Spesifikasi Alat Baru HOPPER

L.4.1.
1 BELT CONVEYOR (BC-01)
untuk mengangkut material Clay dari Crusher Mining menuju Storage

Fungsi =
Raw Material.
Jenis = Horizontal Flat Belt Conveyor
Material = Rubber Belt
Laju Alir (W) = 773.05 Kg/jam = 0.773 Ton/jam
Bulk Density = 1.1 Ton/m3 (Perry,Table 21-4,hal 21-6)
Panjang Belt Conveyor (L) = 1000 m = 3280.8 ft
Safety Factor = 20 %
Kapasitas (Cb) = 1,2 x W
= 1.2 x 0.773
= 0.93 Ton/jam
Kondisi Operasi =
T (Temperatur) = 30 C
P (Tekanan) = 1 atm
Fasa = Padat
Untuk Belt Conveyor kapasitas < 32 ton/jam,maka :

Lebar belt = 14 in = 35 cm (Perry, Tabel 21-7)
Kecepatan Belt Conveyor = Cb x100
(Walas,83) 27.99
= 0.92765696 x100
27.99
= 3.31424422 ft/menit
Power Belt Conveyor :

HP Belt Conveyor = HPhorizontal + HPvertical + HPempty
HPhorizontal = L W
( 0,4+ )( )
300 100
= 0,4 + 3280.8 0.773
300 100
= 0.08763369 HP
HPvertical = 0
HPempty = ( beltspeed . x ( c ))
100
3.31424422 x 3,1
100
0.10274157 HP

= 0.08763369 + 0 + 0.103
= 0.19037526 HP
Faktor Keamanan 20%

Total HP Belt Conveyor = 1,2 x HP Belt Conveyor
= 1,2 x 0.19038
= 0.23 HP
Power Belt Conveyor = 0.23 / 1,34

= 0.17 KW
BELT CONVEYOR (BC-02)
untuk mengangkut material Clay dari Storage menuju Hopper (HP-

Fungsi =
02)
Bulk Density = 1.1 Ton/m 3

Kapasitas BC = 1,2 x W
= 1.2 x 0.77
= 0.93 Ton/jam
Kondisi Operasi =
P (Tekanan) = 1 atm
Fasa = Padat

27.99
= 0.92765696 x100
27.99
= 3.31424422 ft/menit

HPhorizontal = L W
(0,4+ )( )
300 100
= 0,4 + 98.4252 0.77
300 100
= 0.00562843 HP
HPvertical = 0
HPempty = c
( beltspeed . x ( ))
100
3.31424422 x 3,1
100
0.10274157 HP

= 0.00562843 + 0 + 0.103
= 0.10837001 HP
Faktor Keamanan 20%

= 1,2 x 0.10837
= 0.1300 HP

= 0.0970 KW
Fungsi = untuk mengangkut material Limestone dari Crusher Mining menuju Storage Raw Material.

Safety Factor =
= 1.2 x 96.68
= 116.010519 Ton/jam
Kondisi Operasi
P (Tekanan) = 1 atm
Fasa = Padat

(Walas,83) = 27.99
= 116.010519 x100
= 27.99
= 414.471306 ft/menit

HPhorizontal = L W
(0,4+ )( )
300 100
= 0,4 + 3280.84 96.68
300 100
= 10.9592559 HP
HPvertical = 0
HPempty c
= ( beltspeed . x ( ))
100
414.471306 x 3,1
100
12.8486105 HP

= 10.9592559 + 0 + 12.85
= 23.8078664 HP
Faktor Keamanan 20%

= 1,2 x 23.8079
= 28.5694397 HP

= 21.3204774 KW
Fungsi = untuk mengangkut material Limestone dari Storage menuju Hopper (HP-04).
Bulk Density = 1.3617 Ton/m3
= 1.2 x 96.68
= 116.010519 Ton/jam
Kondisi Operasi
P (Tekanan) = 1 atm
Fasa = Padat

27.99
= 116.010519 x100
27.99
= 414.471306 ft/menit

HPhorizontal =
L W
(0,4+ )( )
300 100
= 0,4 + 98.4252 96.68
300 100
= 0.70387835 HP
HPvertical = 0
HPempty = e
(beltspeed . x ( ))
100
414.471306 x 3,1
100
12.8486105 HP

= 0.70387835 + 0 + 12.85
= 13.5524888 HP
Faktor Keamanan 20%

= 1,2 x 13.5525
= 16.2629866 HP
Power Belt Conveyor = 16.2629866 /1,34

= 12.1365572 KW
Fungsi = untuk mengangkut material Iron Sand dari (HP-05) menuju Storage Raw Material.
= 1.2 x 1.84
= 2.21060585 Ton/jam
Kondisi Operasi
P (Tekanan) = 1 atm
Fasa = Padat

27.99
= 2.21060585 x100
27.99
= 7.89784156 ft/menit
HPhorizontal = ( 0,4+ L )( W )
300 100
= 0,4 + 49.2126 1.84
300 100
= 0.01039062 HP
HPvertical = 0
HPempty = e
(beltspeed . x ( ))
100
7.89784156 x 3,1
100
0.24483309 HP

= 0.01039062 + 0 + 0.245
= 0.25522371 HP
Faktor Keamanan 20%

= 1,2 x 0.25522
= 0.30626845 HP

= 0.22855855 KW
Fungsi = untuk mengangkut material Iron Sand dari Storage menuju Hopper (HP-06).
= 1.2 x 1.84
= 2.21060585 Ton/jam
Kondisi Operasi
P (Tekanan) = 1 atm
Fasa = Padat

27.99
= 2.21060585 x100
27.99
= 7.89784156 ft/menit

HPhorizontal = L W
(0,4+ )( )
300 100
= 0,4 + 98.4252 1.84
300 100
= 0.01341256 HP
HPvertical = 0
HPempty = e
(beltspeed . x ( ))
100
7.89784156 x 3,1
100
0.24483309 HP

= 0.01341256 + 0 + 0.245
= 0.25824564 HP
Faktor Keamanan 20%

= 1,2 x 0.25825
= 0.30989477 HP

0.23126476 KW
Fungsi = untuk mengangkut material Silica Sand dari (HP-07) menuju Storage Raw Material.
= 1.2 x 16.36
= 19.6299816 Ton/jam
Kondisi Operasi
P (Tekanan) = 1 atm
Fasa = Padat

27.99
= 19.6299816 x100
27.99
= 70.1321244 ft/menit

HPhorizontal = L W
( 0,4+ )( )
300 100
= 0,4 + 49.2126 16.36
300 100
= 0.09226778 HP
HPvertical = 0
HPempty = e
( beltspeed . x ( ))
100
= 70.1321244 x 3,1
100
= 2.17409586 HP

0.09226778 + 0 + 2.174
2.26636364 HP
Faktor Keamanan 20%

1,2 x 2.26636
2.71963637 HP

2.02957938 KW
Fungsi = untuk mengangkut material Silica Sand dari Storage menuju Hopper
(HP-08).
= 1.2 x 16.36
= 19.6299816 Ton/jam
Kondisi Operasi
P (Tekanan) = 1 atm
Fasa = Padat

27.99
= 19.6299816 x100
27.99
= 70.1321244 ft/menit

HPhorizontal = L W
(0,4+ )( )
300 100
= 0,4 + 98.4252 16.36
300 100
= 0.1191023 HP
HPvertical = 0
e
(beltspeed . x ( ))
100
HPempty = e
(beltspeed . x ( ))
100
= 70.1321244 x 3,1
100
= 2.17409586 HP

= 0.1191023 + 0 + 2.174
= 2.29319815 HP
Faktor Keamanan 20%

= 1,2 x 2.2932
= 2.75183778 HP

= 2.05361029 KW
untuk mengangkut material campuran dari Storage menuju Hopper

Fungsi =
(HP-09).
= 1.2 x 115.65
= 138.778763 Ton/jam
Kondisi Operasi
P (Tekanan) = 1 atm
Fasa = Padat

= 27.99
= 138.778763 x100
= 27.99
= 495.815515 ft/menit

HPhorizontal = L W
(0,4  )( )
300 100
= 0,4 + 98.4252 115.65
300 100
= 0.84202164 HP
HPvertical = 0
HPempty = e
(beltspeed . x ( ))
100
= 495.815515 x 3,1
100
= 15.370281 HP
= 0.84202164 + 0 + 15.37
= 16.2123026 HP
Faktor Keamanan 20%

= 1,2 x 16.2123
= 19.4547631 HP

14.51848 KW
Fungsi = untuk mengangkut material campuran output dari Rotary Dryer (RD-
01) menuju BE-01
Panjang Belt Conveyor (L) = 10 m = 33 ft
= 1.2 x 105.43
= 126.516759 Ton/jam
Kondisi Operasi
P (Tekanan) = 1 atm
Fasa = Padat

= 27.99
= 126.516759 x100
= 27.99
= 452.006997 ft/menit

HPhorizontal = L W
(0,4  )( )
300 100
= 0,4 + 32.8084 105.43
300 100
= 0.53702287 HP
HPvertical = 0
HPempty = e
(beltspeed . x ( ))
100
= 452.006997 x 3,1
100
= 14.0122169 HP

= 0.53702287 + 0 + 14
= 14.5492398 HP
Faktor Keamanan 20%
= 1,2 x 14.5492
= 17.4590877 HP

13.02917 KW
untuk mengangkut tailing material raw mill campuran dari Separator

Fungsi =
(SPR-01) menuju Inlet Vertical Roller Mill (VRM-01).
= 1.2 x 5.27
= 6.32583793 Ton/jam
Kondisi Operasi
P (Tekanan) = 1 atm
Fasa = Padat

= 27.99
= 6.32583793 x100
= 27.99
= 22.6003499 ft/menit

HPhorizontal = LL W W
0,4 
((0,4+ )()( )
300
300 100100
= 0,4 + 16.4042 5.27
300 100
= 0.02396864 HP
HPvertical = 0
HPempty = e
(beltspeed. x ( ))
100
= 22.6003499 x 3,1
100
= 0.70061085 HP

= 0.02396864 + 0 + 0.701
= 0.72457948 HP
Faktor Keamanan 20%

= 1,2 x 0.72458
= 0.86949538 HP

0.64887715 KW
Fungsi = Untuk mengangkut Clinker dari Bucket Elevator (BE-05) menuju

clinker silo (CLS-01)
= 1.2 x 69.15
= 82.9760973 Ton/jam
Kondisi Operasi
P (Tekanan) = 1 atm
Fasa = Padat

= 27.99
= 82.98 x100
= 27.99
= 296.45 ft/menit

HPhorizontal = L W
(0,4  )( )
300 100
= 0,4 + 26.2467 69.15
300 100
= 0.33708284 HP
HPvertical = 0
HPempty = e
(beltspeed . x ( ))
100
= 296.449079 x 3,1
100
= 9.18992146 HP

= 0.33708284 + 0 + 9.19
= 9.52700429 HP
Faktor Keamanan 20%

= 1,2 x 9.527
= 11.4324052 HP

8.53164564 KW
Fungsi = Untuk mengangkut Clinker dari clinker silo (CLS-01) menuju Bucket
Elevator (BE-06)
= 1.2 x 69.15
= 82.9760973 Ton/jam
Kondisi Operasi
P (Tekanan) = 1 atm
Fasa = Padat

= 27.99
= 82.9760973 x100
= 27.99
= 296.449079 ft/menit

HPhorizontal = L W
(0,4  )( )
300 100
= 0,4 + 26.2467 69.15
300 100
= 0.33708284 HP
HPvertical = 0
HPempty = e
(beltspeed . x ( ))
100
= 296.449079 x 3,1
100
= 9.18992146 HP

= 0.33708284 + 0 + 9.19
= 9.52700429 HP
Faktor Keamanan 20%

= 1,2 x 9.527
= 11.4324052 HP

8.53164564 KW
Fungsi = Untuk mengangkut Clinker dari Bucket Elevator (BE-06) menuju

Hopper Inlet Cement Mill (HP-16).

= 1.2 x 69.15
= 82.9760973 Ton/jam
Kondisi Operasi
P (Tekanan) = 1 atm
Fasa = Padat

= 27.99
= 82.9760973 x100
= 27.99
= 296.449079 ft/menit

HPhorizontal = L W
(0,4  )( )
300 100
= 0,4 + 26.2467 69.15
300 100
= 0.33708284 HP
HPvertical = 0
HPempty = e
(beltspeed . x ( ))
100
= 296.449079 x 3,1
100
= 9.18992146 HP

= 0.34 + 0 + 9.19
= 9.53 HP
Faktor Keamanan 20%

= 1,2 x 9.527
= 11.43 HP

8.53 KW
Untuk mengangkut material Gypsum dari Weighing Feeder (WF-08)

Fungsi =
menuju Hopper Inlet Cement Mill (HP-16).
Panjang Belt Conveyor (L) = 5.00 m = 16 ft
Safety Factor = 20.00 %
= 1.20 x 3.19
= 3.83 Ton/jam
Kondisi Operasi
T (Temperatur) = 30.00 C
P (Tekanan) = 1.00 atm
Fasa = Padat

Lebar belt = 14.00 in = 35 cm (Perry, Tabel 21-7)
= 27.99
= 3.83 x100
= 27.99
= 13.68 ft/menit

HPhorizontal = L W
(0,4  )( )
300 100
= 0,4 + 16.4042 3.19
300 100
= 0.01 HP
HPvertical = 0
HPempty = e
(beltspeed . x ( ))
100
= 13.68 x 3,1
100
= 0.42 HP

= 0.01 + 0 + 0.424
= 0.44 HP
Faktor Keamanan 20%

= 1,2 x 0.44
= 0.53 HP

0.39 KW
Untuk mengangkut material Trass dari Weighing Feeder (WF-09)

Fungsi =
= 1.2 x 18.08
= 21.7014408 Ton/jam
Kondisi Operasi
P (Tekanan) = 1 atm
Fasa = Padat

= 27.99
= 21.7014408 x100
= 27.99
= 77.5328361 ft/menit

HPhorizontal = LL W W
0,4 
((0,4+ )()( )
300
300 100100
= 0,4 + 16.4042 18.08
300 100
= 0.08222688 HP
HPvertical = 0
HPempty = e
(beltspeed . x ( ))
100
= 77.5328361 x 3,1
100
= 2.40351792 HP

= 0.08222688 + 0 + 2.404
= 2.4857448 HP
Faktor Keamanan 20%

= 1,2 x 2.48574
= 2.98289376 HP

2.22604012 KW
Fungsi = Untuk mengangkut material Blast slag furnace dari Weighing Feeder
(WF-09) menuju Hopper Inlet Cement Mill (HP-16).
= 1.2 x 10.64
= 12.7655534 Ton/jam
Kondisi Operasi
P (Tekanan) = 1 atm
Fasa = Padat
= 27.99
= 12.7655534 x100
= 27.99
= 45.6075507 ft/menit

HPhorizontal = L W
(0,4  )( )
300 100
= 0,4 + 16.4042 10.64
300 100
= 0.04836875 HP
HPvertical = 0
HPempty = e
(beltspeed. x ( ))
100
= 45.6075507 x 3,1
100
= 1.41383407 HP

= 0.04836875 + 0 + 1.414
= 1.46220282 HP
Faktor Keamanan 20%

= 1,2 x 1.4622
= 1.75464339 HP

1.30943536 KW
Untuk mengangkut tailing material semen dari Separator (SPR-02)

Fungsi =
= 1.2 x 5.32
= 6.38277672 Ton/jam
Kondisi Operasi
P (Tekanan) = 1 atm
Fasa = Padat

27.99
= 6.38277672 x100
27.99
= 22.8037753 ft/menit

HPhorizontal = (0,4  L W
)( )
300 100
= 0,4 + 65.6168 5.32
300 100
= 0.03290974 HP
HPvertical = 0
HPempty = e
(beltspeed . x ( ))
100
= 22.8037753 x 3,1
100
= 0.70691704 HP

= 0.03290974 + 0 + 0.707
= 0.73982677 HP
Faktor Keamanan 20%

= 1,2 x 0.73983
= 0.88779213 HP

0.66253144 KW
Fungsi = Untuk mengangkut semen dari Rotary Packer (RP-01) menuju truck.
= 1.2 x 101.01
= 121.212121 Ton/jam
Kondisi Operasi
P (Tekanan) = 1 atm
Fasa = Padat

27.99
= 121.212121 x100
27.99
= 433.055095 ft/menit

HPhorizontal = L W
(0,4+ )( )
300 100
= 0,4 + 65.6168 101.01
300 100
= 0.62497239 HP
HPvertical = 0
HPempty = e
(beltspeed. x ( ))
100
433.055095 x 3,1
100
13.4 HP

= 0.62 + 0 + 13.4
= 14.05 HP
Faktor Keamanan 20%

= 1,2 x 14.0497
= 16.86 HP

= 12.58 KW
Kebutuhan Power Belt Conveyor
N Power
No Belt
o (kW)
1 BC-01 0.17
2 BC-02 0.10
3 BC-03 21.32
4 BC-04 12.14
5 BC-05 0.23
6 BC-06 0.23
7 BC-07 2.03
8 BC-08 2.05
9 BC-09 14.52
10 BC-10 13.03
11 BC-11 0.65
12 BC-12 8.53
13 BC-13 8.53
14 BC-14 8.53
15 BC-15 0.39
16 BC-16 2.23
17 BC-17 1.31
18 BC-18 0.66
19 BC-19 12.58
Total 109.23
L.4.2.1 BUCKET ELEVATOR (BE-01)
Untuk mengangkut Raw Material dari Rotary Dryer (RD-01) menuju

Fungsi =
Vertical Raw Mill(VRM-01).
Jenis = Spaced –Bucket Centrifugal –Discharge Elevator
Material = Commercial Steel
Laju Alir (W) = 105430.63 Kg/jam 105.4306 Ton/jam
Tinggi Bucket Elevator = 6 m = 20 ft
Safety Factor = 20%
Kapasitas = 1,2 x W
= 1,2 x 105.431
= 126.517 Ton/jam
Kapasitas terpasang = 126.517 Ton/jam = 29.2863 kg/s
Dari Perry, S.M, “Chemical Engineering Handbook”, tabel 21-9 hal 16 diperoleh:
Jumlah Bucket Elevator = 1 buah
Ukuran Bucket = 18 x 8 x 11 3/4
Bucket Spacing = 12 in
Lebar Belt = 18 in
Rpm poros = 20 rpm
HP poros = 20 HP
HP/ft = 0.22 HP/ft
HP yang dibutuhkan adalah, P = 0,07 x m 0,643 x Δz
Dimana, P = Daya (kW)
m = laju alir massa (kg/s)
Δz = Tinggi Elevator(meter)
Maka , P = 0,07 x m0,643 x Δz

= 0.07 x 29,28630,643 x 6
= 0.07 x 8.7713 x 6
= 3.68 kW
HP yang digunakan = 3.68 x 1.34

4.94
HP actual yang digunakan = 5.00 HP
Maka Power aktual yang digunakan = 3.73 kW
Untuk mengangkut Raw Material dari Vertical Roller Mill (VRM-01)

Fungsi =
menuju Separator (SPR-01).
Safety Factor = 20%
Kapasitas = 1,2 x W
= 1,2 x 105.431
= 126.52 Ton/jam
Lebar Belt = 18 in
Rpm poros = 20 rpm
HP poros = 20 HP
HP/ft = 0.22 HP/ft
Maka , P = 0,07 x m0,643 x Δz

= 0.07 x 29,28630,643 x 10
= 0.07 x 8.7713 x 10
= 6.14 kW

8.23 HP
Untuk mengangkut Raw Material dari Separator (SPR-01) menuju Raw

Fungsi =
meal silo (RMS-01).
Safety Factor = 20%
Kapasitas = 1,2 x W
= 1,2 x 110.871
= 133.0450233 Ton/jam
Lebar Belt = 18 in
Rpm poros = 20 rpm
HP poros = 20 HP
HP/ft = 0.22 HP/ft
Maka , P = 0,07 x m0,643 x Δz
= 0.07 x 9,05970,643 x 28 m
= 0.07 x 9.0597 x 28 m
= 17.76 kW

23.79 HP
HP actual yang digunakan = 24 HP
Fungsi = Untuk mengangkut dari Raw meal silo (RMS-01) menuju Suspension
Preheater (SP-01).
Safety Factor = 20%
Kapasitas = 1,2 x W
= 1,2 x 110.871
= 133.05 Ton/jam
Lebar Belt = 18 in
Rpm poros = 20 rpm
HP poros = 20 HP
HP/ft = 0.22 HP/ft
Maka , P = 0,07 x m0,643 x Δz

= 0.07 x 9,05970,643 x 12 m
= 0.07 x 9.0597 x 12 m
= 7.61017 kW

10.1976278 HP

Untuk mengangkut material Clinker dari Grate Cooler/Clinker Cooler
Fungsi =
(GC/CC) menuju Clinker Silo (CLS-01).
Safety Factor = 20%
Kapasitas = 1,2 x W
= 1,2 x 69.1467
= 82.98 Ton/jam
Lebar Belt = 13 in
Rpm poros = 38 rpm
HP poros = 11.7 HP
HP/ft = 0.115 HP/ft
Maka ,P = 0,07 x m0,643 x Δz

= 0.07 x 6,68760,643 x 23 m
= 0.07 x 6.6876 x 23 m
= 10.767047 kW

14.4 HP
Untuk mengangkut material Clinker dari Clinker Silo (CLS-01) menuju

Fungsi =
Belt Conveyor (BC-14).
Tinggi Bucket Elevator = 23 m = 75.5 ft
Safety Factor = 20%
Kapasitas = 1,2 x W
= 1,2 x 69.1467
= 82.9760973 Ton/jam
Lebar Belt = 13 in
Rpm poros = 38 rpm
HP poros = 11.7 HP
HP/ft = 0.115 HP/ft
Maka , P = 0,07 x m0,643 x Δz

= 0.07 x 6,68760,643 x 23 m
= 0.07 x 6.6876 x 23 m
= 10.767047 kW

14.42784297 HP
Fungsi = Untuk mengangkut material Semen dari Vertical Roller Mill (VRM-01)
menuju Separator (SPR-02).
Safety Factor = 20%
Kapasitas = 1,2 x W
= 1,2 x 101.061
= 121.2727576 Ton/jam
Lebar Belt = 18 in
Rpm poros = 20 rpm
HP poros = 20 HP
HP/ft = 0.22 HP/ft
Maka , P = 0,07 x m0,643 x Δz
= 0.07 x 8,53580,643 x 38 m
= 0.07 x 8.5358 x 38 m
= 22.70520143 kW

30.42496992 HP
Untuk mengangkut material Semen dari Separator (SPR-02) menuju

Fungsi . =
Cement Silo (CS-01)
Safety Factor = 20%
Kapasitas = 1,2 x W
= 1,2 x 101.01
= 121.2121212 Ton/jam
Lebar Belt = 18 in
Rpm poros = 20 rpm
HP poros = 20 HP
HP/ft = 0.22 H/ft
Maka , P = 0,07 x m0,643 x Δz

= 0.07 x 8,53300,643 x 18 m
= 0.07 x 8.5330 x 18 m
= 10.8 kW

14.4 HP

Fungsi = Untuk mengangkut material Semen dari Cement Silo (CS-01) menuju
Packing Unit.
Safety Factor = 20%
Kapasitas = 1,2 x W
= 1,2 x 101.01
= 121.2121212 Ton/jam
Lebar Belt = 18 in
Rpm poros = 20 rpm
HP poros = 20 HP
HP/ft = 0.22 HP/ft
Maka , P = 0,07 x m0,643 x Δz

= 0.07 x 8,53300,643 x 26 m
= 0.07 x 8.5330 x 26 m
= 15.53 kW

20.81 HP
Diasumsi semua bucket memiliki speed 150 ft/min (45,7 m/min) (Perry, table 21-8, hal 15)
Kebutuhan Power Bucket Elevator
Power
No No Bucket
(kW)
1 BE-01 3.73134
2 BE-02 6.71642
3 BE-03 17.9104
4 BE-04 8.20896
5 BE-05 11.194
6 BE-06 11.194
7 BE-07 22.7612
8 BE-08 11.194
9 BE-09 15.6716
Total 108.582
er (RD-01) menuju
ller Mill (VRM-01)

SPR-01) menuju Raw
menuju Suspension
oler/Clinker Cooler
Silo (CLS-01) menuju

Roller Mill (VRM-01)
(SPR-02) menuju
ilo (CS-01) menuju
L.4.3.1 AIR SLIDE (AS-01)
Mengangkut material halus Raw Material dari Vertical Roller Mill

Fungsi =
(VRM-01) menuju Bucket Elevator (BE-02).
Jenis = Pneumatic Air Slide Continous
Material = Commercial Steel and Fabric
Menurut Perry’s Chemical Engineering 7th edition, laju Alir yang dibutuhkan untuk menggerakan
material dengan bulk density 1160 kg/m3 adalah:
Laju Alir Massa (V) = 105,430.63 Kg/jam
Bulk density = 1160 kg/m3
Laju Alir Volumetrik(Vu) = 90.89 m3/jam
Densitas Udara (ρ) = 1.1212 kg/m3 = 0.07 lb/ft3
Laju Alir Udara (Q) = (Vu x ρ)

90.89 x 1.1212
101.90 Kg/jam
Diamater Pipa(D) = 8 in = 0.2032 ft
Panjang = 21 m = 69 ft
P=Tekanan operasi= 1 atm = 406.784 in H2O
Power(HP) = 144 x 0,8 xVu

[ 33000 ]
= 144 x 0.8 x 90.89
33000
= 0.3172834069 HP
Efisiensi Motor = 80%

HP = 0.3172834069
0.8
= 0.40
Safety Factor = 20%

HP = 0.3966042587 x 1.2
= 0.4759251104 HP
Power yang dibutuhkan = 0.4759251104 /1,34

= 0.3551679928 kW
Fungsi = Mengangkut material halus Raw Material dari Bucket Elevator (BE-02) menuju Separator (SPR-01)
Laju Alir Massa (V) = 105,430.63 Kg/jam


90.89 x 1.1212
101.90415923 Kg/jam
Diamater Pipa(D) = 8 in

[ 33000 ]
= 144 x 0.8 x 90.88848
33000
= 0.3172834069 HP

HP = 0.3172834069
0.8
= 0.3966042587
Safety Factor = 20%

HP = 0.3966042587 x 1.2
= 0.4759251104 HP

= 0.3551679928 kW
Fungsi = Mengangkut material halus Raw Material dari Separator (SPR-01) menuju Bucket Elevator (BE-03).
Laju Alir Massa (V) = 100159.10049 Kg/jam


86.34 x 1.1212
96.808951265 Kg/jam
Power(HP) = 144 x0,8 xVu 

 33000 
= 144 x 0.8 x 86.34

33000
= 0.3014192366 HP

HP = 0.3014192366
0.8
= 0.3767740457
Safety Factor = 20%

HP = 0.3767740457 x 1.2
= 0.4521288549 HP

= 0.3374095932 kW
Fungsi = Mengangkut material halus Raw Material dari Bucket Elevator (BE-03) menuju Raw meal silo (RMS-01)


86.34 x 1.1212
96.808951265 Kg/jam

[ 33000 ]
= 144 x 0.8 x 86.34
33000
= 0.3014192366 HP

HP = 0.3014192366
0.8
= 0.3767740457
Safety Factor = 20%

HP = 0.3767740457 x 1.2
= 0.4521288549 HP

= 0.3374095932 kW
Fungsi = Mengangkut material halus Raw Material dari Raw meal silo (RMS-01) menuju Bucket elevator (BE-04)

99.70 x 1.1212
111.78071059 Kg/jam

[ 33000 ]
= 144 x 0.8 x 99.70
33000
= 0.3480345155 HP

HP = 0.3480345155
0.8
= 0.4350431444
Safety Factor = 20%

HP = 0.4350431444 x 1.2
= 0.5220517732 HP

= 0.3895908756 kW
Fungsi = Mengangkut debu klinker dari Screw Conveyor (SC-02) menuju Clinker Silo (CLS-01)
material dengan bulk density 1201,5 kg/m3 adalah:

Bulk density = 1201.5 kg/m3

2.30 x 1.1212
2.5823093345 Kg/jam
Diamater Pipa(D) = 4 in 0.1016

[ 33000 ]
= 144 x 0.8 x 2.30
33000
= 0.0080401419 HP
HP = 0.0080401419 = 0.01005
0.8
Safety Factor = 20%

HP = 0.010 x 1.2
= 0.012 HP

= 0.01 kW
Fungsi = Mengangkut semen halus dari Vertical Roller Mill (VRM-02) menuju Bucket Elevator (BE-07).

90.12 x 1.1212
101.04260731 Kg/jam

[ 33000 ]
= 144 x 0.8 x 90.12
33000
= 0.3146009244 HP

HP = 0.3146009244
0.8
= 0.3932511555
Safety Factor = 20%

HP = 0.3933 x 1.2
= 0.4719 HP

= 0.3522 kW
Fungsi = Mengangkut semen halus dari Bucket Elevator (BE-07) menuju separator (SPR-02)

90.12 x 1.1212
101.04260731 Kg/jam
144 x 0,8 xVu

Power(HP) =
[ 33000 ]
= 144 x 0.8 x 90.12
33000
= 0.3146009244 HP
HP = 0.3146009244
0.8
= 0.3932511555
Safety Factor = 20%
HP = 0.3932511555 x 1.2
= 0.4719013866 HP

= 0.3521652139 kW
Fungsi = Mengangkut produk semen halus dari separator (SPR-02) menuju Bucket elevator (BE-08)


90.07 x 1.1212
100.99208601 Kg/jam

[ 33000 ]
= 144 x 0.8 x 90.07
33000
= 0.3144436239 HP

HP = 0.3144436239
0.8
= 0.3930545299
Safety Factor = 20%

HP = 0.3930545299 x 1.2
= 0.4716654359 HP

= 0.3519891313 kW
Fungsi = Mengangkut produk semen halus dari Bucket elevator (BE-08) menuju semen silo (CS-01)


90.07 x 1.1212
100.99208601 Kg/jam
Power(HP) =
144 x 0,8 xVu
[ 33000 ]
= 144 x 0.8 x 90.07
33000
= 0.3144436239 HP

HP = 0.3144436239
0.8
= 0.3930545299
Safety Factor = 20%

HP = 0.3930545299 x 1.2
= 0.4716654359 HP

= 0.3519891313 kW
Fungsi = Mengangkut semen dari semen silo (CS-01) menuju bucket elevator (BE-09)

90.07 x 1.1212
100.99208601 Kg/jam
144 x0,8 xVu

Power(HP) =
[ 33000 ]
= 144 x 0.8 x 90.07
33000
= 0.3144436239 HP

HP = 0.3144436239
0.8
= 0.3930545299
Safety Factor = 20%
HP = 0.3930545299 x 1.2
= 0.4716654359 HP
= 0.3519891313 kW
Fungsi = Mengangkut semen dari bucket elevator (BE-09) menuju packing unit



90.07 x 1.1212
100.99208601 Kg/jam
144 x 0,8xVu
Power(HP) =
[ 33000 ]
= 144 x 0.8 x 90.07
33000
= 0.3144436239 HP
HP = 0.3144436239
0.8
= 0.3930545299
Safety Factor = 20%
HP = 0.3930545299 x 1.2
= 0.4716654359 HP
Power yang dibutuhkan = 0.4716654359 / 1,34

= 0.3519891313 kW
Kebutuhan Power Air Sliding
Power
No No AS
(kW)
1 AS-01 0.36
2 AS-02 0.36
L.4.5.1 Screw Conveyor (SC-01)
Fungsi = Mengangkut material debu raw mill dari Electrical Preciptator (EP-01) menuju
Raw Meal Silo (RMS-01)
Jenis = Centrifugal Discharge Screw
Bahan Kontruksi = Carbon Steel
Densitas Raw Meal = 1.14 ton/m3 = 1140 kg/m3
Laju Alir (Q) = 10709.01 kg/jam = 10.70901 ton/jam
= 10 ton/jam
Data Perry,Tabel 21-6, hal 21-8
Dengan Kapasitas 10 ton maka :
Diameter of flights = 10.00 in
Diameter of pipe = 2.50 in
Diameter of shafts = 2.00 in
Speed = 55.00 rpm
All lumps = 1.50 in
Feed Section = 9.00 in
Panjang = 21.00 m = 69 ft
Power Screw Conveyor

Power motor yang dibutuhkan : W0( faktor gesekan)= 2.5
N0 = Q x L x W0 - Sin 0
367
= 10,70901 x 5 x 2,5 - 0
367
= 1.53 kW
= 2.05 Hp
Screw Conveyor (SC-02)
Mengangkut material debu klinker dari Electrical Preciptator (EP-02) menuju

Fungsi =
klinker Silo (CLS-01)

Speed = 55.00 rpm
All lumps = 1.50 in

N0 = Q x L x W0 - Sin 0
367
= 2,7672 x 5 x 2,5 - 0
367
= 0.40 kW
= 0.53 Hp
Mengangkut material dari Electrical Preciptator (EP-03) menuju semen Silo (CS-
Fungsi =
01)
Laju Alir (Q) = 5,002.50 kg/jam = 5.002501 ton/jam

Speed = 55.00 rpm
All lumps = 1.50 in

N0 = Q x L x W0 - Sin 0
367
= 5,0025 x 5 x 2,5 - 0
367
= 0.71561666392 kW
= 0.95892632965 Hp
Fungsi = Mengangkut material semen dari Hopper (HP-14) menuju rotary packer (RP-01)

Speed = 55.00 rpm
All lumps = 1.50 in

N0 = Q x L x W0 - Sin 0
367
= 101,0101 x 5 x 2,5 - 0
367
= 9.63 kW
= 12.91 Hp
Fungsi = Mengangkut material semen dari cement silo (CS-01) menuju Hopper (HP-17)


Speed = 55.00 rpm
All lumps = 1.50 in

N0 = Q x L x W0 - Sin 0
367
= 101,0101 x 5 x 2,5 - 0
367
= 13.0735144359 kW
= 17.5185093441 Hp
Kebutuhan Power Screw Conveyor
Power
NO No SC
(kW)
1 SC-01 1.53
2 SC-02 0.40
3 SC-03 0.72
4 SC-04 9.63
5 SC-05 13.07
Total 25.35
L.4.7.1 Hammer Crusher (HC - 01)
Fungsi = Mereduksi ukuran material Limestone

Jenis = Double Hammer Crusher
Bahan = Carbon Steel unless otherwise indicated
Laju Alir (Q) = 96,675.43 kg/jam = 96.7 ton/jam
= m3/jam
Dia Feed Size, max (D max) = 100 mm
Dia Product Size, max (d max) = 20 mm
Kapasitas Crusher (Q) = 1,2 x 96,67543
= 116.0105186 Ton/jam
Reduction ratio (n) :
Reduction ratio (n) = D max (Duda,40)
dmax
= 100 mm
20 mm
= 5
Diameter Rotor Hammer :

Q = 45 x D x L (Duda,68)
Dimana,Q = Kapasitas,m3/jam
D = Diameter rotor untuk memutar Hammer, m
L = Panjang Lengan Rotor ,m= 4/3 D
Sehingga,
D = Q
45 x L
D = 116.010518618179
40 x 4
= 10 m = 10 m
V = 33 ft
L = 4/3D
L = 13.7 m
Kecepatan circumferensial Rotor(v)

V = 2π .R.n (Duda,69)
60.0
Dimana, V = kecepata circumferensial rotor, m/s
n = Putaran rotor,250 rpm
R = diameter Rotor,m
Sehingga, V = 2 x3,14 x 10 x 250

60.0
= 261.7 m/s
Daya(N) :
N = G.R2.n3.e.f (Duda,69)
8.100000.η
Dimana, N = Daya, HP
G = berat 1 buah hammer, 30 kg
n = putaran Rotor hammer, 250 rpm
e = jumlah hammer ,2 x 16 hammer = 32
f = konstanta kecepatan hammer untuk V = 261,7 m/s = 11x10 -4
η = faktor tenaga transmisi = 0,85
maka, N = 30 x 102 x2503 x 32 x 11.10-4

8 x 100000 x 0,85
= 24.26470588 HP
Faktor Keamanan = 20 %
Total Motor Power (N) = 1,2 x Motor Power
= 1,2 x24,2647059
= 29.12 Hp
Motor Power yang digunakan = 21.73 kW
L.4.6.1 Roller Crusher (RC - 01)
Fungsi = Mereduksi ukuran material Clay

Laju Alir (W) = 773.05 kg/jam = 0.773047 ton/jam
Feed Size (df) = max 65 mm
= 2.56 in
Produk Size (dp) = 20 mm
= 0.79 in
Bulk Density (ρ) = 1.1 ton/m3
Reduction Ratio (r) = Dmax (duda,40)

dmax
= 2.56
0.79
= 3.25 in
Jarak antar Roll (d0) = 20 mm

= 0.79 in
= 1,2 x W
Kapasitas Crusher (Q) = 1,2 x 0,773047 ton/jam
= 0.927657 ton/jam
Diameter Roll (dr)

Diameter Roll (dr) = 0,961 df - d0 (Walas,pers.12.4,hal 341)
0.039
= 0,961 x 2,56 - 0,79
0.039
= 43 in 4 ft
Q
Putaran rpm Roll :
Putaran rpm Roll (n)
=
[ 50 x L x dr x dp x ρ ]
= 0.927656647867128
50 x 0,55 x 43 x 20 x 1,1
= 9.6 rpm
Motor Power (N) : = 0,12 x r x Q

Motor Power (N) = 0,12 x 3,25 x 0,927657
= 0.36 kW
= 0.48 Hp
Faktor keamanan 10% = 1,1 x motor power

Total Motor Power (N) = 1,1 x0,48
= 0.53 Hp
= 0.40 KW
Motor power yang digunakan = 1 kW
L.4.4.1 HOPPER (HP-01)
Fungsi = Menampung partikel yang tidak seragam dari Clay mining.

Bentuk = Silinder tegak dengan alas kerucut dan tutup datar
Bahan konstruksi = Carbon Steel SA-283 grade C
Jumlah = 1 unit
Bulk Density = 881.1 kg/m3 = 0.8811 Ton/m3
Angle of Respone (θ) = 45°
Lama Penyimpanan = 1 jam
wxt
Volume Hopper(VH) =
[ ] p
= 0.77 x 1
0.8811
= 0.87736603 m3
Safety Factor = 20%

Volume Hopper = 1,2 x 0.87737
= 1.05283923 m3
Volume Hopper yang diambil (Vs) = 1.06 m3 = 37.4 ft3
Menentukan Diameter (D) dan Tinggi Hopper (H)
Diambil , H/D = 2, maka H=2D (walas)
Volume Hopper = π/4 x D2 x H

= 2 x π x D3
4
D3 = 4 x Vs
2 x 3,14
= 0.68 m3
D = 2993,631 ^ 0,33
= 0.9 m 34.6 in
r = 1/2 D
= 0.44 m 17.3 in
H = 2D
= 1.76 m 69.2 in
Menentukan Tebal Hopper (tT)

Vs = π x Di2 x h
4
Dimana, Di=D = 1m
h = Vs
π x Di2
4
= 1.06
3,14/4 x 192
= 1.7 m
Tekanan desain
Poperasi = 1 atm = 14.7 psi
g = 9.8 m/dt2
Tebal Tangki
t = Pxr + c
f x E - 0,6 x P
(Sumber : Persamaan (14.34), Brownell and Young, hal 275)
Dimana, t = Tebal dinding tangki (in)
r (jari - jari dalam tangki) = 17.3 in
f (tegangan maksimum yang
diinginkan (allowable strss) = 12650 (sumber : Table 13.1 brownell n young hal.263)
E (Efisiensi Penyambung) = 80 % (tipe double welded butt joint tanpa diradiografi)
(Sumber : Tabel 13.2, Brownell and Young, Hal 254)
c = faktor korosi (0,0125 in/tahun)
Umur tangki diperkirakan 10 tahun,sehingga :
c = 0.0125 in/tahun 10 tahun
= 0.125 in
Safety Factor 20 %
P = 17.64 psi
Sehingga :
t = 14,7 x 17,2 + 0,125
16250 x 0,8 - 0,6 x14,7
= 305.03 0.125
10109.42
= 0.2 in
Dipilih tebal standar sheell (ts) = 1/4 in = 0.25 in = 0.00635 m

(sumber : Tabel 5.8 ,brownell and Young, hal 93)
Kerucut bawah:
Tinggi Kerucut Bawah (kerucut) 1
=
[( )2
xD x tg 45
]
= 1x 1 x 1
2
= 0.44 m
π
Volume Kerucut =
[ 4
2
xD x H ]
= 3.14 x 1^2 0.43921
4
= 0.3 m3
Silinder :
Volume Silinder = Vol. Hopper – Vol. Kerucut bawah
= 1.06 m3 - 0.27 m3
= 0.79 m3
Tinggi Silinder (HH) = 4 xVol . Silinder

[ π x D2 ]
= 4 x 0.79396
3,14 x 1^2
= 1.31074809 m
Tinggi Hopper:
Tinggi Hopper(HH) = H silinder + H kerucut bawah
= 1.31074809 + 0.44
= 1.74995994 m
HOPPER (HP-02)
Fungsi = Menampung material sementara clay dari Clay Storage.

Jumlah = 1 unit
wxt
Volume Hopper(VH) =
[ ] p
= 0.77 x 1
0.8811
= 0.87736603 m3
Safety Factor = 20%

= 1.05283923 m3
Volume Hopper yang diambil (Vs) = 1.06 m3 = 37.4 ft3
Diambil , H/D = 2, maka H=2D

= 2 x π x D3
4
D3 = 4 x Vs
2 x 3,14
= 0.67515924 m3
D = 0,5369 ^ 0,33
= 1m 34.6 in
r = 1/2 D
= 0.4 m 17.3 in
H = 2D
= 2m 69.2 in

Vs = π x Di2 x h
4
Dimana, Di=D = 1m
h = Vs
π x Di2
4
= 1.06
3,14/4 x 192
= 1.7 m
Tekanan desain
g = 9.8 m/dt2
Tebal Tangki
t = Pxr + c
f x E - 0,6 x P
diinginkan (allowable strss) = 12650 psi (sumber : Apendix D, Brownell and young, Hal 342)
= 0.125 in (Tabel 23-2 Perry's )
Safety Factor 20 %
P = 17.64 psi
Sehingga :
t = 20,67 x 276,2 + 0,125
16250 x 0,8 - 0,6 x20,67
= 305.03 0.125
10109.42
= 0.2 in
Kerucut bawah:
Tinggi Kerucut Bawah (kerucut) =  1  
 2 xD  x tg 45
  
= 1x 1 x 1
2
= 0.43921186
π
Volume Kerucut =
[ 4
2
xD x H ]
= 3.14 x 1^2 0.43921
4
= 0.26604298 m3
Silinder :
= 1.06 m3 - 0.26604 m3
= 0.79395702 m3
Tinggi Silinder (HH) =  4 xVol.Silinder

  x D2 
 
= 4 x 0.79396
3,14 x 1^2
= 1.31074809 m
Tinggi Hopper:
= 1.31074809 + 0.43921
= 1.74995994 m
HOPPER (HP-03)
Fungsi = Menampung partikel material sementara dari Limestone Mining.

Jumlah = 1 unit
wxt
Volume Hopper(VH) =
[ ] p
= 96.68 x 1
1.3617
= 70.9961314 m3
Safety Factor = 20%
= 85.2 m3
Volume Hopper yang diambil (Vs) = 86 m3 = 3037 ft3

= 2 x π x D3
4
D3 = 4 x Vs
2 x 3,14
= 54.7770701 m3
D = 54,77^ 0,33
= 3.7 m 147.5 in
r = 1/2 D
= 1.9 m 73.8 in
H = 2D
= 7.49 m 295.1 in

Vs = π x Di2 x h
4
Dimana, Di=D = 4m
h = Vs
π x Di2
4
= 86
3,14/4 x 192
= 7.8 m
Tekanan desain
g = 9.8 m/dt2
Tebal Tangki
t = Pxr + c
f x E - 0,6 x P
= 0.125 in
Safety Factor 10 %
P = 17.64 psi
Sehingga :
t = 35,74 x 78,9 + 0,125
16250 x 0,8 - 0,6 x 35,74
= 1301.29 0.125
10109.42
= 0.3 in

Kerucut bawah:
 2 xD  x tg 45
  
= 1x 4 x 1
2
= 1.87
π
Volume Kerucut =
[ 4
2
xD x H ]
= 3.14 x 4^2 1.87373
4
= 20.6562971 m3
Silinder :
= 86 m3 - 20.6563 m3
= 65.3437029 m3

  x D2 
 
= 4 x 65.3437
3,14 x 4^2
= 5.92732687 m
Tinggi Hopper:
= 5.92732687 + 1.87373
= 7.80105944 m
HOPPER (HP-04)
Fungsi = Menampung partikel material sementara dari Limestone Storage.

Jumlah = 1 unit
wxt
Volume Hopper(VH) =
[ ] p
= 96.68 x 1
1.3617
= 71.00 m3
Safety Factor = 20%

= 85.1953577 m3

= 2 x π x D3
4
D3 = 4 x Vs
2 x 3,14
= 54.7770701 m3
D = 54,77^ 0,33
= 4m 147.5 in
r = 1/2 D
= 1.9 m 73.8 in
H = 2D
= 7m 295.1 in

Vs = π x Di2 x h
4
Dimana, Di=D = 4m
h = Vs
π x Di2
4
= 86
3,14/4 x 192
= 7.8 m
Tekanan desain
g = 9.8 m/dt2
Tebal Tangki
t = Pxr + c
f x E - 0,6 x P
= 0.125 in
Safety Factor 20 %
P = 17.64 psi
Sehingga :
t = 35,74 x 78,9 + 0,125
16250 x 0,8 - 0,6 x 35,74
= 1301.29 0.125
10109.42
= 0.3 in

Kerucut bawah:
 2 xD  x tg 45
  
= 1x 4 x 1
2
= 1.87
π
Volume Kerucut =
[ 4
2
xD x H ]
= 3.14 x 4^2 1.87373
4
= 20.6562971 m3
Silinder :
= 86 m3 - 20.6563 m3
= 65.3437029 m3

  x D2 
 
= 4 x 65.3437
3,14 x 4^2
= 5.92732687 m
Tinggi Hopper:
= 5.92732687 + 1.87373
= 7.80105944 m
HOPPER (HP-05)
Fungsi = Menampung partikel material sementara dari Iron Sand Supplier.

Jumlah = 1 unit
wxt
Volume Hopper(VH) =
[ ] p
= 1.84 x 1
1.4418
= 1.27768868 m3
Safety Factor = 20%

= 1.53322642 m3
Volume Hopper yang diambil (Vs) = 1.55 m3 = 55 ft3

= 2 x π x D3
4
D3 = 4 x Vs
2 x 3,14
= 0.98726115 m3
D = 0,5923^ 0,33
= 1.00 m 39.2 in
r = 1/2 D
= 0.50 m 19.6 in
H = 2D
= 2.0 m 78.4 in

Vs = π x Di2 x h
4
Dimana, Di=D = 1m
h = Vs
π x Di2
4
= 1.55
3,14/4 x 192
= 2.0 m
Tekanan desain
Poperasi = 1 atm
g = 9.8 m/dt2
Tebal Tangki
t = Pxr + c
f x E - 0,6 x P
= 0.125 in
Safety Factor 20 %
P = 17.64 psi
Sehingga :
t = 22,53 x 78,9 + 0,125
16250 x 0,8 - 0,6 x 22,53
= 345.78 0.125
10109.42
= 0.2 in

Kerucut bawah:
 2 xD  x tg 45
  
= 1x 1 x 1
2
= 0.50
π
Volume Kerucut =
[ 4
2
xD x H ]
= 3.14 x 1^2 0.49789
4
= 0.38754968 m3
Silinder :
= 1.55 m3 - 0.38755 m3
= 1.16245032 m3

  x D2 
 
= 4 x 1.16245
3,14 x 1^2
= 1.49341185 m
Tinggi Hopper:
= 1.49341185 + 0.49789
= 2.0 m
HOPPER (HP-06)
Fungsi = Menampung partikel material sementara dari Iron Sand Storage.

Jumlah = 1 unit
Volume Hopper(VH) =  wxt 
 p 
 
 wxt 
 p 
 
= 1.84 x 1
1.4418
= 1.278 m3
Safety Factor = 20%

= 1.53322642 m3

= 2 x π x D3
4
D3 = 4 x Vs
2 x 3,14
= 0.98726115 m3
D = 0,987^ 0,33
= 1m 39.2 in
r = 1/2 D
= 0.5 m 19.6 in
H = 2D
= 2m 78.4 in

Vs = π x Di2 x h
4
Dimana, Di=D = 1m
h = Vs
π x Di2
4
= 1.55
3,14/4 x 192
= 2.0 m
Tekanan desain
Poperasi = 1 atm
g = 9.8 m/dt2
Tebal Tangki
t = Pxr + c
f x E - 0,6 x P
= 0.125 in
Safety Factor 20 %
P = 17.64 psi
Sehingga :
t = 37,04 x 78,9 + 0,125
16250 x 0,8 - 0,6 x 37,04
= 345.78 0.125
10109.42
= 0.2 in

Kerucut bawah:
 2 xD  x tg 45
  
= 1x 1 x 1
2
= 0.50
π
Volume Kerucut =
[ 4
2
xD x H ]
= 3.14 x 1^2 0.49789
4
= 0.38754968 m3
Silinder :
= 1.55 m3 - 0.38755 m3
= 1.16245032 m3

  x D2 
 
= 4 x 1.16245
3,14 x 1^2
= 1.49341185 m
Tinggi Hopper:
= 1.49341185 + 0.49789
= 1.99130091 m
HOPPER (HP-07)
Fungsi = Menampung partikel material sementara dari silica Sand Supplier.

Jumlah = 1 unit
 p 
 
= 16.36 x 1
1.4418
= 11.35 m3
Safety Factor = 20%

= 13.614913 m3

= 2 x π x D3
4
D3 = 4 x Vs
2 x 3,14
= 8.73 m3
D = 10,414^ 0,33
= 2.0 m 80.5 in
r = 1/2 D
= 1.02 m 40.2 in
H = 2D
= 4.09 m 160.9 in

Vs = π x Di2 x h
4
Dimana, Di=D = 2m
h = Vs
π x Di2
4
= 13.7
3,14/4 x 192
= 4.2 m
Tekanan desain
Poperasi = 1 atm
g = 9.8 m/dt2
Tebal Tangki
t = Pxr + c
f x E - 0,6 x P
= 0.125 in
Safety Factor 20 %
P = 17.64 psi
Sehingga :
t = 27,90 x 78,9 + 0,125
16250 x 0,8 - 0,6 x 27,90
= 709.75 0.125
10109.42
= 0.2 in

Kerucut bawah:
 2 xD  x tg 45
  
= 1x 2 x 1
2
= 1.02
π
Volume Kerucut =
[ 4
2
xD x H ]
π
[ 4
2
xD x H ]
= 3.14 x 2^2 1.02198
4
= 3.35160143 m3
Silinder :
= 13.7 m3 - 3.3516 m3
= 10.3483986 m3

  x D2 
 
= 4 x 10.3484
3,14 x 1^2
= 3.15545279 m
Tinggi Hopper:
= 3.15545279 + 1.02198
= 4.17742928 m
HOPPER (HP-08)
Fungsi = Menampung partikel material sementara dari silica Sand Storage.

Jumlah = 1 unit
 p 
 
= 16.36 x 1
1.4418
= 11.3457609 m3
Safety Factor = 20%

= 13.614913 m3

= 2 x π x D3
4
D3 = 4 x Vs
2 x 3,14
= 8.72611465 m3
D = 8,726^ 0,33
= 2m 80.5 in
r = 1/2 D
= 1.0 m 40.2 in
H = 2D
= 4m 160.9 in

Vs = π x Di2 x h
4
Dimana, Di=D = 2m
h = Vs
π x Di2
4
= 13.7
3,14/4 x 192
= 4.2 m
Tekanan desain
Poperasi = 1 atm
g = 9.8 m/dt2
Tebal Tangki
t = Pxr + c
f x E - 0,6 x P
= 0.125 in
Safety Factor 20 %
P = 17.64 psi
Sehingga :
t = 27,90 x 78,9 + 0,125
16250 x 0,8 - 0,6 x 27,90
= 709.75 0.125
10109.42
= 0.2 in

Kerucut bawah:
 2 xD  x tg 45
  
= 1x 2 x 1
2
= 1.02
π
Volume Kerucut =
[ 4
2
xD x H ]
= 3.14 x 2^2 1.02198
4
= 3.35160143 m3
Silinder :
= 13.7 m3 - 3.35 m3
= 10.35 m3

  x D2 
 
= 4 x 10.3484
3,14 x 2^2
= 3.15545279 m
Tinggi Hopper:
= 3.15545279 + 1.02198
= 4.17742928 m
HOPPER (HP-09)
Fungsi = Sebagai Corong untuk memasukan material ke dalam dryer

Jumlah = 1 unit
 p 
 
 wxt 
 
 p 
= 115.65 x 1
0.9612
= 120.317279 m3
Safety Factor = 20%

= 144.380735 m3

= 2 x π x D3
4
D3 = 4 x Vs
2 x 3,14
= 92.3566879 m3
D = 10,414^ 0,33
= 4.5 m 175.3 in
r = 1/2 D
= 2.2 m 87.6 in
H = 2D
= 8.9 m 350.6 in

Vs = π x Di2 x h
4
Dimana, Di=D = 4m
h = Vs
π x Di2
4
= 145
3,14/4 x 192
= 9.3 m
Tekanan desain
g = 9.8 m/dt2
Tebal Tangki
t = Pxr + c
f x E - 0,6 x P
= 0.125 in
Safety Factor 20 %
P = 17.64 psi
Sehingga :
t = 32,90 x 78,9 + 0,125
16250 x 0,8 - 0,6 x 32,90
= 1546.11 0.125
12989.42
= 0.2 in

Kerucut bawah:
 2 xD  x tg 45
  
= 1x 4 x 1
2
= 2.23
π
Volume Kerucut =
[ 4
2
xD x H ]
= 3.14 x 4^2 2.22625
4
= 34.6460181 m3
Silinder :
= 145 m3 - 35 m3
= 110.4 m3

  x D2 
 
= 4 x 110.354
3,14 x 2^2
= 7.09102866 m
Tinggi Hopper:
= 7.09102866 + 2.22625
= 9.31728188 m
HOPPER (HP-10)
Fungsi = Menampung sementara batu bara

Jumlah = 1 unit
Bulk Density = 801 kg/m3 = 0.801 Ton/m3
 p 
 
= 11.44 x 1
0.801
= 14.28 m3
Safety Factor = 20%

= 17.1320977 m3

= 2 x π x D3
4
D3 = 4 x Vs
2 x 3,14
= 12.7388535 m3
D = 12,73^ 0,33
= 2.3 m 91.2 in
r = 1/2 D
= 1.2 m 45.6 in
H = 2D
= 4.6 m 182.3 in

Vs = π x Di2 x h
4
Dimana, Di=D = 2m
h = Vs
π x Di2
4
= 20
3,14/4 x 192
= 4.7 m
Tekanan desain
Poperasi = 1 atm
g = 9.8 m/dt2
Tebal Tangki
t = Pxr + c
f x E - 0,6 x P
= 0.125 in
Safety Factor 20 %
P = 17.64 psi
Sehingga :
t = 24,12 x 45,6 + 0,125
16250 x 0,8 - 0,6 x 24,12
= 804.13 0.125
10109.42
= 0.2 in

Kerucut bawah:
 2 xD  x tg 45
  
= 1x 2 x 1
2
= 1.16
π
Volume Kerucut =
[ 4
2
xD x H ]
π
[ 4
2
xD x H ]
= 3.14 x 2^2 1.15788
4
= 4.87437234 m3
Silinder :
= 20 m3 - 4.87437 m3
= 15.1256277 m3

  x D2 
 
= 4 x 15.1256
3,14 x 2^2
= 3.59300418 m
Tinggi Hopper:
= 3.59300418 + 1.15788
= 4.75088275 m
HOPPER (HP-11)
Fungsi = Menampung batu bara dari HP-10 untuk bahan bakar suspension preheater
Jumlah = 1 unit
 p 
 
= 6.86 x 1
0.801
= 8.57 m3
Safety Factor = 20%

= 10.2792586 m3

= 2 x π x D3
4
D3 = 4 x Vs
2 x 3,14
= 7.00636943 m3
D = 7,643^ 0,33
= 2m 74.8 in
r = 1/2 D
= 1.0 m 37.4 in
H = 2D
= 4m 149.7 in

Vs = π x Di2 x h
4
Dimana, Di=D = 2m
h = Vs
π x Di2
4
= 11
3,14/4 x 192
= 3.9 m
Tekanan desain
Poperasi = 1 atm
g = 9.8 m/dt2
Tebal Tangki
t = Pxr + c
f x E - 0,6 x P
= 0.125 in
Safety Factor 20 %
P = 17.64 psi
Sehingga :
t = 22,93 x 45,6 + 0,125
16250 x 0,8 - 0,6 x 22,93
= 660.16 0.125
10109.42
= 0.2 in

Kerucut bawah:
 2 xD  x tg 45
  
= 1x 2 x 1
2
= 1
π
Volume Kerucut =
[ 4
2
xD x H ]
= 3.14 x 2^2 0.95057
4
= 3 m3
Silinder :
= 11 m3 - 3 m3
= 8 m3

  x D2 
 
= 4 x 8.30302
3,14 x 2^2
= 2.9 m
Tinggi Hopper:
= 2.92644936 + 0.95057
= 3.8770163 m
HOPPER (HP-12)
Fungsi = Menampung batu bara dari HP-10 untuk bahan bakar Rotary Kiln
Jumlah = 1 unit
 
 p 
 wxt 
 
 p 
= 4.57 x 1
0.801
= 5.71069925 m3
Safety Factor = 20%

= 6.8528391 m3

= 2 x π x D3
4
D3 = 4 x Vs
2 x 3,14
= 4.45859873 m3
D = 7,643^ 0,33
= 1.6 m 64.5 in
r = 1/2 D
= 0.8 m 32.2 in
H = 2D
= 3.3 m 129.0 in

Vs = π x Di2 x h
4
Dimana, Di=D = 2m
h = Vs
π x Di2
4
= 7
3,14/4 x 22
= 3.3 m
Tekanan desain
Poperasi = 1 atm
g = 9.8 m/dt2
Tebal Tangki
t = Pxr + c
f x E - 0,6 x P
= 0.125 in
Safety Factor 20 %
P = 17.64 psi
Sehingga :
t = 22,17 x 32,2 + 0,125
16250 x 0,8 - 0,6 x 22,17
= 568.68 0.125
10109.42
= 0.2 in

Kerucut bawah:
 2 xD  x tg 45
  
= 1x 2 x 1
2
= 1
π
Volume Kerucut =
[ 4
2
xD x H ]
= 3.14 x 2^2 0.8
4
= 1.7 m3
Silinder :
= 7 m3 - 1.68434 m3
= 5.31565683 m3

  x D2 
 
= 4 x 5.31566
3,14 x 2^2
= 2.52473816 m
Tinggi Hopper:
= 2.5 + 1
= 3.3 m
HOPPER (HP-13)
Fungsi = Menampung material gypsum sebelum ditimbang dengan WF-08
Jumlah = 1 unit
 p 
 
= 3.19 x 1
0.9612
= 3.32021261 m3
Safety Factor = 20%

= 3.98425513 m3

= 2 x π x D3
4
D3 = 4 x Vs
2 x 3,14
= 2.5477707 m3
D = 2,547^ 0,33
= 1.4 m 53.6 in
r = 1/2 D
= 0.7 m 26.8 in
H = 2D
= 2.7 m 107.2 in
Vs = π x Di2 x h
4
Dimana, Di=D = 1.4 m
h = Vs
π x Di2
4
= 4
2
3,14/4 x 1
= 2.7 m
Tekanan desain
Poperasi = 1 atm
g = 9.8 m/dt2
Tebal Tangki
t = Pxr + c
f x E - 0,6 x P
= 0.125 in
Safety Factor 20 %
P = 17.64 psi
Sehingga :
t = 22,14 x 26,8 + 0,125
16250 x 0,8 - 0,6 x 22,14
= 472.79 0.125
10109.42
= 0.2 in

Kerucut bawah:
 2 xD  x tg 45
  
= 1x 1 x 1
2
= 0.68
π
[ 4
2
xD x H ]
π
Volume Kerucut =
[ 4
2
xD x H ]
= 3.14 x 1^2 0.68077
4
= 0.99069141 m3
Silinder :
= 4 m3 - 0.99069 m3
= 3.00930859 m3

  x D2 
 
= 4 x 3.00931
3,14 x 2^2
= 2.06790815 m
Tinggi Hopper:
= 2.06790815 + 0.68077
= 3m
HOPPER (HP-14)
Fungsi = Menampung material Trass sebelum ditimbang dengan WF-09

Jumlah = 1 unit
 p 
 
= 18.08 x 1
1.38
= 13.1047348 m3
Safety Factor = 20%

= 15.7256818 m3

= 2 x π x D3
4
D3 = 4 x Vs
2 x 3,14
= 10.2 m3
D = 10,828^ 0,33
= 2.2 m 84.7 in
r = 1/2 D
= 1.1 m 42.3 in
H = 2D
= 4.3 m 169.4 in

Vs = π x Di2 x h
4
Dimana, Di=D = 2m
h = Vs
π x Di2
4
= 16
2
3,14/4 x 1
= 4.4 m
Tekanan desain
Poperasi = 1 atm
g = 9.8 m/dt2
Tebal Tangki
t = Pxr + c
f x E - 0,6 x P
= 0.125 in
Safety Factor 20 %
P = 17.64 psi
Sehingga :
t = 22,99 x 42,3 + 0,125
16250 x 0,8 - 0,6 x 22,99
= 747.05 0.125
10109.42
= 0.2 in

Kerucut bawah:
 2 xD  x tg 45
  
= 1x 2 x 1
2
= 1.08
π
Volume Kerucut =
[ 4
xD 2 x H ]
= 3.14 x 2^2 1.07568
4
= 3.90820907 m3
Silinder :
= 16 m3 - 3.90821 m3
= 12.0917909 m3

  x D2 
 
= 4 x 12.0918
3,14 x 2^2
= 3.32809378 m
Tinggi Hopper:
= 3.32809378 + 1.07568
= 4.40377283 m
HOPPER (HP-15)
Fungsi
= Menampung material blast slag furnace sebelum ditimbang dengan WF-09

Bentuk
Bahan konstruksi = Silinder tegak dengan alas kerucut dan tutup datar
Jumlah = Carbon Steel SA-283 grade C
Laju Alir (W) = 1 unit
Bulk Density = 10637.96 Kg/jam = 10.64 Ton/jam
Angle of Respone (θ) = 2000 kg/m3 = 2 Ton/m3
Lama Penyimpanan = 45°
Volume Hopper(VH) = 1 jam
=  wxt 
 p 
 
= 10.64 x 1
2
3
= 5.3189806 m
Safety Factor = 20%

= 6.38277672 m3

= 2 x π x D3
4
D3 = 4 x Vs
2 x 3,14
= 4.45859873 m3
D = 4,458^ 0,33
= 1.6 m 64.5 in
r = 1/2 D
= 0.8 m 32.2 in
H = 2D
= 3.3 m 129.0 in

Vs = π x Di2 x h
4
Dimana, Di=D = 2m
h = Vs
π x Di2
4
= 7
2
3,14/4 x 1
= 3.3 m
Tekanan desain
Poperasi = 1 atm
g = 9.8 m/dt2
Tebal Tangki
t = Pxr + c
f x E - 0,6 x P
= 0.125 in
Safety Factor 20 %
P = 17.64 psi
Sehingga :
t = 28,97 x 32,2 + 0,125
16250 x 0,8 - 0,6 x 28,97
= 568.68 0.125
10109.42
= 0.2 in

Kerucut bawah:
 2 xD  x tg 45
  
= 1x 2 x 1
2
= 0.82
π
Volume Kerucut =
[ 4
2
xD x H ]
= 3.14 x 2^2 0.81885
4
= 1.72403495 m3
Silinder :
= 7 m3 - 1.72403 m3
= 5.27596505 m3

  x D2 
 
 4 xVol.Silinder
  x D2 
 
= 4 x 5.27597
3,14 x 2^2
= 2.50588605 m
Tinggi Hopper:
= 2.51 + 1
= 3.3 m
HOPPER (HP-16)
Fungsi = Menampung campuran aditif dan klinker dingin

Jumlah = 1 unit
 p 
 
= 101.06 x 1
1.2816
= 78.8550494 m3
Safety Factor = 20%

= 94.63 m3

= 2 x π x D3
4
D3 = 4 x Vs
2 x 3,14
= 60.5095541 m3
D = 55,414^ 0,33
= 4m 152.5 in
r = 1/2 D
= 1.9 m 76.2 in
H = 2D
= 8m 305 in

Vs = π x Di2 x h
4
Dimana, Di=D = 4m
h = Vs
π x Di2
4
= 95
3,14/4 x 12
= 8.1 m
Tekanan desain
Poperasi = 1 atm
g = 9.8 m/dt2
Tebal Tangki
t = Pxr + c
f x E - 0,6 x P
rf (tegangan
(jari - jari maksimum
dalam tangki)
yang = 76.2 in
= 0.125 in
Safety Factor 20 %
P = 17.64 psi
Sehingga :
t = 35,26 x 76,2 + 0,125
16250 x 0,8 - 0,6 x 35,26
= 1344.74 0.125
12989.42
= 0.2 in

Kerucut bawah:
 2 xD  x tg 45
  
= 1x 4 x 1
2
= 1.94
π
Volume Kerucut =
[ 4
2
xD x H ]
= 3.14 x 4^2 1.9363
4
= 22.7953033 m3
Silinder :
= 95 m3 - 22.7953 m3
= 72.2046967 m3

  x D2 
 
= 4 x 72.2047
3,14 x 4^2
= 6.13326857 m
Tinggi Hopper:
= 6.13326857 + 1.9363
= 8.06956529 m
HOPPER (HP-17)
Fungsi = Menampung semen halus dari CS-01 menuju packing unit

Jumlah = 1 unit
 p 
 
= 101.01 x 1
1.1214
= 90.0749964 m3
Safety Factor = 20%

= 108.1 m3


= 2 x π x D3
4
D3 = 4 x Vs
2 x 3,14
= 69.4 m3
D = 55,414^ 0,33
= 4.05 m 159.5 in
r = 1/2 D
= 2.03 m 79.8 in
H = 2D
= 8.10 m 319.1 in

Vs = π x Di2 x h
4
Dimana, Di=D = 4m
h = Vs
π x Di2
4
= 109
3,14/4 x 12
= 8.4 m
Tekanan desain
Poperasi = 1 atm
g = 9.8 m/dt2
Tebal Tangki
t = Pxr + c
f x E - 0,6 x P
= 0.125 in
Safety Factor 20 %
P = 17.64 psi
Sehingga :
t = 33,79 x 79,8 + 0,125
16250 x 0,8 - 0,6 x 33,79
= 1407.14 0.125
10109.42
= 0.3 in

Kerucut bawah: =  1  
Tinggi Kerucut Bawah (kerucut)  2 xD  x tg 45
  
= 1x 4 x 1
2
= 2.03
π
Volume Kerucut
=
[ 4
2
xD x H ]
= 3.14 x 4^2 2.02616
4
= 26.1186808 m3
Silinder : = Vol. Hopper – Vol. Kerucut bawah

Volume Silinder = 109 m3 - 26.1187 m3
= 82.9 m3
=  4 xVol.Silinder
Tinggi Silinder (HH)   x D2 
 
= 4 x 82.8813
3,14 x 4^2
= 6.4 m
Tinggi Hopper: = H silinder + H kerucut bawah

Tinggi Hopper(HH) = 6.42953079 + 2.02616
= 8.45569137 m
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L.4.8.1 Raw Meal Silo (RMS - 01)
Fungsi = Menampung raw meal dari Vertical Raw Mill (VRM-01)

Jenis = Silo Storage
Bentuk = Silinder Tegak dengan alas cone tutup datar
Bahan Kontruksi = Carbon Steel SA-283 grade A
Bulk Density = 1.36 Ton/m3 = 1360 kg/m3
Data, T = 30 °
P = 1 atm
Angle of respone (θ) = 36 °
Lama Penyimpanan = 2 hari
t = 48 jam
Jumlah Tangki = 15 Buah
Volume raw meal(Vrm) = Wxt

ρ
= 110,8709 x 48
1.36
= 3913.0889191 m3
Direncanakan digunakan 15 buah tangki berbentuk silinder, maka volume tiap tangki :
Volume silo (Vs) = 260.87 m3
Volume Silo (Vs) = 1,2 x 260,87
= 313.0 m3
Volume silo yang diambil (Vs) = 313 m3 = 1967 galon
Menentukan Diameter (D) dan Tinggi Tangki (H)
Volume Tangki = π/4 x D2 x H

= 2 x π x D3
4
D3 = 4 x Vs
2 x 3,14
= 199.36305732 m3
D = 199,3631 ^ 0,33
= 6m = 226.0 in
r = 1/2 D
= 2.9 m = 113.0 in
H = 2D
= 11 m = 451.9 in
Menentukan Tebal Tangki (tT)

Vs = π x Di2 x h
4
Dimana, Di=D = 6m
h = Vs
π x Di2
4
= 313.0
3,14/4 x 192
= 12.1 m
Tekanan desain
g = 9.8 m/dt2
Tebal Tangki
t = Pxr + c
f x E - 0,6 x P
r = jari - jari dalam tangki
= 113.0 in
f = tegangan maksimum yang diinginkan (allowable strss)
= 10350 (sumber : Tabel 13.1, Brownell and young, Hal 263)
E = Efisiensi Penyambung
= 80 % (tipe double welded butt joint tanpa diradiografi)
c = 0.0125 in/tahun = 10 tahun
= 0.125 in
Safety Factor 20%
P = 17.64 psi
Sehingga :
t = 45,6899 x 276,2 + 0,125
16250 x 0,8 - 0,6 x 45,6899
= 1993.05 0.125
8269.416
= 0.4 in
Dipilih tebal standar sheell (ts) = 4/9 in = 0.4375 in = 0.01

Menentukan Diameter Tangki Sesungguhnya :

Diameter luar shell (DO) adalah
DO = Di + (2ts)
= 226,0 in + (2x0,4375)
= 226.8 in = 5.8 m
Diambil diameter luar standar shell (Do)

= 228 in
diameter dalam tangki sesungguhnya adalah :
Di = Do - (2ts)
= 228 - (2 x 0,4375)
= 227.125 in = 5.77 m
Menentukan Kerucut
Kerucut Bawah :
1
Tinggi Kerucut Bawah (H kerucut) =
[ ]
2
xD x tan 45
= (1 x 6) x 1
2
= 2.9 m
Volume Kerucut Bawah = π x D2 x H kerucut

12
= 3,14/12 x 62 x 9,5
= 24.74 m3
Silinder :
Vol Silinder = Vol Silo - vol. kerucut bawah
= 313 - 24.74
= 288 m3
Tinggi Silinder (Hs) = Vol. Silinder

π x (r)2
= 288
3,14 x(2,9)2
= 11 m
d young, Hal 263)
anpa diradiografi)
m
L.4.9.1 Clinker Silo (CLS- 01)
Fungsi = Menampung clinker dari clinker cooler

t = 48 jam
Volume raw meal(Vrm) = Wxt

ρ
= 69,14675 x 48
1.6
= 2074.40 m3
= 311.2 m3
Menentukan Diameter Silo (D) dan Tinggi Tangki (H)

= 2 x π x D3
4
D3 = 4 x Vs
2 x 3,14
= 200.63694 m3
D = 200,63^ 0,33
= 5.8 m = 226.4 in
r = 1/2 D
= 2.8758458 m = 113.2 in
H = 2D
= 12 m = 452.9 in
Vs = π x Di2 x h
4
Dimana, Di=D = 6m
h = Vs
π x Di2
4
= 311.16036
3,14/4 x 62
= 12.0 m
Tekanan desain
Poperasi = 1 atm
g = 9.8 m/dt2
Tebal Tangki
t = Pxr + c
f x E - 0,6 x P
= 113.2 in
= 10350 (sumber : Tabel 13.1, Brownell and young, Hal 263)
= 0.125 in
Safety Factor 20%
P = 17.64 psi
Sehingga :
t = 50,304 x 224,3 + 0,125
16250 x 0,8 - 0,6 x 50,304
= 1997.241 0.125
8269.416
= 0.4 in


DO = Di + (2ts)
= 226,4 in + (2x0,4375)
= 227.320 in = 6m

= 228 in
Di = Do - (2ts)
= 228- (2x0,4375)
= 227.125 in = 5.77 m
Menentukan Kerucut
Kerucut Bawah :
1
=
[ ]
2
xD x tan 45
(1 x 11,4) x 1
2
= 2.9 m

12
= 3,14/12 x 11,42 x 5,7
= 24.89 m3
Silinder :
Vol Silinder = Vol Silo -vol. kerucut bawah
= 315 - 24.89
= 290 m3

π x (r)2
= 290
3,14 x(2,87)2
= 11.17 m
L.4.10.1 Cement Silo (CS- 01)
Fungsi = Menampung produk semen dari vertikal raw mill (VRM - 02)
t = 48 jam
Volume Cement (Vc) = Wxt

ρ
= 101,0101 x 48
1.6
= 3030.303 m3
= 363.6364 m3
Menentukan Diameter (D) dan Tinggi Tangki (H)

= 2 x π x D3
4
D3 = 4 x Vs
2 x 3,14
= 232.4841 m3
D = 2356,688^ 0,33
= 6.04 m = 237.7 in
r = 1/2 D
= 3.019116 m = 118.9 in
H = 2D
= 12.1 m = 475.5 in
Vs = π x Di2 x h
4
Dimana, Di=D = 6m
h = Vs
π x Di2
4
= 363.6364
3,14/4 x 62
= 12.7 m
Tekanan desain
Poperasi = 1 atm
g = 9.8 m/dt2
Tebal Tangki
t = Pxr + c
f x E - 0,6 x P
= 118.9 in
= 10350 psi (sumber : Apendix D, Brownell and young, Hal 342)
= 0.125 in
Safety Factor 20%
P = 17.64 psi
Sehingga :
t = 52,2762 x 255,3 + 0,125
16250 x 0,8 - 0,6 x 52,2762
= 2096.74 0.125
8269.416
= 0.38 in


DO = Di + (2ts)
= 237,7 in + (2x0,4375)
= 239 in = 6.060 m

= 240 in
Di = Do - (2ts)
= 240- (2 x 0,4375)
= 239.125 in = 6.074 m
Menentukan Kerucut
Kerucut Bawah :
1
=
[ ]
2
xD x tan 45
(1 x 6) x 1
2
= 3.02 m

12
= 3,14/12 x 62 x 7,7
= 28.80 m3
Silinder :
Vol Silinder = Vol Silo - vol. kerucut bawah
= 365 - 28.80
= 336 m3

π x (r)2
= 336
3,14 x(3,01)2
= 11.7 m
L.4.11.1 Blower (BL- 01)
Meniupkan udara untuk mendorong batubara ke burning gun

Fungsi =
Suspension Preheater (SP-01)
Jenis = Blower Centrifugal
Bahan kontruksi = Carbon steel
Jumlah = 1 buah
Laju Alir (W) = 1372.28 kg/jam
Laju Alir Aktual (Wu) = 1,2 x 1372,281 kg/jam
= 1646.74 kg/jam
Densitas Udara = 1.1212 kg/m3 = 0.07 lb/ft3

Laju Alir Volumetrik (Vu) = Wu
ρu
= 1646.74 kg/jam
1.12 kg/m3
= 1468.73 m3/jam = 52454.5523 ft3/jam
= 874 Ft3/min
Optimum Diameter Pipa (D) = 3,9 x V0,45 x ρ0,13

= 3,19 x 52455 0,45 x 0,070,13 x 0,0393
= 11.8 in = 0.29947758 m
T = Tekanan operasi = 1 atm = 406.784 in H2O

Power (HP) = 144 x 0,8 x Vu
33000
= 144 x 0,8 x 1468,72
33000
= 5.1271940624 HP
Effisiensi Motor = 80 %
HP = 5.1271940624
0.8
= 6.4 HP
Safety Factor = 20.0 %

HP = 6,40 x 1,2
= 7.7 HP
Power yang dibutuhkan = 7.7 HP / 1.34
= 5.7 kW
L.4.11.1 Blower (BL- 02)
Meniupkan udara untuk mendorong batubara ke burning gun Rotary

=
Fungsi Kiln (RK-01)
Jumlah = 1 buah
Laju Alir (W) = 914.85 kg/jam 0.91485402
= 1097.8248231 kg/jam
ρu
= 1097.8248231
1.1212
= 979.15164386 m3/jam = 34969.7016 ft3/jam
= 583 Ft3/min

= 3,19 x 1023696 0,45 x 0,070,13 x 0,0393
= 9.82 in

33000
= 144 x 0,8 x 979,15
33000
= 3.4181293749 HP
HP = 3.4181293749
0.8
= 4.2726617187 HP
HP = 4,272 x 1,2
= 5.13 HP
= 3.83 kW
L.4.11.1 Blower (BL- 03)
= Menghisap udara buang suspension preheter yang akan menuju Rotary

Fungsi dryer
Jumlah = 1 buah
Laju Alir (W) = 162829.44 kg/jam 162.829445 ton/jam
= 195395.3 kg/jam

ρu
= 195395.33396
1.1212
= 174273.39811 m3/jam = 6224050 ft3/jam
= 103734.166 Ft3/min

= 3,19 x 1023696 0,45 x 0,070,13 x 0,0393
= 101.15 in = 2.56918137 m

33000
= 144 x 0,8 x 174.273
33000
= 608.37 HP
HP = 608.37258977
0.8
= 760.5 HP
HP = 4,272 x 1,2
= 912.56 HP
= 681.01 kW
L.4.11.1 Blower (BL- 04)
= Menghisap udara buang suspension preheter yang akan menuju Rotary

Fungsi dryer dari Gas Conditioning Tower
Jumlah = 1 buah
Laju Alir (W) = 162829.44 kg/jam 162.829445 ton/jam
= 195395.3 kg/jam

ρu
= 195395.33396
1.1212
= 174273.39811 m3/jam = 6224049.93 ft3/jam
= 103734.166 Ft3/min

= 3,19 x 1023696 0,45 x 0,070,13 x 0,0393
= 101.15 in = 2.56918137 m

33000
= 144 x 0,8 x 174.273
33000
= 608.37 HP
HP = 608.37258977
0.8
= 760.5 HP
HP = 4,272 x 1,2
= 912.56 HP
= 681.01 kW
L.4.11.1 Blower (BL-5-19)
Fungsi = Mendinginkan klinker pada alat Greate cooler

Jumlah = 15 buah
= 154736.19242 kg/jam
Jumlah blower yang akan digunakan ada 15 buah,maka :
Laju Alir Aktual (Wu)/buah = 154736.19 /15
= 10315.75 kg/jam
= 22694.64 lb/jam

ρu
= 10315.7
1.1
= 9200.6298261 m3/jam = 328593.922 ft3/jam
= 5476.56537 Ft3/min
= 365 ft3/min per 1 buah

= 3,19 x 300000 0,45 x 0,070,13 x 0,0393
= 27 in 1.79486928

33000
= 144 x 0,8 x 9200,63
33000
= 32.118562302 HP
HP = 32.118562302
0.8
= 40.15 HP
HP = 40,1482 x 1,2
= 48.18 HP
= 35.95 kW
Total HP yang dibutuhkan untuk 15 blower adalah :
HP = 48.18 x 15
= 722.67 HP
Total power yang dibutuhkan = 35.95 x 15
= 539.30 kW
Kebutuhan Power Blower
Power
No No BL
(kW)
1 BL -01 5.74
2 BL -02 3.83
3 BL-03 681.01
4 BL-04 681.01
4 BL -04 - BL 18 539.30
Total 1910.90
L.4.11.1 Blower Kiln (BLK- 01)
Fungsi = Meniupkan udara primer ke burning gun

Bahan Kontruksi = Commercial Steel
Jumlah = 1 buah
= 7553.518 kg/jam

ρu
= 7553.518 kg/jam
1.1212 kg/m3
= 6737.0 m3/jam = 240606.9 ft3/jam
= 4010 Ft3/min

= 3,19 x 6736,9 0,45 x 0,070,13
= 23.40 in

33000
= 144 x 0,8 x 6736,9
33000
= 23.51824 HP
HP = 23.51824
0.8
= 29.39779 HP
HP = 125,0771 x 1,2
= 35.27735 HP
= 26.32638 kW
L.4.14.1 Vertikal Raw Mill (VRM- 01)
Fungsi = Mengecilkan ukuran material campuran dari Rotary Dryer(RD-01)

Jenis = Vertical Mill with Four Roller Unit
Bahan = Commercial Steel
Laju Alir Produk = 105,430.63 kg/jam
Faktor Kemanan = 20 %
Kapasitas Mill (PM) = 126,517 ton/jam
Kapasitas Mill Aktual(PM akt) = 127 ton/jam
L/D = 2
(Sumber : FLSMIDTH “Mechanical Design for VRM”, exercise)
Berdasarkan Kapasitas Aktual maka dipilih VRM Tipe (36-4) , dengan Dimensi :
A = 19 m , B = 16,8 m , C = 8,4 m , D = 9,4 m 31 ft
Dimana, A = Height, m
B = Height separator outlet,m
C = Separator Widht, m
D = Widht, m
Data untuk mill type (36 - 4)

Table speed = 25 rpm
Product Fineness (Blaine) = 3300 cm3/g
Capacity = 260 ton/jam
Mill Motor = 3750 kW
Grinding bed thickness H = 80 mm dan (Pρ diasumsi 2000 kb/m3 bahan padat)
Kecepatan Aliran Udara = 120 Nm3/s
Do = 5 m (diameter luar efektif)
Berat satu roller = 57 ton
= 568 kN , DR = 3 m,W = 1
Hydraulic Presure = 160 bar
Hydraulic Cylinder 0,42 / 0,21 m korespondensi (sesuai dengan) = 0.1039 m2
Menghitung Grinding Pressure (kT)
kT = T
W.Di
Roller Force , T = 1/4 x π x (0,42 2 - 0,21 2 ) x 160 x 100 + 568
= 2229.688 kN
maka, kT = 2229.688
3x1
= 743.22933333 kN/m2
Menghitung Friction Factor (μ)
μ= 3750
0,844 x kT x D0 2,5
= 0.107
Menghitung Maximum Pressure (Pmax), Spesific Power Consumption (N) dan circulation
Under Roller (C)
Pmax = 4 x kT /μ
= 27799.81 kN/m2
F-1 = 1/4 x Dr/H x μ2

= 1.07
N = 1/3 x pmax x (F-1)/Pρ

= 4.97 kj/kg
= 1.380 kWh/Ton
C = (N/P)/N
= 10 Kali
Spesific Motor Comsumption = 18 kWh/t

Mill Motor Power(N) = Pm (akt) x Spesific Motor Comsumption
= 2,286 HP
Gear Efficiency = 75 % (Duda)

Mill Motor Power(N) = Mill motor/Effisiensi Gear
= 3,048 HP
Mill Motor yang dibutuhkan = 1,2 x mill motor
= 3,658 HP
= 2729.6 kW
Vertikal Raw Mill (VRM- 02)
Menghaluskan campuran klinker dengan bahan aditif (trass dan blast slag
Fungsi = furnace ) dari Hopper -16
Jenis = Vertical Mill with Four Roller Unit
Bahan = Commercial Steel
Kapasitas Raw Meal = 101,060.63 kg/jam
Faktor Kemanan = 20 %
Kapasitas Mill (PM) = 121,273 ton/jam
Kapasitas Mill Aktual 122 ton/jam
L/D = 2
(Sumber : FLSMIDTH “Mechanical Design for VRM”, exercise)
Berdasarkan Kapasitas Aktual maka dipilih VRM Tipe (36-4) , dengan Dimensi :
A = 19 m , B = 16,8 m , C = 8,4 m , D = 9,4 m 31 ft
Dimana, A = Height, m
B = Height separator outlet,m
C = Separator Widht, m
D = Widht, m
Data untuk mill type (36 - 4)

Table speed = 25 rpm
Product Fineness (blaine) = 3300 cm3/gram
Capacity = 260 ton/jam
Mill Motor = 3750 kW
Grinding bed thickness H = 80 mm dan (Pρ diasumsi 2000 kb/m3 bahan padat)
Kecepatan Aliran Udara = 120 Nm3/s
Do = 5 m (diameter luar efektif)
Berat satu roller = 57 ton
= 568 kN , DR = 3 m,W = 1
Hydraulic Presure = 160 bar
Hydraulic Cylinder 0,42 / 0,21 m korespondensi (sesuai dengan) = 0.1039 m2
Menghitung Grinding Pressure (kT)
kT = T
W.Di
Roller Force , T = 1/4 x π x (0,42 2 - 0,21 2 ) x 160 x 100 + 559
= 2229.688 kN
maka, kT = 2229.688
3x1
= 743.2 kN/m2
Menghitung Friction Factor (μ)

μ= 3750
0,844 x kT x D0 2,5
= 0.107
Menghitung Maximum Pressure (Pmax), Spesific Power Consumption (N) dan circulation
Under Roller (C)
Pmax = 4 x kT /μ
= 27799.81 kN/m2
F-1 = 1/4 x Dr/H x μ2

= 0.107
N = 1/3 x pmax x (F-1)/Pρ

= 0.50 kj/kg
= 0.138 kWh/Ton
C = (N/P)/N
= 104.5 Kali
Spesific Motor Comsumption = 30 kWh/t

Mill Motor Power(N) = Pm (akt) x Spesific Motor Comsumption
= 3,660 HP
Gear Efficiency = 75 % (Duda)

Mill Motor Power(N) = Mill motor/Effisiensi Gear
= 4,880 HP
Mill Motor yang dibutuhkan = 1,2 x mill motor
= 5,856 HP
= 4370.1 kW
Kebutuhan Power VRM
Power
No No VRM
(kW)
1 VRM -01 2729.55
2 VRM -02 4370.15
Total 7099.70
Dryer(RD-01)
ahan padat)
m
f (trass dan blast slag
ahan padat)
m
L.4.12.1 Fan (F - 01)
Menghembuskan udara luar ke dalam vertikal raw mill (VRM - 1) untuk

Fungsi =
menghomogenisasikan material
Jenis = Fan Axial
Jumlah = 1 buah
Laju Alir (W) = 2,549,866 kg/jam
Pressure = 4 kPa = 16.0588 in H2O
Laju Alir Aktual (Wu) = 1,2 x 2549866 kg/jam
= 3,059,840 kg/jam
ρu
= 3059839.72534
1.1212
= 2729076 m3/jam = 9746699.1 ft3/jam
= 162444.98 cfm ( ft3/menit)

= 3,19 x 9746691 0,45 x 0,070,13
= 124 in = 3m
T = Tekanan operasi = 1 atm = 407 in H2O
Power (HP) = 0,000157 x cfm x total pressure
Total Efficiency
= 0,000157 x 1624450 cfm x 200822 in H2O
80%
= 512.0 HP
HP = 5119,5 x 1,2
= 614 HP
Power yang dibutuhkan = 458 kW
Fan (F - 02)
Menghisap gas buang Rotary Dryer (RD-01) dan Vertical Raw Mill (VRM-01)
Fungsi =
menuju Electrical Precipitator (EP-01)
Jenis = Fan Axial
Jumlah = 1 buah
Pressure = 3.5 kPa = 14.05145 in H2O
Laju Alir Aktual (Wu) = 1,2 x 401719 kg/jam
= 3059839.72534 kg/jam
[ ]
ρu
= 3059839.72534
1.1212
= 2729075.74504 m3/jam = 9746699.1 ft3/jam
= 162444.98 cfm
= 3,19 x 974669910,45 x 0,070,13
= 25 in 0.64 m
T = Tekanan operasi = 1 atm = 407 in H2O
Total Efficiency
= 0,000157 x 1624450ft3/jam x 16,0588 in H2O
80%
= 447.957812968 HP
HP = 5119,5 x 1,2
= 537.5 HP
Power yang dibutuhkan = 401.2 kW
Fan (F - 03)
Menghisap gas buang greate cooler (GC-01) menuju Electrical Precipitator

Fungsi =
(EP-01)
Jenis = Fan Axial
Jumlah = 1 buah
Laju Alir Aktual (Wu) = 1,2 x27197,42 kg/jam
= 32636.9019719 kg/jam
[ ]
ρu
= 32636.9019719
1.1212
= 29108.9029361 m3/jam = 1039603.7 ft3/jam
= 17326.728 cfm

= 3,19 x1039604 0,45 x 0,070,13
= 18.0 in 0.46 m
Total Efficiency
= 0,000157 x 288154,0173ft3/jam x14,05145 in H2O
80%
= 47.7801340649 HP
HP = 11356529 x 1,2
= 57.34 HP
Fan (F - 04)
Menghembuskan udara luar ke dalam vertikal raw mill (VRM - 2) untuk

Fungsi = menghomogenisasikan material
Jenis = Fan Axial
Bahan Kontruksi = Stainless Steel
Jumlah = 1 buah
Laju Alir Aktual (Wu) = 1,2 x15730885,1 kg/jam
= 18877062.1355 kg/jam
[ ]ρu
= 18877062.1355
1.1212
= 16,836,481 m3/jam = 6013028.8 ft3/jam
= 100217.15 cfm

= 3,19 x 6,01x10 0,45 x 0,070,13
= 100 in 2.5 m
Total Efficiency
= 0,000157 x 288154,0173ft3/jam x 200822 in H2O
80%
= 276.358509875 HP
HP = 27635,851 x 1,2
= 331.6 HP
Kebutuhan Power Fan
No No BL Power (kW)
1 F-01 458.46
2 F-02 401.16
3 F-03 42.79
4 F-04 247.49
Total 1149.89
L.4.16.1 Rotary Kiln (RK - 01)
Fungsi = Sebagai tempat pembakaran material menjadi klinker

Jenis = Dry Rotary Kiln
Bahan Mentah Masuk = 73038.95 kg/jam
Klinker yang dihasilkan(Q) = 69146.7 Kg/jam
Ratio Bahan masuk = 73038.95

dengan klinker 69146.75
= 1.06
Basis = 1 jam
a.Menghitung Diameter Rotary Kiln

Dari Duda Hal 319 - 324 didapatkan :
Fg = Q x E x (T + Ta)
24 x 3600 x Vg x Ta
Dg =
√ 4 xfg
π
Fw = Q x W
24 x e
Dw = √ 4 xfw
π
N = D x L x Rd
D = Dg + Dw
2
Dimana :
Q = Klinker yang keluar , kg/hari
Fg = Effective internal cross sectional dari Rotary Kiln dengan dasar kecepatan gas, m2
G = Jumlah gas keluar kiln, m3/kg klinker
T = Temperatur gas keluar kiln, °C
Ta = Temperatur reference, °C
Vg = Kecepatan gas keluar kiln, m/detik
Dg = Diameter dalam efektif rotary kiln dengan kecepatan gas, m
Fw = Effective internal cross sectional dari Rotary Kiln dengan dasar

thermal loading pada sintering, m2
W= Panas yang dibutuhkan untuk menghasilkan 1 kg klinker,kkal/kg klinker
e= Muatan panas pada daerah pembakaran, kkal/m2jam
Dw = Diameter effective rotary kiln dengan dasar thermal loading pada sintering, m
L= Panjang rotary kiln, m
D= Diameter roraty kiln, m
N= Power yang dibutuhkan, HP
Rd = Faktor power yang dibutuhkan
Diketahui :
Q= 69146.75 kg/jam
= 1659521.946 kg/hari
= 1659.521946 ton/hari
G = Jumlah gas keluar kiln (Nm3/kg klinker) (Fuller, hal 9)
CO2 = 13411.99295 kg/jam

= 1.3205 kg/m3
= 10156.75346 m3/jam
H2O = 2947.032028 kg/jam

= 1.0787 kg/m3
= 2732.021904 m3/jam
SO2 = 45.69989744 kg/jam

= 1.9216 kg/m3
= 23.78221141 m3/jam
O2 = 1390.722296 kg/jam
= 0.8522 kg/m3
= 1631.920084 m3/jam
N2 = 32880.93003 kg/jam
= 0.8178 kg/m3
= 40206.56643 m3/jam
Total Gas Buang = 54751.0 m3/jam
G = Total Gas Buang
Q
= 54751.04 m3/jam
69146.75 kg/jam
= 0.79 m3/kg klinker jam
T = 900 °C
Ta = 25 °C
Vg = 10 m/det (Duda Hal 351)
Fg = 1659521.946 kg/hari x 0.7918094 m3/kg klin 925 °C

24 jam/hari 3600 det/ 10 m/det x 25 °C
= 56.27190643 m2
Dg = 4xfg 0,5
3.14
= 4.778000182 m
e = 3460000 kkal/m2 jam (Duda, hal 351)
W = 400 kkal/klinker
Fw = 1659521.95 kg/hari 400 kkal/kg klinker

24 jam/hari 3460000 kkal/m2 jam
= 7.99384367 m2
DW = 4 x Fw 0,5
3.14
= 1.800852624 m
D = 4.778000182 + 1.8008526
2
= 3.3 m
= 10.7921 ft
Dengan menggunakan refractory dengan ketebalan 220 mm maka diameter shell kiln :
= 3.3 + 0.22
= 3.5 m = 11.513866 ft
b. Menghitung Panjang Rotary Kiln

Dari Duda didapatkan :
Dimensi rotary kiln L antara 14:1 sampai 16:1

D
Dalam perancangan diambil 15 : 1
Panjang Kiln (L) = 14 x3

= 46.052 m
= 151.089 ft
c. Menghitung Volume Rotary Kiln
V = π x D2 x L
4
= 3,14 x (0,32795)2 m2 x 4,591 m
4
= 391 m3
d. Menghitung spesifik output rotary kiln
Ls = Q
j
Dimana :
Q = Kapasitas klinker, ton/hari
J = Volume efektif dalam rotary kiln, m3
Ls = 1659522 ton/hari
391.163 ton/m3 hari
= 4243 ton/m3 hari
e. Menghitung Putaran Rotary Kiln
Putaran Kiln = V
πxD
Dimana :
D = diameter shell kiln,ft
V = kecepatan rotary kiln
Kecepatan rotary kiln dari data :
= 3,14 x 3,3 rpm x 1,7977681 ft
= 119 ft/menit
Putaran Kiln = 119.3066811 ft/menit

3,14 x 1,7977681 ft
= 3.3 rpm
f. Menentukan Kiln Slope
Diambil 3% (Duda Tabel 19.1 hal 385)

Dari tabel 19.2 Hal 387 Duda didapatkan fraction for inch per feet lenght 11/32" - 3/8"
Dari tabel 19.3 Hal 387 Duda dengan kiln slope inch per feet 3/8" didapatkan slope in
degress (S) = 1,790
g. Menghitung resident time kiln
Dari Duda hal.388

t = 1,77 x L x 6,325
sxDxN
t= 1,77 x 15,064 ft x 6,325
1,790 x 1,7977681 ft x 3,3 rpm
= 25 menit
h. Menentukan % Kiln Load
Dari Duda page 385 tabel 19.1

Untuk kiln slope 3% didapatkan % kiln load = 12 %
i. Menghitung Power
Rotary kiln menggunakan 3 buah penyangga

diameter tire = 276.7718 in
diameter as roler = 11.811 in
diameter roller = 38.189 in
Perkiraan beban yang bekerja pada roller sebesar

= 1600000 lb
a. Power untuk melawan gesekan pada tire dan roller
HPl = N x Dar x Dt x n x f x 0,000009

Dr
Dimana =
N = Gaya vertikal pada roller total,lb
Dar = diameter as roller, in
Dt = diameter tire , in
n = kiln speed, rpm
f = koefesien gesekan pada roller dengan pelumas oil
= 0.018
HP1 = 1600000 lb x 11,811 in x 276,7718 in x 3,301 rpm x 0,018 x 0,0000092

38,1890 in
= 74.83895325 HP
b. Power untuk menahan beban muatan kiln
Hpu = (Db sin θ)3 x N x L x K

(Duda,hal.390)
Dimana :
Db = diameter dalam kiln, ft
Sin θ = Dari fig.19.7 Duda, dengan kiln load = 12% = 0,77
N = putaran kiln, rpm
L = panjang rotary kiln, ft
K = konstan 0,00076
HpII = (1,076 ft x 0,77)3 x 3,3rpm x15,064 ft x 0,00076

= 217.444581 HP
Total HP = Hp1 +HP2

= 74.84 + 217.44
= 292.28 HP
Untuk efisiensi transmisi = 80 %

HP motor = 292.2835342
0.8
= 365.4 HP
HP motor yang diambil = 370 HP

Power Motor = 276.12 kW
L.4.13.1 Separator (SPR- 01)
Memisahkan raw material yang masih kasar dan yang sudah halus di unit
Fungsi =
Vertikal Raw Mill (VRM - 01)
Jenis = Mechanical Air Separator
Jumlah = 1 buah
Laju Alir Produk = 105,430.63 kg/jam 105.43
= 105,430.63 kg/jam
Kapasitas Separator = 1,2 x 110702,164
= 126516.76 kg/jam
Dari Duda,W.H,"Cement Data Book,"tabel 15.2.1,hal.266 didapatkan :

Diameter Separator (dspr) = 7.3 m = 287 in
H = 2D
= 14.6 m
Rpm = 140 rpm
Dari Duda,W.H,"Cement Data Book,"hal.265 didapatkan :

Dari diameter separator didapatkan :
B = 0,1 d = 0.73 m
d1 = 0,7 d = 5.11 m
d1 = 0,7 d = 5.11 m
d2 = 0,5 d = 3.65 m
d3 = 0,33 d = 2.41 m
HP input = 600 HP
Effisiensi = 80 %
HPinput
HP yang dibutuhkan =
=
[ Effisiensi
600
]
0.8
= 750 HP
Total HP yang dibutuhkan = 1,2 x HP yang dibutuhkan
= 1,2 x 750 HP
= 900 HP
HP yang digunakan = 900 HP
= 671.64 kW
Separator (SPR- 02)
Memisahkan raw material yang masih kasar dan yang sudah halus di unit
Fungsi =
Vertikal Raw Mill (VRM - 02)
Jenis = Mechanical Air Separator
Jumlah = 1 buah
Laju Alir Produk = 101,060.63 kg/jam
= 101060.631326 kg/jam
Kapasitas Separator = 1,2 x 101060,63
= 121272.757591 kg/jam
Dari Duda,W.H,"Cement Data Book,"tabel 15.2.1,hal.266 didapatkan :
Diameter Separator (dspr) = 7.3 m = 287 in
H = 2D
= 14.6 m
Rpm = 140 rpm
Dari Duda,W.H,"Cement Data Book,"hal.265 didapatkan :

Dari diameter separator didapatkan :
B = 0,1 d = 0.73 m
d1 = 0,7 d = 5.11 m
d1 = 0,7 d = 5.11 m
d2 = 0,5 d = 3.65 m
d3 = 0,33 d = 2.41 m
HP input = 600 HP
Effisiensi = 80 %
HPinput
HP yang dibutuhkan =
=
[ Effisiensi
600
]
0.8
= 750 HP
Total HP yang dibutuhkan = 1,2 x HP yang dibutuhkan
= 1,2 x 750 HP
= 900 HP
HP yang digunakan = 900 HP
= 671.64 kW
Kebutuhan Power Separator
Power
No No SPR
(kW)
1 SPR -01 671.64
2 SPR -02 671.64
Total 1343.284
L.4.15.1 Suspension Preheater (SP- 01)
Cyclone Suspension Preheater (SP Stage 4 - Line A)
Fungsi = Sebagai pemanasan awal material menuju Rotary Kiln (RK-01)

Jenis = Multi Stage Preheter Single String
Laju Alir udara (F) = 66080.02 kg/jam + 50676 kg/jam
2
= 58,378.20 kg/jam
= 128,432.03 lb/jam
Densitas Raw Meal = 1120 kg/m3 = 69.4085 lb/ft3
Laju Alir = 1,2 x 128432
= 154,118.44 lb/jam
Laju Alir Terpasang (Wg) = 154118.4399 lb/jam = 70054 kg/jam
Densitas Campuran Udara (Vt) = 0.07 lb/ft3 = 1.12955 kg/m3 (Indocement)
Kecepatan Udara (Vg) = 10 ft/sec
ε = Coeffecient for pressure drop : 110
(W.H.Duda Hal 451)
Δp = Pressure drop in cyclone, 520 mm
(W.H.Duda Hal 451)
Dimensi Shell Cyclone :
Wg
Volumetric Flow Rate (v) =
=
[ ]
ρg
70053.8363
1.129545455
= 17.22763692 m3/s
4
Diameter Cyclone (Dc) = 0,536 x V2 x 1,1295 x 110
520
= 0.536 x 2.90192
= 1.6 m = 2m
= 61 in
Tinggi Shell (Lb) = 1,5 x D
= 1,5 x 2
= 3m
Kecepatan Uap Masuk cyclone(Vu) = 18 m/s (Duda, hal 451)
Direncanakan menggunakan cyclone dengan diameter, (D) = 2 m= 78.74 in
Percepatan Sentrifugal Partikel Raw

Meal (as) = Vu2
R
= 18 2
1/2 x 3
= 486 m/s2
Waktu yang dibutuhkan gas untuk melakukan satu kali rotasi :

tr = 2πR
Vu
= 2 x 3,14 x (1/2 x 3)
18
= 0.523333333 s
Bottom Conocal , θ = 60 °
Diameter bottom opening (Product outlet suction)
Dc = 0.1 x D
= 0.2 m = 8 in
Tinggi Conical Head, Hc = 1/2 x (D - Dc)tan 60°
= 1/2 x (3-0,3)tan 60°
= 1.557 m
Fungsi = Sebagai pemanasan awal material menuju Rotary Kiln(RK-01)

2
= 58378.20 kg/jam
= 128432.03 lb/jam
Densitas Raw Meal = 1120.00 kg/m3 = 69.4085 lb/ft3
Faktor Keamanan = 10.00 %
Laju Alir = 1,2 x 128432
= 154118.44 lb/jam
Kecepatan Udara (Vg) = 10.00 ft/sec
(W.H.Duda Hal 451)
(W.H.Duda Hal 451)
Wg
=
[ ]
ρg
70053.8363
1.129545455
= 17.22763692 m3/s
4
520
= 0.536 x 2.90192
= 2m = 2m

= 1,5 x m
= 3m

Meal (as) = Vu2
R
= 18 2
1/2 x 3
= 486 m/s2

tr = 2πR
Vu
= 2 x 3,14 x (1/2 x 3)
18
= 0.523333333 s

Dc = 0.1 D
= 0.2 m

= 1/2 x (3-0,3)tan 60°
= 1.557 m

2
= 58378.19692 kg/jam
= 128432.0332 lb/jam
Laju Alir = 1,2 x 128432
= 154118.4399 lb/jam
(W.H.Duda Hal 451)
(W.H.Duda Hal 451)
Wg
=
[ ]
ρg
70053.8363
1.129545455
= 17.22763692 m3/s
4
520
= 0.536 x 2.90192
= 2m = 2m

= 1,5 x m
= 3m

Meal (as) = Vu2
R
= 18 2
1/2 x 3
= 486 m/s2

tr = 2πR
Vu
= 2 x 3,14 x (1/2 x 3)
18
= 0.523333333 s

Dc = 0.1 D
= 0.2 m

= 1/2 x (3 - 0,3)tan 60°
= 1.557 m

2
= 58378.19692 kg/jam
= 128432.0332 lb/jam
Laju Alir = 1,2 x Laju alir udara lb/jam
= 154118.4399 lb/jam
(W.H.Duda Hal 451)
(W.H.Duda Hal 451)
Wg
=
[ ]
ρg
70053.8363
1.129545455
= 17.22763692 m3/s
4
520
= 0.536 x 2.90192
= 1.555431566 m = 2m

= 1,5 x m
= 3m

Meal (as) = Vu2
R
= 18 2
1/2 x 3
= 486 m/s2

tr = 2πR
Vu
= 2 x 3,14 x (1/2 x 3)
18
= 0.523333333 s

Dc = 0.1 D
= 0.2 m

= 1/2 x (3 - 0,3)tan 60°
= 1.557 m
L.4.17.1 Apron Conveyor (AC-01)
Fungsi = untuk mengangkut klinker dingin dari GC-01 menuju Bucket Elevator (BE-05)
Jenis = Horizontal Flat Apron Conveyor
Material = Carbon Steel
Panjang Conveyor (L) = 100 m = 328 ft
= 1.2 x 69.15
= 82.98 Ton/jam
= 83 Ton/jam
Dikarenakan Kapasitas
Lebar belt = 54 in = 1370 mm (Perry, Table 21-11 hal,19)
Kecepatan Apron Conveyor = Cb x100
40
= 82.98 x100
40.00
= 207.44 ft/menit
Power Apron :
HP Apron Conveyor = HPhorizontal + HPvertical + HPempty
HPhorizontal = L W
( 0,4+ )( )
300 100
= 0,4 + 328.084 82.976
300 100
= 1.239342053 HP
HPvertical = 0
HPempty = e
(beltspeed . x ( ))
100
207.4402432 x 3,1
100
6.430647541 HP
HP Apron Conveyor = HPhorizontal + HPvertical + HPempty

= 1.24 + 0 + 6.43
= 7.67 HP
Faktor Keamanan 20%

Total HP Apron Conveyor = 1,2 x HP Apron Conveyor
= 1,2 x 7.66999
= 9.20 HP
Power Apron Conveyor = 9.20 /1,34

= 6.87 KW
L.4.19.1 Rotary Dryer (RD-01)
Fungsi = Mengeringkan raw material yang akan digrinding pada Vertical Roller Mill (VRM-01)
Jenis = Current Rotary Dryer
Bahan = Carbon Steel
Temperatur Udara Masuk = 180 °C
Laju Alir steam (Gs) = 161201.15 kg/jam = 354642.5 lb/jam
Laju Alir udara pengering aktual = 1,2 x 161201,15 kg/jam = 193441.4 kg/jam
Kecepatan pengering dengan = 30 kg/m3jam
lifting flight
Volume gas pengering = banyaknya gas pengering/ 30 kg/m3 jam
= 193441.4 kg/jam / 30 kg/m3 jam
= 6448.0 m3
Ratio L/D = 5
Bulk Density (ρ) = 1.1 ton/m3
Kemiringan Dryer (ƿ) = 3°
Faktor Hambatan = 1.5
Diameter (D) = 5m = 16.4 ft
Panjang Dryer (L) = 2xD A
= 10 m = 32.8 ft 538.2 ft2
Waktu Tinggal (t) = 1,77 x L x θ X f
ƿxDxn
= 1,77 x 25 x (35)^0,5
x 1,5
3x5x2
= 5.2 menit
Kecepatan putaran Dryer (N) =

Range N x D = 25 s/d 35 ; maka di ambil 20
NxD = 20
Nx 5 = 20
N = 4 rpm
Jumlah Flight :
Range jumlah flight 2D s/d 3,4 D ; dan diambil 3D
Jumlah Flight= = 3x5
= 15 buah
Tinggi Flight :
Range tinggi flight 0,08 D s/d 0,12 D; dan diambil 0,1D
Tinggi Flight = 0,1 x 5 m
= 0.5 m
Power Dryer =
Range HP : 0,5D2 s/d 1,0 D2 : dan diambil HP 0,8D2
HP = 0,8 x 52
= 20 HP
HP = 20 HP x effisiensi motor
= 16 HP
Safety Faktor = 20 %
HP = 1,2 x HP
= 19.2 HP
= 14.33 kW
L.4.20.1 Electrical Precipitator (EP-01)
Memisahkan debu yang terbawa oleh gas buang Rotary Dryer (RD-01) dan Vertical Roller
Fungsi = Mill (VRM - 01)
Jenis = Electric Dust Collector
Laju Alir Udara (Gas) (Q) = 2,549,866 kg/jam = 42,498 kg/menit
Laju Alir Udara Volumetrik (Q) = 46,128 m3/menit = 37 acfm
Densitas Udara = 0.9213 kg/m3 (120°C)
Effisiensi = 99 %
Effective Drift Velocity (We) = 4,2 m /menit (semen) ; 6 m/menit (dust)
(Air Pollution Control Equipment)
Velocity = 0.2 ft/detik ((Air Pollution Control Equipment,tabel 10.1,Hal.407)
Plate Area = 3mx6m
Luas Total Penampang Plate Area
In ( 1 - ŋ) = − AWe
Q
A =
Q
ln(1)
We
A = -42497.77
ln (1 - 0,01)
6
A = 71 m2
Jumlah Plate yang dibutuhkan:

A = Ap(n-1)
n = A +1
Ap
n = 71 +1
3x2x6
n = 2.977326983 plate = 3 plate
Power EP
Pc = W xQ
1000cfm
= 150 W x Q m3 x 35,3 ft3 x 1 kW
1000 cfm menit 1 m3 1000 W
= 245.6 kW
Power EP = Pc x 1,2
= 294.8 kW
Electrical Precipitator (EP-02)
Fungsi = Memisahkan debu yang terbawa oleh gas buang (EP -02)
Laju Alir Udara (Gas) (Q) = 27197.42 kg/jam = 453.290305 kg/menit
Laju Alir Udara Volumetrik (Q) = 492 m3/menit = 0.39902142 acfm
Effisiensi = 99 %
Velocity = 0.2 ft/detik ((Air Pollution Control Equipment,Hal.407)
Plate Area = 3mx6m
In ( 1 - ŋ) = − AWe
Q
A =
−Q
ln(1−η)
A =
We
-453.29030517
ln (1 - 0,01)
6
A = 0.76 m2
A = Ap(n-1)
n = A +1
Ap
n = 45,56 +1
3x2x6
n = 1.02 plate = 2 plate
Power EP
Pc = W xQ
1000cfm
= 150 W x Q m3 x 35,3 ft3 x 1 kW
1000 cfm menit 1 m3 1000 W
= 2.620 kW
Power EP = Pc x 1,2
= 3.14395424944 kW
Electrical Precipitator (EP-03)
Fungsi = Memisahkan debu yang terbawa oleh gas buang (EP -03)
Laju Alir Udara (Gas) (Q) = 15,730,885 kg/jam = 262,181 kg/menit
Laju Alir Udara Volumetrik (Q) = 284,578 m3/menit = 230.7925 acfm
Effisiensi = 99 %
Velocity = 0.2 ft/detik ((Air Pollution Control Equipment,Hal.407)
Plate Area = 3mx6m
In ( 1 - ŋ) = − AWe
Q
A = −Q
ln(1−η)
We
A = (262,181)
ln (1 - 0,01)
6
A = 439.2 m2

A = Ap(n-1)
n = A +1
Ap
n = 439,2 + 1
3x2x6
n = 13.1987187797 plate = 14 plate
Power EP
Pc = W xQ
1000cfm
= 150 W x Q m3 x 35,3 ft3 x 1 kW
1000 cfm menit 1 m3 1000 W
= 1515.37615736 kW
Power EP = Pc x 1,2
= 1818.5 kW
Kebutuhan Power EP
No No VRM Power (kW)
1 EP -01 294.76
2 EP -02 3.14
3 EP -03 1818.45
Total 2116.35
L.4.21.1 Grate cooler (GC-01)
Fungsi = Mendinginkan Klinker Panas keluaran RK -01

Jenis = Air Trough Grate
Kondisi Operasi
Temperatur = 80 C
Massa Klinker = 69838.56 kg/jam

Densitas klinker = 1300 kg/m3
Volume klinker = 69838.5611
1300
= 53.7 m3/jam
Volume klinker cooler = 80 % volume klinker

= 43.0 m3/jam
Kecepatan Material = 24 m/jam

Maka:
Luas = Volume klinker cooler
Kecepatan material
= 42.9775761
24
= 1.79073234 m2
= 1.8 m2 = 20 ft2
Tinggi = 0.5 m
Lebar = Luas
Tinggi
= 1.79073234
0.5
= 3.58146467 m
= 3.6 m
L.4.22.1 Gas Conditioning Tower (GCT-01)
Menurunkan tempertur gas panas dari Suspension Preheater(SP -01)

Fungsi =
menuju Electrical Precipitator (EP-01)
Velocity = 2 m/s
Waktu Tinggal = 12 s
Laju Alir Gas (Q) = 162829.44 kg/jam = 2713.824 kg/menit
L/D = 3 :1 - 3,5 : 1
Diambil = 3,5 : 1
A = Laju Alir Gas/detik

velocity
162829.44 / 3600
2 45.2304
= 23 m2
= 246 ft2
Diameter GCT = 6m
Panjang Kolom GCT = 3,5 x D
= 3,5 x 6
= 21 m
Total Power Keseluruhan Alat
No Jenis Alat Alat Kode Alat Power (kW)

1 Alat Utama Rotary Dryer RD 14.33
2 Vertikal Roller Mill VRM 7099.70
4 Rotary Kiln RK 276.12
5 Separator SPR 1343.28
6 Electrical Precipitator EP 2116.35
Alat Angkut
7 Belt Conveyor BC 109.23
8 Bucket Elevator BE 108.58
9 Air Slide AS 3.95
10 Screw Conveyor SC 25.35
11 Apron Conveyor AC 6.87
Alat Bantu
12 Fan F 1149.89
13 Blower BL 1910.90
14 Blower Kiln BLK 26.33
15 Hammer Crusher HC 21.73
16 Roller Crusher RC 1.00
Total Power Keseluruhan Alat 14213.62

Spesifikasi Alat Baru HOPPER

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L.4.1.

1 BELT CONVEYOR (BC-01)

untuk mengangkut material Clay dari Crusher Mining menuju Storage

Untuk Belt Conveyor kapasitas < 32 ton/jam,maka :

Power Belt Conveyor :

HP Belt Conveyor = HPhorizontal + HPvertical + HPempty

Faktor Keamanan 20%

Power Belt Conveyor = 0.23 / 1,34

BELT CONVEYOR (BC-02)

untuk mengangkut material Clay dari Storage menuju Hopper (HP-

Panjang Belt Conveyor (L) = 30 m = 98.4252 ft

Untuk Belt Conveyor kapasitas < 32 ton/jam,maka :

Power Belt Conveyor :

HP Belt Conveyor = HPhorizontal + HPvertical + HPempty

Faktor Keamanan 20%

Power Belt Conveyor = 0.1300 / 1,34

BELT CONVEYOR (BC-03)

Panjang Belt Conveyor (L) = 1000 m = 3280.84 ft

Untuk Belt Conveyor kapasitas < 32 ton/jam,maka :

Power Belt Conveyor :

HP Belt Conveyor = HPhorizontal + HPvertical + HPempty

Faktor Keamanan 20%

Power Belt Conveyor = 28.5694397 / 1,34

BELT CONVEYOR (BC-04)

Untuk Belt Conveyor kapasitas < 32 ton/jam,maka :

Power Belt Conveyor :

HP Belt Conveyor = HPhorizontal + HPvertical + HPempty

Faktor Keamanan 20%

Power Belt Conveyor = 16.2629866 /1,34

BELT CONVEYOR (BC-05)

Untuk Belt Conveyor kapasitas < 32 ton/jam,maka :

HP Belt Conveyor = HPhorizontal + HPvertical + HPempty

HP Belt Conveyor = HPhorizontal + HPvertical + HPempty

Faktor Keamanan 20%

Power Belt Conveyor = 0.30626845 / 1,34

BELT CONVEYOR (BC-06)

Untuk Belt Conveyor kapasitas < 32 ton/jam,maka :

Power Belt Conveyor :

HP Belt Conveyor = HPhorizontal + HPvertical + HPempty

Faktor Keamanan 20%

Power Belt Conveyor = 0.30989477 / 1,34

BELT CONVEYOR (BC-07)

Untuk Belt Conveyor kapasitas < 32 ton/jam,maka :

Power Belt Conveyor :

HP Belt Conveyor = HPhorizontal + HPvertical + HPempty

Faktor Keamanan 20%

Power Belt Conveyor = 2.71963637 / 1,34

BELT CONVEYOR (BC-08)

Untuk Belt Conveyor kapasitas < 32 ton/jam,maka :

Power Belt Conveyor :

HP Belt Conveyor = HPhorizontal + HPvertical + HPempty

Faktor Keamanan 20%

Power Belt Conveyor = 2.75183778 /1,34

BELT CONVEYOR (BC-09)

untuk mengangkut material campuran dari Storage menuju Hopper

Untuk Belt Conveyor kapasitas < 32 ton/jam,maka :

Power Belt Conveyor :

Faktor Keamanan 20%

Power Belt Conveyor = 19.4547631 / 1,34

BELT CONVEYOR (BC-10)

Untuk Belt Conveyor kapasitas < 32 ton/jam,maka :

Power Belt Conveyor :

HP Belt Conveyor = HPhorizontal + HPvertical + HPempty