LAMPIRAN 1

PERHITUNGAN NERACA MASSA GRATE COOLER

Basis = kg raw meal / hour

Hari / tanggal = Rabu / 25 Februari 2010

Sumber = CCR dan QC

MASSA INPUT

1. Hot Clinker

Kiln feed = 544 ton /h

Clinker factor = 1.64

Klinker panas masuk cooler = 544 ton/h x 1

1.64 x 1000 kg/ton

= 331707 kg/h

2. Total cooling air = 9993,7 m3/min x 60 min/h

Grate cooler cooling air = 599622 m3/h

Additional fans (seal and crusher) = 83516,4 m3/h

Total cooling air = (599622 + 83516,4) m3/h

= 683138,4 m3/h

Massa udara pendingin masuk = total cooling air x densitas (T =30°C)

= 683138,4 m3/h x 1,17 kg/m3

= 799271,93 kg/h

MASSA OUTPUT

1. Cold clinker

Massa klinker dingin = massa klinker panas – (debu klinker keluar cooler +

debu klinker yang kembali ke TAD)

Massa klinker dingin = 331707 – (3610,20132+9492,54745+13927,7866)

= 304676,8 kg/h

2. ILC TAD

Volume udara panas TAD ILC = 112818,79 Nm3/h

Densitas udara TAD ILC (888°C) = 0,302739 kg/m3

Massa udara TAD ILC = 112818,79 Nm3/h x 0,302739

kg/h

=34154,6786 kg/h

Massa dust content = 34154,6786

kgh

x 32 gr / N m3

1000 gr /kg

= 3610,20132 kg/h

3. SLC TAD

Volume udara panas TAD SLC = 296642,11 Nm3/h

Densitas udara TAD SLC (898°C) = 0,300388 kg/m3

Massa udara TAD SLC = 296642,11 Nm3/h x 0,300388

kg/h

=89107,814 kg/h

Massa dust content = 89107,814

kgh

x32 gr /N m3

1000 gr /kg

= 9492,54745 kg/h

4. Secondary air

Massa udara sekunder dihitung dari pendekatan gas buang kiln. Udara

sekunder diasumsikan sebagai udara yang lewat dari kiln setelah digunakan

dalam proses pembakaran.

Massa udara sekunder = 167760,099 kg/h

5. Excess air to chimney (stack gas)

Massa udara TAD ILC = total cooling air – (SLC TAD+ILC TAD +

Secondary air)

= 799271,93 kg/h – (89107,814 kg/h +

34154,6786 kg/h + 167760,099 kg/h)

= 508249,337 kg/h

Massa dust content = 508249,337 x32 gr /N m3

1000 gr / kg

= 13927,7866 kg/h

LAMPIRAN 2

PERHITUNGAN NERACA PANAS GRATE COOLER

HEAT INPUT

1. hot klinker

massa klinker panas = 331707 kg/h

temperatur = 1413,1984 °C

Cp.T = 0,186 T x (54 x 10-6 T2)

= 0,186 x 1413,1984 x (54 x 10-6 x 1413,19842)

= 370,6999 kcal/kg

Q = 331707 kg/h x 370,6999 kcal/kg

= 122963871,6 kcal/h

2. cooling airmassa udara pendingin = 799271,928 kg/h

temperatur = 30 °C

Cp.T = 0,237 T x (23 x 10-6 T2)

= 0,237 x 30 x (23 x 10-6 x 302)

= 7,1307 kcal/kg

Q = 799271,928 kg/h x 7,1307 kcal/kg

= 5699368,337 kcal/h

HEAT OUTPUT

1. Cold clinker

massa klinker dingin = 304676,8 kg/h

temperatur = 128 °C

Cp.T = 0,186 T x (54 x 10-6 T2)

= 0,186 x 128 x (54 x 10-6 x 1282)

= 24,6927 kcal/kg

Q = 304676,8 kg/h x 24,6927 kcal/kg

= 7523303,336 kcal/h

2. TAD ILC

massa udara = 34154,6785 kg/h

temperatur = 888 °C

Cp.T = 0,237 T x (23 x 10-6 T2)

= 0,237 x 888 x (23 x 10-6 x 8882)

= 228,5925 kcal/kg

Q = 34154,6785 kg/h x 228,5925 kcal/kg

= 7807503,775 kcal/h

massa dust content = 3610,2013 kg/h

temperatur = 888 °C

Cp.T = 0,186 T x (54 x 10-6 T2)

= 0,186 x 888 x (54 x 10-6 x 8882)

= 207,7493 kcal/kg

Q = 3610,2013 kg/h x 207,7493 kcal/kg

= 750017,0718 kcal/h

Total Q TAD ILC = 8557520,847 kcal/h

3. SLC TAD

massa udara = 89107,8140 kg/h

temperatur = 898 °C

Cp.T = 0,237 T x (23 x 10-6 T2)

= 0,237 x 898 x (23 x 10-6 x 8982)

= 231,3732 kcal/kg

Q = 89107,8140 kg/h x 231,3732 kcal/kg

= 20617168,27 kcal/h

massa dust content = 9492,5474 kg/h

temperatur = 898 °C

Cp.T = 0,186 T x (54 x 10-6 T2)

= 0,186 x 898 x (54 x 10-6 x 8982)

= 210,5738 kcal/kg

Q = 9492,5474 kg/h x 210,5738 kcal/kg

= 1998881,94 kcal/h

Total Q TAD SLC = 22616050,21 kcal/h

4. Excess air to chimney

massa udara = 508249,3368 kg/h

temperatur = 260 °C

Cp.T = 0,237 T x (23 x 10-6 T2)

= 0,237 x 260 x (23 x 10-6 x 2602)

= 63,1748 kcal/kg

Q = 508249,3368 kg/h x 63,1748 kcal/kg

= 32108550,2 kcal/h

massa dust content = 13927,7866 kg/h

temperatur = 260 °C

Cp.T = 0,186 T x (54 x 10-6 T2)

= 0,186 x 260 x (54 x 10-6 x 2602)

= 52,0104 kcal/kg

Q = 13927,7866 kg/h x 52,0104 kcal/kg

= 724389,7529 kcal/h

Total Q = 32832939,95 kcal/h

5. Secondary air

massa udara = 167760,0986 kg/h

temperatur = 1169,0240 °C

Cp.T = 0,237 T x (23 x 10-6 T2)

= 0,237 x 1169,0240 x (23 x 10-6 x 1169,02402)

= 308,4908 kcal/kg

Q = 167760,0986 kg/h x 308,4908 kcal/kg

= 51752461,26 kcal/h

6. Radiasi

No Area Ai, m2 Ti, o C Cr, kCal/m2 o C Q , kcal/hr1 KilnHood 394.97 200 17.83 1197175

2 KilnHood 172.67 200 17.83523371.

9

3 Bottom area 196.09 50 11.6145532.5

6

4 Duct ke cooler 83.20 150 15.45154292.

6

5 Dinding Depan 36.01 150 15.4566779.7

5

6 Dinding belakang & samping 416.33 85 12.83293836.

3

Total1299.2

7 2280988

LAMPIRAN 3

PERHITUNGAN GAS BUANG KILN

DATA MENTAH

Sumber: QC (25 Februari 2010)

Komposisi Raw Meal Komposisi Clinker

SiO2 13,64% C3S 60.84%

Al2O3 3,20 % C2S 15,39%

Fe2O3 2,21 % C3A 8,62 %

CaO 43,63 % C4AF 10,42 %

MgO 0,81 %    

LOI 35,17 %    

SO3 0,08 %    

Na2O 0,02 %    

K2O 0,33 %    

 

Komposisi Coal (Ultimate) Komposisi Fine Coal

C 58,75 % Ash 11,66 %

H 4,84 % Moisture 4,12 %

N 0,87% NHV 5394 kcal/kg

S 0.61%    

O 21,16 %    

 

Komposisi Cangkang   Komposisi Cangkang (Proximate)

C 54,44 % Ash 6,57 %

H 6,57 % Moisture 22,82 %

N 0,41 % NHV 4179 kcal/kg

S 0,17 %    

O 38,41 %    

DATA PENGAMATAN DAN REFERENSI

Sumber: CCR (25 Februari 2010)

1. Kiln feed

Kiln feed = 549000 kg/h

Kadar H2O = 0,44%

2. Dust Return

Dust return = 7%

3. Coal

Kiln = 13.65 ton/h

ILC = 3.23 ton/h

SLC = 17.42 ton/h

4. ILC

Input kiln feed = 62%

Derajat kalsinasi = 72,74%

Temperatur masuk = 60°C

Kadar O2 = 2,57%

5. SLC

Input kiln feed = 38%

Derajat kalsinasi = 90,67%

Temperatur masuk = 60°C

Kadar O2 = 2,95%

6. Kiln

Kadar O2 = 3.81%

Temperatur fine coal bin = 78°C

7. Primary Fan

Kapasitas = 842 m3/min

Temperatur = 30,7°C

8. Cooler/AQC

Kapasitas = 9791.8 m3/min

Temperatur= 30,7°C

9. Udara

Kelembaban = 60,1%

Kandungan uap air:

Dari Perry fig 3-4 = 0,0169 kgH2O/kg udara kering

Dari Perry fig 12-2 = 0,0185 kgH2O/kg udara kering

ρ (T=0°C) = 1,2928 kg/m3

10. Kapasitas Panas

Cp N2 = 0,25 kkal/kg°C (Perry p.3-12)

Cp H2O = 1 kkal/kg°C

Cp SO2 = 0,150 kkal/kg°C (Perry p.3-12)

PERHITUNGAN GAS BUANG KILN

Coal input = 13.65 ton/h =13650 kg/h

Ash Coal = 1591,59 kg/h

H2O = 578,76 kg/h

Coal yang jadi gas = (13650 – 1591,59 – 578,76) kg/h

= 11479,65 kg/h

Reaksi Pembakaran :

1) H2 + ½ O2 H2O

H2 = 4,84 % x 11479,65 kg/h x 0.5

= 277,9989 kgmol/h

O2 =

12 x 277,9989 kgmol/h x 32 kg/kgmol

= 4447,9817 kg/h

H2O =

11 x 277,9989 kgmol/h x 18 kg/kgmol

= 5003,9794 kg/h

2) C + O2 CO2

C = 58,75 % x 11479,65 kg/h x 1

12 kgmol/kg

= 562,0883 kgmol/h

O2 =

11 x 562,0883 kgmol/h x 32 kg/kgmol

= 17986,8258 kg/h

CO2 =

11 x 562,0883 kgmol/h x 44 kg/kgmol

= 24731,8855 kg/h

3) S + O2 SO2

S = 0,61% x 11479,65kg/h x 1

32 kg/kgmol

= 2,2002 kgmol/h

O2 =

11 x 2,2002 kgmol/h x 32 kg/kgmol

= 70,4085 kg/h

SO2 =

11 x 2,2002 kgmol/h x 64 kg/kgmol

= 140,8170 kg/h

N2 = 0,87% x 11479,65 kg/h

= 100,2556 kg/h

O2 = 21,16% x 11479,65kg/h

= 2440,574 kg/h

Jadi O2 yang dibutuhkan untuk reaksi pembakaran di kiln adalah :

O2 reaksi = (4447,9817 + 17986,8258 + 70,4085)kg/h

= 22505,22 kg/h

Total O2 masuk :

Primary = 12012,12 kg/h

Blower = 1640,61 kg/h

Coal = 2440,574 kg/h

O2 excess = x kg/h

Total = 16093.3 + x kg/h

Total gas buang di kiln :

N2

N2 primer = 45188,46 kg/h

N2 blower = 6171,82 kg/h

N2 coal = 100,2556 kg/h

N2 excess =

7921

⋅2832

x = 3,2916 x kg/h

Total N2 = 51460,53 + 3,2916 x kg/h

H2O

H2O kiln feed = 2415,6 kg/h

H2O primer = 983,3076 kg/h

H2O excess = 0,0185 kg H2O/kg dry air x (N2 + O2)

= 0,0185 x (3,2916 x + x)

= 0,07939 x kg/h

H2O coal = 578,76 kg/h

H2O blower = 134,2997 kg/h

H2O dari H2 = 5003,979 kg/h

Total H2O = 9115,974 + 0,07939 x kg/h

CO2

CO2 kalsinasi = 39142,27 kg/h

CO2 dari C = 24731,89 kg/h

Total CO2 = 63881,16 kg/h

SO2

SO2 dari S = 140,817 kg/h

Total gas buang di kiln = 124598,5 + 3,3710 x kg/h

Total O2 yang keluar = % O2 outlet kiln x total gas buang

= 3,81% x (124598,5 + 3,3710 x)

= 4747,201 + 0,1284 x kg/h

Mencari x:

Total O2 masuk = Total O2 bereaksi + Total O2 keluar

16093,3 + x = 22505,22 + 4747,201 + 0,1284 x kg/h

x = 12803,5735 kg/h

Maka total udara excess :

O2 = x = 12803,5735 kg/h

N2 = 3,2916 x = 42145,1 kg/h

H2O = 0,07939 x = 1016,55 kg/h

Total excess air = 55965,22 kg/h

Total gas buang di kiln :

1. N2 = 51460,53 + (3,2916 x 12803,5735) = 93605,63 kg/h

2. H2O = 9115,947+ (0,0794 x 12803,5735) = 10132,5 kg/h

3. CO2 = 63881,16 kg/h

4. SO2 = 140,817 kg/h

Total gas buang di kiln = 167760,1 kg/h

LAMPIRAN 4

PERHITUNGAN HEAT RECOVERY DAN EFISIENSI COOLER

Diketahui :

Cooling air : 5.699.368,34 Kcal/jam

Secondary air : 48.270.856,88 Kcal/jam

ILC Tertiary air : 8.557.520,85 Kcal/jam

SLC Tertiary air : 22.616.050,21 Kcal/jam

Heat losses : 5.860.146,26 Kcal/jam

Total heat in : 128.663.239,98 Kcal/jam

Total heat out : 128.663.239,98 Kcal/jam

Heat recovery, η = (Secondary air+ ILC Tertiary air+SLC Tertiary air )−Cooling air

Total heat∈¿ X 100 %¿

= [(48.270 .856,88+8.557 .520,85+22.616 .050,21 )−5.699 .368,34

128.663 .239,98¿

Kcal/jamX 100 %

= 60.02 %

Efisiensi Cooler = Totalheat out−Heat losses

Totalheat∈¿ X 100 %¿

= [128.663.239,98−5.860 .146,26

128.663 .239,98¿ Kcal

jamX 100 %

= 97.59 %