PRODUCTION OF ADVANCED

AND LOW CARBON CEMENT

Group 32
ADITHA OKTARIANY| FITRIANI MEIZVIRA| IVA RAUDYATUZZAHRA| RICKY|
YUGO WIDHI NUGROHO| ZHOFRAN BINTANG
CHAPTER I
INTRODUCTION

Background
Background

Cement is the primary ingredient in concrete, which in turn forms the

foundations and structures of the buildings we live and work in, and the roads
and bridges we drive on.
Cement production accounts for around 5% of total global industrial and energy
CO2 emissions.
In Indonesia, cement industry takes around 61.6% emissions generated by
industrial activities.
 The production of cement releases greenhouse gas emissions both directly and
indirectly: the heating of limestone releases CO2 directly, while the burning of
fossil fuels to heat the kiln indirectly results in CO2 emissions.
How to Reduce CO2 Emissions?

Indirect emissions from burning fossil fuels to heat the kiln can be
reduced by switching to alternative fuels.
Efficiency measures can reduce the demand for fuel by addressing the
production process itself or through technical and mechanical
improvements.
Reducing emissions from the calcination process means looking to a
material other than limestone.
CO2 emissions can be captured after they are produced through carbon
capture and storage (CCS).
CHAPTER I
INTRODUCTION
Literature Review
Raw Material Analysis
Cement Manufacturing
Limestone

Limestone is a sedimentary rock composed

primarily of calcium carbonate (CaCO3) in
the form of the mineral calcite.
Limestone is heated in a kiln with shale,
sand, and other materials and ground to a
powder that will harden after being mixed
with water.
Fly Ash

Fly ash is a by-product of burning pulverized coal in an electrical generating

station.

Component Percentage
SiO2 40-60
Al2O3 20-30
Fe2O3 4-10
CaO 5-30
Loss on Ignition 0-3
Iron Ore

Iron ore is a mineral substance which, when heated in the presence of a

reductant, will yield metallic iron (Fe). It almost always consists of iron oxides,
the primary forms of which are magnetite (Fe3O4) and hematite (Fe2O3).
Gypsum

Gypsum is an evaporite mineral most commonly found in layered sedimentary

deposits in association with halite, anhydrite, sulfur, calcite, and dolomite.
Gypsum (CaSO4.2H2O) is very similar to Anhydrite (CaSO4).
Raw Material Supply Analysis

Supplier
Raw
Supplier Price /unit
Materials Location Travel Time
Company (Rp)
CV Red
Limestone Cilegon 1 day Rp300/kg
Production
Fly Ash Cilegon PLTU Suralaya 1 day Rp500/kg
CV Kharisma
Iron Ore Surabaya 2 days Rp900/kg
Nusantara
PT
Gypsum Gresik Metabisulphite 2 days Rp300/kg
Nusantara
 Market Analysis

Indonesia Cement Supply and Demand Indonesia Cement Future Supply and Demand
120 500

450
100
400

350

Cement (million tons)

80
Cement (million tons)

300

60 250

200

40 150

100
20
50

0
0
2017 2018 2019 2020 2021 2022 2023 2024 2025 2026 2026
2011 2012 2013 2014 2015 2016 2017
Year
Year

Supply Demand
Supply Demand
Overseas Cement Demand

Country Imported Demand (tons)

Sri Lanka 4,410,000
Myanmar 4,000,000
Cambodia 4,000,000
Brunei Darussalam 85,000
Philippines 314,000
Total 12,809,000
Capacity Analysis
Total Indonesian Demand
Year Demand (ton/year) Average Demand (ton/year)
2018 71,974,000
2019 76,292,440
2020 80,869,986
2021 85,722,185
2022 90,865,516
92,415,867
2023 96,317,447
2024 102,096,494
2025 108,222,284
2026 114,715,621
2027 121,598,558
1% Market Share 924,158.67
Capacity Analysis

Total Myanmar Demand

Year Estimated Imported Demand (ton/year)

2018-2027 4,000,000
2,5% Market Share 100,000
 Capacity Analysis

Total Production Capacity

Production Capacity Production

(ton/year) Capacity (ton/day)
Indonesia 924,158.67 2,800.480
Exported to Myanmar 100,000.00 303.303
Total 911,448.25 3,103.783
Plant Location Analysis

Below are the facts that should be concerned regarding plant location:
Availability of raw material
Infrastructure facilities
Environment and climate conditions
Labour force availability

Based on that fact, we choose Jln. Narogong km 18, Kp. Rawa hingkik,
Limusnunggal, Desa Pasir Angin, Cileungsi, Bogor, West Java.
CHAPTER II
PROCESS SELECTION
Process Synthesis
Process Alternatives and Description
Process Selection
Process Synthesis

The main stages for cement production

Mainly limestones
Grinding the Uniform materials are then fed to the
cement kiln
raw materials

calcinate the materials

Heating in high temperature about 1450oC
temperature CaCO3 will be thermally decomposed
into CaO (lime) and CO2
Process Alternatives and Description

grinding and mixing

Wet Process the raw materials in
the existence of water
1.Conventional
Process
grinding and mixing
Dry Process the raw materials in
their dry state
 Supplementary Cementitious
Materials (SCM)

Clinker Substitution

fly ash, silica fume, slag

cement, rice husk ash, and
natural pozzolans

1.Advanced Process alternative fuels such as

agricultural biomass, non-
Fuel Substitution agricultural biomass chemical
and hazardous waste, and
petroleum-based fuels

They are post combustion

Carbon Capture and Storage capture, pre-combustion
capture, and oxy-combustion
 Process Selection
Conventional Process
Wet Process Dry Process
35-50% 12%
Moisture Content
(slurry) (pellets)
Size of the kiln needed to
Bigger Smaller
manufacture
Heat and fuel amount required Higher Lower
Economist Less economically More economically
Can obtaine better Difficult to obtain homogeneous
homogeneous material (Can be material (the mixing of raw
Homogeneous material
mixed easily) material process are difficult to
control)
Maintenance of the machinery
Do not need much maintenance Need more maintenance
and euipment
Process SynthesisHeuristics

Heuristic 1: Select raw materials and chemical reactions to avoid, or reduce, the
handling and storage of hazardous and toxic chemical.
Based on this heuristic, Fuel Substitution and CCS have good potential because it
does not involve any toxic materials.
For Clinker Substitution. our choice is fly ash, residue from coal combustion, at
some point is being debated whether it is environmentally safe or not, but recent
studies show that the toxic materials in fly ash is binded and sealed upon reaction
with another cementitious material. In conclusion, the benefit of fly ash in cement
making weighs more than its drawbacks, and with suitable handling and material
scheduling, the possible harm of fly ash can be diminished.
 Process Selection
Advanced Process

Value Engineering Scoring method

Code Parameter Advanced

A B C D Total Weight % Code
Process
A Low carbon A 1A 2A 2A 5 0.556 55.56
Clinker
P
B Economic B 2B 1B 2 0.222 22.22 Substitution
C 1C 1 0.111 11.11 Fuel
C Efficiency Q
Substitution
D 1 0.111 11.11
Operation R CCS
D TOTAL 9 1 100
condition
 A P Q R Total Score
C P Q R Total Score

P 1Q 1P 1 0,333333 P 1Q 1P 1 0,25

Q 2Q 3 0,75
Q 1R 1 0,333333
R 0 0

R 1 0,333333

TOTAL 3 1 TOTAL 4 1

B P Q R Total Score D P Q R Total Score

P 1P 2P 3 0,75 P 1Q 2P 2 0,5

Q 1Q 1 0,25 Q 1Q 2 0,5

R 0 0 R 0 0

TOTAL 4 1 TOTAL 4 1
Final Score

A B C D TOTAL %

Score 0,3333 0,7500 0,2500 0,5000

P
Weight 0,556 0,222 0,111 0,111
0,4349 43,5

Final Score 0,2083 0,2813 0,0000 0,0000

Score 0,3333 0,2500 0,7500 0,5000

Weight 0,556 0,222 0,111 0,111

Q 0,3974 39,7

Final Score 0,2083 0,0938 0,0000 0,0000

Score 0,3333 0,0000 0,0000 0,0000

Weight 0,556 0,222 0,111 0,111

R 0,1852 18,5

Final Score 0,2083 0,0000 0,0000 0,0000

CHAPTER II
PROCESS SELECTION
Selected Process and Description
Block Flow Diagram
Process Flow Diagram
Process Highlight

Material Substitution Fuel substitution Crushing Grinding Blending Raw Mill Silo

A certain amount of To reduce the size of the

limestone is materials. Crushing The
Coal has a long
substituted to fly ash, reduces the size from continuation
life cycle, and
a waste from coal about 4 cm to 15 mm, from the
the carbon Mixing
combustion. Fly ash and grinding reduces the blending
emitted in the
has pozzolanic size from about 15 mm to process,
combustion materials
quality, which makes carry much 0.5 mm. together
it suitable for cement where the
harms. To to
manufacture. raw meal
minimize the become
will be kept
carbon emission raw
For fly ash, the grinding until it is fed
Fly ash is cheap, so the in environment, meal.
process acts the to the pre-
products price will not it is decided to
mechanical activation as heater and
rise too high (it will use biomass as
well. the kiln.
impact economic the substitution.
aspect)
Process Highlight

Heating (in Electrostatic

Pre-heating Cooling Grinding
rotary kiln) Precipitator

The process
The cooled
Raw meal is heated to a to capture
clinker is
certain temperature (1350- flue gas
grinded
1450oC) until CaCO3 is The cooling produced in
together
thermally decomposed to process of the process
with
CaO. Pre-heaters are used to clinker, to and
gypsum, to
make the process more tempe- separating
reach a
efficient and also making use rature the fly ash
certain
of the very hot gas that about from the gas
composition
coming out from the kiln. 150oC. to be the
of good
material in
cement
The output is called clinker. manufacture
product.
process.
B
Block Flow Diagram
F
D
Stream Information

Stream Name
No Stream Name No Stream Name No Stream Name No

Grinded limestone and iron

1 Fly ash 6 11 Cement 16 Coal
ore

Cement to packaging
2 Limestone and iron ore 7 Raw meal 12 17 Palm shell
station

Crushed limestone and iron Crushed coal and palm

3 8 Preheated raw meal 13 Exhaust gas from clinker 18
ore shell

4 Gypsum 9 Clinker 14 Exhaust gas to ESP 19 Dried coal and palm shell

5 Activated fly ash 10 Cooled clinker 15 ESP exit gas 20 Fuel to kiln
P
Block Flow Diagram
F
D
Stream Information
CHAPTER III
MASS AND ENERGY
BALANCE
Mass Balance
 Mass Balance for Limestone Jaw Crusher

Input (ton) Output (ton)

Components
Limestone Iron Ore Recycled Crushed Feed

5564.63 0.00 1349.00 4215.63

CaCO3

130.42 0.00 31.62 98.80

MgCO3
Fe2O3 0.00 26.80 6.50 20.30

Total 5695.05 26.80 1387.11 4334.73

 Mass Balance for Limestone Ball Mill

Input (ton) Output (ton)

Components
Crushed Feed Recycled Ground Feed

CaCO3 4215.63 731.64 3483.99

MgCO3 98.80 17.15 81.65

Fe2O3 20.30 3.52 16.78

Total 4334.73 752.31 3582.423894

Mass Balance for Fly Ash Ball Mill

Input (ton) Output (ton)

Components

Fly Ash Recycled Ground Fly Ash

SiO2 437.42 75.92 361.50
Al2O3 261.51 45.39 216.12
Fe2O3 41.61 7.22 34.39
CaCO3 39.34 6.83 32.51
Inert 64.24 11.15 53.09
Total 844.11 146.50 697.61
 Mass Balance for Blender

Input (ton) Output (ton)

Components

Ground Feed Ground Fly Ash Recycled Blended Feed

3483.99 32.51 167.45 3349.05

CaCO3

81.65 0 3.89 77.77

MgCO3

16.78 34.39 2.44 48.73

Fe2O3
Mass Balance for Preheating Tower

Input (ton) Output (ton)

Components
Blended Feed Recycled Raw Meal

CaCO3 3349.05 159.48 3189.57

MgCO3 77.77 3.70 74.06
Fe2O3 48.73 2.32 46.41

SiO2 344.29 16.39 327.89

Al2O3 205.83 9.80 196.03

Inert 50.56 2.41 48.15
Total 4076.23 194.11 3882.12
 Mass Balance for Rotary Kiln

Type of Reactant
Reaction No. List of Reactions
Reactions Conversion

1 CaCO3 CaO + CO2 56%

Calcination
2 MgCO3 MgO + CO2 56%

2CaO + SiO2 2CaO.SiO2

3 56%
3CaO + SiO2 3CaO.SiO2
4 56%
Clinker formation 3CaO + Al2O3 3CaO.Al2O3
5 56%
4CaO + Al2O3 + Fe2O3
6 56%
4CaO.Al2O3.Fe2O3
 Calcination

Reaction no. 1 Reaction no. 2

Reaction CaCO3 CaO + CO2

Reaction MgCO3 MgO + CO2
Coeff. 1 1 1
Coeff. 1 1 1
Var. (known) X1 Y1
Var. (known) X2 Y2
33406.2176
Feed Feed 919.2225496
8
Reacted 18707.4819 18707.4819 18707.4819 Reacted 514.7646278 514.7646278 514.7646278
14698.7357
Excess 18707.4819 18707.4819 Excess 404.4579218 514.7646278 514.7646278
8

CaCO3 conversion : 56% MgCO3 conversion : 56%

 Clinkerisation

Reaction no. 3 Reaction no. 4

Reaction 2CaO + SiO2 2CaO.SiO2

Reaction 3CaO + SiO2 3CaO.SiO2
Coeff. 2 1 1
Coeff. 3 1 1
Var. X3 (known) Y3
Var. X4 (known) Y4
Feed 6274.944504
Feed 2760.975582
Reacted 7027.937845 3513.968922 3513.968922
Reacted 4638.438977 1546.146326 1546.146326
Excess 7027.937845 2760.975582 3513.968922 Excess 4638.438977 1214.829256 1546.146326

SiO2 conversion: 56% SiO2 conversion : 56%

 Clinkerisation

Reaction no. 5 Reaction no. 6

Reactio
3CaO + Al2O3 3CaO.Al2O3 Reactio
n 4CaO + Al2O3 + Fe2O3 4CaO.Al2O3.Fe2O3
n
Coeff. 3 1 1
Coeff. 4 1 1 1
Var. X5 (known) Y5
Var. X6 Y6 (known) Z6
Feed 2206.708524
Feed 318.9786354

Reacted 3707.270321 1235.756774 1235.756774 Reacted 714.5121434 178.6280358 178.6280358 178.6280358

Excess 3707.270321 970.9517507 1235.756774 Excess 714.5121434 178.6280358 140.3505996 178.6280358

Al2O3 conversion : 56% Fe2O3 conversion : 56%

 Clinker Composition Analysis

Components Kmoles Mass (ton) Percentage

C2S 3513.97 604.40 14.58%

C3S 1546.15 352.52 8.51%

C3A 1235.76 333.65 8.05%

C4AF 178.63 86.81 2.09%

CaCO3 14698.74 1469.87 35.47%

CaO 2619.32 146.68 3.54%

 Mass Balance for Clinker Grinding

Input Output
Components
Clinker Gypsum Recycled Cement
C2S 604.40 0 28.78 575.62
C3S 352.52 0 16.79 335.73
C3A 333.65 0 15.89 317.77
C4AF 86.81 0 4.13 82.68
CaCO2 1469.87 0 69.99 1399.88
SiO2 72.89 0 3.47 69.42
Al2O3 99.04 0 4.72 94.32
Fe2O3 22.46 0 1.07 21.39
MgCO3 34.10 0 1.62 32.48
MgO 20.75 0 0.99 19.76
Inerts 55.29 0 2.63 52.66
CaO 0 34.91 1.66 33.25
H2O 0 22.43 1.07 21.37
SO3 0 49.84 2.37 47.47
Total 3151.78 107.19 155.19 3103.78
 CO2 from Fuel Combustion

Parameter Value Unit

Coal for 1 ton clinker formation 0.0654 ton

70% of clinker production 2206.246 ton

Coal need 144.2885 ton

Fly ash formation 82.24444 ton

CO2 emission per ton coal combustion 3.67 ton

Total CO2 emission from coal combustion 529.54 ton

 Total CO2 Emission

Sources Value (ton)

Rotary kiln 845.78

Fuel combustion 529.54

Total 1375.32

CO2/Cement Ratio 0.443

CHAPTER III
MASS AND ENERGY
BALANCE
Energy Balance
 Mechanical Equipment Duty

Most of the process

Equipment Quantity Energy Required per hour (kWh)
are using
mechanical Jaw Crusher (limestone and iron ore) 1 110
equipment that
Ball Mill (fly ash activator) 1 120
needed electricity,
Ball Mill (limestone and iron ore) 1 2500
we can write the Blending Machine 3 20
energy balance or ESP 1 75
energy input of all Cyclone for Preheater 1 190
the mechanical Rotary Kiln 1 315
Grate Cooler 1 120
equipment in this
Crusher for Fuel 1 55
table Mill for Fuel 1 132
Flash Dryer 1 22
Overall Duty 4009
 Heat Balance using Cement Handbook Calculation by Kurt E. Peray
Based of Calculation consist of :

Fuel Analysis Kiln Feed Analysis (Loss Free Kiln Dimensions

Basis)
AA Percent ash L1 Kiln length m
AH Percent hydrogen CSi Percent SiO2 % L2 Kiln Diameter m
AC Percent carbon CAl Percent Al2O3 % Effective bruner tip
AN Percent Nitrogen CFe percent Fe2O3 % L3 orifice area m2
AO Percent oxygen CCa percent Cao % L4 Length of chain section m
AS Percent Sulpher CMg percent Mgo % L5 Total chain surface area m2
AM Percent Moisture CNa percent Na2O % Effective kiln feedend
AQ Heat value CK percent K2O % L6 throat area m2
CS percent SO3 % L7 Refractory thickness m
CIg percent igintion loss % Sum total of (all) chain
CM percent Moisture % L8 length m
L9 kiln shell thickness m
Heat Balance using Cement Handbook Calculation by Kurt E. Peray
Based of Calculation consist of :

Temperatures
Cliinker Analysis (Loss Free oC
TC Feed entering kiln
Basis) oC
TSa Secondary air
TPa Primary air oC
HSi Percent SiO2 % oC
TBe Kiln exit gas
HAl Percent Al2O3 % oC
TSt Cooler stack
HFe percent Fe2O3 % oC
TCl Clinker at cooler exit
HCa Percent CaO % oC
TF Fuel as fired
HMg percent MgO %
Average shell,lower
HS percent SO3 % oC
TZ1 third
percent alkalies (total as
Average shell,middle
HAlk Na2O) % oC
TZ2 third
HIg percent Ignition loss %
Average shell,upper
TZ3 third oC

T Kiln room oC
 Heat Balance

Enthalpy Enthalpy
Input Stream % Output Stream %
kcal/kg.clinker kcal/kg.clinker

17 11
Heat Inputs from the 646.48 64.67 Heat Required for clinker 419.29 41.95
Combustion of Fuel cooling

17
9
Heat Inputs from Sensible 0.73 0.07 567.85 56.81
Heat Loss with kiln exit gas
Heat in Fuel

8 9a
Heat Input from Sensible Heat 285.94 28.61 Heat Loss Due to Moisture in 73.27 7.33
In Kiln Feed Feed or Slurry

10 11
Heat Input from Cooler Air 18.12 1.81 Heat Loss with Clinker at 27.75 2.78
Sensible Heat Cooler Discharge
9
11
Heat input from Primary Air 1.10 0.11 131.27 13.13
Heat Loss at Cooler Stack
Sensible heat
11
Heat Losses By radiation on 23.78 2.38
Kiln Shell
Unaccounted losses -269.54 -26.96
Total 999.60 100 Total 999.60 100
Overall Energy Balance
(Simulation Result)
Equipment In (kJ/h) Out (kJ/h) Requirement (kJ/h)
2 3
CR-101 0.00.E+00
-9.8476.E+08 -9.8476.E+08
1 5
MI-101 0.00.E+00
-3.277E+08 -3.277E+08
3 6
MI-102 0.00.E+00
-9.848E+08 -9.848E+08
5 7
-3.277E+08
BR-101 -4.000E+04
6 -1.313E+09
-9.848E+08
7 8
CY-101 8.810E+07
-1.313E+09 -1.224E+09
8 10
RK-101 7.374E+08
-1.224E+09 -4.870E+08
10 11
E-101 -6.928E+08
-4.870E+08 -1.180E+09
11 12
MI-103 0.00.E+00
-1.180E+09 -1.180E+09
15 16
DR-101 0.00E+00
-3.572E+07 -3.572E+07
16 17
MI-104 0.00E+00
Energy Required per 1 kg Product

Total Energy Requirement perhour 132,630,000 kJ/h

With capacity 3041 tonnes product per day with 24 hour working time

kJ
132,630,000 24
h
= 1,043.92

3043 1000

CHAPTER III
MASS AND ENERGY
BALANCE
Process Simulation
Cement Manufacturing Process Simulation
Fuel Combustion Process Simulation
CHAPTER IV
HEAT INTEGRATION
Heat Integration Network
 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.
Cyclone Preheater

Mass (kg / 1 hr Cp m.Cp

basis)

Raw Meal 82480.8 2166.32 178,678,073.6

Flue Gas 270905.4 605.4 164,006,189.7

Q Flue Gas Raw Meal

Stage
transferred T in T out T in T out
33,055,764,2
1 478 293 27 228.552
31
30,732,926,7
2 650 478 228.552 415.94
45
26,623,291,1
3 799 650 415.94 578.271
92
16,259,862,4
4 890 799 578.271 677.413
06
19,654,778,7
5 1000 890 677.413 797.255
32
P
Block Flow Diagram
F
D
CHAPTER V
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)
 Net Heating Value % mass Fuel requirement Duty (kJ/hr)
(kJ/kg) (kg/hr)

Fuel
Coal 22950 0.7 13288.51582 422347000

Biomass 20610 0.3 5695.078209

Total mass 18983.59403

Target duty 422347000

Target Duty is the power requirement for rotary kiln. Total Mass is substituted by any
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.
CHAPTER V
UTILITY

Electricity
 EQUIPMENT ELECTRICITY REQUIREMENT

Usage Power Energy

No. Equipment Tag number Qty
Time (h) (kW) Required (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
 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)
 Power Generation

To prevent power outage, there should be built a power generator that might be used if there
is any disturbance and electricity failure from Perusahaan Gas Negara. Diesel power generator
is a common type of power generator that has been used by many cement plant, since solar
fuel has a higher calorific value and lower carbon dioxide emission than the coal fuel.

To count the total fuel and cost required, the SAIDI ( system average interruption duration
index) and SAIFI (system average interruption frequency) should be known first, we can get it
from data that surveyed and issued by BPPT in 2013, for West Java Province the SAIDI number
is 1.22 and for the SAIFI number is 1.89
 Specifications Value

Type 3612

Frequency 50 Hz

Minimum Rating 3550 kVA (2840 kW)

Maximum Rating 5375 kVA (4300 kW)

Speed 750 & 1000 rpm

Fuel Diesel

Fuel Consumption 100% Load 1200 L/h

The calculation of the fuel and cost for emergency diesel power generator (one hour basis):

Electricity Requirement = 95,183 kWh / 24 h = 4000 kW

Fuel Requirement = (1200L / 4000 kW ) 4300 kW = 1290 L
Fuel Requirement Corrected = Fuel Requirement SAIDI SAIFI
= 1290 L 1.89 1.22 = 2975 L

Solar cost from Pertamina is about IDR 8,200.00 per Liter for industrial category. So, the total
cost for electricity need in this basis is:
Fuel (Solar) Cost = IDR 8,200/L 2975 L = IDR 24, 395, 000.00
CHAPTER VI
Conclusion
 Conclusion

Cement is manufactured through several steps such as crushing, grinding, preheating, pre-calcining, clinker
production in rotary kiln, cooling and storing.
The cement plant is located in Cileungsi, Bogor, West Java.
The plant capacity is 911,448.25 per year or 3,103.8 tonnes cement per day.
The process selected to develop low carbon cement is by substituting limestone in clinker with fly ash, and
substituting coal as fuel by biomass.
The chosen process has lower CO2 emission compared to average CO2 emission by 55.4%
Total energy requirement per 1 kg cement is 1,043.92 kJ.
The main stream is solid, it is impossible to use heat exchanger to recover heat from stream. So, instead of applying
HEN, the heat integration in the plant is applied in the overall process
The plant needs fuel for 18.98 ton/hour, rounded up to 19 ton/hour, with coal 13.29 ton/hour and biomass 5.7
ton/hour.
Total annual plant operation electricity requirement is 31,410.324 MWh
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Thank You