Data Perhitungan

Kapasitas giling = TCD = Data tahun 2011

Sabut % tebu = % = Dalam proses pengumpulan data
Uap tekanan 18 kg/cm2 = Hasil perhitungan kebutuhan uap
Pressure = 18 kg/cm2
Temperatur = 340 'C
Enthalpy = 745 kcal/kg
Uap tekanan 17 kg/cm2
Pressure = 17 kg/cm2
Temperatur = 325 'C
Enthalpy = 738 kcal/kg
Uap bekas 0.5 kg/cm2
Pressure = 0,5 kg/cm2
Temperatur = 150 'C
Enthalpy = 664 kcal/kg
# KEBUTUHAN UAP BARU
POWER HOUSE
1. T/A Shinko
Power maksimal = kW
Power terpakai = kW ( 71 % )
2900
12,5
3500
2500 Power terpakai = kW ( 71 % )
Steam consumption = 12 kg/kWh
G = N x Steam Consmpt
= x 12
= kg/h
= ton/h
2. TA Kanis
(OFF)
Power maksimal = kW
Power terpakai = kW
N x
x
= kg/jam
= ton/jam
Jika TA Allen I dan II operasional, maka kebutuhan uap :
G = 2 x
=
STASIUN GILINGAN
1. Turbin CC II (EBARA)
Power = 298 kW
Power terpakai = 238 kW
Inlet steam = 17 kg/cm2
Steam chest = 12 kg/cm2
Power needed ( N' ) :
12 x
2500
0
0
0,00
2500
30000
30
2500
G =
860
kg/jam
h
=
0 860
81,00
0,00
0,00
N' =
238
= kW
Steam consumption = 14,0 kg/kWh
G = N x Steam Consmpt
= x 14,0
= kg/h
= ton/h
2 Turbin Unigrator (DRESER REND)
Power = 820 kW
Power terpakai = 660 kW
Inlet steam = 17 kg/cm2
Steam chest = 7 kg/cm2
Power needed ( N' ) :
7 x
= kW
Steam consumption = 25,0 kg/kWh
G = N x Steam Consmpt
= x 25,0
N' =
660
17
272
272
6794,1
N' =
17
168
168
2356,0
2,36
= x 25,0
= kg/h
= ton/h
3 Turbin Penggerak Gilingan I (DRESER REND)
Power = 328 kW
Power terpakai = 286 kW
Inlet steam = 17 kg/cm2
Steam chest = 7 kg/cm2
Power needed ( N' ) :
7 x
= kW
Steam consumption = 25,0 kg/kWh
G = N x Steam Consmpt
= x 25,0
= kg/h
= ton/h
4 Turbin Penggerak Gilingan II (DRESER REND)
Power = 328 kW
Power terpakai = 198 kW
Inlet steam = 17 kg/cm2
Steam chest = 7 kg/cm2
Power needed ( N' ) :
7 x
272
6794,1
6,79
N' =
286
17
118
118
2944,1
2,94
N' =
198
17
= kW
Steam consumption = 25,0 kg/kWh
G = N x Steam Consmpt
= x 25,0
= kg/h
= ton/h
Total kebutuhan uap stasiun gilingan :
G = ton/jam
STASIUN KETEL
1. TU penggerak FWP KU. Stork I
Daya turbin = 75 HP = 56,0 kW
Asumsi tenaga terpakai = 95 %
Tekanan uap masuk = 17 kg/cm2
Kebutuhan uap :
N x
1 x 56,0 x 860
82
82
2038,2
14,13
2,04
G =
860
kg/jam
h
=
73,66
620,57 = kg/jam
= ton/jam
2 TU penggerak FWP KU. Stork II
Daya turbin = 75 HP = 56,0 kW
Asumsi tenaga terpakai = 95 %
Tekanan uap masuk = 17 kg/cm2
Kebutuhan uap :
N x
1 x 56,0 x 860
= kg/jam
= ton/jam
3 Turbin penggerak IDF JTA
Power = 191 kW
Power terpakai = 191 kW
Inlet steam = 18 kg/cm2
Steam chest = 12 kg/cm2
Power needed ( N' ) :
12 x
= kW
Steam consumption = 14,0 kg/kWh
G = N x Steam Consmpt
= x 14,0
=
73,66
620,57
0,62
G =
860
kg/jam
h
=
73,66
620,57
0,62
N' =
191
18
127
127
= kg/h
= ton/h
4 Turbin penggerak FDF JTA
Power = 59 kW
Power terpakai = 59 kW
Inlet steam = 18 kg/cm2
Steam chest = 7 kg/cm2
Power needed ( N' ) :
7 x
= kW
Steam consumption = 25,0 kg/kWh
G = N x Steam Consmpt
= x 25,0
= kg/h
= ton/h
5 Turbin Penggerak FWP JTA
Power = 59 kW
Power terpakai = 59 kW
23
23
573,6
0,57
1782,7
1,78
N' =
59
18
Power terpakai = 59 kW
Inlet steam = 18 kg/cm2
Steam chest = 7 kg/cm2
Power needed ( N' ) :
7 x
= kW
Steam consumption = 25,0 kg/kWh
G = N x Steam Consmpt
= x 25,0
= kg/h
= ton/h
6 Uap Pemanas Deaerator
Kondisi uap pemanas :
Tekanan uap = kg/cm2
Temperatur uap = 'C
Enthalpy = kJ/kg
Air pengisi ketel :
m ( JTA ) = 40 + 0.1 x 40 ton/jam = 12 kg/dtk
m ( Stork I ) = 20 + 0.1 x 20 ton/jam = 6,1 kg/dtk
m ( Stork II ) = 20 + 0.2 x 20 ton/jam = 6,1 kg/dtk
T in = 'C
T out = 'C
Cp = kJ/kg'C
Kebutuhan uap pemanas deaerator :
Q (CC) = m x Cp x T
= 12 x x ( 100 - 60 )
N' =
59
18
23
23
573,6
0,57
17
325
738
60
100
1,007
1,007
= kJ/dtk
G (CC) = Q / h
x 3600
x 1000
= ton/jam
Q (St I) = m x Cp x T
= 6 x x ( 100 - 60 )
= kJ/dtk
G (St I) = Q / h
x 3600
x 1000
= ton/jam
Q (St II) = m x Cp x T
= 6 x x ( 100 - 60 )
= kJ/dtk
G (St II) = Q / h
x 3600
x 1000
= ton/jam
=
492,31
738
1,007
246,16
=
246,16
738
2,40
1,20
1,20
492,31
1,007
246,16
=
246,16
738
Total kebutuhan uap ST. Ketel
G = ton/jam
MESIN UAP DI STASIUN TENGAH DAN PUTERAN
Tenaga yang diperlukan ( T ), Hugot 1972, p.825 :
T = x V x n (HP)
V = volume silinder dalam ft
3
= S x L = D
2
L = panjang langkah dalam ft
n = Rpm mesin uap
Kebutuhan uap :
632 x T
h x Eff.th x 1000
Eff.th = 0,6 (slide valve engine,Tromp)
Data perhitungan
Uap baru tekanan rendah:
Pressure = 7 kg/cm2
Temperatur = 180 'C
Enthalpy = 668 kcal/kg
Uap bekas :
Pressure = 0,5 kg/cm2
Temperatur = 115 'C
Enthalpy = 647 kcal/kg
MU pompa vakum BP
8,98
0,0736
0.785 x
G = ton/jam
Mesin Uap L D n V T G
2,62 1,64 60 11,06 48,86 2,45
MU pompa vakum KP
UAP BARU UNTUK SERVICE STEAM (TEK. 3 kg/cm
2
)
1. Puteran SHS
Pemakaian uap = 20% x produksi SHS (Hugot 1972, p.745)
Produksi SHS = 250 ton/hari = 10 ton/jam
Kebutuhan uap =
2,1
ton/jam
Total kebutuhan uap untuk service steam :
G =
2,1
ton/jam
# KEBUTUHAN UAP BEKAS
Dasar Perhitungan :
Kapasitas = 2900 TCD
Nira Mentah % Tebu = 100 %
Brix Nira Mentah = 12,5 %
Nira Encer % Tebu = 105 %
Brix Nira Encer = 11,5 %
Brix Nira Kental = 64 %
Panas laten ( r ) Ube 0.5 kg/cm2 = 531 kcal/kg
Total
4,90
2,62 1,64 60 11,06 48,86 2,45
Panas laten ( r ) Ube 0.5 kg/cm2 = 531 kcal/kg
Panas laten ( r ) Uni 0.25 kg/cm2 = 535 kcal/kg
1. Pemanas Pendahuluan ( Juice Heater )
J = berat NM%T
= ton/jam
C = panas jenis NM
= ( 1 - 0.006 bnm )
= kcal/kg'C
p = faktor kehilangan panas pada heater
= ( Hugot p.449 )
Pemanas Pendahuluan I :
x x ( 75 - 30 )
531 x 0,95
= ton/jam Ube
Pemanas Pendahuluan II :
x x ( 105 - 75 )
531 x 0,95
= ton/jam Ube
Total kebutuhan Uap untuk Pemanas Pendahuluan :
G = ton/jam
2. Badan Penguapan ( Evaporator )
Data Luas Pemanas ( LP ) : Jadwal sekrap BP :
= 1000 m
2
4 - 5 - (3+1B) - 2
G =
J x C x ( t2 - t1 )
r x p
120,83
0,9993
0,95
G =
120,83 0,9993
10,771
G =
120,83 0,9993
7,1807
17,952
BP 1
= 1000 m
2
4 - 5 - (3+1B) - 1A
= 750 m
2
= 750 m
2
= 525 m
2
= 525 m
2
LP terbesar = m
2
LP terkecil = m
2
bne
bnk
E = jumlah air yang diuapkan ( ton/jam )
J = berat NE%T
= ton/jam
11,5
64
= ton/jam
Jika BP 1 + 2 sebagai badan pertama :
= ton/jam
Skema BP operasional?
Jika BP 1B+2 sebagai badan pertama :
BP 2
BP 3
BP 4
BP 5A
BP 5B
4025
3550
E = J x ( 1 - )
127
E = 127 x ( 1 - )
104,08
G =
2000
x 104,08
4025
51,7154
G =
1750
x 104,08
Skema BP operasional?
Jika BP 1B+2 sebagai badan pertama :
= ton/jam
3. Pan Masakan
Dari perhitungan material balance didapatkan data sbb :
% Brix Strop
/Klare
Masakan A
Masakan C
Masakan D
Kebutuhan uap pemanas Masakan A :
= ton/jam
Kebutuhan uap pemanas Masakan C :
= ton/jam
Kebutuhan uap pemanas Masakan D :
G =
1750
x 104,08
3550
51,3056
Masakan % Tebu % Brix Faktor cuci
20,17 93 81 1,27
98 80,0 1,38
G = KG x Mas.A%T x (
%BrixMas.A
- %BrixMas.A
G = KG x Mas.C%T x (
%BrixMas.C
)
%BrixNK
= 120,83 x 0,2017 x (
0,93
- 0,93 )
0,64
= 120,83 x 0,0501 x (
0,95
- 0,95
0,81
1,7807
G = KG x Mas.D%T x (
%BrixMas.D
%BrixMas.D -
1,32
faktor cuci
1,27
faktor cuci
- %BrixMas.C ) x
%BrixStropA
) x
16,192
x
x
5,01 95 86,5 1,32
9,55
= ton/jam
Total kebutuhan uap pemanas Pan Masakan :
G = ton/jam
NERACA UAP BARU
Produksi Uap Baru ton/jam Pemakaian Uap Baru ton/jam
KU JTA 35 ST. Listrik
KU Stork I 16 ST. Gilingan
KU Stork II 16 ST. Ketel
ST. Tengah dan Puteran
Service steam
Losses 5%
Surplus/(minus)
Total Produksi Total Pemakaian
G = KG x Mas.D%T x (
(%BrixStropC+%BrixKlareD)/2
= 120,83 x 0,0955 x (
0,98
- 0,98
0,8325
%BrixMas.D
14,13
8,98
4,90
2,1
3,00
4,05
-
3,14
21,113
67,15 67,15
30,00
Perbandingan jumlah uap sebelum dan sesudah desuperheater :
h1 ( 0.5 ; 150 ) = 664 kcal/kg
h2 ( 0.5 ; 120 ) = 650 kcal/kg
r sprayer = 538 kcal/kg
G1 x ( h1 - h2 )
r
G1 x ( 664 - 650 )
538
G2 = G1 x ( 1 + )
G1 : G2 = 1 :
NERACA UAP BEKAS
Produksi Uap Bekas ton/jam Pemakaian Uap Bekas ton/jam
ST. Listrik Pemanas Pendahuluan Bleeding untuk JH dan VP belum diperhitungkan
ST. Gilingan Badan Penguapan
ST. Ketel Pan Masakan
ST. Tengah dan Puteran Losses 5%
Surplus/(minus)
Total Produksi Total Pemakaian
G2 = G1 +
G2 = G1 +
-35,8
59,52 59,52
0,026
1,026
30,78 17,95
14,50 51,72
9,21 21,11
5,03 4,54
Dalam proses pengumpulan data
Hasil perhitungan kebutuhan uap
N x
=
2500
G =
860
h
x
= kg/jam
= ton/jam
=
2500
81,00
26543
26,54
G =
h
Kebutuhan uap turbin :
G = N' x 860
h h
= 0 x 860
###
faktor cuci %BrixMas.D ) x
1,32
faktor cuci
1,27
faktor cuci
faktor cuci
0,98 ) x 1,38
%BrixMas.D ) x
Bleeding untuk JH dan VP belum diperhitungkan
860
860
kg/jam
h
kg/jam
ton/jam
860
81,00
kg/jam
h
kg/jam