Perhitungan Efisiensi Energi Kiln

IV.1.1 Panas Masuk

1. Arus 1, Arus 2a dan Arus 2b

a. Combustion heat pulvurized = 791 kcal/kg clinker

b. Fine coal consumption:

Fine coal consumption =

pulvurized

GHV

Fine coal consumption =

791 kcalkg clinker

4800 kcalkg coal

= 0,16479 kg coalkg clinker

Heat in coal = Fine coal CPcoal (Tcoal Tref)

= 0,16479 kg coalkg clk 0,2932 kcalkg coal.C (80 0)C

= 3,86531 kcalkg clinker

c. Water from coal:

Water from coal = Fine coal consumption %water in coal

= 0,16479 kg coalkg clinker 13,7%

= 0,02258 kg waterkg clinker

Heat in water = Water CPwater (Twater Tref)

= 0,02258 kg waterkg clk 1 kcalkg water.C (80 0)C

= 1,80640 kcalkg clinker

Arus 1 + 2a + 2b = Combustion heat pulvurized + Fine coal + water from coal

= 791 kcalkg clk + 3,86531 kcalkg clk + 1,8064 kcalkg clk

= 796,67171 kcalkg clk

Arus 5

Kiln primary air =

Flow kiln primary air

Clinker

932,376 kg airmin 60 minhour

365400 kg clinkerhour

= 0,1531 kg airkg clinker

Heat in air = Kiln primary air CPair (Tair Tref)

= 0,1531 kg airkg clk 0.23769 kcalkg air.C (30 0)C

= 1,80640 kcalkg clinker

3. Arus 6

a. Kiln coal transport

Kiln coal transport =

Flow kiln coal transport

Clinker

119,281 kg airmin 60 minhour

365400 kg clinkerhour

= 0,01959 kg airkg clinker

Heat in air = kiln coal transport CPair (Tair Tref)

= 0,01959 kg airkg clk 0.23769 kcalkg air.C (30 0)C

= 0,13969 kcalkg clinker

b. Remaining kiln burner

Kiln burner = (Combustion air rate excess air)

(Kiln coal transport + Kiln primary air)

Dimana:

Excess air = (1 + %excess air ILC 1 + %excess air ILC 2) %PW1

Combustion air rate = fine coal consumption L min

Didapatkan:

Excess air = (1 + 15,8% + 14,9%) 41,5%

= 0,54241

Combustion air rate = 0,16479 kg coalkg clinker 8,542 kg airkg coal

= 1,40764 kg airkg clinker

Kiln burner = (1,40764 kg airkg clinker 0,54241)

(0,01959 kg airkg clk + 0,1531 kg airkg clk)

= 0,59083 kg airkg clinker

Heat in air = kiln burner CPair (Tair Tref)

= 0,59083 kg airkg clk 0.23769 kcalkg air.C (30 0)C

= 4,21303 kcalkg clinker

Arus 6 = kiln coal transport + remaining kiln burner

= 0,13969 kcalkg clinker + 4,21303 kcalkg clinker

= 4,35272 kcalkg clinker

4. Arus 3a

a. ILC String 1 Coal Transport

ILC coal transport =

Flow ILC coal transport

Clinker

112,005 kg airmin 60 minhour

365400 kg clinkerhour

= 0,01839 kg airkg clinker

Heat in air = ILC coal transport CPair (Tair Tref)

= 0,01839 kg airkg clk 0.23769 kcalkg air.C (30 0)C

= 0,13113 kcalkg clinker

b. Remaining Air ILC String 1

Calsiner string 1 = (Comb air rate excess air) ILC 1 coal transport

Dimana:

Excess air = (1 + %excess air ILC 1) %PW2

Didapatkan:

Excess air = (1 + 15,8%) 27,4%

= 0,31729

Calsiner string 1 = (1,40764 kg airkg clk 0,31729) 0,01839 kg airkg clk

= 0,42824 kg airkg clinker

Heat in air = Calsiner string 1 CPair (Tair Tref)

= 0,42824 kg airkg clk 0.23769 kcalkg air.C (30 0)C

= 3,05365 kcalkg clinker

c. Extra Air for ILC String 1

Extra air ILC string 1 = (1 + %excess air ILC 1) Air

= (1 + 15,8%) 0,01914 kg airkg clinker

= 0,02216 kg airkg clinker

Heat in air = Extra air for ILC string 1 CPair (Tair Tref)

= 0,02216 kg airkg clk 0.23769 kcalkg air.C (30 0)C

= 0,15802 kcalkg clinker

Arus 3a = ILC coal transport + remaining air ILC + extra air

= 0,13113 kcalkg clk + 3,05365 kcalkg clk + 0,15802 kcalkg clk

= 3,3428 kcalkg clinker

5. Arus 3b
a. ILC string 2 coal transport

ILC coal transport =

Flow ILC coal transport

Clinker

119,378 kg airmin 60 minhour

365400 kg clinkerhour

= 0,0196 kg airkg clinker

Heat in air = ILC coal transport CPair (Tair Tref)

= 0,0196 kg airkg clk 0.23769 kcalkg air.C (30 0) C

= 0,13976 kcalkg clinker

b. Remaining Air ILC String 2

Calsiner string 2 = (Comb air rate excess air) ILC 2 coal transport

Dimana:

Excess air = (1 + %excess air ILC 2) %PW3

Didapatkan:

Excess air = (1 + 14,9%) 31,1%

= 0,35734
Calsiner String 2 = (1,40764 kg airkg clk 0,35734) 0,0196 kg airkg clk

= 0,48361 kg airkg clinker

Heat in air = Calsiner string 2 CPair (Tair Tref)

= 0,48361 kg airkg clk 0.23769 kcalkg air.C (30 0)C

= 3,44848 kcalkg clinker

c. Extra Air for ILC String 2

Extra air ILC string 2 = (1 + %excess air ILC 2) Air

= (1 + 14,9%) 0,01914 kg airkg clinker

= 0,02199 kg airkg clinker

Heat in air = Extra air for ILC string 2 CPair (Tair Tref)

= 0,02199 kg airkg clk 0.23769 kcalkg air.C (30 0)C

= 0,1568 kcalkg clinker

Arus 3b = ILC coal transport + remaining air ILC + extra air

= 0,13976 kcalkg clk + 3,44848 kcalkg clk + 0,1568 kcalkg clk

= 3,74504 kcalkg clinker

6. Arus 7

a. Cooler Excess Air

Flow = 185961 Nm3hr

185961 Nm3hr 1,293 kg air/Nm3

365400 kg clinkerhr

= 0,65804 kg airkg clinker

Heat in air = Cooler excess air CPair (Tair Tref)

= 0,65804 kg airkg clk 0.23769 kcalkg air.C (30 0)C

= 4,69229 kcalkg clinker

b. Hot Air for Raw Mill

Flow = 151716 Nm3hr

151716 Nm3hr 1,293 kg air/Nm3

365400 kg clinkerhr

= 0,53686 kg airkg clinker

Heat in air = Hot air for raw mill CPair (Tair Tref)

= 0,53686 kg airkg clk 0.23769 kcalkg air.C (30 0)C

= 3,82819 kcalkg clinker

Arus 7 = Cooler excess air + hot air for raw mill

= 4,69229 kcalkg clk + 3,82819 kcalkg clk

= 8,52048 kcalkg clinker

7. Arus 4a dan Arus 4b

a. Raw Mix

Jumlah raw mix ILC String 1 dan 2 dihitung dengan rumus berikut:

Raw mix to clinker =

(1 Coal ash) 100

100 LOI

Coal ash = Fine coal consumption %ash in coal

Didapatkan:

Coal ash = 0,16479 kg coalkg clinker 11,5% kg ashkg coal

= 0.01895 kg ashkg clinker

Raw mix to clinker =

(1 0.01895) 100

100 35.18

= 1,5135 kg raw mixkg clinker

Heat in raw mix = Raw mix to clinker CPraw mix (Traw mix Tref)

= 1,5135 kg rawkg clk 0,21483 kcalkg raw.C (90 0)C

= 29,26307 kcalkg clinker

b. Dust in Raw Mix

Jumlah debu dalam raw mix dihitung dengan rumus berikut:

Dust =

(%dust in exit gas) kiln feed

clinker

Dimana:

%dust in exit gas = 100% efficiency

Efficiency =

clinker coal ash

[kiln feed (1 H2O) (1 LOI)]

100%

Didapatkan:

Efficiency =
365,4 tonhr (11,2% 57,8 tonhr)

[599 tonhr (1 0,53%) (1 35,18%)]

100%

= 92,9%

%dust in exit gas = 100% 92,9%

= 7,1% ton dustton kiln feed

Dust =

7,1% 599 ton kiln feedhr

365,4 ton clinkerhr

= 0,11639 ton dustton clinker

= 0,11639 kg dustkg clinker

Heat in dust = Dust CPdust (Tdust Tref)

= 0,11639 kg dustkg clk 0,21483 kcalkg dust.C (90 0)C

= 2,25037 kcalkg clinker

Arus 4a + 4b = raw mix + dust in raw mix

= 29,26307 kcalkg clk + 2,25037 kcalkg clk

= 31,51344 kcalkg clinker

IV.1.2 Panas Keluar

1. Arus 8a dan 8b

Jumlah gas hasil pembakaran batu bara dihitung dengan rumus berikut:

Combustion product = 9,349 kg gaskg coal fine coal consumption

= 9,349 kg gaskg coal 0,16479 kg coalkg clinker

= 1,54062 kg gaskg clinker

Heat in gas = Coal combustion product CPgas (Tgas Tref)

= 1,54062 kg gaskg clk 0,2579 kcalkg gas.C (380 0)C

= 150,98384 kcalkg clinker

2. Arus 9a dan 9b

a. Raw mix combustion product

Jumlah gas hasil pembakaran raw mix dihitung dengan kesetimbangan reaksi

pembakaran karbon (basis 1 kg karbon) berikut:

C + Udara CO2 + N2

1 kg + 11,53 kg 3,67 kg + 8,86 kg

Sedangkan jumlah karbon dalam raw mix dihitung dengan rumus berikut:

Carbon in raw mix = Raw mix to clinker %carbon in raw mix

Didapatkan:

Carbon in raw mix = 1,51296

kg raw mix

kg clinker 0.11%

kg carbon

kg raw mix

= 0,00166 kg carbonkg clinker

C + Udara CO2 + N2

0,00166 kg + 0,01914 kg 0,00609 kg + 0,01471kg

Sehingga diperoleh gas hasil pembakaran raw mix dalam ILC String 1 dan

ILC String 2 sebagai berikut:

Tabel IV.3 Hasil Pembakaran Raw Mix dalam ILC String 1 dan 2

Suspension

Preheater

Excess

Udara

CO2

kg CO2/kg clinker

N2
kg N2/kg clinker

ILC String 1 15,8% 0,00609 0,01703

ILC String 2 14,9% 0.00609 0.0169

Heat in CO2 = CO2 in ILC String 1 CPCO2 (TCO2 Tref)

= 0,00609 kg CO2kg clk 0,23446 kcalkg CO2.C (378 0)C

= 0,53973 kcalkg clinker

Heat in N2 = N2 in ILC String 1 CPN2 (TN2 Tref)

= 0,01703 kg N2kg clk 0,2524 kcalkg N2.C (378 0)C

= 1,62478 kcalkg clinker

Heat in CO2 = CO2 in ILC String 2 CPCO2 (TCO2 Tref)

= 0,00609 kg CO2kg clk 0,23446 kcalkg CO2.C (382 0)C

= 0,54544 kcalkg clinker

Heat in N2 = N2 in ILC String 2 CPN2 (TN2 Tref)

= 0,0169 kg N2kg clk 0,2524 kcalkg N2.C (382 0)C

= 1,62944 kcalkg clinker

b. Excess Air in Exit Gas Suspension Preheater

Jumlah excess udara pada ILC String 1 dan ILC String 2 dihitung dengan

rumus berikut:

String 1 = [

L min %PW2 %excess air pulvurized

GHV ]

+ (excess air flow ILC 1 equilibria air flow)

String 2 = [

L min %PW3 %excess air pulvurized

GHV ]

+ (excess air flow ILC 2 equilibria air flow)

Didapatkan:

String 1 = [

8,542 kg airkg coal 27,4% 15,8% 791 kcal kg clinker

4800 kcalkg coal ]

+ (0,0227 kg airkg clinker 0,0196 kg airkg clinker)

= 0,06404 kg airkg clinker

Heat in gas = Excess air in ILC String 1 CPgas (Tgas Tref)

= 0,06404 kg gaskg clk 0,24569 kcalkg gas.C (378 0)C

= 5,94745 kcalkg clinker

String 2 = [

8,542 kg airkg coal 31,1% 14,9% 791 kcal kg clinker

4800 kcalkg coal ]

+ (0,02252 kg airkg clinker 0,0196 kg airkg clinker)

= 0,06815 kg airkg clinker

Heat in gas = Excess air in ILC String 2 CPgas (Tgas Tref)

= 0,06815 kg gaskg clk 0,24579 kcalkg gas.C (382 0)C

= 6,39872 kcalkg clinker

c. CO2 dalam raw mix

CO2 from raw mix = Raw mix to clinker %CO2 in raw mix

= 1,5135 kg raw mixkg clinker 77,22%

= 1,16872 kg CO2kg clinker

Heat in CO2 = CO2 from raw mix CPCO2 (TCO2 Tref)

= 1,16872 kg CO2kg clk 0,23463 kcalkg CO2.C (380 0)C

= 104,20237 kcalkg clinker

d. H2O bebas dalam raw mix

Free H2O in raw mix = Raw mix to clinker %free H2O in raw mix

= 1,5135 kg raw mixkg clinker 0,53%

= 0,00802 kg H2Okg clinker

Heat in H2O = Free H2O in raw mix CPH2O (TH2O Tref)

= 0,00802 kg H2Okg clk 0,46186 kcalkg H2O.C (380 0)C

= 1,40756 kcalkg clinker

e. H2O hidrat dalam raw mix

Combined H2O in raw mix = Raw mix to clinker %combined H2O

= 1,5135 kg raw mixkg clinker 1,12%

= 0,01695 kg H2Okg clinker

Heat in H2O = Combined H2O in raw mix CPH2O (TH2O Tref)

= 0,01695 kg H2Okg clk 0,46186 kcalkg H2O.C (380 0)C

= 2,97484 kcalkg clinker

f. Dust in exit gas

Jumlah debu dalam gas keluar sama dengan jumlah debu dalam suspension

preheater.
Dust = 0,11639 kg dustkg clinker

Heat in dust = Dust CPdust (Tdust Tref)

= 0,11639 kg dustkg clk 0,23904 kcalkg dust.C (380 0)C

= 10,57231 kcalkg clinker

Arus 9a + 9b = CO2 in ILC String 1 + N2 in ILC String 1 + CO2 in ILC String 2

+ N2 in ILC String 1 + Excess air in ILC String 1

+ Excess air in ILC String 2 + CO2 from raw mix

+ Free H2O in raw mix + Combined H2O in raw mix

+ dust in raw mix

= 0,53973 kcalkg clk + 1,62478 kcalkg clk +

0,54544 kcalkg clk + 1,62944 kcalkg clk +

5,94745 kcalkg clk + 6,39872 kcalkg clk +

104,20237 kcalkg clk + 1,40756 kcalkg clk +

2,97484 kcalkg clk + 10,57231 kcalkg clk

= 135,84264 kcalkg clinker

3. Arus 10

Excess air = 185961 Nm3hr

185961 Nm3hr 1,293 kg air/Nm3

365400 kg clinkerhr

= 0,65804 kg airkg clinker

Heat in excess air = flow CPair (Tair Tref)

= 0,65804 kg airkg clk 0,2416 kcalkg air.C (200 0)C

= 31,796 kcalkg clinker

4. Arus 11

Hot air for Mill = 151716 Nm3hr

151716 Nm3hr 1,293 kg air/Nm3

365400 kg clinkerhr

= 0,53686 kg airkg clinker

Heat in RM air = flow CPair (Tair Tref)

= 0,53686 kg airkg clk 0,2451 kcalkg air.C (354 0)C

= 46,58 kcalkg clinker

5. Arus 12

Heat in clinker = Clinker CPclinker (Tclinker Tref)

= 1 kg clkkg clk 0,18986 kcalkg clk.C (131 0)C

= 24,87166 kcalkg clinker

6. Radiasi

a. Suspension preheater

Heat loss = [7. (Tpermukaan Tlingkungan) + 0,000000051. (Tpermukaan + 273)

(Tlingkungan + 273)

] 0,86 Luas permukaan

Suhu lingkungan = 30C