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
1
Klinker panas masuk cooler = 544 ton/h x x 1000 kg/ton
1.64
= 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
kg
34154,6786 x 32 gr /N m3
Massa dust content = h
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
kg
89107,814 x 32 gr / N m3
Massa dust content = h
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
508249,337 x 32 gr / N m 3
Massa dust content =
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 air
massa 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

N
o Area Ai, m2 Ti, o C Cr, kCal/m2 o C Q , kcal/hr
1 KilnHood 394.97 200 17.83 1197175
523371.
2 KilnHood 172.67 200 17.83 9
45532.5
3 Bottom area 196.09 50 11.61 6
154292.
4 Duct ke cooler 83.20 150 15.45 6
66779.7
5 Dinding Depan 36.01 150 15.45 5
293836.
6 Dinding belakang & samping 416.33 85 12.83 3
1299.2
Total 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 %
Moistur
H 4,84 % e 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 %
Moistur
H 6,57 % e 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
1
O2 = 2 x 277,9989 kgmol/h x 32 kg/kgmol
= 4447,9817 kg/h
1
H2O = 1 x 277,9989 kgmol/h x 18 kg/kgmol
= 5003,9794 kg/h

2) C + O2 CO2
1
C = 58,75 % x 11479,65 kg/h x kgmol/kg
12
= 562,0883 kgmol/h
1
O2 = 1 x 562,0883 kgmol/h x 32 kg/kgmol
= 17986,8258 kg/h
1
CO2 = 1 x 562,0883 kgmol/h x 44 kg/kgmol
 = 24731,8855 kg/h

3) S + O2 SO2
1
S = 0,61% x 11479,65kg/h x kg/kgmol
32
= 2,2002 kgmol/h
1
O2 = 1 x 2,2002 kgmol/h x 32 kg/kgmol
= 70,4085 kg/h
1
SO2 = 1 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
79 28
⋅ x
N2 excess = 21 32 = 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

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

Total heat out−Heat losses

Efisiensi Cooler =
Total heat ∈¿ X 100 % ¿
128.663.239,98−5.860.146,26 Kcal
=[ ¿ X 100 %
128.663 .239,98 jam
= 97.59 %