A.

DATA PENGAMATAN DAN PENGOLAHAN DATA

1 Kiln Feed dan Produk Klinker

Kiln Feed

Data IDF untuk O2 excess

String A (ke kiln)
% O2 excess

Tabel A.1 Komposisi Kiln Feed

Komponen Komposisi (% massa)
CaMg(CO3)2 0.0551690454
Mg(OH)2 87.39
Ca(OH)2 7.80
H2O (l) 2
H2O (v) 2.7540924061
100

CaMg(CO3)2 5.2572452754
MgO 5743.2197289321
CaO 562.5573956204
H2O 3218.3044722841

Total 9529.3388421119

Tabel A.2 Komposisi Klinker

Komponen Komposisi (% massa)
CaMg(CO3)2 0.0551690454
MgO 60.2688163795
CaO 5.9034252527
H2 33.7725893224
100

Bahan Bakar Batubara (Coal)

Heat of Consumption
NHV Fine Coal
 Total Heat of Consumption
Jumlah batubara yang digunakan

Jumlah batubara yang masuk ke kiln

Komponen Komposisi (%)

C 51.4
H2 3.5
O2 11.1
N2 0.5
S 0.5
H2O 27
Ash 6

Harga kapasitas panas untuk beberapa material dan gas dengan temperatur yang tidak diteta
Tabel A.4 ketetapan variabel A, B dan C pada material dan gas
Material A
CO2 0.196
H2 O 0.443
N2 0.244
O2 0.218
Udara 0.237
Kiln feed 0.206
Klinker 0.186
batubara 0.262
= 9,529 kg/jam
= 9,529.33884 kg/jam

= 2.0 %

5.2572452754 0.0551690454
8,327.67 87.39
743.3794156413 7.8009547982
190.5867768422 2
262.4467974016 2.7540924061
9529.3388421119

0.0551690454
60.2688163795
5.9034252527
33.7725893224
0

Faktor Klinker = 1.79 Kiln feed/produk klinker

Produk Klinker = 6,311.03437 kg/jam

=
=
 =
= Heat of Consumption x Produk klinker

an temperatur yang tidak ditetapkan . C p = A + B x 10-6T + C x 10-9T (kkal/kg0C)

(F.L. Smidth)
B C
118 -43
39 28
22 0
30 0
23 0
101 -37
54 0
390 0
produk klinker

849.3 kkal/kg
1,463 kkal/kg
 5,359,779.4 kkal/jam
onsumption x Produk klinker
NHV Fine Coal
3,664.81 kg/jam

3,664.81 kg/jam
C. Menghitung Neraca Panas pada Kiln

Harga kapasitas panas untuk beberapa material dan gas dengan temperatur yang tidak ditetapkan . Cp*T = A + B x 1
Tabel A.1 ketetapan variabel A, B dan pada material dan gas
Material
CO2
H2 O
N2
O2
Udara
Kiln feed
Klinker
batubara

INPUT
1. Panas Pembakaran Batubara (Qa)
Massa Coal
NHV coal
Qa

2. Panas Sensibel Batubara (Qb)

Massa Coal
T
Tref
Cpbatubara t
Cpbatubara *T

3. Panas Sensibel Udara Primer (Qc)

Massa
Tin
Tref
Cpudara *T
4. Panas Sensibel Udara Sekunder (Qd)
Massa
Tin
Tref
Cpudara *T

5. Panas Sensibel dari Kiln Feed (Qe)

Massa
Tin
Tref
Cp*T

Total Panas Input

Qtotal1

OUTPUT
1. Panas dari Klinker yang Dihasilkan
Massa
Tin
Tref
Cp

2. Panas dari Gas Buang

a. CO2
Massa
Tin
Tref
Cp

b. SO2
Massa
Tin
Tref
Cp
Qh

c. O2
Massa
Tin
Tref
Cp

d. H2O
Massa
Tin
Tref
Cp

e. N2
Massa
Tin
Tref
Cp

Total gas panas yang ke luar Rotary Kiln

Qtotal2

3. Panas Vaporasi air pada bahan bakar

Masa

Ql

4. Panas yang ke luar dari permukaa kiln ke luar sistem

T lingkungan (T0)
D kiln (Da)
R kiln (Ra)
P kiln (Pa)
R baja (Rb)
Tebal baja (tb)
D baja (Db)
R batu tahan api (Rc)
Tebal batu tahan api (tc)
D batu tahan api (Dc)

a. Panas Konveksi (Q1)

Q
dimana :
hi
hi
A
A
Ts

Panjang (m)
 3
3
3
3
3
3
3
3.384

TOTAL PANAS KONV

b. Panas Konduksi (Q2)

Q

dimana :
Td

Ts
Rb
Pb
Ab
Rc
Pc
Ac
A
Maka
Ab
Ac

Pb, Pc
3
3
3
3
3
 3
3
3.384

C. Panas Radiasi (Q3)

Q
dimana :
A
A

Ts
To
Produksi klinker

Panjang (m)
3
3
3
3
3
3
3
3.348

Total Panas yang Hilang dari Permukaan Kiln ke Lingkungan

Qtotal3

5.Panas Pembentukan Klinker

percentage CaMg(CO3)2
percentage MgO
percentage CaO
percentage SiO2
percentage Fe2O3
Qm/Kg

Qm

TOTAL PANAS OUTPUT

Qtotal4

Efisiensi Panas

% Heat Loss

input
Panas pembakaran batubara
Panas yang sensibel batubara
Panas sensibel umpan rotary kiln
Panas sensibel udara primer
Panas sensibel udara sekunder
Total

output
Panas klinker ke luar rotary kiln
Panas gas buang
Panas evaporasi air
Heatloss pada dinding rotary kiln
Panas pembentukan klinker
Total
n temperatur yang tidak ditetapkan . Cp*T = A + B x 10-6T^2 + C x 10-9T^3 (kkal/kgoC)

A B
0.196 118
0.443 39
0.244 22
0.218 30
0.237 23
0.206 101
0.186 54
0.262 390

= 3,664.81
= 1462.5
= m x NHV
= 5,359,779.45

= 3,664.81
= 800
= 25
= Cp*T = A + B x 10-6T^2 + C x 10-9T^3 (kkal/kgoC)
= 234.24385218

= 858,553.78

= 15,706.92
= 32
= 25
= Cp*T = A + B x 10-6T^2 + C x 10-9T^3 (kkal/kgoC)
= 0.238127
= 3,740.24

= 12,971.90
= 32
= 25
= Cp*T = A + B x 10-6T^2 + C x 10-9T^3 (kkal/kgoC)
= 0.238127

= 3,088.96

= 9,529.34
= 100
= 25
= Cp*T = A + B x 10-6T^2 + C x 10-9T^3 (kkal/kgoC)
= 0.1987

= 211,183.76

= Qa + Qb + Qc + Qd + Qe
= 6,436,346.19

= 9,529.34
= 450
= 25
= Cp*T = A + B x 10-6T^2 + C x 10-9T^3 (kkal/kgoC)
= 9.93975

= 1,341,091.45

= 6,906.94
= 450
= 25
= Cp*T = A + B x 10-6T^2 + C x 10-9T^3 (kkal/kgoC)
= 18.208828125

= 125,767.26

= 36.65
= 450
= 25
= 0.185
= m x cp x T
= 2881.4540779692

= 577.88
= 450
= 25
= Cp*T = A + B x 10-6T^2 + C x 10-9T^3 (kkal/kgoC)
= 0.218

= 125.98

= 1,154.41
= 450
= 25
= Cp*T = A + B x 10-6T^2 + C x 10-9T^3 (kkal/kgoC)
= 9.6368125

= 11,124.87

= 9,894.43
= 450
= 25
= Cp*T = A + B x 10-6T^2 + C x 10-9T^3 (kkal/kgoC)
= 4.21775

= 41,732.23

= Qg + Qh+ Qi+ Qj + Qk
= 181631.786752792

= 10% x fine coal ke kiln

= 366.48
= 685.3
= mx
= 251,149.19

= 30
= 2.4384
= 1.2192
= 24.384
= 1.21285
= 0.00635
= 2.4257
= 1.11285
= 0.1
= 2.2257

= hi x A x (Ts - T0)

= Koefisien perpindahan panas konveksi (kkal/m2 0C)

= (1 x 10-4) ((Ts-T0)/Da))0,25
= Luas permukaan perpindahan panas (m2)
= 2xxRxp
= Suhu permukaan kiln (0C)

Luas (m2)
 22.969728
22.969728
22.969728
22.969728
22.969728
22.969728
22.969728
25.909853184

TOTAL PANAS KONVEKSI

= Td - Ts
(Rb/(Pb x Ab)) + (Rc/(Pc x Ac))

= Suhu dalam kiln (oC)

Calsining Zone
Transition Zone
Sintering Zone
Cooling Zone
= Suhu permukaan kiln (oC)
= Jari-jari baja (m)
= Panjang baja (m)
= Lua s Permukaan baja (m2)
= Jari-jari batu tahan api (m)
= Panjang batu tahan api (m)
= Luas Permukaan batu tahan api (m2)
= 2xxRxp

= 22.850094
= 20.966094

Ab
22.850094
22.850094
22.850094
22.850094
22.850094
 22.850094
22.850094
25.774906032

TOTAL PANAS KONDUKSI

= A x x ((Ts-To)/produk klinker)

= Luas permukaan perpindahan panas (m2)

= 2xxRxp
= Koefisien perpindahan panas radiasi (kkal/m2 0C)
= Suhu permukaan kiln (0C)
= Suhu lingkungan (0C)
= 6,311.03

Luas (m2)
22.969728
22.969728
22.969728
22.969728
22.969728
22.969728
22.969728
25.634216448

= Qa + Qb + Qc
= 123,378.05
= 0.06
= 60.27
= 5.90
= 0.00
= 0.00
= 4,11 x Hal + 6,48 x HMg + 7,646 x Hca - 5,116 x Hsi - 0,59 x Hf
= 435.91
= 5,113,462.46

= Qf + Qtotal2 + Ql + Qtotal3 + Qm
= 7,010,712.93

= total panas output/total panas input x 100%

= 108.92

= total panas input - total panas output

total panas input
= (8.92)

5,359,779.45
858,553.78
211,183.76
3,740.24
3,088.96
6,436,346.2

1341091.44670524
181631.786752792
251,149.19
123,378.05
5,113,462.46
7010712.9
 (F.L. Smidth)
C
-43
28
0
0
0
-37
0
0

kg/jam
kj/kg

kj/jam

kg/jam
C
o

C
o

x 10-9T^3 (kkal/kgoC)

kj/jam

kg/jam
C
o

C
o

x 10-9T^3 (kkal/kgoC)
 kj/jam

kg/jam
C
o

C
o

x 10-9T^3 (kkal/kgoC)

kkal/jam

komponen massa
kg/jam dolomit 5.7829698029
C
o
mgoh 9,160.44
o
C caoh 817.7173572054
x 10-9T^3 (kkal/kgoC) air vap 209.6454545265
air liq 288.6914771417

kkal/jam

kkal/jam

komponen massa
kg/jam dolomit 5.7829698029
C
o
mgo 6317.5417018253
o
C cao 618.8131351825
x 10-9T^3 (kkal/kgoC) air 3540.1349195125

kkal/jam

kg/jam
 C
o

o
C
x 10-9T^3 (kkal/kgoC)

kkal/jam

kg/jam
C
o

C
o

kkal/kg0C (Kurt Perray, hal 140)

kkal/jam

kg/jam
C
o

o
C
x 10-9T^3 (kkal/kgoC)

kkal/jam

kg/jam
C
o

o
C
x 10-9T^3 (kkal/kgoC)

kkal/jam

kg/jam
 o
C
C
o

x 10-9T^3 (kkal/kgoC)

kkal/jam

kkal/jam

kg/jam
kkal/kg 685.3

kkal/jam

C
o

m
m
m
m
m
m
m
m
m

kkal

konveksi (kkal/m2 0C)

panas (m2)

Ts T (oC) hi (kkal/m2 oC)

 195 165 0.0002868103
187 157 0.0002832688
155 125 0.0002675785
205 175 0.0002910605
215 185 0.0002951323
210 180 0.0002931176
208 178 0.0002923
225 195 0.0002990422

16 m - 24.384 m = 450 oC
13 m - 15 m = 550 oC
4 m - 12 m = 700 oC
0 m - 3 m = 450 oC

m2
m2

Ac Td Ts T
20.966094 700 200 500
20.966094 800 187 613
20.966094 800 155 645
20.966094 800 220 580
20.966094 700 231 469
 20.966094 700 270 430
20.966094 700 208 492
20.966094 700 230 470

panas (m2)

radiasi (kkal/m2 0C) (Kurt Peray,149)

kg/jam

Ts T (oC) Q
195 165 357.48 214.67971031
187 157 354.24 202.41959832
155 125 326.16 148.38705602
205 175 378 240.76045513
215 185 457.2 307.84581732
210 180 594 389.14751114
208 178 363.6 235.55871903
225 195 460.8 364.97791300

TOTAL PANAS RADIASI = 2,103.77678027

kkal/jam
,646 x Hca - 5,116 x Hsi - 0,59 x Hfe = Kcal/Kg
Kcal/Kg
Kcal/jam

kkal/jam

nas input x 100%

%

x 100%

%
cp cpdt bm mol q
153.24 11493 184 0.03142918 361.215608
64.65 4848.75 58 157.938543 765804.508
70.21 5265.75 74 11.0502346 58187.7726
28.54 2140.5 18 11.6469697 24930.3386
28.54 2140.5 18 16.0384154 34330.2282
883614.063 kj/jam
211183.761 kkal/jam

cp cpdt bm mol q
153.24 65127 184 0.03142918 2046.88845
45.11 19171.75 40 157.938543 3027958.25
41.67 17709.75 56 11.0502346 195696.891
28.54 12129.5 18 196.674162 2385559.25
5611261.28 kj/jam
1341091.45 kkal/jam
Q (kkal)
1.0870125177
1.0215371862
0.7682757607
1.1699766003
1.2541349635
1.2119096578
1.1951010224
1.5108869806

9.2188346893 kkal/jam

Q
14,130.00
17,323.38
18,227.70
16,390.80
13,253.94
 12,151.80
13,903.92
15,883.51

121,265.05 kkal/jam

kkal/jam
A. Menghitung Neraca Massa pada Kiln

1. KILN

Kiln Feed = 9529.3388421119 kg/jam

Komposisi Kiln Feed

Senyawa Komposisi (%) Massa (kg/jam)
CaMg(CO3)2 0.0551690454 5.2572452754
Mg(OH)2 87.39 8,327.67
Ca(OH)2 7.80 743.38
H2O (v) 2.7540924061 262.4467974016
H2O (l) 2 190.5867768422

Komposisi Klinker
Senyawa Komposisi (%) Massa (kg/jam)
CaMg(CO3)2 0.0551690454 5.2572452754
MgO 60.2688163795 5743.2197289321
CaO 5.9034252527 562.5573956204
H2 33.7725893224 3218.3044722841
O2 0 0

2. COAL

NHV =
Heat of Consumption =
Total Heat of Consumption =
Fine Coal =
Fine Coal Ke Kiln =

Komposisi Fine Coal

Komponen Komposisi (%)
C 51.4
H 3.5
O 11.1
N 0.5
S 0.5
H2O 27
Ash 6
KILN
 Komponen Komposisi (%) Massa (kg/jam)
C 51.4 1,883.71
H 3.5 128.27
O 11.1 406.79
N 0.5 18.32
S 0.5 18.32
H2O 27 989.50
Ash 6 219.89
3,664.81

3. REAKSI PEMBAKARAN DI KILN

a. C + O2 CO2
C =
O2 =
CO2 =
massa CO2 =

b. 2H + 1/2 O2 H2O
2H =
1/2 O2 =
H2 O =
massa H2O =

c. S + O2 SO2
S =
O2 =
SO2 =
massa SO2 =

Jumlah mol O2 teoritis untuk =

pembakaran

O
25.42 kmol
O2 dalam batubara =

N
1.31 kmol
N2 dalam batubara =
Udara teoritis
Jumlah mol udara teoritis =
=
N2 teoritis =

Data IDF untuk O2 excess

String A (ke kiln)
% O2 excess =

% udara excess =
=

% udara excess =

9.524 % =

Udara supply =
=

Udara excess =
=
=

O2 excess =
=
=

4. DEKOMPOSISI KILN FEED

Reaksi kalsinasi
a. Mg(OH)2

Mg(OH)2 pada kiln feed

massa Mg(OH)2
Mr Mg(OH)2
mol Mg(OH)2

Dari reaksi diatas,

mol MgO

Mr MgO
 Massa MgO

mol H2O

Mr H2O
massa H2O

b. Ca(OH)2

Ca(OH)2 pada kiln feed

massa Ca(OH)2
Mr Ca(OH)2
mol Ca(OH)2

Dari reaksi diatas,

mol CaO

Mr CaO
Massa CaO

mol H2O

Mr H2O
massa H2O

Total mol H2O

Total massa H2O

5. Menghitung udara primer

Udara primer fan to kiln
V1

P1 g

P1 absolut

T1

Rumus Gas Ideal =

n=
 n1

massa udara primer fan

Udara pendorong blower to kiln

V1

P1 g

P1 absolut

T1

Rumus Gas Ideal =

n=

n1

massa udara primer blower

Jadi, total udara primer

massa
mol

Udara sekunder

Gas combustion
Gas hasil pembakaran
(CO2)A
(H2O)A

(SO2)A

N2

N2 coal

O2 excess
Total Gas hasil pembakaran

Klinker

Input

Debu

kiln feed
bahan bakar(coal)
udara primer
udara sekunder
TOTAL

klinker
gas combustion(exhaust gas)
debu
TOTAL
6311.0343698279

1,463 kkal/kg
849
5,359,779.45
3,664.81 kg/jam
3,664.81
 Jumlah Mol (kmol/jam)
156.98
128.27
25.42
1.31
0.57
54.97

156.98 kmol/jam
156.98 kmol/jam
156.98 kmol/jam
6,906.94 kg/jam

128.27 kmol/jam
32.07 kmol/jam
64.13 kmol/jam
1,154.41 kg/jam

0.57 kmol/jam
0.57 kmol/jam
0.57 kmol/jam
36.65 kg/jam

mol O2 pada pembakaran C + mol

O2 pada pembakaran H + mol O2
pada pembakaran S
189.62

1/2 O2
12.71 kmol/jam
12.71 kmol/jam

1/2 N2
0.65 kmol/jam
0.65 kmol/jam
jumlah mol O2 teoritis : 21%
902.93
jumlah mol udara teoritis - jumlah mol
O2 teoritis
713.32

2.0 %

% O2 excess (String A) : 21%

9.52 %

(udara supply - udara teoritis) x 100%

udara teoritis
(udara supply - 902,93) x 100%
902.93

988.92
28,678.82

mol udara supply - mol udara teoritis

85.99
2,493.81

21.00 % x mol udara excess

18.06
577.88

MgO + H2O

= 87.39
= 8,327.67
= 58
= 143.58

= mol Mg(OH)2
= 143.58
= 40
= 5,743.22

= mol MgO
= 143.58
= 18
= 2,584.45

CaO + H2O

5.90
= 743.38
= 74
= 10.05

= mol Ca(OH)2
= 10.05
56
562.56

= mol CaO
= 10.05
= 18
= 180.82

= 153.63
= 2,765.27

= 9,540
= 9,540,000
= 195
= 0.1988415
= 1.1988415
10,183.02
= 32
= 305

PxV=nxRx T

P x V/ R x T
= 456,877.12
= 456.88
= 13,249.44

= 1,392
= 1,392,000
= 700
= 0.71379
= 1.71379
1,873.53
= 70
= 343

PxV=nxRx T

P x V/ R x T

= 84,740.66
= 84.74
= 2,457.48

= udara primer fan + udara primer blower

= 15,706.92
= 541.62

= udara supply - udara primer

= 447.31
= 12,971.90

= CO2 reaksi + CO2 kalsinasi

= 6,906.94
= H2O reaksi
= 1,154.41

= SO2 reaksi
= 36.65

= 353.37
= 9,894.43

= 0.65
= 18.32

= 577.88
= 18,588.63

= KF yang masuk kiln - H2O yang

terkalsinasi di kiln
=
= Kiln feed yg masuk kiln + Bahan bakar +
Udara supply pembakaran
=
= Input - (Klinker + Gas combustion)
=

INPUT
9,529.34
3,664.81
15,706.92
12,971.90
41,872.96

OUTPUT
6,311.03
18,588.63
16,973.30
41,872.96
 100.00

ASH FINE COAL

KOMPONEN PERCENTAGE MASS (Kg)
SiO2 32.44 71.3317929076
Al2O3 10.31 22.6704927521
Fe2O3 3.27 7.1903502715
CaO 26.93 59.2159427559
MgO 0.77 1.6931405838
SO3 - -
kmol/jam

kmol/jam

kmol/jam
kg/jam

kmol/jam
kg/jam

kmol/jam
kg/jam

%
kg/jam
kg/kmol
kmol/jam
kmol/jam
kg/kmol
kg/jam

%
kg/jam
kg/kmol
kmol/jam

kmol/jam
kg/kmol
kg/jam

kmol/jam
kg/jam

m3
liter
mBar
atm
atm
Nm3/h
C
o

K
mol/jam
kmol/jam
kg/jam

m3/jam
liter/jam
mBar
atm
atm
Nm3/h
C
o

KOMPONEN

SiO2
Al2O3
mol/jam Fe2O3
kmol/jam CaO
kg/jam MgO
K2O
SO3
kg/jam
kmol/jam

kmol/jam
kg/jam

KOMPONEN

SiO2
Al2O3
Fe2O3
CaO
MgO
K2O
SO3
TOTAL =

kg/jam
kg/jam

kg/jam

kmol/jam
kg/jam

kmol/jam
kg/jam

kg/jam
kg/jam

6,311.03 kg/jam

41,872.96 kg/jam

16,973.30 kg/jam

kg/jam
kg/jam
kg/jam
kg/jam
kg/jam

kg/jam
kg/jam
kg/jam
kg/jam
57.01 98.25
5.61
12.9
0.75
0.37
7.01
14.6
Kmol
1.19
0.23
0.05
1.06
0.04
-
 PERCENTAGE

21.47
5.32
2.89
66.63
1.41
0.51
1.01

KLINKER = 6311.0343698279 Kg/Jam

INPUT ALIRAN 4 INPUT ALIRAN 5 KLINKER

KF clinker ASH FINE COAL
135426.576127296 71.3317929076 135497.907920204
33552.0323547321 22.6704927521 33574.7028474842
18231.698978531 7.1903502715 18238.8893288025
420445.004118874 59.2159427559 420504.22006163
8896.8653208735 1.6931405838 8898.5584614573
3218.6275286122 3218.6275286122
6374.1447135261 6374.1447135261
626144.949142445
kiln

Komponen input aliran 1 input aliran 2 output aliran 3

fine coal ke kiln (kg) air combustion (kg) GHP (kg)
C 3860
H 517.44
O 1030.26
N 138.6
S 55.44
H2O (moisture) 693
O2 2575.65
N2 9689.35
CO2 6,906.94
SO2 36.65
H2O (Evaporated) 1,154.41

O2 teoritis = jumlah O2 reaction 1+2+3 = 2575.65

udara teoritis = 100/21 x O2 Teoritis

= 12265

N2 teoritis = 79/21 x O2 teoritis

= 9689.35
KALSINER

Komponen input aliran 1 input aliran 2

fine coal ke kiln (kg) air combustion (kg)
C 1.19
H 0.23
O 0.05
N 1.06
S 0.04
H2O (moisture) -
O2 0.11826234
N2 0.44489166
CO2
SO2
H2O (Evaporated)

O2 teoritis = jumlah O2 reaction 1+2+3 =

udara teoritis = 100/21 x O2 Teoritis

= 0.563154

N2 teoritis = 79/21 x O2 teoritis

= 0.44489166
output aliran 3
GHP (kg)

-
-
-

0.11826234