LAMPIRAN A

DATA PENGAMATAN

Data aktual pengamatan yang dilakukan pada hari rabu tanggal 3 Agustus 2011
Berdasarkan pada tekanan Tekanan Atmosfer = 760
Temperatur Lingkungan = 30
Kelembaban udara = 72.00

1 Kiln Feed = 300,000.00 kg/jam

String A = 120,000.00 kg/jam (40%)
String B = 180,000.00 kg/jam (60%)
Komponen Komposisi(%)
SiO2 13.31
Al2O3 3.17
Fe2O3 2.19
CaO 43.43
MgO 0.85
LOI 35.06
H2O 0.42

2 Clinker Out = 170,454.55 kg/jam

Faktor Clinker 1.76
Komponen Komposisi(%)
SiO2 21.97
Al2O3 5.56
Fe2O3 3.77
CaO 66.09
MgO 1.29
3 Bahan Bakar (Coal)
NHV = 5,300 kcal/kg batubara
Heat of Consumption = 800.0 kcal/kg clinker
Total Heat of Consumption = 136,363,636.36 kcal/jam
Fine Coal = 25,728.99 kg/jam
Ke Kiln = 10,291.60 kg/jam (40%)
Ke Kalsiner = 15,437.39 kg/jam (60%)
Komponen Komposisi (%)
C 63.24 61.00
H 6.22 6.00
O 14.31 13.80
N 0.83 0.80
S 0.41 0.40
H2O 8.22 8.22
Ash 13.38 13.38

4 Persen Ash Raw Coal = 6.36 %

Raw Coal = 25,580.00 kg/jam
 Komposisi Ash Fine Coal Raw Coal
SiO2 68.38 55.44 %
Al2O3 27.66 34.15 %
Fe2O3 2.59 4.35 %
CaO 2.46 4.09 %
MgO 0.52 0.81 %

5 Bahan Baku
Batu Kapur 291.00 ton/jam 291,000 kg/jam
Tanah liat 46.10 ton/jam 46,100 kg/jam
Pasir Besi 3.80 ton/jam 3,800 kg/jam
Pasir Silika 2.75 ton/jam 2,750 kg/jam

Komposisi Batu Kapur Tanah Liat Pasir Besi Pasir Silika

SiO2 8.32 57.66 19.28 78.28
Al2O3 1.74 17.35 11.18 11.83
Fe2O3 0.5 6.9 68.42 2.36
CaO 48.02 3.09 0.93 0.98
MgO 0.62 1.16 0.96 0.31
H2O 7.5 33 9.5 12.5

6 Cooler Fan (12 Buah)

Fan Tekanan (mbar) Volume(m3/jam) Suhu(oK)
Fan K10 58 17,899.75 303
Fan K11 33 37,589.47 303
Fan K12 36 35,799.50 303
Fan K13 22 31,324.56 303
Fan K14 20 39,379.44 303
Fan K15 19 55,489.22 303
Fan K16 7 23,269.67 303
Fan K17 27 28,639.60 303
Fan K18 14 39,379.44 303
Fan K20 75 32,219.55 303
Fan K21 83 15,214.79 303
Fan K22 61 24,164.66 303
380,369.64

7 Primary Air Fan

Kapasitas 3,000.00 m3/jam (Data Desain)
Tekanan 1.055 atm
Suhu 30 oC
Bukaan 94 %

8 Coal Conveying Air

Volume 3,420 m3/jam (Data actual)
 Tekanan 1.045 atm
Suhu 343.00 K

9 Stack Fan
Volume 131,040 m3
Tekanan 1.052 atm
Suhu 219 oC 492 K

10 O2 Excess
Kiln Line 5.90 %
Calsiner 1.45 %

11 Raw Material Grinding

Temperatur Input Gas Panas 359.78 oC
Temperatur Input Bahan Mentah 30 oC
Temperatur Output 86 oC
H2O Raw Meal Output 0.63 %

12 Raw Mill
Motor Power 1,703 kWh
Efisiensi Motor 85 %
 mmHg
oC
%

13,31
3,17
2,19
43,43
0,85
35,06
0,42

ubara
ker
(16,132,779.95)

58 20,000 19,799.75
33 42,000 41,579.47
36 40,000 39,599.50
22 35,000 34,649.56
20 44,000 43,559.44
19 62,000 19,938.45
7 26,000 25,739.67
15 32,000 31,679.60
14 44,000 43,559.44
75 36,000 35,639.55
83 17,000 16,829.79
61 27,000 26,729.66
425,000.00
LAMPIRAN B
PERHITUNGAN NERACA MASSA

A. Menghitung Jumlah dan Komposisi Gas Panas

1 Clinker dari ash Batubara
Ash Clinker (Ash FC) = %Ash x Total Fine Coal ……………(1)
= 13.38 % x 25728.99
= 3442.54 kg
Ash Raw Coal = %Ash x Raw Coal
= 6.36 % x 25580.00
= 1626.89 kg
(Sumber : Maniso Budiawan,2001)

2 Clinker dari Kiln Feed

KF Klinker = Clinker Out - Ash Coal ……………(2)
= 170454.55 kg - 3442.54
= 167012.01 kg
(Sumber : Maniso Budiawan,2001)

Komponen Komposisi Clinker Berat (kg) Komposisi Ash Berat (kg)

A B C D E
SiO2 21.97 37448.86 68.38 2354.01
Al2O3 5.56 9477.27 27.66 952.21
Fe2O3 3.77 6426.14 2.59 89.16
CaO 66.09 112653.41 2.46 84.69
MgO 1.29 2198.86 0.52 17.90

C = B/100 x Clinker Out

E = D/100 x Ash Clinker
F=C-E

3 Kiln Feed Tersaring

KF Tersaring = KF Klinker/[1-(%LOI/100)] ………(3)
= 167012.01
(1- 35,06/100)
= 257178.94 kg
String A = 102871.58 kg (40%)
String B = 154307.37 kg (60%)

(sumber : Prihadi Setyo, 2001)

4 Total Dust
Total Dust = (KF - KF Tersaring)(1-H2O)
= ( 300000.00 - 257178.94
= 42641.21 kg

5 Dust ke Coal Mill

Dust ke Coal Mill = Ash Fine Coal - Ash Raw Coal …………………………..(4)
Dust = (%Ash x Fine Coal)-(%Ashx Raw Coal)
( 13.38 % x 25728.99 kg ) - (
= 3442.54 - 1636.36 +
Dust =

0.94 Dust = 1806.17 kg

Dust = 1928.85 kg

(Sumber : Maniso Budiawan,2001)

6 Dust ke Raw Mill

Dust ke Raw Mill = Total Dust - Dust ke Coal Mill
= 42641.21 - 1928.85 kg
= 40712.36 kg

7 Komposisi Dust Total

Kiln Feed = 300000.00 kg/h
KF Klinker = 167012.01 kg/h
Komponen %Kiln Feed Berat (kg) Berat KF KlinkerKomposisi Dust total
A B C D F
SiO2 13.31 39930.00 35094.86 4835.14
Al2O3 3.17 9510.00 8525.07 984.93
Fe2O3 2.19 6570.00 6336.97 233.03
CaO 43.43 130290.00 112568.72 17721.28
MgO 0.85 2550.00 2180.96 369.04

C = B/100 x Kiln Feed

F=C-D

8 Komposisi Dust ke Coal Mill

Ash Fine Coal 3442.54 kg

 Ash Raw Coal 1626.89 kg
Komponen %Fine Coal Berat (kg) %Raw Coal Berat (kg)
A B C D E
SiO2 68.38 2354.01 55.44 901.95
Al2O3 27.66 952.21 34.15 555.58
Fe2O3 2.59 89.16 4.35 70.77
CaO 2.46 84.69 4.09 66.54
MgO 0.52 17.90 0.81 13.18

C = B/100 x Ash Fine Coal

E = D/100 x Ash Raw Coal
F=C-E

9 Komposisi Dust ke Raw Mill

Komponen Dust Total Dust Coal Mill Dust Raw Mill

A B C D
SiO2 4835.14 1452.06 3383.08
Al2O3 984.93 396.62 588.31
Fe2O3 233.03 18.39 214.63
CaO 17721.28 18.15 17703.13
MgO 369.04 4.72 364.31
ToTal 24143.42 1889.95 22253.47

10 Menghitung Gas Hasil Pembakaran fine Coal

a. Kiln Line
Fine Coal = 25728.99 kg/jam
Kiln Line = 10291.60 kg/jam (40%)

Komponen Komposisi(%) Kiln Line (kg) BM

A B C D
C 63.24 6508.40 12.00
H 6.22 640.14 1.00
O 14.31 1472.73 16.00
N 0.83 85.42 14.00
S 0.41 42.20 32.00
H2O 8.22 845.97 18.00
Ash 13.38 1377.02

C = B X Kiln Line
E = C/D
Reaksi Pembakaran
C (s)+ O2 (g) CO2(g)

S(s) + O2(g) SO2(g)

2H(s) + 1/2 O2(g) H2O(g)

Total O2 pembakaran 703.72 kmol

O dari coal 92.05 kmol
O2 Teoritis 657.70
Udara teoritis 667.96/0.21 3131.89 187913.50
N2 suplay 2474.19 kmol 69277.44

string A = 5.90
O2 excess = 5.90 %(analyzer)
%Udara excess = % O2 excess
% O2
= 100/21 x 4.8 %
= 28.10 %

%Udara excess = Udara suplay-Udara teoritis

x 100%
Udara Teoritis
28.0952 = Udara supplay - 3131.89
100.00 3131.89

Udara supplay = 4011.80 kmol

Udara excess = 4011.80 - 3131.89
= 879.91 kmol
Dimana : O2 = 184.78 kmol
N2 = 695.13 kmol
(Sumber : Himmelblau, 1996)

Gas Hasil Pembakaran Coal

CO2 =CO2 yang dihasilkan
= 542.37 kmol = 23864.15

SO2 = SO2 yang dihasilkan

 = 1.32 kmol = 84.39

H2O = H2O Coal + H2O yang dihasilkan

= 47.00 kmol + 320.07
= 367.07 kmol
= 6607.20 kg

O2 = O2 Excess
= 184.78 kmol 5913.01

N2 = N2 Coal + N2 Udara supplay

N Coal = 85.42 kg 3.05
N2 Coal = 3.05 kmol 85.42
N2 = 69362.86 kg

b. Calsiner Line 15437.39 kg

Fine Coal = 25728.99 kg/jam
Kalsiner Line = 15437.39 kg/jam (60%)
Komponen Komposisi(%) Kiln Line (kg) BM
A B C D
C 63.24 9762.61 12.00
H 6.22 960.21 1.00
O 14.31 2209.09 16.00
N 0.83 128.13 14.00
S 0.41 63.29 32.00
H2O 8.22 1268.95 18.00
Ash 13.38 2065.52

C = B X Kalsiner Line
E = C/D

Reaksi Pembakaran
C (s)+ O2 (g) CO2(g)

S(s) + O2(g) SO2(g)

2H(s) + 1/2 O2(g) H2O(g)

Total O2 pembakaran 1055.58 kmol
O dari coal 138.07 kmol
O2 Teoritis 986.55 kmol
Udara teoritis 4697.84 281870.25
N2 suplay 3711.29 kmol 89071.00

string B = 1.45
O2 excess = 1.45 %(analyzer)
%Udara excess = % O2 excess
% O2
= 100/21 x 7.1 %
= 6.90 %

%Udara excess = Udara suplay-Udara teoritis

x 100%
Udara Teoritis
6.90 = Udara supplay - 4697.84
100.00 4697.84

Udara supplay = 5022.21 kmol

Udara excess = 5022.21 - 4697.84
= 324.37 kmol
Dimana : O2 = 68.12 kmol
N2 = 256.26 kmol
(Sumber : Himmelblau, 1996)

Gas Hasil Pembakaran Coal

CO2 =CO2 yang dihasilkan
= 813.55 kmol = 35796.23

SO2 = SO2 yang dihasilkan

= 1.98 kmol = 126.59

H2O = H2O Coal + H2O yang dihasilkan

= 1.98 kmol + 480.10
= 482.08 kmol
= 8677.45 kg

O2 = O2 Excess
= 68.12 kmol 2179.80
 N2 = N2 Coal + N2 Udara supplay
N Coal = 2209.09 kg
N2 Coal = 4.58 kmol 128.13
N2 = 7303.29 kg

11 Total Gas Hasil Pembakaran Coal

Kiln Line Kalsiner Line
Komponen
Jumlah Mol (kmolBerat (kg) Jumlah Mol (kmol)
CO2 542.37 23864.15 813.55
SO2 1.32 84.39 1.98
H2O 367.07 6607.20 482.08
O2 184.78 5913.01 68.12
N2 2477.25 69362.86 260.83
1626.56

12 Reaksi Kalsinasi (Kiln Feed Clinker)

Clinker Out = 170454.55 kg/h
Kiln Line = 68181.82 kg/h
Kalsiner Line = 102272.73 kg/h
Komponen % massa Massa (kg/jam) Kiln Line (kg)
A B C D
CaO 66.09 112653.41 45061.36
MgO 1.29 2198.86 879.55

C = B/100 X Clinker out

D = 0.4 C
E = 0.6 C

Komponen Kiln Line (kg) Kalsiner Line (kg) BM

A B C D
CaO 45061.36 67592.05 56.00
MgO 879.55 1319.32 40.00

E=BXD
F=CXD

Reaksi Kalsinasi
CaCO3(s) CaO(s) + CO2(g)
MgCO3(s) MgO(s) + CO2(s)
 CaO = 112653.41 kg, String A = 45061.36
String B = 67592.05

MgO = 2198.86 kg, String A = 879.55

String B = 1319.32

a Kiln Line (String A)

CaO = 804.67 kmol, CO2 yang dihasilkan =
MgO = 32.98 kmol, CO2 yang dihasilkan =
Total CO2 yang dihasilkan = 837.65 kmol
> 25% Calsinasi terjadi di siklon 1 sampai 3
CO2 yang dihasilkan = 209.41 kmol

> 60% Calsinasi terjadi di kalsiner

CO2 yang dihasilkan = 502.59 kmol

> 15% Calsinasi terjadi di Kiln

CO2 yang dihasilkan = 125.65 kmol

CO2 yang ke luar dari string A = 335.06 kmol

CO2 yang ke luar dari string B = 502.59 kmol

b Calsiner Line (String B)

CaO = 1207.00 kmol, CO2 yang dihasilkan =

MgO = 32.98 kmol, CO2 yang dihasilkan =
Total CO2 yang dihasilkan = 1239.98 kmol
> 85% Calsinasi terjadi di siklon 1 sampai 3
CO2 yang dihasilkan = 1053.99 kmol

> 15% Calsinasi terjadi di Kiln

CO2 yang dihasilkan = 186.00 kmol

CO2 yang ke luar dari string A = 186.00 kmol

CO2 yang ke luar dari string B = 1053.99 kmol

> Total CO2 hasil kalsinasi yang ke luar dari String A = 521.06
> Total CO2 hasil kalsinasi yang ke luar dari String B = 1556.58

13 Vapour H2O dari Kiln Feed

 String A = %H2O x Kiln Feed ke string A ………………(7)
= 0,6% x Kiln Feed ke string A
= 720.00 kg

String B = %H2O x Kiln Feed ke string B ………………(8)

= 0,6% x Kiln Feed ke string B
= 1080.00 kg

(Sumber : Maniso Budiawan, 2001)

14 Exhaust Gas yang ke luar dari String B

O2 = O2 Hasil Pembakaran Coal
= 2179.80 kg
N2 = N2 Hasil Pembakaran Coal
= 7303.29 kg
CO2 = Co2 Hasil Pembakaran Coal + CO2 Hasil Kalsinasi
= 104285.58 kg
SO2 = SO2 Hasil Pembakaran Coal
= 126.59 kg
H2O = H2O Hasil Pembakaran Coal + Vapour H2O
= 9757.45 kg
Total = 123652.72 kg

15 Menghitung Udara Pendingin Grate Cooler (12 Fan)

Fan P abs(atm) V(m3/jam) Suhu(oK) R(m3.atm/kmol.K)
Fan K10 1.0572 17899.75 303.00 0.082057
Fan K11 1.0326 37589.47 303.00 0.082057
Fan K12 1.0355 35799.50 303.00 0.082057
Fan K13 1.0217 31324.56 303.00 0.082057
Fan K14 1.0197 39379.44 303.00 0.082057
Fan K15 1.0188 55489.22 303.00 0.082057
Fan K16 1.0069 23269.67 303.00 0.082057
Fan K17 1.0266 28639.60 303.00 0.082057
Fan K18 1.0138 39379.44 303.00 0.082057
Fan K20 1.0740 32219.55 303.00 0.082057
Fan K21 1.0819 15214.79 303.00 0.082057
Fan K22 1.0602 24164.66 303.00 0.082057

Pabs (atm) = [P (mbar) x 0.0009869233]+1

Total Udara Masuk Grate Cooler = 15804.13 kmol
16 Menghitung Udara Primer
a Primary Air Fan
Kapasitas 3,000.00 m3/jam (Data Desain)
Tekanan 1.055 atm
Suhu 30 oC = 303.00
Bukaan 94 %
Volume = 3000 m3 x 0,94 = 2820.00 m3

n = PV/RT = 119.66 kmol

b. Coal Conveying Air

Volume 3420.00 m3/jam (Data actual)
Tekanan 1.05 atm
Suhu 343.00 K
n = PV/RT = 126.98 kmol

Total Udara Primer ke Kiln = Primary Air Fan + Coal Conveying Fan
= 246.64 kmol

17 Menghitung Udara Sekunder

Secondary Air = Udara supplay ke kiln - udara Primer
= 3765.17 kmol

18 Menghitung Udara Tersier

Tersier air = Udara Supply ke Calsiner -Coal Conveying Air
= 4895.23 kmol

19 Menghitung Udara yang dibuang ke stack

Stack Fan
Volume 131040.00 m3
Tekanan 1.05 atm
Suhu 219.00 oC 492.00 K
n = PV/RT = 3414.59 kmol

20 Gas Panas dari Grate Cooler yang dialirkan ke Raw Mill

= Total Udara Cooler - Secondary Air - Tersier Air - Udara ke Stack
= 3729.14 kmol =
Dimana O2 = 783.12 kmol = 25059.79
N2 = 2946.02 kmol = 94272.54
Total = 119332.33
21 Total Gas Panas yang masuk ke Raw Mill
 = Exhaust Gas dari String B + Gas Panas dari Cooler
= 242985.05 kg

Gas Panas Masuk Raw Mill

> O2 = O2 Exhaust Calsiner + O2 gas Panas dari Grate Cooler = 27239.59
> N2 = N2 Exhaust Calsiner + N2 gas Panas dari Grate Cooler = 101575.84
> CO2 = CO2 Exhaust Calsiner = 104285.58
> SO2 = SO2 Exhaust Calsiner = 126.59
> H2O = H2O Exhaust Calsiner = 9757.45
Total 242985.05

B INPUT RAW MILL

Batu Kapur 291.00 ton/jam 291000.00 kg/jam

Tanah liat 46.10 ton/jam 46100.00 kg/jam
Pasir Besi 3.80 ton/jam 3800.00 kg/jam
Pasir Silika 2.75 ton/jam 2750.00 kg/jam
Komposisi Batu Kapur Tanah Liat Pasir Besi Pasir Silika
SiO2 8.32 57.66 19.28 78.28
Al2O3 1.74 17.35 11.18 11.83
Fe2O3 0.50 6.90 68.42 2.36
CaO 48.02 3.09 0.93 0.98
MgO 0.62 1.16 0.96 0.31
H2O 7.50 33.00 9.50 12.50

Total Fresh Feed Massa (kg/jam) Komposisi feed mill (

H2O SiO2 Al2O3
Lime stone (LS) 291000.00 7.50 8.32 1.74
Clay (CL) 46100.00 33.00 57.66 17.35
Iron Sand (IS) 3800.00 9.50 19.28 11.18
Silica Sand (SS) 2750.00 8.75 91.33 5.57
Total 343650.00

1 Batu Kapur /Lime Stone (LS) 291000.00 kg

SiO2 = 8.32 % x 291000.00 kg =
Al2O3 = 1.74 % x 291000.00 kg =
Fe2O3 = 0.50 % x 291000.00 kg =
CaO = 48.02 % x 291000.00 kg =
MgO = 0.62 % x 291000.00 kg =
H2O = 7.50 % x 291000.00 kg =
2 Tanah Liat /Clay (CL) 46100.00 kg
SiO2 = 57.66 % x 46100.00 kg =
Al2O3 = 17.35 % x 46100.00 kg =
Fe2O3 = 6.90 % x 46100.00 kg =
CaO = 3.09 % x 46100.00 kg =
MgO = 1.16 % x 46100.00 kg =
H2O = 33.00 % x 46100.00 kg =

3 Pasir Besi / Iron Sand (IS) 3800.00 kg

SiO2 = 19.28 % x 3800.00 kg =
Al2O3 = 11.18 % x 3800.00 kg =
Fe2O3 = 68.42 % x 3800.00 kg =
CaO = 0.93 % x 3800.00 kg =
MgO = 0.96 % x 3800.00 kg =
H2O = 9.50 % x 3800.00 kg =

4 Pasir Silika / Silika Sand (SS) 2750.00 kg

SiO2 = 78.28 % x 2750.00 kg =
Al2O3 = 11.83 % x 2750.00 kg =
Fe2O3 = 2.36 % x 2750.00 kg =
CaO = 0.98 % x 2750.00 kg =
MgO = 0.31 % x 2750.00 kg =
H2O = 12.50 % x 2750.00 kg =

Komposisi Feed Mill

Senyawa
Feed Mill
SiO2 Al2O3 Fe2O3 CaO
Lime stone (LS) 24211.20 5063.40 1455.00 139738.20
Clay (CL) 26581.26 7998.35 3180.90 1424.49
Iron Sand (IS) 732.64 424.84 2599.96 35.34
Silica Sand (SS) 2511.58 153.18 18.98 22.83
Total 54036.68 13639.77 7254.84 141220.86

5 Dust 22253.47 kg 14.6931

SiO2 = 3383.08 kg
Al2O3 = 588.31 kg
Fe2O3 = 214.63 kg
CaO = 17703.13 kg
MgO = 364.31 kg
 6 Gas Panas 242985.05 kg
O2 27239.59 kg
N2 101575.84 kg
CO2 104285.58 kg
SO2 126.59 kg
H2O 9757.45 kg

C Menghitung H2O yang diuapkan

Feed Mill Berat Kering(kg)

Lime stone (LS) 172272.00
Clay (CL) 39719.76
Iron Sand (IS) 3829.26
Silica Sand (SS) 2710.68
Dust 22253.47
Total 240785.17

Raw Meal Output (dry) = Dust + Batu kapur (dry) + Tanah Liat (dry) + Pasir Besi (dry) + Pasir Silika (dry)
= 240785.17 kg
H2O Raw Meal Input = 37742.75 kg
Kandungan H2O pada Raw Meal Output = 0.90 %
0.009 .= H2O pada Raw Meal
240785.17 .+ H2O pada Raw Meal

H2O Raw Meal = 2186.75 kg

H2O yang diuapkan = H2O Raw Meal Input - H2O Raw Meal Output
= 35556.00 kg

Persen Pengeringa.= H2O yang diuapkan x 100%

H2O Raw Meal Input
= 94.21 %

D OUTPUT RAW MEAL

1 Raw Meal
Raw Meal Output = Raw Meal Output Dry + H2O Raw Meal Output
= 242971.91 kg

SiO2 = 57419.76 kg
Al2O3 = 14228.07 kg
Fe2O3 = 7469.47 kg
 CaO = 158923.99 kg
MgO = 27603.90 kg
H2O = 2186.75 kg

2 Gas Panas
O2 27239.59 kg
N2 101575.84 kg
CO2 104285.58 kg
SO2 126.59 kg
H2O 45313.46 kg
Total 278541.05 kg

INPUT OUTPUT
>Raw Mix > Raw Meal
SiO2 = 54036.68 kg SiO2 = 57419.76
Al2O3 = 13639.77 kg Al2O3 = 14228.07
Fe2O3 = 7254.84 kg Fe2O3 = 7469.47
CaO = 141220.86 kg CaO = 158923.99
MgO = 2379.57 kg MgO = 2743.88
H2O = 37639.63 kg H2O = 2186.75
Total 256171.32 kg Total 242971.91
> Gas Panas > Gas Panas
O2 27239.59 kg O2 27239.59
N2 101575.84 kg N2 101575.84
CO2 104285.58 kg CO2 104285.58
SO2 126.59 kg SO2 126.59
H2O 9757.45 kg H2O 45313.46
Total 242985.05 kg Total 278541.05

> Dust dari Kiln

SiO2 = 3383.08 kg
Al2O3 = 588.31 kg
Fe2O3 = 214.63 kg
CaO = 17703.13 kg
MgO = 364.31 kg
Total 22253.47 kg

Total 521409.84 kg Total 521512.97

kg

kg

kg

Berat KF Klinker(kg)
F
35094.86
8525.07
6336.97
112568.72
2180.96
 )( 1- 0.0042 )

6.36 % x ( 25728.99 _Dust)

0.06 Dust

isi Dust total

Komposisi Dust Ke CM
F
1452.06
396.62
18.39
18.15
4.72

Jumlah mol (kmol)

E
542.37
640.14
92.05
6.10
1.32
47.00
O2(g) dibutuhkan 542.37 kmol
CO2 dihasilkan 542.37 kmol

O2(g) dibutuhkan 1.32 kmol

SO2 dihasilkan 1.32 kmol

O2(g) dibutuhkan 160.03 kmol

H2O dihasilkan 320.07 kmol

O2 dari coal 46.02 kmol

(O2 Pembakaran-O2 coal)
kg
kg

…………….(6)

kmol

kg
kg

kmol

kg

kmol
kg

Jumlah mol (kmol)

E
813.55
960.21
138.07
9.15
1.98
70.50

O2(g) dibutuhkan 813.55 kmol

CO2 dihasilkan 813.55 kmol

O2(g) dibutuhkan 1.98 kmol

SO2 dihasilkan 1.98 kmol

O2(g) dibutuhkan 240.05 kmol

H2O dihasilkan 480.10 kmol
O2 dari coal 69.03 kmol
(O2 Pembakaran-O2 coal)
kg
kg

…………….(6)

kmol

7175.16

kg

kg

kmol

kg
 kmol
kg

Kalsiner Line
Berat (kg)
35796.23
126.59
8677.45
2179.80
7303.29

Kalsiner Line (kg)

E
67592.05
1319.32

Kiln Line (kmol) Kalsiner Line (kmol)

E F
804.67 1207.00
21.99 32.98

+ CO2(g)
) + CO2(s)
kg = 804.67 kmol
kg = 1207.00 kmol

kg = 21.99 kmol
kg = 32.98 kmol

804.67 kmol
32.98 kmol

1207.00 kmol
32.98 kmol

kmol = 22926.54 kg
kmol = 68489.36 kg
n = PV/RT (kmol)
761.14
1561.09
1491.01
1287.23
1615.10
2273.62
942.37
1182.58
1605.72
1391.79
662.06
1030.41
15804.13
K

kg
kg
kg
 kg
kg
kg
kg
kg
kg

Komposisi feed mill (%)

Fe2O3 CaO MgO
0.50 48.02 0.62
6.90 3.09 1.16
68.42 0.93 0.96
0.69 0.83 0.15

24211.20 kg
5063.40 kg
1455.00 kg
139738.20 kg
1804.20 kg
21825.00 kg
 26581.26 kg
7998.35 kg
3180.90 kg
1424.49 kg
534.76 kg
15213.00 kg

732.64 kg
424.84 kg
2599.96 kg
35.34 kg
36.48 kg
361.00 kg

2152.70 kg
325.33 kg
64.90 kg
26.95 kg
8.53 kg
343.75 kg

MgO H2O
1804.20 21825.00
534.76 15213.00
36.48 361.00
4.13 240.63
2379.57 37639.63 256171.32

%
+ Pasir Silika (dry)
OUTPUT

kg
kg
kg
kg
kg
kg
kg

kg
kg
kg
kg
kg
kg

kg
LAMPIRAN C
PERHITUNGAN NERACA ENERGI

Data temperatur untuk perhitungan neraca panas

Temperatur Referensi 28 oC
Temperatur Input Gas Panas 360 oC
Temperatur Input Raw Mix 30 oC
Temperatur Output 86 oC

A. Panas Input
1. Feed Raw Mix (Dry Material)

Senyawa Massa (kg) Mr Mol(kmol) Fraksi mol (X) A

SiO2 54,036.675 60.090 899.262 0.246 10.870
Al2O3 13,639.765 102.000 133.723 0.037 22.080
Fe2O3 7,254.835 159.700 45.428 0.012 24.720
CaO 141,220.855 56.000 2,521.801 0.689 10.000
MgO 2,379.565 40.000 59.489 0.016 10.870
Total 218,531.695 3,659.704 1.000

Senyawa XA XB XC
SiO2 2.671E+00 2.141E-03 -5.927E+04
Al2O3 8.068E-01 3.278E-04 -1.909E+04
Fe2O3 3.068E-01 1.991E-04 -5.256E+03
CaO 6.891E+00 3.335E-03 -7.442E+04
MgO 1.767E-01 1.946E-05 -3.392E+03
Total 1.085E+01 6.022E-03 -1.614E+05

A= 1.085E+01
B= 6.022E-03
C= -1.614E+05
T in 303.000 K
T ref 301.000 K
m= 3,659.704 kmol

Cp mix = A + BT + CT-2 (cal/(kmol.K))

Q1 = m ∫Cpdt
Q1 = m [A.(Tin - Tref) + B/2(Tin2 - Tref2) + C/-1(Tin-1 - Tref-1)
 Q1 = 79,787.042 cal
= 335,105.578 Joule
= 335.106 kJ
= 0.335 MJ

2. Air (Material Bonding)

Total Air yang terkandung dalam material
m = 37639.63 kg
= 2091.0902777778 kmol
= 2091090.2777778 mol
T input 30.000 C
T ref 28.000 C

A 18.000
B 6.880E-03
C 7.604E-06
D -3.593E-09
m= 2,091,090.278 mol

Cp = A + BT + CT2 + DT3 (J/moloC)

Q2 = m ∫Cpdt
Q2 = m [A.(Tin - Tref) + B/2(Tin2 - Tref2) + C/3(Tin3 - Tref3) + D/4(Tin4 - Tref4)
Q2 = 76,140,067.240 Joule
= 76,140.067 kJ
= 76.140 MJ

3. Dust dari Kiln

Senyawa Massa (kg) Mr Mol(kmol) Fraksi mol (X) A

SiO2 3,383.083 60.090 56.300 0.145 10.870
Al2O3 588.310 102.000 5.768 0.015 22.080
Fe2O3 214.633 159.700 1.344 0.003 24.720
CaO 17,703.131 56.000 316.127 0.813 10.000
MgO 364.314 40.000 9.108 0.023 10.870
Total 22,253.471 388.647 1.000

Senyawa XA XB XC
SiO2 1.575E+00 1.262E-03 -3.494E+04
Al2O3 3.277E-01 1.331E-04 -7.754E+03
 Fe2O3 8.548E-02 5.547E-05 -1.464E+03
CaO 8.134E+00 3.937E-03 -8.785E+04
MgO 2.547E-01 2.805E-05 -4.891E+03
Total 1.038E+01 5.416E-03 -1.369E+05

A= 1.038E+01
B= 5.416E-03
C= -1.369E+05
T input 632.780 K
T ref 301.000 K
m= 388.647 kmol

Cp mix = A + BT + CT-2 (cal/(kmol.K))

Q3 = m ∫Cpdt
Q3 = m [A.(Tin - Tref) + B/2(Tin2 - Tref2) + C/-1(Tin-1 - Tref-1)

Q3 = 1,571,369.799 cal
= 6,599,753.157 Joule
= 6,599.753 kJ
= 6.600 MJ

4. Gas Panas dari Kiln

Senyawa Massa (kg) Mr Mol(kmol) Fraksi mol (X)
O2 27,239.587 32.000 851.237 0.115
N2 101,575.838 28.000 3,627.709 0.491
CO2 104,285.584 44.000 2,370.127 0.321
SO2 126.587 64.000 1.978 0.000
H2O 9,757.455 18.000 542.081 0.073
Total 242,985.050 7,393.131 1.000

Senyawa Mol(kmol) Fraksi mol (X) A B C

O2 851.237 0.115139 32.000 1.158E-02 -6.076E-06
N2 3,627.709 0.490686 28.000 2.199E-03 5.723E-06
CO2 2,370.127 0.320585 44.000 4.233E-02 -2.887E-05
SO2 1.978 0.000268 64.000 3.904E-02 -3.104E-05
H2O 542.081 0.073322 18.000 6.880E-03 7.604E-06
Total 7,393.131 1.000
 Senyawa XA XB XC XD
O2 3.684 1.333E-03 -6.996E-07 1.509E-10
N2 13.739 1.079E-03 2.808E-06 -1.409E-09
CO2 14.106 1.357E-02 -9.255E-06 2.393E-09
SO2 0.017 1.044E-05 -8.304E-09 2.302E-12
H2O 1.320 5.045E-04 5.575E-07 -2.634E-10
Total 32.866 1.650E-02 -6.597E-06 8.739E-10

A= 3.287E+01
B= 1.650E-02
C= -6.597E-06
D= 8.739E-10

Cp mix = A + BT + CT2 + DT3 (J/moloC)

Q4 = m ∫Cpdt
Q4 = m [A.(Tin - Tref) + B/2(Tin2 - Tref2) + C/3(Tin3 - Tref3) + D/4(Tin4 - Tref4)
Tinput = 359.780
Tref = 28.000
m= 7,393.131 kmol
7,393,131.244 mol

Q4 = 8.773E+10 Joule
= 87733942.063 kJ
= 87,733.942 MJ

5. Grinding Heat

Motor Power 1,703.33 kWh

Efisiensi Motor 85 %

Grinding Heat = Mill Power X Efisiensi Motor

= 1,447.83 kWh
= 5,212,189.80 kJ

B. PANAS OUTPUT

1. Raw Meal (Dry Material)

Senyawa Massa (kg) Mr Mol(kmol) Fraksi mol (X) A

SiO2 57,419.758 60.090 955.563 0.236 10.870
 Al2O3 14,228.075 102.000 139.491 0.034 22.080
Fe2O3 7,469.468 159.700 46.772 0.012 24.720
CaO 158,923.986 56.000 2,837.928 0.701 10.000
MgO 2,743.879 40.000 68.597 0.017 10.870
Total 240,785.166 4,048.351 1.000

Senyawa XA XB XC
SiO2 2.566E+00 2.056E-03 -5.693E+04
Al2O3 7.608E-01 3.091E-04 -1.800E+04
Fe2O3 2.856E-01 1.853E-04 -4.892E+03
CaO 7.010E+00 3.393E-03 -7.571E+04
MgO 1.842E-01 2.028E-05 -3.536E+03
Total 1.081E+01 5.964E-03 -1.591E+05

A= 1.081E+01
B= 5.964E-03
C= -1.591E+05
T output 358.880 K
T ref 301.000 K
m= 4,048.351 kmol

Cp mix = A + BT + CT-2 (cal/(kmol.K))

Q1 = m ∫Cpdt
Q1 = m [A.(Tin - Tref) + B/2(Tin2 - Tref2) + C/-1(Tin-1 - Tref-1)

Q1 = 2,648,163.276 cal
= 11,122,285.758 Joule
= 11,122.286 kJ
= 11.122 MJ

2. Air (Material Water)

Panas Sensibel
Total Air yang terkandung dalam material
m = 2186.75 kg
= 121.4859564302 kmol
= 121485.9564302 mol
 T output 85.880 C
T ref 28.000 C
A 1.800E+01
B 6.880E-03
C 7.604E-06
D -3.593E-09
m= 121,485.956 kmol

Cp = A + BT + CT2 + DT3 (J/moloC)

Q2 = m ∫Cpdt
Q2 = m [A.(Tout - Tref) + B/2(Tout2 - Tref2) + C/3(Tout3 - Tref3) + D/4(Tout4 - Tref4)
Q2 = 129,505,952.478 Joule
= 129,505.952 kJ
= 129.506 MJ

Panas Laten
m= 2186.75 kg
λ= 2257.10 kJ/kg 539.1 kcal/kg
Q2 laten =m x λ
4935715.63 kJ
4935.715625234 MJ

Q2 = Q2 sensibel + Q2 laten
= 5,065,221.578 kJ
= 5065.2215777121 MJ

3. Gas Panas dari Kiln

Senyawa Massa (kg) Mr Mol(kmol) Fraksi mol (X)
O2 27,239.587 32.000 851.237 0.091
N2 101,575.838 28.000 3,627.709 0.387
CO2 104,285.584 44.000 2,370.127 0.253
SO2 126.587 64.000 1.978 0.000
H2O 45,313.458 18.000 2,517.414 0.269
Total 278,541.053 9,368.465 1.000

Senyawa Mol(kmol) Fraksi mol (X) A B C

O2 851.237 0.090862 32.000 1.158E-02 -6.076E-06
N2 3,627.709 0.387226 28.000 2.199E-03 5.723E-06
CO2 2,370.127 0.252990 44.000 4.233E-02 -2.887E-05
 SO2 1.978 0.000211 64.000 3.904E-02 -3.104E-05
H2O 2,517.414 0.268712 18.000 6.880E-03 7.604E-06
Total 9,368.465 1.000

Senyawa XA XB XC XD
O2 2.908 1.052E-03 -5.521E-07 1.191E-10
N2 10.842 8.515E-04 2.216E-06 -1.112E-09
CO2 11.132 1.071E-02 -7.304E-06 1.888E-09
SO2 0.014 8.242E-06 -6.553E-09 1.817E-12
H2O 4.837 1.849E-03 2.043E-06 -9.655E-10
Total 29.732 1.447E-02 -3.603E-06 -6.795E-11

A= 2.973E+01
B= 1.447E-02
C= -3.603E-06
D= -6.795E-11

Cp mix = A + BT + CT2 + DT3 (J/moloC)

Q3 = m ∫Cpdt
Q3 = m [A.(Tout - Tref) + B/2(Tout2 - Tref2) + C/3(Tout3 - Tref3) + D/4(Tout4 - Tref4)
Toutput = 85.880
Tref = 28.000
m= 9,368.465 kmol
9,368,464.732 mol

Q3 = 1.656E+10 Joule
= 16561828.331531 kJ
= 16,561.828 MJ

4. Evaporasi
H2O (l) H2O (g) DH = 44

Air Raw Mix = 37639.63 kg

Air Raw Meal = 2186.75 kg
Air yang diuapkan = Kandungan air Raw Mix - Kandungan air Raw Meal
= 35452.88 kg
= 1969.6043213476 kmol
= 1969604.3213476 mol
 Q4 = 86662590.139294 kJ

5. Heat Loss
Heat Loss = Panas Masuk - Panas Keluar
= 861224.40110764 kJ

Efisiensi Pengeringan = Panas Evaporasi x 100%

Panas Input

= 93.1563249122 %

Efisiensi Panas = Panas Output X 100%

Panas Input
= 108,300,762.33 x 100%
93,029,206.79
= 116.4158720394

INPUT OUT
> Raw Mix (Dry Material) 335.11 kJ Raw Meal (Dry Material)
Air(Material Bonding) 76,140.07 kJ Air (Material Water)
Dust dari Kiln 6,599.75 kJ Gas Panas
Gas Panas 87,733,942.06 kJ Evaporasi
Grinding Heat 5,212,189.80 kJ Heat Loss

Total 93,029,206.79 kJ Total

-16,132,779.95
 B C
8.712E-03 -2.412E+05
8.971E-03 -5.225E+05
1.604E-02 -4.234E+05
4.840E-03 -1.080E+05
1.197E-03 -2.087E+05
B C
8.712E-03 -2.412E+05
8.971E-03 -5.225E+05
1.604E-02 -4.234E+05
4.840E-03 -1.080E+05
1.197E-03 -2.087E+05
 D
1.311E-09
-2.871E-09
7.464E-09
8.606E-09
-3.593E-09
 B C
8.712E-03 -2.412E+05
8.971E-03 -5.225E+05
1.604E-02 -4.234E+05
4.840E-03 -1.080E+05
1.197E-03 -2.087E+05
 D
1.311E-09
-2.871E-09
7.464E-09
 8.606E-09
-3.593E-09

kJ/mol
 OUTPUT
aw Meal (Dry Material) 11,122.29 kJ
Air (Material Water) 5,065,221.58 kJ
16,561,828.33 kJ
86,662,590.14 kJ
861,224.40 kJ

109,161,986.74 kJ