LAMPIRAN B PERHITUNGAN NERACA MASSA

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 24.626,53 kg

=

3.295.03 kg

Ash Raw Coal = %Ash x Raw Coal

= 6,18 %

x 24.626,53 kg

= 1521,92

kg

(Sumber : Maniso Budiawan,2001)

2. Clinker dari Kiln Feed

KF Klinker = Clinker Out - Ash Coal

……………………(2)

= 160.932,96 kg

- 3.295,03 kg

= 157.637,93 kg


Komponen KomposisiClinker

Berat(kg)

Komposisi Ash

Berat(kg)

BeratKF

Klinker(kg)

A B C D E F

SiO221,35 33.655,

7042,48 1.399

,7332.255,97

Al2O35,43 8.559,7

427,03 890,6

57.669,09

Fe2O33,33 5.406,9

84,56 150,2

55.256,73

CaO65,95 103.962

,226,56 216,1

5103.746,06

MgO1,52 2380,33 0,72 23,72 2.356,6

1C = B/100 x KF Klinker

E = D/100 x Ash Klinker

F = C - E

3. Kiln Feed Tersaring

KF Tersaring = KF Klinker/[1-(%LOI/100)] ………(3)

= 240.009,03 kg

String A = 96.003,61 kg (40%)

String B = 144.005,42 kg (60%)

(sumber : Prihadi Setyo, 2001)

4. Total Dust

Total Dust = (KF - KF Tersaring)(1-H2O%)

= (288.070 – 240.009,03) x

( 1- 0.0071)

= 47.719,74 kg

5. Dust ke Coal Mill

Dust ke Coal Mill = Ash Fine Coal - Ash Raw Coal

………………..(4)

Dust = ( % Ash x Fine Coal) - ( % Ash

x Raw Coal )

= (13,38 % x 24.626,53 kg )

- ( 6,18 % x 23833,17 - Dust)

= 3.295.03 – 1.521.92 + 0.06 Dust

0,94 Dust = 1.773,11 kg

Dust = 1.889,91 kg


6. Dust ke Raw Mill

Dust ke Raw Mill = Total Dust - Dust ke Coal

Mill

= 47.719,74 -

1.889,91 kg

= 45.829,83 kg

7. Komposisi Dust Total

Kiln Feed = 288.070,00 kg

KF Klinker = 157.637,93 kg

Komponen %KilnFeed

Berat(kg) Berat KF

Klinker

Komposisi Dusttotal

A B C D F

SiO2 12,91 37.189,84

32.255,97

6.160,62

Al2O3 3,14 9.045,40 7.669,09 1.498,40Fe2O3 2,31 6.654,42 5256,73 1.102,33

CaO 42,88 123.524,42

103.746,06

20.462,22

MgO 0,57 1.642,00 2.356,61 272C = B/100 x Kiln Feed

F = B/100 x Dust Total

8. Komposisi Dust ke Coal Mill

Ash Fine Coal 3.295,03 kg

Ash Raw Coal 1.521,92 kg

Komponen %FineCoal

Berat(kg)

%RawCoal

Berat(kg)

KomposisiDust Ke

CMA B C D E F

SiO2 42,48 1.399,73

45,84 697,65 702,08

Al2O3 27,03 890,65 29,04 441,97 448,68Fe2O3 4,56 150,25 6,31 96,03 54,22CaO 6,56 216,15 5,13 78,07 138,08MgO 0,72 23,72 0,95 14,46 9,27C = 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

MillA B C D

SiO2 6.160,62 702,08 5.458,54Al2O3 1.498,40 448,68 1.049,72Fe2O3 1.102,33 138,08 1.048,11CaO 20.462,22 9,27 20.324,14MgO 272,00 15,85 262,74Total 29.495,57 1.352,33 28.143,24

10. Menghitung Gas Hasil Pembakaran fine Coal

a. Kiln Line

Fine Coal = 24.626,53 kg/jam

Kiln Line = 9.850,61 kg/jam (40%)

Komponen Komposisi(%)

Kiln Line(kg) BM

Jumlahmol

(kmol)A B C D EC 58,64 5.776,40 12,00 481,37H 4,25 418,65 1,00 418,65O 27,62 2.720,74 16,00 170,05N 0,79 77,82 14,00 5,56S 3,82 376,29 32,00 11,76H2O 10,06 990,97 18,00 55,05Ash 13,50 1.329.83

C = B X Kiln Line

E = C / D

Reaksi Pembakaran

C (s)+ O2 (g) CO2(g) O2(g) dibutuhkan

481,37 kmol

CO2 dihasilkan

481,37 kmol

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

11,76 kmol

SO2

dihasilkan 11,76 kmol

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

dibutuhkan 104,66 kmol

H2O dihasilkan

209,33 kmol

Total O2 pembakaran = 597,79 kmol

O dari coal = 170,05 kmol

O2 dari coal = 170,05/2 = 85,02

kmol

O2 Teoritis = O2 Pembakaran - O2

coal

= 512,77

kmol

Udara teoritis = 475.293/0.21 kmol

= 2.441,74 kmol =

70.419,78 kg

N2 suplay = 1.928,97 kmol

= 54.011,29 kg

Udara excess String A = 4.80 % (analyzer)

…………..(6)

Udara supply = 2.558,94 kmol

Udara excess = 2.558,94 – 2.441,74 kmol

= 117,20 kmol

Dimana :

O2 = 117,20 x 0.21 = 24,61

kmol

N2 = 117,20 x 0,79 = 92,59

kmol

(Sumber : Himmelblau, 1996)

Gas Hasil Pembakaran Coal

CO2 = CO2 yang dihasilkan

= 481,37 kmol

= 21.180,13 kg

SO2 = SO2 yang dihasilkan

= 11,76 kmol

= 752,59 kg

H2O = H2O Coal + H2O yang dihasilkan

= 55,05 kmol + 209,33

kmol

= 264,38 kmol = 4.758,83

kg

O2 = O2 Excess

= 24,61 kmol =

787,61 kg

N2 = N2 Coal + N2 Udara

supplay

N Coal = 77,82 kg = 5,56

kmol

N2 Coal = 11,12 kmol = 311,28 kg

N2 = 54.322,57 kg

b. Calsiner Line 14.775,92 kg

Fine Coal = 24.626,63 kg/jam

Kalsiner Line = 14.775,92 kg/jam (60%)

Komponen Komposisi(%)

KilnLine(kg)

BMJumlahmol

(kmol)A B C D EC 58,64 8.664,60 12,00 722,05H 4,25 627,98 1,00 627,98O 27,62 4.081,11 16,00 255,07N 0,79 116,73 14,00 8,34S 3,82 564,44 32,00 17,64H2O 10,06 1.486,46 18,00 82,58Ash 13,50 1.994,75

C = B / Kalsiner Line

E = C / D

Reaksi Pembakaran

C (s)+ O2 (g) CO2(g) O2(g) dibutuhkan=

722,05 kmol

CO2 dihasilkan

= 722,05 kmol

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

dibutuhkan 17,64 kmol

SO2 dihasilkan

17,64 kmol

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

156,99 kmol

H2O dihasilkan

313,99 kmol

Total O2 pembakaran = 896,68 kmol

O dari coal = 255,07 kmol

O2 dari coal = 127,53 kmol

O2 Teoritis = O2 Pembakaran - O2 coal

= 769,15 kmol

Udara teoritis = 3.662,61 kmol

= 105.629,67

kg

N2 suplay = 3.662,61 kmol

= 81.016,93 kg

Udara excess String B = 7.10 % (analyzer)

…………..(6)

Udara supply = 3.922,66 kmol

Udara excess = 3.922,66 - 3.662,61 kmol

= 260,05 kmol

Dimana :

O2 = 260,05 x 0.21 =

55,31 kmol

N2 = 260,05 x 079 =

208,06 kmol

(Sumber : Himmelblau, 1996)

Gas Hasil Pembakaran Coal

CO2 = CO2 yang dihasilkan

= 722,05 kmol =

31.770,19 kg

SO2 = SO2 yang dihasilkan

= 17,64 kmol =

1.128,88 kg

H2O = H2O Coal + H2O yang dihasilkan

= 17,64 kmol +

313,99 kmol

= 331,63 kmol

= 5.969,29 kg

O2 = O2 Excess

= 54,61 kmol 1.747,50

kg

N2 = N2 Coal + N2 Udara

supplay

N Coal = 116,73 kg = 8,34 kmol

N2 Coal = 16,68 kmol = 466,92

kg

N2 = 81.483,85 kg

11. Total Gas Hasil Pembakaran Coal

Komponen

Kiln Line Kalsiner LineJumlahMol

(kmol)

Berat(kg)

Jumlah Mol(kmol)

Berat(kg)

CO2 481,37 21.180,13

722,05 31.770,19

SO2 11,76 752,59 17,64 1.128,8

8

H2O 264,38 4.758,83

331,63 5.969,29

O2 24,61 787,61 54,61 1.474,50

N2 1.940.09 54.322,57

2.910,14 81.483,85

12. Reaksi Kalsinasi (Kiln Feed Clinker)

Clinker Out = 160.932,96 kg/h

Kiln Line = 64.373,18 kg/h

Kalsiner Line = 96.559,78 kg/h

Komponen%

massa

Massa

(kg/jam)

Kiln

Line

(kg)

Kalsiner

Line (kg)

A B C D E

CaO 65,95 106.135,29

42.454,12

63.681,17

MgO 1,51 2.430,09 972,04 1.458,05C = B/100 X Clinker out

D = 0.4 C

E = 0.6 C

Komponen

Kiln Line (kg)

Kalsiner Line (kg) BM

Kiln Line (kmol)

Kalsiner Line (kmol)

A B C D E F

CaO42.454

,1263.681,

1756,00 758,11 1.137,16

MgO 972,041.458,0

540,00 24,30 36,45

E = B/D

F = C x D

Reaksi Kalsinasi

CaCO3(s) CaO(s) + CO2(g)

MgCO3(s) MgO(s) +

CO2(s)

CaO = 106.135,29 kg

String A = 42.454.12 kg = 758,11 kmol

String B = 63.681,17 kg = 1.137,16 kmol

MgO = 2.430,09 kg

String A = 972,04 kg = 24,30 kmol

String B = 1.458,05 kg = 36,45 kmol

Kiln line ( String A )

CaO = 758,11 kmol, CO2 yang dihasilkan =

758,11 kmol

MgO = 24,30 kmol, CO2 yang dihasilkan =

24,30 kmol

Total CO2 yang dihasilkan = 782,41

kmol

25% Calsinasi terjadi disiklon 1 sampai 3

CO2 yang dihasilkan = 195,60 kmol

60% Calsinasi terjadi di kalsiner


15% Calsinasi terjadi di kiln


CO2 yang keluar dari String A = 312,96

kmol

CO2 yang keluar dari String B = 469,45

kmol

Calsiner Line (String B)

CaO = 1.137,16 kmol, CO2 yang dihasilkan =

1.137,16 kmol

MgO = 36,45 kmol, CO2 yang dihasilkan =

36,45 kmol

Total CO2 yang dihasilkan = 1.173,62

kmol

85% Calsinasi terjadi di siklon 1 sampai 3


15% Calsinasi terjadi di kiln


CO2 yang keluar dari String A = 176,04

kmol

CO2 yang keluar dari String B = 997,57

kmol

Total CO2 hasil kalsinasi yang keluar dari

String A = 489,01 kmol

21.516,28 kg

Total CO2 hasil kalsinasi yang keluar dari

String B = 1.467,02 kmol = 64.548,83 kg

13. Vapour H2O dari Kiln Feed

String A = %H2O x Kiln Feed ke string A

………………(7)

= 0,52% x Kiln Feed ke string A

= 778,94 kg

String B = %H2O x Kiln Feed ke string B

………………(8)

= 0,48% x Kiln Feed ke string B

= 663,71 kg

(Sumber : Maniso Budiawan, 2001)

14. Exhaust Gas yang ke luar dari String B

O2 = O2 Hasil Pembakaran Coal

= 1.747,50 kg

N2 = N2 Hasil Pembakaran Coal

= 81.250,39 kg

CO2 = Co2 Hasil Pembakaran Coal + CO2 Hasil

Kalsinasi

= 96.319,02 kg

SO2 = SO2 Hasil Pembakaran Coal

= 1.128,88 kg

H2O = H2O Hasil Pembakaran Coal + Vapour H2O

= 6.633,00 kg

Total = 187.078,80 kg

15. Menghitung Udara Pendingin Grate Cooler

(12 Fan)

Fan Pabs(a

V(m3/jam)

Suhu(oK)

R(m3.atm/kmo

n =PV/RT

tm) l.K) (kmol)Fan

K21

1,0997

18.200,00

303,00 0,082057 804,969

Fan

K20

1,0740

33800,00

303,00 0,082057 1.460,059

Fan

K12

1,0355

40.000,00

303,00 0,082057 1.665,958

Fan

K13

1,0237

21.600,00

303,00 0,082057 889,329

Fan

K15

1,0188

53.500,00

303,00 0,082057 2.192,117

Fan

K16

1,0069

9.500,00

303,00 0,082057 384,729

Fan

K18

1,0118

9.700,00

303,00 0,082057 394,754

Fan

K17

1,0266

12.600,00

303,00 0,082057 520,276

Fan

K14

1,0197

31.000,00

303,00 0,082057 1.271,429

Fan

K11

1,0168

42.000,00

303,00 0,082057 1.717,580

Fan

K10

1,0553

33.500,00

303,00 0,082057 1.421,835

Fan

K22

1,0592

31000,00

303,00 0,082057 1.320,650

Total 14.043,686

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

Total Udara Masuk Grate Cooler =

14.043,69 kmol

16. Menghitung Udara Primer

a. Primary Air Fan

Kapasitas = 3000 m3/jam (Data Desain)

Tekanan = 1.06 atm

Suhu = 30.00 oC = 303 K

Bukaan = 94.00 %

Volume = 3000 m3 x 0,94 =

2820.00 m3

n = PV/RT = 119.66 kmol

b. Coal Conveying Air

Volume = 5.400,00 m3/jam (Data Desain)

Tekanan = 1.05 atm

Suhu = 303,00 K

n = PV/RT = 226,96 kmol

Total Udara Primer ke Kiln = Primary Air Fan +

Coal Conveying Fan

=

346,62 kmol

17. Menghitung Udara Sekunder

Secondary Air = Udara supply ke kiln - udara

Primer

= 2.212,32 kmol

18. Menghitung Udara Tersier

Tersier air = Udara Supply ke Calsiner -

Coal Conveying Air =

3.695,69 kmol

19. Menghitung Udara yang dibuang ke stack

Stack Fan

Volume = 131040.00 m3

Tekanan = 1.05 atm

Suhu = 219 oC = 492.00 K

n = PV/RT = 3.414.59 kmol

20. Gas Panas dari Grate Cooler yang dialirkan

ke Raw Mill

= Total Udara Cooler - Secondary Air - Tersier

Air - Udara ke Stack = 4.721,08 kmol

Dimana :

O2 = 991,43 kmol = 31.725,63

kg

N2 = 3.729,65 kmol = 104.430,20

kg

Total =

136.155,83 kg

21. Total Gas Panas yang masuk ke Raw Mill

= Exhaust Gas dari String B + Gas Panas dari

Cooler

= 323.234,63 kg

Gas Panas Masuk Raw Mill

O2 = O2 Exhaust Calsiner + O2 gas

Panas dari Grate Cooler

= 33.473,13 kg

N2 = N2 Exhaust Calsiner + N2 gas

Panas dari Grate Cooler

= 185.680,59 kg

CO2 = CO2 Exhaust Calsiner

= 96.319,02 kg

SO2 = SO2 Exhaust Calsiner

= 1.128,88 kg

H2O = H2O Exhaust Calsiner

= 6.633,00 kg

Total = 323.234,63 kg

B. INPUT RAW MILL

Batu Kapur = 319,34 ton/jam = 319.340,00

kg/jam

Tanah liat = 63,79 ton/jam =

63.790,00 kg/jam

Pasir Besi = 3,64 ton/jam =

3.640,00 kg/jam

Pasir Silika = 0,00 ton/jam = 0,00

kg/jam

Komposi

si

Batu

Kapur

Tanah

Liat

Pasir

Besi

Pasir

SilikaSiO2 6,47 58,90 19,75 -Al2O3 1,56 14,10 11,03 -Fe2O3 0,43 5,76 69,66 -CaO 49,17 4,96 1,46 -MgO 0,60 0,95 1,03 -H2O 6,56 30,50 13,50 -

Total FreshFeed

Massa(kg/jam

)Komposisi feed mill (%)

H2O SiO2 Al2O3

Fe2O3 CaO MgO

Lime stone (LS)

319.340,00

6,56

6,47 1,56 0,43 49,17

0,60

Clay (CL) 63.790,00

30,50

58,90

14,10

5,76 4,96

0.95

Iron Sand (IS)

3.640,00

13,50

19,75

11,03

69,66

1,49

1,03

Silica Sand(SS)

0,00 8,75

91,33

5,57 0,69 0,83

0,15

Total 386.770,00

1. Batu Kapur /Lime Stone (LS) =

319.340,00 kg

SiO2 = 6,47 % x 319.340,00 kg

= 20.661,30 kg

Al2O3 = 1,56 % x 319.340,00 kg

= 4.981,70 kg

Fe2O3 = 0,43 % x 319.340,00 kg

= 1.373,16 kg

CaO = 49,17 % x 319.340,00

kg = 157.019,48 kg

MgO = 0,60 % x 319.340,00 kg

= 1.916,04 kg

H2O = 6,50 % x 319.340,00 kg

= 20.948,70 kg

2. Tanah Liat /Clay (CL) = 63.790,00

kg

SiO2 = 58,90 % x 63.790,00 kg =

37,572,31 kg

Al2O3 = 14,10 % x 63.790,00 kg =

8.994,39 kg

Fe2O3 = 5,76 % x 63.790,00 kg =

3.674,30 kg

CaO = 4,96 % x 63.790,00 kg =

3.163,98 kg

MgO = 0,95 % x 63.790,00 kg =

606,01 kg

H2O = 30,50 % x 63.790,00 kg =

19.445,95 kg

3. Pasir Besi / Iron Sand (IS) = 3.640,00

kg

SiO2 = 19,75 % x 3.640,00 kg =

718,90 kg

Al2O3 = 11,03 % x 3.640,00 kg =

401,49 kg

Fe2O3 = 69,66 % x 3.640,00 kg =

2.535,62 kg

CaO = 1,49 % x 3.640,00 kg = 54,24 kg

MgO = 1,03 % x 3.640,00 kg = 37,49

kg

H2O = 13,50 % x 3.640,00 kg =

491,40 kg

Komposisi Feed Mill

FeedMill

SenyawaSiO2 Al2O3 Fe2O3 CaO MgO H2O

Lime stone (LS)

20.661,30

4.981,70

1.373,16

157.019,48

1.916,04

20.948,70

Clay (CL)

37.572,31

8.994,39

3.674,30

3.163,98 606,01

19.455,95

Iron Sand (IS) 718,90 401,49

2.535,62 54,24 37,49 491,40

Pasir silika 0,00 0,00 0,00 0,00 0,00 0,00

Total58.952,51

14.377,59

7.583,09

160.237,70

2.559,54

40.896,05

4. Dust = 28.143,24 kg

SiO2 = 5.458,54 kg

Al2O3 = 1.049,72 kg

Fe2O3 = 1.048,11 kg

CaO = 20.324,14 kg

MgO = 262,74 kg

5. Gas Panas = 323.234,63 kg

O2 = 33.473,13 kg

N2 = 185.680,59 kg

CO2 = 96.319,02 kg

SO2 = 1.128,88 kg

H2O = 6.633,00 kg

C. Menghitung H2O yang diuapkan

Feed Mill Berat Kering (kg)

Lime stone (LS) 206.900,39Clay (CL) 73.466,94Iron Sand (IS) 4.239,14Silica Sand (SS) 0,00Dust 284.606,47Total 569.212,95

Raw Meal Output (dry) = Dust + Batu kapur

(dry) + Tanah Liat (dry)

+Pasir Besi(dry) + Pasir

Silika (dry)

=

569.212,95 kg

H2O Raw Meal Input = 40.896,05

kg

Kandungan H2O pada Raw Meal Output

= 0.90 %

H2O Raw Meal = 5.169,44 kg

H2O yang diuapkan = H2O Raw Meal Input - H2O Raw

Meal Output

= 35.169,44

kg

= 87,36

%

D OUTPUT RAW MEAL

1 Raw Meal

Raw Meal Output = Raw Meal Output Dry + H2O Raw

Meal Output

= 574.382,39 kg

SiO2 = 64.411,05 kg

Al2O3 = 15.427,30 kg

Fe2O3 = 8.631,02 kg

CaO = 180.561,84 kg

MgO = 33.735,87 kg

H2O = 5.169,44 kg

2 Gas Panas

O2 = 33.473,13 kg

N2 = 185.680,59 kg

CO2 = 96.319,02 kg

SO2 = 1.128,88 kg

H2O = 42.359,61 kg

Total = 358.961,24 kg

INPUT OUTPUT>Raw Mix > Raw

MealSiO2 =

58.952,51

kg

SiO2 = 64.411,05

kg

Al2O3 = 14.377,59

kg

Al2O3 = 15.427,30

kg

Fe2O3 = 7.583,09 kg

Fe2O3 =

8.631,20 kg

CaO =

160.237,70

kg

CaO = 180.561,84

kg

MgO = 2.559,54 kg

MgO = 2.822,27 kg

H2O =

40.896,05

kg

H2O = 5.169,44 kg

Total 284.606,47

kg

Total 277.023,10

kg

> Gas Panas > Gas Panas

O2 33.473.13

kg

O2 33.473,13

kg

N2 185.680,59

kg

N2 185.680,59

kg

CO2 96.319,02

kg

CO2 96.319,02

kg

SO2 1.128,88 kg

SO2 1.128,88 kg

H2O 6.633,00 kg

H2O 42.359,61

kg

Total 323.234, k Total 358.961, kg

63 g 24

> Dust dariKiln SiO2 = 5.458,54 k

gAl2O3 = 1.049,72 k

gFe2O3 = 1.048,11 k

gCaO = 20.324,1

4kg

MgO = 262,74 kg

Total 28.143,24

kg

Total 635.984,34

kg

Total 635.984,34

kg

LAMPIRAN B PERHITUNGAN NERACA MASSA

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