feed entered SP = 20833.

33 kg
H2O content in sp = 0.01
H2O content in sp = 208.33333 kg
dry feed = 20625 kg

composition of incoming feed sp

component Mass fraction (%)
SiO2 13%
Al2O3 3.89%
Fe2O3 1.92%
CaO 44.06%
MgO 0.70%
IL 36.67%
total 1

%CaCO3 = BM CaCO3 x %CaO

BM CaO
= 0.78678571

%MgCO3 = BM MgCO3 x %MgO

BM MgO
= 0.0147

so the composition:
SiO2 = %SiO2 x 100%
% the feed without IL
= 0.12925633
Al2O3 = %Al2O3 x 100%
% the feed without IL
= 0.03940495
Fe2O3 = %Fe2O3 x 100%
% the feed without IL
= 0.01944923
CaCO3 = %CaCO3 x 100%
% the feed without IL
= 0.79699868
MgCO3 = %MgCO3 x 100%
% the feed without IL
= 0.01489082

Dust return/back to ball mill

The ideal ratio of Sp towards clinker = 1.76
Reality Feeds = 20833.333
Clinker = feed/weight ratio
 = 11837.121 kg
clinker the theoritical = mass feedback x
= 13193.75 kg
dust return = theoretical weight of clinker-the weight of real clinker

= 0.1028236

SP feed that to be form clinker:

SiO2 = the mass of the SiO2 in the SP-mass dust return
= 2391.793 kg
Al2O3 = 729.1595 kg
Fe2O3 = 359.8936 kg
CaCO3 = 14747.87 kg
MgCO3 = 275.5436 kg
Total Feed = 18504.26 kg

degrees calcination = 0.95

Reaction 1:
CaCO3 > CaO CO2
CaCO3 that calcined = 14010.48 kg
CaO formed = BM CaO x mass CaCO3 that calcined
BM CaCO3
= 7845.8687 kg
CO2 is formed = BM CO2 x mass CaCO3 that calcined
BM CaCO3
= 6164.6111 kg
The rest of CaCO3 = mass of CaCO3 - mass of CaO
= 737.39368 kg

Reaction 2:
MgCO3 > MgO CO2
MgCO3 that calcined = 261.77 kg
MgO formed = BM MgO x mass of MgCO3 that calcined
BM MgCO3
= 124.65 kg
CO2 = BM CO2 x mass of MgCO3 that calcined
BM MgCO3
= 137.12 kg
MgCO3 left over = mass of MgCO3-mass of MgO
= 13.78 kg
CO2 calcined = CO2 from reaction 1+reaction 2
= 6,301.73 kg

Coal
Feed enter = 707.4005 kg
water content = 7.08%
mass of water in coal = 50.083955 kg
dry coal feed = 657.31654 kg

coal components mass fraction mass of coal feed (kg):

C 66.31% C
H 4.19% H
N 0.87% N
S 0.15% S
O 19.53% O
Ash 8.95% Ash
TOTAL 100.00% Total

coal ash composition

component mass fraction
SiO2 28.68%
Al2O3 14.53%
Fe2O3 4.93%
CaO 33.58%
MgO 1.31%
SO3 4.52%
IL 12.45%
Total 100.00%

because the IL component does not react, the new composition of coal ash is:
SiO2 = SiO2 fraction
Feed fraction without IL
= 28.68%
87.55%
= 32.76%

Al2O3 = Al2O3 fraction

Feed fraction without IL
= 14.53%
87.55%
= 16.60%

Fe2O3 = Fe2O3 fraction

Feed fraction without IL
= 4.93%
87.55%
= 5.63%

CaO = CaO fraction

Feed fraction without IL
 = 33.58%
87.55%
= 38.36%

MgO = 1.31%
87.55%
= 1.50%

SO3 = 4.52%
87.55%
= 5.16%

Table 8 Coal Composition without IL

Component mass fraction (%) Mass (Kg)
SiO2 32.76% 19.2717253
Al2O3 16.60% 9.76353445
Fe2O3 5.63% 3.31274775
CaO 38.36% 22.5643143
MgO 1.50% 0.8802636
SO3 5.16% 3.0372454
Total 100.00% 58.8298307

Husk
Husk feed to SP 513.0597
H2O = 27.44%
Dry husk feed 372.276118 kg

composition of husk feed

component mass fraction (%) mass (kg)
C 49.3 183.532126
H 5.9 21.964291
N 0.5 1.86138059
S 0.14 0.52118657
O 44.1 164.173768
ASH 0.06 0.22336567
TOTAL 100 372.276118

reactions occurs during husk burning

a) C + O2 CO2
Amount of C that reacts = BM CO2 X Mass C
BM C
= 44 X 183.5321
12
= 672.9511
O2 NEEDED = BM O2 X Mass C
BM C
= 32 X 183.5321
12
= 489.419

b) S + O2 SO2
Amount of S that reacts = BM SO2 X Mass S
BM S
= 64 X 0.521187
32
= 1.042373

O2 NEEDED = BM O2 X Mass S
BM S
= 32 X 0.521187
32
= 0.521187

c) H2O (l) H2O (g)

H2O FORMED = 140.7836

d) H2 + 1/2 O2 H2O
number of H that reacts = 21.96429

H2O FORMED = BM H2O X MASS H2

BM H2
= 18 X 21.96429
2
= 197.6786

e) N + O2 NO2
number of N that reacts 1.86138059

NO2 that formed = BM NO2 X MASS N

BM N
= 46 X 1.861381
14
= 6.115965

O2 NEEDED = BM O2 X MASS N
BM N
= 32 X 1.861381
14
= 4.254584
TOTAL O2 NEEDS FOR BURNING THEORETICAL RICE HUSK

845.6234300205

GAS FUEL
Gas volume = 114.7388 Nm3
Average gas density = 0.99245 kg/m3

incoming gas mass = 113.8725 kg

Table 10. composition of gas fuel

Component mass fraction mass (kg)
N2 2.8 3.18843062
CO2 33.75 38.4319762
CH4 53.19 60.5687945
C2H6 4.53 5.15842525
C3H8 3.11 3.54143544
C4H10 1.46 1.66253882
C5H12 0.59 0.67184788
C6H14 0.57 0.64907338
TOTAL 100 113.872522

COMBUSTION REACTIONS THAT HAPPEN

1) CH4 + 2 O2 CO2 + 2 H2O
MOL CH4 = 3.78554966 KMOL

MOL O2 = 7.57109931 KMOL

MASS O2 = 242.275178 KG

MOL CO2 = 3.78554966 KMOL

MASS CO2 = 166.564185 KG

MOL H2O = 7.57109931 KMOL

MASS H2O = 136.279788 KG

2) C2H6 + 7/2 O2 2 CO2 + 3 H2O

MOL C2H6 = 0.17194751 KMOL

MOL O2 = 0.60181628 KMOL

MASS O2 = 19.2581209 KG
MOL CO2 = 0.34389502 KMOL

MASS CO2 = 15.1313807 KG

MOL H2O = 0.51584252 KMOL

MASS H2O = 9.28516545 KG

3) C3H8 + 5 O2 3 CO2 + 4 H2O

MOL C3H8 = 0.08048717 KMOL

MOL O2 = 0.40243585 KMOL

MASS O2 = 12.877947 KG

MOL CO2 = 0.24146151 KMOL

MASS CO2 = 10.6243063 KG

MOL H2O = 0.32194868 KMOL

MASS H2O = 5.79507617 KG

4) C4H10 + 13/2 O2 4 CO2 + 5 H2O

MOL C4H10 = 0.02866446 KMOL

MOL O2 = 0.18631901 KMOL

MASS O2 = 5.96220819 KG

MOL CO2 = 0.11465785 KMOL

MASS CO2 = 5.04494539 KG

MOL H2O = 0.14332231 KMOL

MASS H2O = 2.57980162 KG

5) C5H12 + 8 O2 5 CO2 + 6 H2O

MOL C5H12 = 0.00933122 KMOL

MOL O2 = 0.07464976 KMOL

MASS O2 = 2.38879246 KG
MOL CO2 = 0.0466561 KMOL

MASS CO2 = 2.05286852 KG

MOL H2O = 0.05598732 KMOL

MASS H2O = 1.00777182 KG

6) C6H14 + 19/2 O2 6 CO2 + 7 H2O

MOL C6H14 = 0.00754736 KMOL

MOL O2 = 0.07169997 KMOL

MASS O2 = 2.29439891 KG

MOL CO2 = 0.04528419 KMOL

MASS CO2 = 1.99250432 KG

MOL H2O = 0.05283155 KMOL

MASS H2O = 0.95096797 KG

Total O2 mass required

285.0566454678

MASS of CO2 formed

201.4101900998

MASS of H2O formed

155.898570615

(10) MASS CALCULATIONS IN KILN

SiO2 = 2411.06485
Al2O3 = 738.923037
Fe2O3 = 363.206384
CaCO3 SISA = 737.393676
MgCO3 SISA = 13.78
CAO = 7868.43303
MgO = 125.53
SO3 = 3.0372454

TABLE 11. FEED COMPOSITION

component mass fraction (%) MASS (KG)
SiO2 19.27 2411.06485
Al2O3 5.92 738.923037
Fe2O3 2.89 363.206384
CaCO3 SISA 10.38 737.393676
MgCO3 SISA 0.19 13.78
CAO 60.37 7868.43303
MgO 0.96 125.53
SO3 0.02 3.0372454
TOTAL 100 12,261.37

COAL COMBUSTION REACTIONS IN SP

a) C + 1/2 O2 CO
For example: C that reacts = R kg, then
CO2 formed = BM CO X R kg
BM C
= 2.33333333 R kg
O2 that needed = BM O2 X R kg X 1/2
BM C
= 1.33333333 R kg

b) C + O2 CO2
C that reacts = 435.866601 - R
CO2 formed = BM CO2 X 435.8666 - R
BM C
= 1598.17754 - 3.6666667 R

O2 that needed = BM O2 X 435.8666 - R

BM C
= 1162.31094 - 2.6666667 R

c) S + O2 SO2
S that reacts = 0.98597482
SO2 that formed = BM SO2 X 0.9859748
BM S
= 1.97194963

O2 that needed = BM O2 X 0.9859748

BM S
= 0.98597482

d) H2O (l) H2O (g)

H2O formed = H2O in coal = 50.08396 kg

e) H2 + 1/2 O2 H2O (g)

H2 that reacts = H umpan dalam batubara = 27.54156
H2O (g) that formed = BM H2O X MASSA H2
BMH2
= 247.874069

O2 that needed = BM O2 X 1/2 MASSA H2

BM H2
= 220.332506

f) N + O2 NO2
N that reacts = N in coal feed = 5.718654
NO2 that formed = BM NO2 X MASS N
BM N
= 18.7898629

O2 that needed = BM O2 X MASS N

BM N
= 13.071209

so the theoretical air requirements in the kiln feed

1396.7006248327 - 1.33333333 R

DATA :
Temperature = 27 C
Moisture = 80%
Pressure = 1 atm
from the Pshychometric chart (perry. Figure 3-4)
Humidity = 0.022 kg H2O/kg of dry air
dry air = 21% O2 dan 79% N2
airbone dust = 28.84 kg/kmol
ρ of air = 1.16 kg/m3
dry air = 1
(1+humidity)
= 1
(1 + 0,022)
= 0.97847358

Air composition
H2O = 0.02152642 kg
O2 = 0.22799384 kg
N2 = 0.75047974 kg

A5) TERSURY AIR FROM COOLER TOWARDS SP

MISAL, Tertiary Air = T kg
Dry air = 1 T kg
(1 + 0,022)
H2O = (1-0,978) T kg
= 0.228 T kg
O2 = 0.22799384 T kg
N2 = 0.75047974 T kg

(A7) PRIMARY FAN AIR SP

Capacity = 9000 m3/jam (CCR Plant 9 PT.Indocement Tunggal Prakarsa, Tbk, mar
ρ of air = 1.16 kg/m3
mass of air = 9000 m3 X 1.16 kg
jam m3
= 10440 kg/jam
dry air mass = 10215.2642 kg
mole of dry air = 354.204722 kmol
mass H2O = 224.735812 kg
mass O2 = 2380.25573 kg
= 7835.00845 kg

Table 24. Primary fan air composition

component mass fraction mass (kg)
H2O 2.16 225.504
O2 22.8 2380.32
N2 75.04 7834.176
Total 100 10440

(2) Feed Carrier Air

capacity = 3000 m3/jam (CCR Plant 9 PT.Indocement Tunggal Prakarsa, Tbk, mar
ρ of air = 1.16 kg/m3
mass of air = 3000 m3 X 1.16 kg
jam m3
= 3480 kg
dry air mass = 3405.08806 kg
mole of dry air = 121.610288 kmol
mass H2O = 74.9119374 kg
mass O2 = 817.221135 kg
mass N2 = 2690.01957 kg

Table 13. Air composition of feed carrier SP

component mass fraction mass (kg)
H2O 2.16 75.168
O2 22.8 793.44
N2 75.04 2611.392
Total 100 3480

(4) Fuel Carrier Air

capacity = 3850 m3/jam (CCR Plant 9 PT. Indocement Tunggal Prakarsa, Tb
ρ of air = 1.16 kg/m3
mass of air = 3850 m3 X 1.16 kg
jam m3
= 4466 kg
dry air mass = 4369.86301 kg
mole of dry air = 151.520909 kmol
mass H2O = 96.1369863 kg
mass O2 = 1018.22051 kg
mass N2 = 3351.64251 kg

Table 14. Fuel Carrier Air Composition

component mass fraction massa (kg)
H2O 2.16 96.4656
O2 22.8 1018.248
N2 75.04 3351.2864
Total 100 4466

(7) Kiln Exhaust Gas

The composition of the kiln exhaust gas is obtained from the calculation of exhaust gas in the kiln
Table 15. Composition of kiln exhaust gases
component mass fraction MASS (KG)
H2O 5.37 6591.59177
O2 3.57 4382.11967
N2 66.45 81566.345
CO2 24.52 30097.9199
SO2 0.02 24.54969
NO2 0.07 85.923915
TOTAL 100 122748.45

(9) KILN WASTE GAS

The composition of the exhaust gas SP
CO = 2.33333333 R kg
CO2 =
 compound Molecular Formula BM (Kg/Kmol)
Calcium Oxide CaO(s) 56
Magnesium Oksida MgO(s) 40
Silicon Dioxide SiO2(s) 60
Iron (III) Oxide Fe2O3 160
Manganese Dioxide MnO2 87
Chormium (III) Oxide Cr2O3 152
Potassium Oxide K2O 94
Sodium Oxide Na2O 62
Ammonium cloride NH4Cl 54
Calcium chloride CaCl2 111
magnesium chloride MgCl2 95
Calcium carbonate CaCO3 100
magnesium carbonate MgCO3 84
Alumunium Oxide Al2O3 102
Carbon dioxide CO2 44

Total 98.72%
The original feed feed (kg):
SiO2 2665.91175
Al2O3 812.727015
Fe2O3 401.140326
CaCO3 16438.0978
MgCO3 307.123062
Total 20625

the composition of the dust return (kg):

SiO2 274.1186264
Al2O3 83.56751228
Fe2O3 41.24668986
 CaCO3 1690.224289
(1-mass fraction of IL) MgCO3 31.57949693
Total 2120.736614
clinker-the weight of real clinker x 100%

mass dust return

mass CaCO3 that calcined

mass CaCO3 that calcined

mass of MgCO3 that calcined

mass of MgCO3 that calcined

mass of coal feed (kg):
= 435.8666
= 27.54156
= 5.718654
= 0.985975
= 128.3739
= 58.82983
657.3165

coal ash mass in SP

SiO2 = 32.76% X 58.82983
= 19.27173

Al2O3 = 16.60% X 58.82983

= 9.763534

Fe2O3 = 5.63% X 58.82983

= 3.312748

CaO = 38.36% X 58.82983

= 22.56431

MgO = 1.50% X 58.82983

= 0.880264

SO3 = 5.16% X 58.82983

= 3.037245
O2 that needed = BM O2 X MASS H2
BM H2
= 32 X 21.96429
2
= 351.428656
BM
CH4 16
C2H6 30
C3H8 44
C4H10 58
C5H12 72
C6H14 86
H2O 18
CO2 44
O2 32
BM
CO2 44
C 12
CO 28
O2 32
SO2 64
S 32
H2 2
H2O 18
N 14
NO2 46
N2 28
ement Tunggal Prakarsa, Tbk, maret 2011)

ement Tunggal Prakarsa, Tbk, maret 2011)

docement Tunggal Prakarsa, Tbk, March 2011)

st gas in the kiln