Beruflich Dokumente
Kultur Dokumente
PNJ-HOLCIM INDONESIA
ELECTROSTATIC PRECIPITATOR
424-EPl
MAKALAH
'All praise to Allah SWT, the writers want to say thanks to Allah SWT,
because of God's blessing, the writers can finish Case Study Report -
Electrostatic Precipitator 424-EPl punctually without matter problems.
This report is made to complete the equipment study based on curriculum
of education between PT. Holcim Indonesia Tbk. and State Polytechnic of Jakarta
at fourth semester of studying period.
This report contains explanation about electrostatic precipitator 424-EPl
that used at NAR 2 plant, such as technical process, flow sheet in the cement
plant, general design, technical data, operational parameters, performance, general
problem, economical aspect, environmental and safety hazards.
Hopefully this report can be useful for the reader. For sure the writers
accept any critics and suggestion to improve this report.
11
TABLE OF CONTENT
PREFACE ............................................................................................................... ii
TABLE OF CONTENT ........................................................................................ iiii
CHAPTER I TECHNICAL PROCESS ................................................................... 1
A. Historical Invention of Electrostatic Field ............................................................. 1
B. Technical Process ................................................................................................... 2
CHAPTER II FLOW SHEET .................................................................................. 5
CHAPTER III TECHNICAL DATA ....................................................................... 6
CHAPTER IV OPERATION PARAMETERS ....................................................... 7
CHAPTER V PERFORMANCE ............................................................................. 8
CHAPTER VI GENERAL PROBLEMS ................................................................ 9
A. Mechanical ............................................................................................................. 9
B. Electrical ................................................................................................................ 9
C. Process/Operation................................................................................................. 10
CHAPTER VII MAINTENANCE ........................................................................ 11
A. Periodical Maintenance (Running Inspection) ..................................................... 11
B. Annual Maintenance ............................................................................................ 11
CHAPTER VIII ECONOMICAL ASPECT .......................................................... 12
111
CHAPTER I
TECHNICAL PROCESS
1
B. 'technical Process
2
glow extending into the gas a short distance beyond the surface of the discharge
electro4f.
Max. height
12,5m
The corona produces large number of gas ions, the positive ions being
immediately attracted to the discharge electrodes while the negative ions migrate
towards the collecting plates. Some of the moving ions attach themselves to dust
particles suspended in the gas between the electrodes. Dust particles are charged
either by bombardment by the ions moving under the influences of the electrical
field, or by ion diffusion, both type of charging taking place simultaneously. The
particles size determines which type of charging is predominant, ion diffusion
being the prevailing mechanism for particle sizes below 1 micron.
Dust that is easy to collect is mainly in the first zones, while difficult dust
is concentrated in the last zones. The difficult dust are very fine dust <1 micron
(having a high specific surface and thus enriched in absorbed substances e.g. Hg)
sand Salts (KCl, NaCl, K2S04, Na2S04).
to filter exit Collecting
Electrode
e
Gas flow
, direction Electron Charged
~
Dust particles
',,',,,\',,, Corona >-+-<
discharge
:;o-o
----
\\, Discharge
\ Electrode
Neutral Jonized
Gas molecules
Transformer/
Rectifier set
figure 4 shows the flowsheet diagram ofEP kiln at Narogong 2 plant. This
EP actually consist of two "smaller" EPs. But in this case study we only take up
one EP, 424-EPl.
['%
5
CHAPTER III
't
TECHNICAL DATA
Technical data of 424-EPl are given in Table 1. The technical data may
not be the same with current specification because there were some improvements
and modifications made, for example motor rapping has been replaced because
the old one has broken.
6
CHAPTER IV
OPERATION PARAMETERS
During operation, there are some parameters that critical to maintain the
performance of 424-EPl. The parameters are given in Table 2. If the peak high
value is reached, there will be alarm in Central Control Room (CCR) display. If
the high high value is reached, the EP will be shutted down and will cause
interlock to some other equipment, such as kiln.
7
CHAPTERV
PERFORMANCE
8000
7000
6000
5000
~running hour
4000
~failure
3000
2000
1000
0
2010 2011 2012
8
CHAPTER VI
GENERAL PROBLEMS
A. Mechanical
B. Electrical
9
C. Process/Operation
't
1. CO level too high due to fuel fluctuation
Ifthere's too much Alternative Fuel (AF) feed at pre-calciner, the CO
concentration tend to rise due to incomplete combustion, especially
when the AF is wet (high moisture).
2. Inlet temperature too high
Inlet temperature is maintained by spraying water in Conditioning
Tower.
10
CHAPTER VII
MAINTENANCE
B. Annual Maintenance
11
-~
CHAPTER VIII
ECONOMICAL ASPECT
Operation cost
Energy electric Rp/to 6,845.66
Manpower 827.13
Consumable 0.00
Others 0.00
Total operation cost per to 7,672.79
perhr 386,516.67
Maintenance cost (last 2 years)
Manpower Rp 720,000,000.00
Consumable Rp 0.00
Spare parts Rp 2,854,999,117.00
Others Rp 0.00
Total maintenance cost Rp 3,574,999,117.00
per to 168.78
perhr 8,502.19
12
Table 5 Cost of 424-EPl
Value
Investment Cost Rp5,389.37
Operation Cost Rp7,672.79
Maintenance Cost Rp168.78
Cost Diagram
11 Investment Cost
11 Operation Cost
13