi = 100%
𝑀𝑎𝑠𝑠𝑎 𝑀𝑔𝐶𝑂3
Mol MgCO3 mula-mula = 𝐵𝑀 𝑀𝑔𝐶𝑂3
714,895 𝑘𝑔/𝑗𝑎𝑚
= 84 𝑘𝑔/𝑘𝑔𝑚𝑜𝑙

= 8,511 kgmol/jam
Mol MgCO3 terkalsinasi = 100% × Mol MgCO3 mula-mula
= 100% × 8,511 kgmol/jam
= 8,511kgmol/jam
Massa MgCO3 terkalsinasi = Mol MgCO3 terkalsinasi × BM MgCO3
= 8,511 kgmol/jam × 84 kg/kgmol
= 714,895 kg/jam
Massa MgO terbentuk = Mol MgO terbentuk × BM MgO
= 8,511 kgmol/jam × 40 kg/kgmol
= 340,426 kg/jam
Massa CO2 terbentuk = Mol CO2 terbentuk × BM CO2
= 8,511 kgmol/jam × 44 kg/kgmol
= 374,469 kg/jam
Massa MgCO3 sisa = Mol MgCO3 sisa × BM MgO
= 0,000 kgmol/jam × 40 kg/kgmol
= 0,000 kg/jam
Massa Total CO2 terbentuk = 374,469 kg/jam

Massa Total CaO Terbentuk = Massa CaO Feed Kiln + Massa CaO Kalsinasi
= 189966,139 kg/jam + 21262,047
= 211228,186 kg/jam
Massa Total MgO Terbentuk = Massa Mg Feed Kiln + Massa MgO Kalsinasi
= 3137,144 kg/jam + 340,426
= 3477,570 kg/jam

Tabel
Komponen Persen Massa Massa (kg/jam)
(%)
SiO2 19,511 37722,614
Al2O3 5,397 10434,538
Fe2O3 3,487 6741,415
CaCO3 sisa 7,587 14668,084
MgCO3 sisa 0,143 276,184
CaO 62,031 119931,379
MgO 0,993 1920,219
K2O 0,334 644,831
Na2O 0,106 205,174
SO3 0,334 644,831
Cl 0,079 152,415
Total 100,000 193341,682

Bahan Bakar Kiln

Batu bara (Coal)
Feed batubara masuk = 23629,167 kg/jam
Tabel 2,19 Komposisi Umpan Batubara
Komposisi Persen Massa
C 70,35
 H2 5,3
N2 0,86
O2 19,27
S 0,12
Ash (abu) 4,1
Total 100
Sumber :
Massa umpan batu bara SP = % massa × massa umpan batu bara kering, sehingga
didapatkan komposisi umpan batu bara,
Tabel 2,20 Komposisi Massa Umpan Batubara
Komposisi Persen Massa (%) Massa (kg/jam)
C 70,35 16623,119
H2 5,3 1252,346
N2 0,86 203,211
O2 19,27 4553,340
S 0,12 28,355
Ash (abu) 4,1 968,796
Total 100 23629,167

Tabel 2,21 Komposisi Ash (debu) SP

Komponen Persen Massa (%)
SiO2 40,850
Al2O3 11,321
Fe2O3 14,860
CaO 18,299
MgO 7,621
TiO2 0,501
Na2O 0,852
K2O 0,812
P2O5 0,031
Mn3O4 0,219
SO3 4,633
Total 100
Sumber :
Massa Komponen=Persen Komponen × Massa Ash

Tabel 2,22 Komposisi Massa Abu Batubara SP Tanpa IL

Komponen Persen Massa (%) Massa (kg/jam)
SiO2 40,850 395,757
Al2O3 11,321 109,673
Fe2O3 14,860 143,965
CaO 18,299 177,284
MgO 7,621 73,828
TiO2 0,501 4,857
Na2O 0,852 8,257
K2O 0,812 7,869
P2O5 0,031 0,301
Mn3O4 0,219 2,118
SO3 4,633 44,880
Total 100 968,789

Reaksi pembakaran batubara di SP

C + O2  CO2
m 1385,259896
r 1385,259896 1385,259896 1385,259896
s 0 1385,259896

𝑀𝑎𝑠𝑠𝑎 𝐶
Mol C mula-mula = 𝐵𝑀 𝐶
16623,119 𝑘𝑔/𝑗𝑎𝑚
= 12 𝑘𝑔/𝑘𝑔𝑚𝑜𝑙

= 1385,260 kgmol/jam
Massa CO2 terbentuk = Mol C terbentuk × BM C
= 1385,260 kgmol/jam × 12 kg/kgmol
= 60951,435 kg/jam
Massa O2 diperlukan = Mol O2 diperlukan × BM O2
= 1213,293 kgmol/jam × 32 kg/kgmol
= 44328,317 kg/jam
 S + O2  SO2
m 0,886
r 0,886 0,886 0,886
s 0,000 0,886 0,886

𝑀𝑎𝑠𝑠𝑎 𝑆
Mol S mula-mula = 𝐵𝑀 𝑆
28,355 𝑘𝑔/𝑗𝑎𝑚
= 32 𝑘𝑔/𝑘𝑔𝑚𝑜𝑙

= 0,886 kgmol/jam
Massa SO2 terbentuk = Mol S terbentuk × BM S
= 0,886 kgmol/jam × 32 kg/kgmol
= 56,710 kg/jam
Massa O2 diperlukan = Mol O2 diperlukan × BM O2
= 0,886 kgmol/jam × 32 kg/kgmol
= 28,355 kg/jam

H2 + 1/2O2  H2O
m 626,173
r 626,173 313,086 626,173
s 0,000 313,086 626,173

𝑀𝑎𝑠𝑠𝑎 𝐻2
Mol H2 mula-mula = 𝐵𝑀 𝐻2
1252,346 𝑘𝑔/𝑗𝑎𝑚
= 2 𝑘𝑔/𝑘𝑔𝑚𝑜𝑙

= 626,173 kgmol/jam
Massa H2O terbentuk = Mol H2O terbentuk × BM H2O
= 548,440 kgmol/jam × 32 kg/kgmol
= 11271,113 kg/jam
Massa O2 diperlukan = Mol O2 diperlukan × BM O2
= 274,220kgmol/jam × 32 kg/kgmol
= 10018,767 kg/jam
Kebutuhan O2 total untuk reaksi pembakaran :
 = (44328,317 + 28,355 + 10018,767) kg/jam
= 54375,438 kg/jam
Massa O2 di Batubara = 3988,087kg/jam
Kebutuhan O2 Teoritis = Total O2 kebutuhan – O2 di batu bara
= 47625,252 kg/jam – 4553,340 kg/jam
= 49822,098 kg/jam
Excess Udara Pembakaran = 4%
Kebutuhan O2 Sesungguhnya = (100+4)% × Kebutuhan O2 Teoritis
= 102% × 49822,098 kg/jam
= 51814,982 kg/jam
Kebutuhan Udara Sesungguhnya:
100%
= × Kebutuhan O2 Sesungguhnya
21%
100%
= × 51814,982 kg/jam
21%

= 246738,009 kg/jam
Udara Luar Masuk Kiln (Primary Air)
= 211951,942 kg/jam
79%
Massa N2 di Udara = 21% × Kebutuhan O2 Sesungguhnya
79%
= 21% × 51814,982 kg/jam

= 194923,027 kg/jam
Massa N2 Total = Massa N2 di udara + Massa N2 di batubara
= 194923,027 kg/jam + 203,211 kg/jam
= 195126,238 kg/jam
Massa O2 Sisa Pembakaran = Kebutuhan O2 Sesungguhnya – Kebutuhan O2 Teoritis
= 51814,982 kg/jam - 49822,098 kg/jam
= 1992,884 kg/jam
Massa H2O terbentuk = Massa H2O Hasil Pembakaran
= 11271,113 kg/jam
GHP
Komponen Massa (kg/jam)
CO2 60951,435
 N2 195126,238
H2O 11271,113
O2 1992,884
SO2 56,710
Total 269398,380

Total Massa Komponen = Massa Komponen di feed + Massa Komponen di

batubara
Komposisi Klinker Keluar Kiln
Komponen Massa (kg/jam)
SiO2 63038,368
Al2O3 17437,661
Fe2O3 11437,466
CaO 211405,470
MgO 3551,398
K2O 1080,168
Na2O 357,191
SO3 1167,022
Cl 250,948
Ash 10,533
Total 309736,226

Exhaust Gas Kiln = Gas Hasil Pembakaran + CO2 Hasil Kalsinasi

= 286478,7422 kg/jam
Massa Secondary Air = Kebutuhan Udara Sesungguhnya – Udara Masuk Primer
= 222520,1187kg/jam
TABEL
Stream Input Output
Hot Meal 325844.2915
Fuel 23629.16667
Primary Air 24217.89
Secondary Air 222520.1187
Exhaust Gas Kiln 286478.7422
Hot Clinker 309730.0993
Total 596211.4669 596208.8415
NERACA MASSA COOLER
Tertiary Air

Secondary Air Waste Air

Hot Clinker
COOLER Cold Clinker

Cooling Air

Gambar Diagram Alir Massa di Cooler

Hot Clinker massuk Cooler = 309736,226 kg/jam
Udara Masuk Cooler:
Laju alir Cooling air = 598440 m3/jam
Densitas Cooling air = 1,292 saat 32 oC
Massa Cooling Air = 773058,808 kg/jam

Massa Secondary Air = Kebutuhan Udara Masuk Kiln

= 222520,119 kg/jam

Massa Cold Clinker = 309736,226 kg/jam

Massa Tertiary Air – Kebutuhan udara Pre-Heater ILC + Kebutuhan udara Pre-Heater SLC
= (113934,304 + 211951,942) kg/jam
= 325886,246 kg/jam

Massa Waste Air = Massa Hot Clinker + Massa Cooling Air – (Massa Cold Clinker + Massa
Secondary Air + Massa Tertiary Air)
= 309736,226 + 773058,808 – (309736,226 + 222520,119 + 325886,246)
= 224652,443 kg/jam
NERACA PANAS PRE-HEATER ILC
INPUT
1. Panas Yang di Bawa Batu Bara masuk Pre-Heater ILC
Suhu Ref = 200C
Massa = 11125 kg/jam
T = 600C
Cp = 1,27 kJ/kg0C
Q1 = m.Cp.∆t
= 11125 kg/jam x 1,27 kJ/kg0C x (60 - 20 )0C
= 565150 kJ/jam
2. Panas Sensibel Dari Batu Bara
Massa = 11125 kg/jam
GHV = 27112,32 kJ/kg
Q2 = m x GHV
= 11125 kg/jam x 27112,32 kJ/kg
= 301624560 kg/jam
3. Panas Exhaust Gas dari Kiln
Q3 = 603972783,2
4. Panas Tertiary Air
Massa = 113934,304 kg/jam
T = 554 0C
Cp = 1,114 kJ/kg0C
Q4 = m.Cp.∆t
= 113934,304kg/jam x 1,114 kJ/kg0C x (554 - 20 )0C
= 67801119,139 kJ/jam
 5. Panas Hot Meal Masuk Pre-Heater
T = 70
Komposisi Massa Cp Q
SiO2 26222,625 0,891 1168469,681
Al2O3 7253,500 0,900 326247,923
Fe2O3 4686,250 0,962 225483,605
CaCO3 159070,536 0,962 7653837,896
MgCO3 2995,125 0,962 144113,435
K2O 448,250 0,920 20630,258
Na2O 142,625 0,920 6564,173
SO3 448,250 0,920 20630,258
Cl 105,950 0,138 731,436
H2O 2375,725 1,880 223318,150
Total Q5 9790026,815

OUTPUT
6. Panas Kalsinasi CO2 di Pre-Heater ILC
Massa = 56068,979 kg/jam
T = 750 0C
Cp = 1,244 kJ/kg0C
Q6 = m.Cp.∆t
= 56068,979 kg/jam x 0, 1,244 kJ/kg0C x
(750 - 20)0C
= 50917361,248 kJ/jam
7. Panas Sensible H2O dari Bahan
Massa = 5306,625 kg/jam
T = 100 0C
Cp = 1,899 kJ/kg0C
Q7 = m.Cp.∆t
= 5306,625 kg/jam x 1,899 kJ/kg0C x
(100 - 20)0C
 = 806182,470 kJ/jam
8. Panas Penguapan H2O dari Bahan
Massa = 5306,625kg/jam
Hf = 2441,742 kJ/kgoC
Q = 12957407,867 kJ/jam
9. Panas Dissosiasi MgCO3
Massa = 2346,755 kg/jam
Hf = 1094,116 kJ/kgoC
Q = 2567622,539 kJ/jam
10. Panas Dissosiasi MgCO3
Massa = 124635,741kg/jam
Hf = 1130,349kJ/kgoC
Q = 140881940,603 kJ/jam
11. Panas Exhaust Gas Pre-Heater ILC
T = 388 oC
Komposisi Massa Cp Q
CO2 84765,917 1,104 34438018,446
N2 90103,775 1,090 36142426,156
H2O 7682,350 2,057 5815354,574
O2 469,141 1,023 176614,792
SO2 26,700 0,778 7644,317
Dust Lost 14096,118 1,025 5317055,615
Total Q 81897113,899

11, Panas Hot Meal

Massa = 565150 kg/jam
Q = 0,450 kJ/kg
Q = m,Q
= 565150 kg/jam x 0,450 kJ/kg
= 164463367,866 kJ/jam
12, Panas Radiasi
Q = 529262642,681 kJ/jam
Neraca Panas Pre Heater SLC
INPUT
1. Panas Yang di Bawa Batu Bara masuk Pre-Heater ILC
Suhu referensi = 200C
Massa = 20695,833kg/jam
T = 600C
Cp = 1,27 kJ/kg0C
Q1` = m.Cp.∆t
= 20695,833kg/jam x 1,27 kJ/kg0C x (60 - 20 )0C
= 1051348,333 kJ/jam

2. Panas Sensibel Dari Batu Bara

Massa = 20695,833kg/jam
GHV = 27112,32 kJ/kg
Q2 = m x GHV
= 20695,833 kg/jam x 27112,32 kJ/kg
= 561112056 kg/jam

3. Panas Exhaust Gas dari Kiln

Q3 =0

4. Panas Tertiary Air

Massa = 211951,942 kg/jam
T = 554 0C
Cp = 1,114 kJ/kg0C
Q1` = m.Cp.∆t
= 211951,942 kg/jam x 1,114 kJ/kg0C x (554 - 20 )0C
= 126130396,540 kJ/jam
 5. Panas Hot Meal Masuk Pre-Heater
T = 70
Komposisi Massa CP Q
SiO2 40561,950 0,891 1807424,267
Al2O3 11219,933 0,900 504650,161
Fe2O3 7248,833 0,962 348784,865
CaCO3 246055,119 0,962 11839188,108
MgCO3 4632,950 0,962 222919,022
K2O 693,367 0,920 31911,507
Na2O 220,617 0,920 10153,661
SO3 693,367 0,920 31911,507
Cl 163,887 0,138 1131,408
H2O 3674,843 1,880 345435,273
TOTAL Q5 15143509,781

OUTPUT
6. Panas Kalsunasi CO2 di Pre-Heater SLC
Massa = 96344,039 kg/jam
T = 750 0C
Cp = 1,244 kJ/kg0C
Q = m.Cp.∆t
= 96344,039 kg/jam x 0, 1,244 kJ/kg0C x
(750 - 20)0C
= 87491948,245 kJ/jam

7. Panas Sensible H2O dari Bahan

Massa = 9871,913 kg/jam
T = 100 0C
Cp = 1,899 kJ/kg0C
Q = m.Cp.∆t
 = 9871,913 kg/jam x 1,899 kJ/kg0C x
(100 - 20)0C
= 1499740,947 kJ/jam
8. Panas Penguapan H2O dari Bahan
Massa = 3674,843 kg/jam
Hf = 2441,742 kJ/kgoC
Q = 8973018,428 kJ/jam

9. Panas Dissosiasi MgCO3

Massa = 4032,459 kg/jam
Hf = 1094,116 kJ/kgoC
Q = 4411978,405 kJ/jam

10. Panas Dissosiasi MgCO3

Massa = 214163,177 kg/jam
Hf = 1130,349kJ/kgoC
Q = 242079227,080 kJ/jam

10. Panas Exhaust Gas Pre-Heater SLC

T = 388 oC
Komposisi Massa Cp Q
CO2 149728,941 1,101 60637825,274
N2 167620,019 1,088 67112373,509
H2O 13546,756 2,052 10229643,013
O2 872,743 1,021 327914,091
SO2 49,670 0,776 14184,163
Dust Lost 21804,302 1,025 8224582,551
Total Q 146546522,601

11. Panas Hot Meal

Massa = 1051348,333 kg/jam
 Q = 0,550 kJ/kg
Q = m,Q
= 1051348,333 kg/jam x 0,450 kJ/kg
= 201010782,947 kJ/jam

12, Panas Radiasi

Q = 11424092,001 kJ/jam

ILC SLC
Stream Stream
Input Output Input Output
Q1 565150.0 Q1 1051348.3
Q2 301624560.0 Q2 561112056.0
Q3 598555494.5 Q3 0.0
Q4 67801119.1 Q4 126130396.5
Q5 9790026.8 Q5 15143509.8
Q6 50917361.2 Q6 87491948.2
Q7 806182.5 Q7 1499740.9
Q8 12957407.9 Q8 8973018.4
Q9 2567622.5 Q9 4411978.4
Q10 140881940.6 Q10 242079227.1
Q11 81897113.9 Q11 146546522.6
Q12 164461597.1 Q12 201008618.7
Q13 523847124.7 11426256.3
Total 978336350.41 978336350.41 703437310.65 703437310.65
Neraca Panas Kiln
INPUT
1. Panas Yang di Bawa Batu Bara masuk Kiln
Suhu referensi = 200C
Massa = 23629,167 kg/jam
T = 600C
Cp = 1,27 kJ/kg0C
Q1` = m.Cp.∆t
= 23629,167kg/jam x 1,27 kJ/kg0C x (60 - 20 )0C
= 1200361,667 kJ/jam

2. Panas Dari Batu Bara

Massa = 23629,167 kg/jam
GHV = 27112,32 kJ/kg
Q2 = m x GHV
= 23629,167 kg/jam x 27112,32 kJ/kg
= 640641528 kg/jam

3. Panas Secondary Air

Massa = 222520,119 kg/jam
T = 856 0C
Cp = 1,185 kJ/kg0C
Q3` = m.Cp.∆t
= 222520,119 kg/jam x 1,185 kJ/kg0C x (856 - 20 )0C
= 220441780,821 kJ/jam

4. Panas Primary Air

Massa = 24217,890 kg/jam
T = 250 0C
Cp = 1,039 kJ/kg0C
Q4` = m.Cp.∆t
 = 24217,890 kg/jam x 1,039 kJ/kg0C x (250 - 20 )0C
= 5787349,173 kJ/jam

5. Panas Hot Meal Masuk Kiln

Massa = 325847,800 kg/jam
T = 1029 0C
Cp = 1,090 kJ/kg0C
Q = m.Cp.∆t
= 325847,800 kg/jam x 0, 1,244 kJ/kg0C x
1029 - 20)0C
= 365474150,812 kJ/jam

OUTPUT
6. Panas Kalsunasi CO2 di Kiln
Massa = 17080,363 kg/jam
T = 825 0C
Cp = 2,157 kJ/kg0C
Q = m.Cp.∆t
= 17080,363 kg/jam x 2,157kJ/kg0C x
(825 - 20)0C
= 29658085,472 kJ/jam

7. Panas Dissosiasi MgCO3

Massa = 714,895kg/jam
Hf = 1094,116 kJ/kgoC
Q = 782178,039 kJ/jam

8. Panas Dissosiasi MgCO3

Massa = 37967,941kg/jam
Hf = 1130,349kJ/kgoC
 Q = 42917040,317 kJ/jam

9. Panas Exhaust Gas Kiln

Massa = 286478,742 kg/jam
T = 754 0C
Cp = 1,500 kJ/kg0C
Q = m.Cp.∆t
= 286478,742 kg/jam x 1,500 kJ/kg0C x
(754 - 20)0C
= 315413095,159kJ/jam

10. Panas Hot Clinker

Massa = 309736,226 kg/jam
T = 1450 0C
Cp = 1,1 kJ/kg0C
Q = m.Cp.∆t
= 309736,226 kg/jam x 1,1 kJ/kg0C x
(1450 - 20)0C
= 487215083,427 kJ/jam

11. Panas Radiasi

Q = 69000000 kJ/jam

Heat Input Output

Q1 365470215.81
Q2 1200361.67
Q3 220441780.82
Q4 364358.16
Q5 640641528.00
Q6 598555494.46
Q7 29658085.47
Q8 43699218.36
Q9 487205446.17
 Qrad 69000000.00
Total 1228118244.45 1228118244.45

Neraca Panas Cooler

INPUT
1. Panas Hot Clinker
Q = 487215083,427 kJ/jam

2. Panas Cooling Air

Massa = 773058,808 kg/jam
T = 35 0C
Cp = 1,003 kJ/kg0C
Q3 = m.Cp.∆t
= 773058kg/jam x 1,003 kJ/kg0C x (35 - 20 )0C
= 11630669,760 kJ/jam

OUTPUT
3. Panas Waste Air
Massa = 224652,443kg/jam
T = 250 0C
Cp = 1,039 kJ/kg0C
Q3` = m.Cp.∆t
= 224652,443kg/jam x 1,039 kJ/kg0C x (250 - 20 )0C
= 53685194,312 kJ/jam

4. Panas Tertiary Air

Massa = 325886,246 kg/jam
T = 554 0C
Cp = 1,114 kJ/kg0C
Q4` = m.Cp.∆t
= 325886,246 kg/jam x 1,114 kJ/kg0C x (554 - 20 )0C
 = 193931515,678 kJ/jam

5. Panas Secodary Air

Massa = 222520,119 kg/jam
T = 856 0C
Cp = 1,185 kJ/kg0C
Q = m.Cp.∆t
= 222520,119 kg/jam x 1,185 kJ/kg0C x
856 - 20)0C
= 220441780,821 kJ/jam

6. Panas Cold Clinker

Massa = 309736,226 kg/jam
T = 112 0C
Cp = 0,790 kJ/kg0C
Q = m.Cp.∆t
= 309736,226kg/jam x 0,790 kJ/kg0C x
(112 - 20)0C

Panas Radiasi
Q = 8275633,473 kJ/jam

Heat Input Output

Q1 487205446.17
Q2 11630669.76
Q3 53685194.31
Q4 193931515.68
Q5 220441780.82
Q6 22511183.62
Q Rad 8266441.50
TOTAL 498836115.93 498836115.93
Penggunaan Batubara
Panas yang dibawa Primary Air
Massa = 24218,89 kg/jam
T = 35 0C
Cp = 1,003 kJ/kg0C
Q = m.Cp.∆t
= 24218,89kg/jam x 1,003 kJ/kg0C x (35 - 20 )0C
= 364358,155 kJ/jam

Panas yang dibuang Waste Air

Massa = 24218,89 kg/jam
T = 250 0C
Cp = 1,039 kJ/kg0C
Q = m.Cp.∆t
= 24218,89kg/jam x 1,039 kJ/kg0C x (250-20 )0C
= 5787349,173 kJ/jam

Panas yang dibawa Waste Air dengan massa yang sama dengan massa primary air
Massa = 224652,443 kg/jam
T = 250 0C
Cp = 1,039 kJ/kg0C
Q = m.Cp.∆t
= 224652,443 kg/jam x 1,039 kJ/kg0C x (250-20 )0C
= 53685194,31 kJ/jam

Pengurangan
𝑄 𝑆𝑒𝑐𝑜𝑛𝑑𝑎𝑟𝑦 𝐴𝑖𝑟+𝑄 𝑇𝑒𝑟𝑡𝑖𝑎𝑟𝑦 𝐴𝑖𝑟
Recuperation Efficiency awal = 𝑄 𝐶𝑜𝑙𝑑 𝐶𝑙𝑖𝑛𝑘𝑒𝑟
220441780.8 +193931515.7
= 22511183.62

= 18.4%
Recuperation Efficiency Baru
𝑄 𝑆𝑒𝑐𝑜𝑛𝑑𝑎𝑟𝑦 𝐴𝑖𝑟+𝑄 𝑇𝑒𝑟𝑡𝑖𝑎𝑟𝑦 𝐴𝑖𝑟+𝑄 𝑊𝑎𝑠𝑡𝑒 𝐴𝑖𝑟 𝑀𝑎𝑠𝑢𝑘 𝐾𝑖𝑙𝑛
= 𝑄 𝐶𝑜𝑙𝑑 𝐶𝑙𝑖𝑛𝑘𝑒𝑟
220441780.8 +193931515.7+5787349.173
= 22511183.62

= 18.7%