Data Perhitungan

Kapasitas giling = 2900 TCD = Data tahun 2011

Sabut % tebu = 12,5 % = Dalam proses pengumpulan data
Uap tekanan 18 kg/cm2 = Hasil perhitungan kebutuhan uap
Pressure = 18 kg/cm2
Temperatur = 340 'C
Enthalpy = 745 kcal/kg
Uap tekanan 17 kg/cm2
Pressure = 17 kg/cm2
Temperatur = 325 'C
Enthalpy = 738 kcal/kg
Uap bekas 0.5 kg/cm2
Pressure = 0,5 kg/cm2
Temperatur = 150 'C
Enthalpy = 664 kcal/kg

# KEBUTUHAN UAP BARU

POWER HOUSE
1. T/A Shinko
Power maksimal = 3500 kW
Power terpakai = 2500 kW ( 71 % )
Steam consumption = 12 kg/kWh
G = N x Steam Consmpt
= 2500 x 12
= 30000 kg/h
= 30 ton/h

2. TA Kanis (OFF)
Power maksimal = 2500 kW
Power terpakai = 0 kW
N x 860
G = kg/jam
Δh
0 x 860
=
81,00
= 0 kg/jam
= 0,00 ton/jam
Jika TA Allen I dan II operasional, maka kebutuhan uap :
G = 2 x 0,00
= 0,00

STASIUN GILINGAN
1. Turbin CC II (EBARA)
Power = 298 kW
Power terpakai = 238 kW
Inlet steam = 17 kg/cm2
Steam chest = 12 kg/cm2

Power needed ( N' ) :

12 x 238
N' =
 N' =
17
= 168 kW

Steam consumption = 14,0 kg/kWh

G = N x Steam Consmpt
= 168 x 14,0
= 2356,0 kg/h
= 2,36 ton/h

2 Turbin Unigrator (DRESER REND)

Power = 820 kW
Power terpakai = 660 kW
Inlet steam = 17 kg/cm2
Steam chest = 7 kg/cm2

Power needed ( N' ) :

7 x 660
N' =
17
= 272 kW

Steam consumption = 25,0 kg/kWh

G = N x Steam Consmpt
= 272 x 25,0
= 6794,1 kg/h
= 6,79 ton/h

3 Turbin Penggerak Gilingan I (DRESER REND)

Power = 328 kW
Power terpakai = 286 kW
Inlet steam = 17 kg/cm2
Steam chest = 7 kg/cm2

Power needed ( N' ) :

7 x 286
N' =
17
= 118 kW

Steam consumption = 25,0 kg/kWh

G = N x Steam Consmpt
= 118 x 25,0
= 2944,1 kg/h
= 2,94 ton/h

4 Turbin Penggerak Gilingan II (DRESER REND)

Power = 328 kW
Power terpakai = 198 kW
Inlet steam = 17 kg/cm2
Steam chest = 7 kg/cm2

Power needed ( N' ) :

7 x 198
N' =
17
 = 82 kW

Steam consumption = 25,0 kg/kWh

G = N x Steam Consmpt
= 82 x 25,0
= 2038,2 kg/h
= 2,04 ton/h

Total kebutuhan uap stasiun gilingan :

G = 14,13 ton/jam

STASIUN KETEL
1. TU penggerak FWP KU. Stork I
Daya turbin = 75 HP = 56,0 kW
Asumsi tenaga terpakai = 95 %
Tekanan uap masuk = 17 kg/cm2
Kebutuhan uap :
N x 860
G = kg/jam
Δh
1 x 56,0 x 860
=
73,66
= 620,57 kg/jam
= 0,62 ton/jam

2 TU penggerak FWP KU. Stork II

Daya turbin = 75 HP = 56,0 kW
Asumsi tenaga terpakai = 95 %
Tekanan uap masuk = 17 kg/cm2
Kebutuhan uap :
N x 860
G = kg/jam
Δh
1 x 56,0 x 860
=
73,66
= 620,57 kg/jam
= 0,62 ton/jam

3 Turbin penggerak IDF JTA

Power = 191 kW
Power terpakai = 191 kW
Inlet steam = 18 kg/cm2
Steam chest = 12 kg/cm2

Power needed ( N' ) :

12 x 191
N' =
18
= 127 kW

Steam consumption = 14,0 kg/kWh

G = N x Steam Consmpt
= 127 x 14,0
 = 1782,7 kg/h
= 1,78 ton/h

4 Turbin penggerak FDF JTA

Power = 59 kW
Power terpakai = 59 kW
Inlet steam = 18 kg/cm2
Steam chest = 7 kg/cm2

Power needed ( N' ) :

7 x 59
N' =
18
= 23 kW

Steam consumption = 25,0 kg/kWh

G = N x Steam Consmpt
= 23 x 25,0
= 573,6 kg/h
= 0,57 ton/h

5 Turbin Penggerak FWP JTA

Power = 59 kW
Power terpakai = 59 kW
Inlet steam = 18 kg/cm2
Steam chest = 7 kg/cm2

Power needed ( N' ) :

7 x 59
N' =
18
= 23 kW

Steam consumption = 25,0 kg/kWh

G = N x Steam Consmpt
= 23 x 25,0
= 573,6 kg/h
= 0,57 ton/h

6 Uap Pemanas Deaerator

Kondisi uap pemanas :
Tekanan uap = 17 kg/cm2
Temperatur uap = 325 'C
Enthalpy = 738 kJ/kg
Air pengisi ketel :
m ( JTA ) = 40 + 0.1 x 40 ton/jam = 12 kg/dtk
m ( Stork I ) = 20 + 0.1 x 20 ton/jam = 6,1 kg/dtk
m ( Stork II ) = 20 + 0.2 x 20 ton/jam = 6,1 kg/dtk
T in = 60 'C
T out = 100 'C
Cp = 1,007 kJ/kg'C
Kebutuhan uap pemanas deaerator :
Q (CC) = m x Cp x ΔT
= 12 x 1,007 x ( 100 - 60 )
 = 492,31 kJ/dtk
G (CC) = Q/h
492,31 x 3600
=
738 x 1000
= 2,40 ton/jam

Q (St I) = m x Cp x ΔT
= 6 x 1,007 x ( 100 - 60 )
= 246,16 kJ/dtk
G (St I) = Q/h
246,16 x 3600
=
738 x 1000
= 1,20 ton/jam

Q (St II) = m x Cp x ΔT
= 6 x 1,007 x ( 100 - 60 )
= 246,16 kJ/dtk
G (St II) = Q/h
246,16 x 3600
=
738 x 1000
= 1,20 ton/jam

Total kebutuhan uap ST. Ketel

G = 8,98 ton/jam

MESIN UAP DI STASIUN TENGAH DAN PUTERAN

Tenaga yang diperlukan ( T ), Hugot 1972, p.825 :
T = 0,0736 x V x n (HP)
3
V = volume silinder dalam ft
2
= S x L = 0.785 x D
L = panjang langkah dalam ft
n = Rpm mesin uap

Kebutuhan uap :
632 x T
G = ton/jam
Δh x Eff.th x 1000
Eff.th = 0,6 (slide valve engine,Tromp)

Data perhitungan
Uap baru tekanan rendah:
Pressure = 7 kg/cm2
Temperatur = 180 'C
Enthalpy = 668 kcal/kg
Uap bekas :
Pressure = 0,5 kg/cm2
Temperatur = 115 'C
Enthalpy = 647 kcal/kg

Mesin Uap L D n V T G
MU pompa vakum BP 2,62 1,64 60 11,06 48,86 2,45
 MU pompa vakum KP 2,62 1,64 60 11,06 48,86 2,45
Total 4,90

2
UAP BARU UNTUK SERVICE STEAM (TEK. 3 kg/cm )
1. Puteran SHS
Pemakaian uap = 20% x produksi SHS (Hugot 1972, p.745)
Produksi SHS = 250 ton/hari = 10 ton/jam
Kebutuhan uap = 2,1 ton/jam

Total kebutuhan uap untuk service steam :

G = 2,1 ton/jam

# KEBUTUHAN UAP BEKAS

Dasar Perhitungan :
Kapasitas = 2900 TCD
Nira Mentah % Tebu = 100 %
Brix Nira Mentah = 12,5 %
Nira Encer % Tebu = 105 %
Brix Nira Encer = 11,5 %
Brix Nira Kental = 64 %
Panas laten ( r ) Ube 0.5 kg/cm2 = 531 kcal/kg
Panas laten ( r ) Uni 0.25 kg/cm2 = 535 kcal/kg

1. Pemanas Pendahuluan ( Juice Heater )

J x C x ( t2 - t1 )
G =
rxp
J = berat NM%T
= 120,83 ton/jam
C = panas jenis NM
= ( 1 - 0.006 bnm )
= 0,9993 kcal/kg'C
p = faktor kehilangan panas pada heater
= 0,95 ( Hugot p.449 )

Pemanas Pendahuluan I :
120,83 x 0,9993 x ( 75 - 30 )
G =
531 x 0,95
= 10,771 ton/jam Ube

Pemanas Pendahuluan II :
120,83 x 0,9993 x ( 105 - 75 )
G =
531 x 0,95
= 7,1807 ton/jam Ube

Total kebutuhan Uap untuk Pemanas Pendahuluan :

G = 17,952 ton/jam

2. Badan Penguapan ( Evaporator )

Data Luas Pemanas ( LP ) : Jadwal sekrap BP :
2
BP 1 = 1000 m 4 - 5 - (3+1B) - 2
 2
BP 2 = 1000 m 4 - 5 - (3+1B) - 1A
2
BP 3 = 750 m
2
BP 4 = 750 m
2
BP 5A = 525 m
2
BP 5B = 525 m
2
LP terbesar = 4025 m
2
LP terkecil = 3550 m

bne
E = J x ( 1 - )
bnk
E = jumlah air yang diuapkan ( ton/jam )
J = berat NE%T
= 127 ton/jam
11,5
E = 127 x ( 1 - )
64
= 104,08 ton/jam

Jika BP 1 + 2 sebagai badan pertama :

2000
G = x 104,08
4025
= 51,7154 ton/jam
Skema BP operasional?
Jika BP 1B+2 sebagai badan pertama :
1750
G = x 104,08
3550
= 51,3056 ton/jam

3. Pan Masakan
Dari perhitungan material balance didapatkan data sbb :
% Brix Strop
Masakan % Tebu % Brix Faktor cuci
/Klare
Masakan A 20,17 93 81 1,27
Masakan C 5,01 95 86,5 1,32
Masakan D 9,55 98 80,0 1,38

Kebutuhan uap pemanas Masakan A :

%BrixMas.A
G = KG x Mas.A%T x ( - %BrixMas.A ) x faktor cuci
%BrixNK
0,93
= 120,83 x 0,2017 x ( - 0,93 ) x 1,27
0,64
= 16,192 ton/jam

Kebutuhan uap pemanas Masakan C :

%BrixMas.C
G = KG x Mas.C%T x ( - %BrixMas.C ) x faktor cuci
%BrixStropA
0,95
= 120,83 x 0,0501 x ( - 0,95 ) x 1,32
0,81
= 1,7807 ton/jam

Kebutuhan uap pemanas Masakan D :

%BrixMas.D
G = KG x Mas.D%T x ( - %BrixMas.D
 G = KG x Mas.D%T x ( - %BrixMas.D
(%BrixStropC+%BrixKlareD)/2
0,98
= 120,83 x 0,0955 x ( - 0,98
0,8325
= 3,14 ton/jam

Total kebutuhan uap pemanas Pan Masakan :

G = 21,113 ton/jam

NERACA UAP BARU

Produksi Uap Baru ton/jam Pemakaian Uap Baru ton/jam
KU JTA 35 ST. Listrik 30,00
KU Stork I 16 ST. Gilingan 14,13
KU Stork II 16 ST. Ketel 8,98
ST. Tengah dan Puteran 4,90
Service steam 2,1
Losses 5% 3,00
Surplus/(minus) 4,05

Total Produksi 67,15 Total Pemakaian 67,15

Perbandingan jumlah uap sebelum dan sesudah desuperheater :

h1 ( 0.5 ; 150 ) = 664 kcal/kg
h2 ( 0.5 ; 120 ) = 650 kcal/kg
r sprayer = 538 kcal/kg

G1 x ( h1 - h2 )
G2 = G1 +
r
G1 x ( 664 - 650 )
G2 = G1 +
538
G2 = G1 x ( 1 + 0,026 )
G1 : G2 = 1 : 1,026

NERACA UAP BEKAS

Produksi Uap Bekas ton/jam Pemakaian Uap Bekas ton/jam
ST. Listrik 30,78 Pemanas Pendahuluan 17,95 Bleeding untuk JH dan VP
ST. Gilingan 14,50 Badan Penguapan 51,72
ST. Ketel 9,21 Pan Masakan 21,11
ST. Tengah dan Puteran 5,03 Losses 5% 4,54
Surplus/(minus) -35,8

Total Produksi 59,52 Total Pemakaian 59,52

oses pengumpulan data
itungan kebutuhan uap

N x 860
G =
Δh
2500 x
=
81,00
= 26543 kg/jam
= 26,54 ton/jam
Kebutuhan uap turbin :
G = N' x 860
Δh
= 0 x 860
###
 faktor cuci

1,27

faktor cuci

1,32

%BrixMas.D ) x faktor cuci

%BrixMas.D ) x faktor cuci

0,98 ) x 1,38

Bleeding untuk JH dan VP belum diperhitungkan

 860
kg/jam
Δh
860
81,00
kg/jam
ton/jam
kg/jam