Tugas II Alat Industri Kimia

PT Laprindo Aman Sentosa adalah suplier pasir silika bagi pabrik-pabrik keramik di
wilayah Jawa Tengah. Perusahaan ini melakukan penambangan pasir silika (qwartz)
sendiri di daerah Argo Wilis. Setiap hari diperoleh 150 ton silika (Bulk density 105
lb/ft3) yang selanjutnya diproses (diumpankan) dalam sebuah Triple Roll Mill yang
dirangkai dengan Vibrating Screen Single Deck 48 Mesh. 20% dari total umpan akan
diperoleh sebagai hasil atas (oversize). Screen ini beroperasi secara open circuit. Pada
awal bulan April ini, tim process engineer harus melaporkan hasil evaluasi kinerja
dari alat-alat yang ada. Hasil laporan akan dipublikasikan di rapat pemegang saham
pada tanggal 9 April 2007 untuk menjamin kelayakan perusahaan baik dari segi
operasi maupun keamanan. Tim lapangan telah berhasil mengumpulkan data rata-rata
hasil analisis ayakan selama bulan Januari-pertengahan Maret yaitu sebagai berikut:
Mesh

Fraksi massa di

Fraksi massa di

Fraksi massa di

umpan

oversize

undersize

-28 + 35

0,15

-35 + 48

0,25

0,25

-48 + 65

0,4

0,175

0,05

-65 + 100

0,1

0,25

0,667

-100 + 150

0,05

0,2

0,116

-150 + 200

0,05

0,125

0,167

Dari data tersebut akan ditentukan parameter kinerja dari alat. Adapun parameter
kinerja alat yang harus dilaporkan adalah:
a. True Average Arithmetic Diameter (TAAD), Mean Surface Diameter (MSD),
dan Mean Volume Diameter (MVD) dari umpan.
b. Efektivitas dari Vibrating Screen single deck
c. Jika Mulai bulan Mei sistem operasi screen akan dirubah menjadi closed
circuit, berapa Hp motor yang harus dibeli untuk pengoperasian roll mill ?
(Efisiensi mill berkisar antara 70-80%, Bilangan Rittinger = 243 cm2/ft.lb)
Sebagai bagian dari tim engineer, diharuskan partisipasi anda dan semua perhitungan
harap disertakan.
(Pengumpulan data parameter paling lambat tanggal 5 April 2007 pukul 13.00 WIB. )

CLIMA ceramic tile making machine

1 2 3 Next page
We are a professional ceramic tile making machine exporter and we've been
providing ceramic tile making machine to oversea customers for many years. The
machine is engaged to make hard-wearing ceramic tiles which can be used for the
pavement of roofs, floors, walls, showers, or other objects. Complete set of tile
making machine includes machines from batching system to the final output of
ceramic tiles. It will be a satisfactory project for those who want to invest in the
ceramic tile making machine.

Tile making machine - Workshop

Tile making Machine Equipment List

(For reference, final decision will be based on customers' needs)
Tile Making Machine Equipment list
Batching & Feeding

Feeding unit

Belt Conveyor

Two-way Belt
Conveyor

Grinding
Pneumatic
Ball Mill Inner Diaphragm
Pump
Body Preparation
Servo Tank (
Spray Dryer ( 25
Plunger Pump
5m 3 )
00)
Belt Conveyor Vibrating Sieve Magnetic Filter
Dryer & Biscuit Firing
Connection
Dryer Loading Biscuit Firing
Line
machine
Kiln
Glaze Preparation
Pneumatic
Stainless steel
SCS-1 Scale
Diagraphm
Slip Tank
Pump
Wet Type
Vibrating sieve
Magnetic Filter
Glazing
MediGlazing Line
Bell Glazing
compensator
Firing
Kiln Loading Glost Firing
Kiln Unloading
Machine
Roller Kiln
Machine
Ball mill

Stirrer

Vibrating
Sieve

V-Belt Conveyor

B-Belt
Conveyor

Powder Silos
Unloading Machine

Ball mill

Ball mill
inner cover

f 660 Printing
Machine(Belt Type)
Roller cleaning
machine

Roller kiln

The structure of this roller kiln is box structure. According to functions of each part,
the kiln can be divided into 7 parts: steel structure part, refractory material structure
part, pipeline system, firing system, gas or oil pipe, transmission system, temperature
controlling system, and safety system.
Refractory and Heat Preservation Materials of the Kiln

The selection of the refractory and heat preservation materials is according to the
temperature requirement of different kiln sections. In order to ensure the life of the
kiln, higher level than temperature requirement of the materials is to be selected. To
reduce the energy consumption, it's better to select materials with low heat conduction
coefficient.
Refractory and Heat Preservation Materials of the Kiln

After filtering impurities by the system and through leveling off the voltage, the
gas/oil enters the burner by auto controlled valve. Many burners are interlaced
collocated on the body of the kiln, and make the heat source of the kiln even and easy
to adjust. 4-8 burners are set at every part of the firing parts. These burners are
interlaced collocated to the kiln. 6-8 branch burners are set to be one group, adopting
intelligent instrument and upper machine to auto control.
Firing system considers the characteristics of the fuel. Safety shutting off valve,
voltage leveling off valve and electromagnetism valve are set at the main pipe. When
gas pressure oversteps the setting or power cut, the valve cut the supply of the gas
automatically.
Each control loop can control 6 or 8 burners. Set the roller as the border, the upper
and lower burner controls separately to adjust the up and low difference of
temperature. The section of the kiln chamber sets upper fire resisting plate and low
fire resisting wall. Space between the fire resisting plate and the roller can be adjusted
according to demand. The function is to adjust the burning curve according to
technical demand, and can improve the temperature equality of the section.
Transmission System

The whole kiln adopts 45 bevel wheel driving method. Every 3 kiln sections forms a
driving group, each with a decelerating motor, dragging by motors and with
transducer control for tile ' s distance control. The whole kiln consists of 3 groups of
transducers for controlling the distance of the tiles. The driving system has the
functions as follows: switch of supply power and generating power, group driving
swing function, supply power driving function without transducers. It has the
advantages of steady, reliable driving, low faults, long life and wide range of speed
adjustment.
Control System

The control system of the kiln consists of 5 systems: driving system, fan system,
temperature control system, oil or gas/oil control system, warning and safety system,
power cut switch system and intelligence management supervising system.
Fan Control System: The fan control systems are divided into two types, manual
control and automatic control.
Manual control

The control power source is sent to the field from central control room through
manual medium relay.
Automatic Control

It is a sequence starting procedure for automatic control condition. When starting, the
smoking drawing fan starts and after delay for some time, the fast cooling fan can
start, and delay for another time, the heat drawing fan can start. After starting, the
switch on the operation panel or choosing switch for the field fan can be used. The
opening degree of the wind gate shall be paid attention to when starting Automatic fan
starting. The automatic starting fan system is locked when generating electricity.
Gas System

This picture is the gas system of the gas roller kiln. The calorific value of the
artificial occurred furnace gas is low and the flux is large. Water draining pipe and tar
draining pipe need to be set and the pipe design shall satisfy the energy consumption
requirement of the products sufficiently
Fast Cooling System

This picture shows the fast cooling system of the kiln; the drawing fan inputs the wind
equally into the kiln through refractory steel pipe, adopting frequency conversion to
control the temperature of the fast cooling section. The high precision can satisfy the
requirement of the technics and adjustment of thermal system.

Flowchart

Process description
1 Raw Materials Weighing:
The raw materials for single process type of ground ceramic tile, including various
clays, feldspar and frit, are processed homogeneously by mixing and ball milling. All
the raw materials should be accurately weighed, so that the quality of the product can
be stabilized. It is therefore essential that precision weighing equipment be prepared.
Roof tile making machine.
2 Ball Milling:
After weighing, the raw materials are transferred to the ball mill, where water is
added. After crushing and agitating, the clay is forced to pass through a 80-100 mesh
screen

in

order

to

make

into

delicate

products.

Nowadays, the ball mill is lined with oxidized aluminum, which is more efficient and
can save 1/3 of time.

3 Mixing:
Making the ingredients of the clay well-distributed in the solution, and keep it from
sedimentation,

which

is

good

for

forming.

Vibrating

Roof

tile

making machine.

screening:

Vibrating screen is placed at the outlet of ball mill, refraining the coarse particle
materials from flowing through the 80-100 mesh screen down to the ground tanks.

Roof

tile

making

machine.

Spray

Drying:

The most modernized and efficient method for making body slip is by spray drying
powder method. The powder formed is round shape, and ball. The size of granules
can be adjustable depending on the demand of the users. After spray drying, the water
content

of

the

granules

is

between

Powder

35-40%.

Storage:

The granules have to be kept in a storage bin for a few days so that its composition
becomes even more homogeneous. This process makes the granules more pliable and
less likely to stick to the mold. The size of powder storage bin needed will be
determined by the production capacity of the plant. Generally, the most suitable size
is capable of holding 400 tons of powder. Roof tile making machine.

Shaping:

After storage, the granules is conveyed to a shaping machine and to be molded by

squeezed with high pressure into what is called a biscuit. Roof tile making machine.

Speed

Body

Drying:

The water content ranges between 6-6.5% after squashed. The biscuit is then
conveyed through the speed drying kiln to lower the water content to below 1%, and
to

be

ready

for

firing

in

the

kiln.

Roof

tile

making

machine.

Glazing:

The dried biscuit to be put on raw-body glazing lines and sprayed with glaze on the
surface, the different glazes, after firing, will turn out different colors. After the
biscuit is glazed, it can be embossed and printed with various designs and colors by
different

10

glazing

process.

Roof

Car

tile

making

machine.

Storage:

After glazing, the biscuit is loaded into the stock car for storage, which is proceeded
by the fully-automatic hydraulic controlled system. Roof tile making machine.

11

Speed

Rolling

Kiln

Firing:

The biscuit is conveyed along the high speed rolling kiln and heated with a
temperature

12

of

1,150-1,200C.

Selecting:

At the outlet of the kiln, the defective products will be selected out. Roof tile making
machine.

13

Packing:

The finished products are then packed and stored or shipped. Roof tile making
machine.