Research article
Vol 18 No 1 (2024): Volume 18, Number 1, 2024
Auditing approach at the finish mill to reduce energy consumption in cement production in indonesia
Teknik Kimia Universitas Jayabaya
P.T Indocement Tunggal Prakasa tbk., Jalan Mayor Oking Jayaatmaja, Citeureup Jawa Barat, Indonesia
Abstract
Cement plants are substantial consumers of both thermal and electrical energy, with these energy expenditures accounting for over 40% of the overall production cost. A pivotal factor in this energy-intensive process is the clinker finish mill, a cornerstone of the cement industry. This study, therefore, centered its focus on a detailed examination of the performance of a tube-type finish mill equipped with two chambers and steel balls as the grinding medium. The methodology employed in this investigation included a comprehensive longitudinal test involving a series of meticulous steps to gauge and optimize the mill's performance. These steps encompassed steel ball sampling, the measurement of material levels within the mill, filling degree assessment, and sampling at one-meter intervals along the mill, with each sample weighing approximately 1 to 2 kilograms. This meticulous approach involved sampling during a period when the mill was operating steadily for at least 8 hours before a controlled shutdown, known as a "crash stop." The subsequent evaluation of the tube mill's performance extended to both its operation during the steady run and the crash stop. The findings stemming from this thorough audit are nothing short of remarkable. It is clear that the systematic evaluation conducted in this study led to a substantial enhancement in the production capacity of the finish mill, boasting an impressive 13.24% increase. Furthermore, the study also recorded a significant reduction in specific power consumption, effectively decreasing it by 3%. These outcomes not only underscore the vital importance of regular audits in cement grinding operations but also demonstrate the tangible benefits in terms of both increased production capacity and improved energy efficiency. Such improvements are not only pivotal for cost reduction but also contribute to the sustainability and competitiveness of cement production in an increasingly energy-conscious and cost-competitive industrial landscape
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