ADVANCED AND LOW

CARBON CEMENT
PLANT DESIGN: HEAT INTEGRATION
GROUP
ADITHA32
OKTARIANY
FITRIANI MEIZVIRA
IVA RAUDYATUZZAHRA
RICKY
YUGO WIDHI NUGROHO
ZHOFRAN BINTANG
 CHAPTER 1
HEAT INTEGRATION
Heat Exchanger
Network
There are two
In heat exchange
kind of methods
network, the
which can be
streams
used to
arrangement,
determine the
such as which
pinch from all
streams can
heat exchangers
exchange heat,
in a plant:
can be
composite curve
determined from
and problem
a method called
table cascade.
heat recovery
pinch.
 Energy Integration in Cement Plant

In this plant, whole materials processed are in the form of solids.

There is little amount of heat transfer found in the main process
because most of the process in the plant is mechanical.

Because the main stream is solid, it is impossible to use heat exchanger to

recover heat from stream. So, instead of applying HEN using mentioned
method above, the heat integration in the plant is applied in the overall
process.
The heat integration is created through the flue gas usage from the clinker that is
transferred to the preheater cyclones. Hot gas that has been used in calcination process
still has much enthalpy in it, so instead of releasing it right away, it is moved to the
preheater cyclones to heat the raw meal.
CHAPTER 2
UTILITY
UTILITY: FUEL
 Utility: Fuel

Used in rotary kiln, to heat the raw

meal so calcination reaction will take
place

Composition of the fuel is 70% coal

and 30% biomass (palm shell)

NHV from coal is evaluated from simulation,

while NHV from biomass is taken from existing
research (Kavalek, 2013)
 Fuel
Net Heating %
requirement Duty (kJ/hr)
Value (kJ/kg) mass
(kg/hr)

Fuel Coal 22,950 0.7 13,288.51582

422,347,000
Biomass 20,610 0.3 5,695.078209
18,983.5940
Total mass
3
Target
Target Duty is the power requirement for 422,347,000
rotary kiln. Total Mass is substituted by any
duty
value at first, and then the Fuel Requirement will be calculated by multiplying NHV
and mass percentage. Duty column will be calculated by multiplying NHV and Fuel
Requirement. After that, by using Goal Seek feature in Excel, the value in Duty is set to
Target Duty, to acquire Total Mass from the fuel.

By knowing the Total Mass, Fuel Requirement column will calculate mass needed for
each fuel.
UTILITY: ELECTRICITY
 EQUIPMENT ELECTRICITY REQUIREMENT
Usage Power Energy Required
No. Equipment Tag number Qty
Time (h) (kW) (kWh)
1 Jaw crusher CR-101 1 24 110 2,640
2 Rod mill MI-101 1 24 2500 60,000
3 Ball mill MI-102 1 24 120 2,880
4 Blending machine BR-101 3 24 20 1,440
5 Electrostatic precipitator EP-101 1 24 75 1,800
6 Cyclone for preheater CY-101 1 24 190 4,560
7 Rotary kiln RK-101 1 24 315 7,560
8 Grate cooler E-101 1 24 120 2,880
9 Air cooler E-102 1 24 120 2,880
10 Fuel crusher CR-102 1 24 55 1,320
11 Fuel mill MI-104 1 24 132 3,168
12 Flash dryer DR-101 1 24 22 528
13 Screw conveyor (no tag number) 1 24 146.95 3526.8
Overall Duty 95,182.8
 Daily plant operation electricity requirement = 95,182.8 kWh

Annual plant operation electricity requirement = 31,410 MWh

Annual plant operation electricity cost = IDR

34,928,280,288.00

NB:
1 year = 330 days
Electricity price = IDR 1,112.00/kWh (I-1/3500 VA-14 kVA)
 OFFICE ELECTRICITY REQUIREMENT

Power
Working Hour Power per
No Type of Electricity Amount per Hour
per Day Day (kWh)
(kW)
1 Lighting 800 10 and 24 3.2 and 22.4 570
2 AC 20 10 0.75 7.5
3 Computer 15 10 0.25 2.5
4 Control System Room 10 24 0.25 8
Office Equipments
5 10 10 0.1 1
(Printer, Scanner)
Total 589
 DETAILS FOR LIGHTINGS ELECTRICITY
REQUIREMENT

=

E = Illuminance
= Total of lumen
LLF = Light Loss Factor = 0.8 (SNI)
UF = Utility Factor = 0.8 (SNI)
n = Number of lamp each lamp point
A = Area of the building (m2)
 Lighting Details Daily office and lighting
Parameters Office Plant electricity requirement = 589
Hours operating 10 24 kWh
Fluorescent Fluorescent
Type of light lamp PL-C lamp PL-L 40 Annual office and lighting
26 Watt Watt electricity requirement =
214,985 kWh
Lighting lumen (Lm) 1800 3500
Lighting illuminance (lux) 192 224 Annual office and lighting
Power per lighting unit (kW) 3.2 22.4 electricity cost = IDR
Total energy required (kWh) 32 537.6 239,063,320.00

NB:
1 year = 365 days
Electricity price = IDR 1,112.00/kWh (I-1/3500 VA-14 kVA)
UTILITY: WATER
The main process of the plant has no need for water. Water as
utility will be discussed in the scope of human needs for
sanitation and consumption.

Total Needs
No. Activity Qty Unit Information of water
(m3/day)
Drinking Assumed there are 5000
1. 2 Liter/day 10
water employees

Assumed there are 5000

2 Sanitation 10 Liter/day 50
employees
Assumed there are 4500
3 Mosque 2 Liter/day 9
Muslim workers
4 Canteen 10 m3/day For sanitation 10
5 Garden 5 m3/day For gardening 5
Total 84
Annual Amount of Water Needs

The total number of water needs is supposed to be excess

around 30% for spare so that the total number of daily water
needs is now 104 m3/day.
Assumed that the water utility is used every single day in a
year.
Annual number of water needs = daily number of water needs
x number of days
Annual number of water needs = (104 m3/day) (365 days)
Annual number of water needs = 37,960 m3
Annual Water Expense

For total annual number of water needs of 37, 960 m3, the
annual water expense is IDR 383,391,000.00.

NB: The calculation for water expense is simulated monthly via its own website.
THANK YOU