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Suspension Preheater KP
Suspension Preheater KP
DATA 1
A. Perhitungan Neraca Massa
Komposisi umpan SP
Komponen
SiO2
Al2O3
Fe2O3
CaO
MgO
H2O
SO3
K2O
% Massa
13,53
3,68
2,41
43,44
0,51
0,64
0,40
0,41
Data BM komponen
CaCO3 = 100 kg/kmol; MgCO3 = 84 kg/kmol; CaO = 56 kg/kmol;
MgO = 40 kg/kmol
Dilakukan koreksi terhadap komposisi umpan karena CaO dan MgO yang
ada terikat dalam bentuk MgCO3 dan CaCO3
BM CaCO3
x %CaO
BM CaO
%CaCO3 =
kg
kmol
%CaCO3 =
x 43,44 =77,85
kg
56
kmol
100
%MgCO3=
BM Mg CO3
x %MgO
BM MgO
kg
kmol
%MgCO3=
x 0,51 =1,07
kg
40
kmol
84
Umpan Masuk SP
Massa umpan masuk
% massa
13,53
3,68
2,41
77,85
1,07
0,64
0,40
0,41
100,00
SP
: 269.130 kg/jam
Massa(kg/jam
)
Kompone
n
% massa
SiO2
13,53
36408,9119
Al2O3
3,68
9912,5153
Fe2O3
2,41
6482,2988
CaCO3
77,85
209517,1592
MgCO3
1,07
2892,7259
H2O
0,64
1728,6130
SO3
0,40
1080,3831
K2O
0,41
1107,3927
Total
100,00
269130
kg
kg
1.728,6130
jam
jam
= 267.401,3870 kg/jam
Debu keluar SP
kg
jam
= 21.392,111 kg/jam
kg
kg
=2.912,7129
jam
jam
Massa (kg/h)
2912,7129
793,0012
518,5839
16761,3727
231,4181
86,4307
88,5914
21392,1110
% massa
13,62
3,71
2,42
78,35
1,08
0,40
0,41
100,00
kg
kg
21.392,111
jam
jam
= 246.009,2760 kg/jam
Ratio umpan string A = 40 % umpan masuk kalsiner
Ratio umpan string B = 60 % umpan masuk kalsiner
Umpan kering masuk string A = 40% x 246.009,2760 kg/jam
= 98.403,7104 kg/jam
Umpan kering masuk string B = 60% x 246.009,2760 kg/jam
= 147.605,5656 kg/jam
Komposisi umpan masuk kalsiner
Komponen
SiO2
Al2O3
Fe2O3
CaCO3
% Massa
13,62
3,71
2,42
78,35
Massa(kg/h)
33496,1989
9119,5141
5963,7149
192755,786
MgCO3
K2O
SO3
1,08
0,41
0,40
Total
100,00
5
2661,3078
1018,8013
993,9525
246009,276
0
kg
jam
= 173.480,2078 kg/jam
BM CaO
CaO terbentuk =
x CaCO3 terkalsinasi
BM CaCO3
kg
kmol
kg
CaO terbentuk =
x 173.480,2078
kg
jam
100
kmol
56
= 97.148,9164 kg/jam
BM CO 2
CO2 terbentuk =
x CaCO3 terkalsinasi
BM CaCO3
kg
kmol
kg
CO2 terbentuk =
x 173.480,2078
kg
jam
100
kmol
44
= 76.331,2914 kg/jam
CaCO3 Sisa=CaCO3 umpan masuk CaCO3 terkalsinasi
CaCO3 Sisa=192.755,7865
kg
kg
173.480,2078
jam
jam
= 19.275,5786 kg/jam
Reaksi II : MgCO3
MgO + CO2
MgCO 3 terkalsinasi=90 x MgCO 3 umpan kalsiner
MgCo3 terkalsinasi=90 x 2.661,3078
kg
ja m
= 2.395,1770 kg/jam
MgO terbentuk=
BM MgO
x MgCO 3 terkalsinasi
BM MgCO 3
kg
kmol
kg
MgO terbentuk=
x 2.395,1770
kg
jam
84
kmol
40
= 1.140,5605 kg/jam
BM CO 2
CO2 terbentuk =
x MgCO 3 terkalsinasi
BM MgCO 3
kg
kmol
kg
CO2 terbentuk =
x 2.395,1770
kg
jam
84
kmol
44
= 1.254,6165 kg/jam
MgCO 3 Sisa=MgCO 3 umpan masuk MgCO 3 terkalsinasi
MgCO 3 Sisa=2.661,3078
kg
kg
2.395,1770
jam
jam
= 266,1308 kg/jam
Total CO 2 hasil kalsinasi=CO 2 terbentuk (Reaksi I + Reaksi II )
76.331,2914
kg
kg
+1.254,6165
jam
jam
= 77.585,9080 kg/jam
Massa
(kg/h)
33496,1989
9119,5141
5963,7149
19275,5786
266,1308
97148,9164
MgO
K2O
SO3
1140,5605
1018,8013
993,9525
168423,368
0
Total
Pembakaran Batubara
Umpan batubara masuk kalsiner : 9240 kg/jam
Komposisi batubara
Kompone
%
Massa(kg/ja
n
massa
m)
C
64,82
6106,0440
H
4,48
422,0160
O
14,14
1331,9880
N
0,84
79,1280
S
0,56
52,7520
H2O
9,17
863,8140
Ash
5,99
564,2580
Total
100 % Massa 9420
Komponen
Massa(kg/ja
m)
SiO2
37,72
212,8381
Al2O3
17,45
98,4630
Fe2O3
5,7
32,1627
CaO
29,04
163,8605
MgO
1,33
7,5046
SO3
8,76
49,4290
Total
100
564,2580
Komposisi Ash
Batubara
Konversi pembakaran
= 100 %
Data BM (kg/kmol)
C = 12; S = 32; H2 = 2; CO2 = 44; O2 = 32; SO2 = 64; H2O = 18
Reaksi Pembakaran
o Pembakaran C
C + O2
CO2
C bereaksi
= 6.106,044 kg/jam
BM CO 2
CO2 terbentuk =
x C b ereaksi
BM C
kg
kmol
kg
CO2 terbentuk =
x 6.106,044
kg
jam
12
kmol
44
= 22.388,828 kg/jam
O2 dibutuhkan = (BM O2/BM C) x C bereaksi
BM O2
O2 dibutuhkan=
x C bereaksi
BM C
kg
kmol
kg
O2 dibutuhkan=
x 6.106,044
kg
jam
12
kmol
32
= 16.282,784 kg/jam
o Pembakaran S
S + O2
SO2
S bereaksi
= 57,752 kg/jam
BM SO 2
S O2 terbentuk =
x S bereaksi
BM S
kg
kmol
kg
S O2 terbentuk =
x 57,752
kg
jam
32
kmol
64
= 105,504 kg/jam
BM O2
O2 dibutuhkan=
x S bereaksi
BM S
kg
kmol
kg
O2 dibutuhkan=
x 57,752
kg
jam
32
kmol
32
= 57,752 kg/jam
o Pembakaran H2
H2 + O2
H bereaksi
H2O
= 422,016 kg/jam
BM H 2 O
H 2 O terbentuk =
x H bereaksi
BM H 2
kg
kmol
kg
H 2 O terbentuk =
x 422,016
kg
jam
2
kmol
18
= 3.798,144 kg/jam
BM O2
O2 dibutuhkan=0,5 x
x H bereaksi
BM H 2
kg
kmol
kg
O2 dibutuhkan=0,5 x
x 422,016
kg
jam
2
kmol
32
= 3.376,128 kg/jam
Total O2 teoritis dibutuhkan untuk pembakaran batubara
= O2( pembakaran C+ pembakaran S+ pembakaran H)
O2 (Pembakaran C+ pembakaran S+ pembakaran H )
16.282,784
kg
kg
kg
+57,752
+3.376,128
jam
j am
jam
= 19.711,664 kg/jam
Kebutuhan O2 tambahan teoritis
= Total kebutuhan O2 teoritis O2 terdapat dalam batubara
= 19.711,664 kg/jam 1.331,9880 kg/jam
= 18.379,676 kg/jam
= 22.388,828 kg/jam
H2O
= 3.798,144 kg/jam
SO2
=105,504 kg/jam
O2 sisa
= O2 excess
Total massa gas buang string B
kg
kg
kg
kg
kg
77.585,9080
+22.388,828
+3.798,144
+105,504
+1.037,168
+7
jam
jam
jam
jam
jam
175.001,0845
kg
+4,762 O2 sisa
jam
O2 sisa
kg
175.001,0845
+ 4,762O2 sisa
jam
7962,550
kg
+0,2167 O2 sisa=O2 sisa
jam
kg
jam
kg
O2 sisa=
=10.165,0128
jam
(10,2167)
7962,550
100
kg
x 10.165,0128
4,55
jam
= 223.405,9075 kg/jam
Total O2 masuk kalsiner = kebutuhan O2 tambahan teoritis + O2 sisa
kg
kg
= 18.379,676 jam +10.165,0128 jam
N2 dalam gas buang
= 28.544,6888 kg/jam
= (79/21) x total O2 masuk kalsiner
79
kg
= 21 x 28.544,6888 jam
= 107.382,4009 kg/jam
= (100/21) x total O2 masuk kalsiner
100
kg
= 21 x 28.544,6888 jam
= 135.927,0897 kg/jam
Komponen
CO2
H2O
SO2
O2
N2
Total
Massa(kg/h)
25.899,5078
2.132,2910
81,4240
1.337,8296
58.455,4939
87.906,5462
% massa
29,46
2,43
0,09
1,52
66,50
100,00
Massa(kg/h) % Massa
25.841,8879
29,17
1.390,9884
1,57
58.467,4895
65,99
81,1375
0,09
2.816,4883
3,18
88.597,9915
100
Umpan Kiln
Umpan Kiln
Massa(kg/h)
% Massa
99.974,736
44,75
10.165,0128
4,55
107.461,5289
48,1
105,504
0,05
5699,1258
2,55
223.405,9075
100
kg
kg
=33.709,0370
jam
jam
Massa(kg/h) % Massa
33.709,0370
19,95
9.217,9771
5,45
5.995,8776
3,55
19.275,5786
11,41
266,1308
0,16
97.312,7769
57,59
1.148,0651
0,68
1.043,3815
0,62
1.018,8013
0,60
168.987,626
0
100,00
Komponen
Raw meal
coal
CO2
H2O
N2
O2
B
0,206
0,262
0,196
0,443
0,244
0,218
C
101
390
118
39
22
30
-37
0
-43
28
0
0
udara
0,237
Cp(j) = A + B x T C/T2
Komponen
CaCO3
CaO
MgCO3
MgO
23
(kcal/kmol Kelvin)
B
19,68
10
16,9
10,86
0,0119
0,00484
0
0,001197
Cp SO2
Suhu
950
331,62
369,72
C
-307600
-108000
0
-208700
(Peray K.E.,1979)
Cp(Kcal/kg0C)
0,185
0,169
0,172
Heat Input
Panas Sensibel Umpan SP (Q1)
Panas sensibel Umpan SP
= Panas sensibel (umpan kering + H2O umpan SP)
o Panas Sensibel Umpan Kering
Massa umpan kering (M)
= 267.401,387 kg/h
Suhu Umpan (T)
= 80 celcius
Suhu referensi (Tref)
= 25 celcius
Panas Sensibel Umpan kering (Quk)
T
= M.
(Perry,1997)
Cp ( raw meal ) . dT
Tref
80
kg (
267.401,387
0,206+101 T 37 T 2 ) dT
jam 25
= 3.106.004,966 kcal/h
o Panas Sensibel H2O Umpan SP
Massa H2O umpan SP (M) = 1728,613 kg/h
Suhu Umpan (T)
= 80 celcius
Suhu referensi (Tref)
= 25 celcius
Panas Sensibel H2O Umpan SP (QH2O Umpan)
= M.
Cp ( H 2O ) . dT
Tref
1728,613
Q1
kg
jam
60,22
( 0,443+39 T +28 T 2 ) dT
25
= 42.320,3282 kcal/h
= Quk + QH2O Umpan
= 3.106.004,966 kcal/h + 42.320,3282 kcal/h
= 3.148.325,294 kcal/h
Panas Sensibel coal (Q2)
o Panas Sensibel coal kering (Qcoal kering)
Massa coal kering (M)
= 8556,186 kg/h
Suhu coal (T)
= 88,86 celcius
Suhu referensi (Tref)
= 25 celcius
Panas Sensibel coal kering
T
= M.
Cp ( coal ) . dT
Tref
kg
8.556,186
jam
88,86
( 0,262+390 T + 0 T 2 ) dT
25
=155.287,7977 kcal/h
o Panas Sensibel H2O coal (Q H2O coal)
Massa H2O coal (M)
= 8556,186 kg/h
Suhu H2O coal (T)
= 88,86 celcius
Suhu referensi (Tref)
= 25 celcius
Panas Sensibel H2O coal
T
= M.
Cp ( H 2O ) . dT
Tref
kg
8.556,186
jam
88,86
( 0,443+39T +28 T 2) dT
25
= 24.565,2888 kcal/h
Q2
= Qcoal kering + Q H2O coal
= 155.287,7977 kcal/h + 24.565,2888 kcal/h
= 179.853,0865 kcal/h
Panas Sensibel Udara Tersier (Q3)
Massa udara tersier (M)
= 135.927,0897 kg/h
Suhu udara tersier (T)
= 567,33 celcius
Suhu referensi (Tref)
= 25 celcius
T
= M.
Cp ( udara ) . dT
Tref
135.927,0897
kg
jam
567,33
(0,237+23 T +0 T 2 )dT
25
= 17.973.156,64 kcal/h
Panas Sensibel Gas Buang Kiln (Q4)
Panas sensibel gas buang kiln dihitung dari panas yang dibawa masingmasing komponennya. Menggunakan data Cp yang ada, panas sensibel
masing-masing komponen diketahui dengan rumus berikut :
T
Q(komponen) = M.
Cp ( Komponen ) . dT
Tref
kg
Q(C O2 )=25.899,5078
jam
1000
(0,196+118 T 43 T 2 ) dT
25
= 7.632.407,287 kcal/jam
Sehingga didapatkan hasil sebagai berikut
Komposisi
CO2
H2O
N2
O2
SO2
Massa(kg/h) T gas(0C)
T ref(0C) Q(kcal/h)
25.899,5078
1000
25 7.632.407,287
2.132,291
1000
25 1.023.998,236
15.191.779,10
58.455,4938
1000
25
0
1.337,8295
1000
25
324.465,479
81,424
1000
25
14.686,854
87.906,5462
Total
24.187.336,96
Q4 = 24.187.336,96 kcal/h
Panas Pembakaran Coal (Q5)
Massa coal(M) = 9240 kg/h
NHV coal
= 6100 kcal/kg
Panas Pembakaran coal (Q5) = M x NHV
= 9.240 kg/jam x 6.100 kcal/kg
= 56.364.000 kcal/h
Panas Sensibel Gas Keluar Kalsiner (Q6)
Panas sensibel gas dari kalsiner dihitung dari panas yang dibawa masingmasing komponennya. Menggunakan data Cp yang ada, panas sensibel
masing-masing komponen diketahui dengan rumus berikut :
T
Q(komponen) = M.
Cp ( Komponen ) . dT
Tref
850
(C O2 )=99.974,735998
kg
(0,196+ 118 T 43 T 2) dT
jam 25
Massa(kg/h)
T gas(0C)
T ref(0C)
Q(kcal/h)
19.543.900,239
25 0
99.974,73598
850
H2O
5.699,125816
850
N2
10.7461,5289
850
25 2.195.777,7165
22.485.317,465
25 0
O2
10.165,01284
850
25 1.938.245,5889
SO2
105,504
850
25 14.971,0176
Q6
46.178.212,027
Q6 = 46.178.212,027 kcal/h
Heat Output
Panas Penguapan H2O
Panas laten penguapan H2O () = 9.729 kcal/kmol (Perry)
o Panas penguapan H2O umpan
Massa H2O umpan SP = 1.728,613 kg/h
Massa H 2 O umpan SP
Mol H 2 O umpanSP=
BM H 2 O
1.728,613
Mol H 2 O umpanSP=
18
kg
jam
kg
kmol
= 96,0341 kmol/jam
Panas penguapan H2O umpan = Mol H2O umpan SP x
= 96,0341 kmol/jam x 9.729 kcal/kmol
= 934.315,3407 kcal/h
o Panas penguapan H2O coal
Massa H2O coal
= 863,814 kg/h
Massa H 2 O coal
Mol H 2 O coal=
BM H 2 O
kg
jam
kg
18
kmol
863,814
Mol H 2 O coal=
= 47,9897 kmol/h
Panas penguapan H2O coal = Mol H2O umpan SP x
= 47,9897 kmol/jam x 9.729 kcal/kmol
= 466.891,467 kcal/h
Panas Penguapan Total H2O (Q7) = 934.315,3407 kcal/h + 466.891,467 kcal/h
= 1.401.206,808 kcal/h
1055K K
Hreaktan
1123K
1046K
Hreaktan
Hproduk
H298
298K
298K 0C
298K
Suhu umpan kalsiner
string B (T awalB)
Hproduk
H298
= 1055 K
= 1046 K298K
= 298 K
string
= 1123BK
Suhu reaksi
(T standar)
string standar
A
Suhu reaksi di kalsiner (Treaksi)
o Panas dari reaksi disosiasi CaCO3
Reaksi I : CaCO3
CaO + CO2
Massa CaCO3 string A bereaksi
= 69.392,0831 kg/h
Massa CaCO3 string B bereaksi
= 104.088,1247 kg/h
Massa CaO terbentuk
= 97.148,9164 kg/h
Massa CO2 terbentuk (MCO2) = 76331,2914 kg/h
Massa CaCO3
BM CaCO3
Mol CaCO3 =
(69.392,0831 104.088,2941)kg / h
100kg/kmol
Mol CaCO3 =
Mol CaCO3 = 1.734,8021 kmol/h
Massa CaO
BM CaO
Mol CaO
=
97.148,9164kg/h
56kg/kmol
Mol CaO
=
Mol CaO
= 1.734,8021 kmol/h
H298
H298
Hreaktan
Tstandar
= nA.
Tmasuk
Tstandar
Cp ( CaCO3 ) . dT + nB.
Cp ( CaCO3 ) . dT
Tmasuk
298
kmol
307.600
)dT +
= 693,9028 h (19,68+0,0119 T
2
T
1055
298
1.040,8812
kmol
307.600
(19,68+0,0119 T
)dT
h 1055
T2
=n.
Tstandar
Treaksi
Cp ( CaO ) . dT + MCO2
Tstandar
Cp ( CO 2 ) .dT
298
kmol
108.000
. dT
= 1734,8021 h 10+0,00484 T
T2
1055
0,196+118 T 43 T
(). dT
298
kg
76.331,2914
h 1055
= 18.771.914 kcal/h + 14.921.881,32 kcal/h
= 33.693.795,32 kcal/h
Htotal = {(H298 + Hproduk - Hreaktan)}
= 75.894.121,32 kcal/h - 34.854.413,22 kcal/h +
33.693.795,32 kcal/h
= 74.733.503,4141 kcal/h
o Panas dari reaksi disosiasi MgCO3
Massa MgCO3 string A bereaksi
= 958,0708 kg/h
Massa MgCO3 string B bereaksi
= 1.437,1062 kg/h
Massa MgO terbentuk
= 1.140,5605 kg/h
Massa CO2 terbentuk (MCO2)
= 1.254,6165 kg/h
Massa MgCO3
BM MgCO3
Mol MgCO3 =
(958,0708 1.437,1062) kg/h
84 kg/kmol
Mol MgCO3 =
= 28,5140 kmol/h
Massa MgO
BM MgO
Mol MgCO3 =
1.140,5605 kg/h
40 kg/kmol
Mol MgCO3 =
= 28,5140 kmol/h
Mol String A (nA)
= 11,4056 kmol/h
Mol String B (nB)
= 17,1084 kmol/h
Mol MgO terbentuk (n)
= 28,5140 kmol/h
Karena mempunyai koefisien reaksi yang sama, maka :
Mol MgCO3 bereaksi = mol MgO terbentuk = mol CO2 terbentuk
Mol CO2 terbentuk
= 28,5140 kmol/h
Massa CO2
= 28,5140 kmol/h x 44 kg/kmol
= 1.254,6160 kg/h
H298
H298
Hreaktan
Tstandar
= nA.
Tmasuk
Tstandar
Cp ( MgCO 3 ) . dT + nB.
298
= 11,4056 kmol /h
Cp
1055
298
16,9+0 T
0
. dT
T2
Cp ( MgCO 3 ) . dT
Tmasuk
0
. dT
T2
Hproduk
Treaksi
=n.
Treaksi
Cp ( Mg O ) . dT
Tstandar
298
= 28,5140 kmol /h
Cp
1055
+ MCO2
Cp ( CO 2 ) .dT
Tstandar
(10,86+0,001197 T 208.700
) . dT
T
0,196+118 T 43 T
(). dT
298
kg
1.254,6160
h 1055
= M.
Cp ( raw meal ) . dT
Tref
kg
= 168.987,6260 h
858,61
( 0,206+101 T37T 2 ) . dT
25
= 33.985.902,12 kcal/h
= M.
Cp ( raw meal ) . dT
Tref
kg
= 8 .556,8444 h
369,72
( 0,206+101 T 37 T 2 ) . dT
25
= 661.107,2516 kcal/h
o Panas Debu Keluar String B
Massa Debu Keluar String B (M)
= 12.835,2666 kg/h
Suhu Debu Keluar String B (T)
= 331,62 celcius
Suhu referensi (Tref)
= 25 celcius
Panas Sensibel Debu Keluar String B (Q10B)
T
= M.
Cp ( raw meal ) . dT
Tref
kg
= 12.835,2666 h
331,62
( 0,206+101 T 37 T 2 ) . dT
25
= 875.829,1083 kcal/h
Q10
= Q10A + Q10B
= 661.107,2516 kcal/h + 875.829,1083 kcal/h
= 1.536.936,3598 kcal/h
Q(komponen) = M.
Cp ( Komponen ) . dT
Tref
kg
( C O2 )=25. 899,50778 jam
387,79
( 0,196+118 T 43 T 2) dT
25
= 2.048.827,3431 kcal/h
Massa(kg/h)
T gas(0C) T ref(0C)
25.899,50778
387,79
25
2.823,736211
387,79
25
58.455,49389
387,79
25
1.337,829575
387,79
25
81,424
387,79
25
88.597,99145 Qgas String A
Q(kcal/h)
2.048.827,3431
463.602,0081
5.270.819,4700
108.811,7815
4.992,2284
7.897.052,8310
Massa(kg/h)
99974,7360
5699,1258
107461,5289
10165,0128
105,5040
T gas(0C)
325,27
325,27
325,27
325,27
325,27
T ref(0C)
25
25
25
25
25
Q(kcal/h)
6.454.892,7198
771.613,6651
7.997.589,0856
681.426,8181
5.448,9060
15.910.971,1946
Q input (kcal/h)
Q1
3.148.325,2940
Q2
179.853,0865
Q3
17.973.156,6400
Q4
24.187.336,9600
Q5
56.364.000,0000
Q6
46.178.212,0270
Total Q input
148.030.884,0016
Q7
Q8
Q9
Q10
Q11
Q (output kcal/h)
1.401.206,8080
75.555.986,2205
33.985.902,1200
1.536.936,3598
23.808.034,0300
Total Q output
136.288.055,532
1
Heat Loss
Heat Loss
= Q input Q output
= 148.030.884,0016 kcal/h - 136.288.055,5321 kcal/h
= 11.742.828,4695 kcal/h
Heat Loss/ kg umpan Kiln = Heat Loss/ Massa Umpan Kiln
= 69,4893 kcal/ kg
Efisiensi Panas
Qinput Heat loss
x 100
Efisiensi panas =
Qinput
Efisiensi panas
= 92,07%