SISTEM PENGATURAN DITEBAR

TE091468
Flow and Temperature Control System in Cement Materials
Processing in PT. Indonesia Semen Second Tuban Unit

OLEH
MUHAMAD ZULFIQAR RUSRETIN
(2214105047)

DAFTAR ISI
BAB I.........................................................................................................................................2
1.1

Latar Belakang.............................................................................................................2

1.2

Deskripsi Sistem..........................................................................................................2

1.3 Proses Raw Mill................................................................................................................4

1.3.1 Diagram Fungsional................................................................................................4
1.3.1 Deskripsi Proses.......................................................................................................5
1.4 Diagram P&ID (Piping and Instrumentation Diagram)..................................................6
1.3

Alarm...........................................................................................................................7

DAFTAR PUSTAKA.................................................................................................................8

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BAB I
PENDAHULUAN
1.1 Latar Belakang
Semen Gresik which was inaugurated on August 7, 1957 is the first cement factory which
was built after the Proclamation of Independence of the Republic of Indonesia. On October
24, 1969, Semen Gresik is a State Owned Enterprise (SOE) first to change the status of a
limited liability company and in 1991, PT Semen Gresik being the first SOE to Go Public.
Then in 1994, the company successfully completed the expansion of a cement plant in Tuban
(Tuban Cement Plant I) and continue to grow until the results of the expansion can be built
Semen Tuban Tuban II and then III. Semen Gresik units I and II is situated in the village
Sidomoro districts Kebomas Gresik district with an area of 150,000 m2 located in the area of
750 Ha. Gresik cement plant unit III is located in the village of Sumber Arum districts hoist
Tuban, East Java district with a building area of 400,000 m2 which is located in an area of
1,500 hectares. The factory unit III is located in Tuban Kerek. While these operations are
factory Tuban I, II and III while the Tuban IV were not operating due to lack of capital and
others. Semen Gresik, Semen Padang and Semen Tonasa merged into one that is the name of
PT Semen Indonesia (Persero), Tbk. [1]
1.2 Deskripsi Sistem
Cement manufacturing process actually mix the ingredients and changing the size of large
materials become small to micron size. Cement manufacturing process there are two kinds of
wet process and dry process. The process used by PT. Semen Gresik Tuban is a dry process.
Kind of portland cement produced cement are Ordinary Portland Cement (OPC) and
Pozzolan Portland Cement (PPC). Cement OPC is used for all construction, no special
requirements, among other things used for buildings, housing, highways, as well as building
components such as concrete. PPC cement type is a hydraulic binder that is made by grinding
together slag Portland cement and cement is resistant to acid or salt, suitable for building building near the sea. [2]

Figure 1 Cement Process Overall

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Secara umum, beberapa proses pembuatan semen bisa dilihat pada Gambar 1 diatas
dengan penjelasan ringkas seperti dibawah ini :
a. Crusher Unit
Raw material supply unit (crusher). Cement raw material used consisted of major
raw materials (such as limestone (limestone), clay (clay), silica sand, iron sand)
and additional materials such as gypsum (rocky gypsum is added after the
mixture of raw materials is burned into slag which aims to slow hardening when
grinding slag cement and trass ie volcanic eruption material results in the form of
fine grains that are used for the production of cement types PPC). These materials
undergo a process of mixing (crusher).
b. SILO Unit
Is a place where the material after the process of manufacture of cement crusher,
before being sent to the raw mill.
c. Raw Mill
Materials from the crusher to the raw mill together with the hot gas from the
suspension preheater. During the mixing process material in the raw mill drying
process occurs also where the expected output material measuring 90 microns
with a moisture content that is owned by 1%.
d. Homogenizing SILO
Wet process, slurry is mixed in the mixing basin, then the slurry into the tube then
the slurry is fed into a tube correction to correcting process. While the dry process
occurs in the blending silo with funnel flow system.
e. Rotary Kiln
The most complicated stage in the production of portland cement is the
combustion process, where there is a chemical conversion process according to
the design and the physical processes for preparing the mixture of raw materials
to form clinker. This process is carried out in a rotary kiln by using either solid
fossil fuels (coal), liquid (diesel), or alternative fuels. Coal is the fuel most
commonly used because of cost considerations. In this process will affect the
quality of cement production with regard predetermined temperature at any part
in it.
f. Grater Cooller
The reactions that occur:
Alite with water Reaction:
2Ca3OSiO4 + 6H2O 3CaO.2SiO2.3H2O + 3Ca(OH)2

This reaction is relatively fast, causing the establishment and development

of strength in the first few weeks.
Reaction from belite :
2Ca2SiO4 + 4H2O 3CaO.2SiO2.3H2O + Ca(OH)2
This reaction is relatively slow, and serves to improve the strength after
one week. Hydration of tricalcium aluminate is controlled by the addition of
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calcium sulfate, which immediately becomes a liquid upon the addition of

water. First of all, etringit be formed rapidly, causing a slow hydration.
Ca3(AlO3)2 + 3CaSO4 + 32H2O Ca6(AlO3)2(SO4)3.32H2O
After that etringit reacts slowly with tricalcium aluminate further to form
"monosulfat".
Ca6(AlO3)2(SO4)3.32H2O + Ca3(AlO3)2 + 4H2O 3Ca4(AlO3)2(SO4).12H2O
This reaction will be perfect after 1-2 days. Calcium aluminoferit reacted
slowly because their hydrated iron oxide.
2Ca2AlFeO5 + CaSO4 + 16H2O Ca4(AlO3)2(SO4).12H2O + Ca(OH)2 +
2Fe(OH)3
g. Packer
Cement packing stage starts from cement storage silo with a capacity of 18,000
tons. Entered into a bag of cement has been set weighing 49.75 kg or 50.75 kg. If
the weight of cement is less than specified, then the cement is already in the bag
of cement weighing monitored and will be issued through the reject.
1.3 Proses Raw Mill
1.3.1 Diagram Fungsional
Raw materials such as silica sand, iron sand, clay, and limestone that has been processed in
the crusher will be undergoing some process of mixing, refining and drying. It is this process
that occurs in the raw mill before it is fed into the kiln Shown in Figure 2.1 and Figure 2.2 for
a specific scope.

Gambar 2 Raw Mill Process View in Tuban 2 Unit

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1.3.1 Deskripsi Proses

Material size almost 90 mikron

Blending Silo
Material from crusher

Raw
Mill
Preheater

Gambar 3 Raw Mill Process

The process of raw mill is equipped with some of the processes in it as follows :
a.
Grinding Table
Shaped like a plate, in the margins have holes to perfuse a hot air for drying material.
b.
Grinding roller
This section serves to grind by utilizing their power to press down and turn the force
between the roller and the grinding table.
c.
Clasiffier
Located at the top of the mill controls the fineness of the product or to separate the
material that has been refined from a rough material.
d.
ID Fan Mill
This section is used to pull the material from the mill to mix with the air and into the
cyclone separator.
e.
Cyclone Separator
Serves to separate the product from the air by rotating.
Material limestone / Clay Mix and iron sands as a decoy with a flow rate of 570 tonnes / hour
in through the chimney on a raw mill feed material then falls amid the grinding table. At the
same time the hot gas entered into the raw mill grinding through gaps in the table. The need
of hot gas for drying material in the raw mill supplied by residual gas from the preheater with
a temperature of 330 degree C. Milling system is equipped with air heating. If the heat taken
from the preheater insufficient gas, the gas can be heated first with air heating, lack of heat
obtained from the gas preheater may occur due to the cessation process kiln. This hot gas will
dry the material presented above grinding table. Fineness of the product is governed by a
classifier which rotates at 900 rpm speed that will produce a product with a fineness of 90
microns and a maximum water content of 1%. The material will subtly pulled upwards
towards the cyclone separator by ID Fan Mill berrfungsi to experience separation between
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material and gas. While the material is not smooth because of the influence of gravity will fall
down and fed back into the raw mill for grinding back. Material next process will enter into a
blending silo.
1.4 P&ID Diagram (Piping and Instrumentation Diagram)
The process in Figure 3.1 below existing material in the raw mill need for regulating the
flow rate at the time of the material entered into this process and temperature settings for hot
gas is obtained from the preheater. Below is a diagram P & ID flow rate and temperature:

Gambar 4 Flow rate and temperature in Materials Processing P&ID Diagram

Keterangan :
TC : Temperature Controller
FC : Flow Controller
TT : Temperature Transmitter
FT : Flow Transmitter

: Electric Line
Pneumatic Line

Broadly speaking, the block diagram of this process as follows:

Gambar 5 Single Loop Flow Rate in Raw Materials Block Diagram

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Gambar 6 Single Loop Temperature in Hot Gas Production Block Diagram

Flow rate into the raw mill has a set point of 570 tons / hour and the set point
temperature of the preheater at 330C. When the flow rate of material from the crusher
process that goes into this process needs to be maintained in order to obtain the composition
of the raw mill products according to the standard feed Klin. The material in the raw mill will
undergo size reduction and evaporation of water. In this process for drying raw materials are
ground using residual heat from the air preheater. Exodus materials are very influential on the
set temperature.
1.2 Alarm
The function of the alarm is when the temperature of the preheater is less than a
predetermined set point is at 330C. Thus the output material in accordance with the standard
kiln feed.
NO
1
2
3
4
5
6

Alarm Type
Low
Temperature
Normal
Temperature
High
Temperature
Low Flow
Normal
Flow
High Flow

Condition
Temperatures in the preheater process
< 330C.
Temperatures in the preheater process
330C < X < 350C
Temperatures in the preheater
process > 350C.
Flowrate in the preheater process <
145 kg/second.
Flowrate in the preheater process
152 < X < 160 kg/ second .
Flowrate in the preheater process
> 165 kg/ second .

Status
Low Temperature
Yellow Lamp : ON
Low Temperature
Green Lamp : ON
High Temperature
Red Lamp : ON
Low Flow
Yellow Lamp : ON
Low Flow
Green Lamp : ON
High Flow
Red Lamp : ON

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BAB II
PERANCANGAN SISTEM
1 Temperature Indicator Control
Temperatures on the system will be set in the process rawmill to keep the mixture of
cement according to the standard that is fed to the rotary kiln at about 90 microns.
TIC in Rawmill Process
The temperature on this rawmill system has a normal range between 335-350 degrees
Celsius. With the reading scale between 0-400 degrees Celsius. The arrangement is done
automatically using a 2 point 2 point alarm representing the critical temperature at rawmill,
so the need for action. The point is as follows:
Range 1 (LL) : signal to raise the temperature of the heating (temperatur range 0 330
celcius degree)
Range 2 (HH) : signal to lower the temperature of the heating (temperatur range 350 370
celcius degree)
The normal temperature at this rawmill process is 335-350 degrees Celsius.
Sensors are used to reading the temperature of the preheater is Thermocouple
Amount
: 1 Piece
Material

: Copper-Nikel

Temperature Range : 0 - 750 oC

Type

: Type J

Media

: steam bersuhu 0 - 350 oC

Flow Indicator Control

The rate of material entering the rawmill must be maintained in the range of 550-570
tonnes per hour, equivalent to 152-160 kg / sec. The rate of material needs to be maintained
so that the efficiency of time and have an optimal production costs.
FIC in Rawmill
The rate of material on this rawmill system has a normal range between 152-160 kg / sec.
With the reading scale between 0-200 kg / sec. The arrangement is done automatically by
using two alarm points that represent two points on rawmill critical flow rate, so that the need
for action. The point is as follows:
Range 1 (LL)
Range 2 (HH)

: To increase the flow rate signal (Flowrate < 145 kg/second.)

: To decrease the flow rate signal (Flowrate > 165 kg/second.)

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Flow Rate normal rawmill process is 152-160 kg / second.

Sensors are used to reading the flow rate of the crusher is Clamp on flowmeter
Amount

: 1 Piece

Material

: Metal

Flowrate Range

: 0 500 kg/detik

Media

: sludge liquid with flowrate 150 160 kg/second.

Langkah langkah mendesain project pada software DCS Yokogawa Centum3000

1

Buat project baru pada sistem view di oracle virtual box dan buat project default.

Rancangan input dan output pada FCS

Rancangan function block pada FCS

Rancangan Faceplat pada HIS

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Rancangan konfigurasi pada HIS

HMI pada DCS Yokogawa

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DAFTAR PUSTAKA
[1] PT Semen Indonesia, Sejarah PT Semen Indonesia , http:// www.semenindonesia.com/, 30
Maret 2016.
[2] Sigit, Proses Pembuatan Semen, http://vampiregiet.blogspot.co.id/, 30 Maret 2016.
[3] Pasha, Proses Pada Vertical Raw Mill, http://www.slideshare.net/mkpasha/vrm, 24 Maret
2016

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