Optimization of Raw Mill Operating Parameters to Minimize SEEC While Maintaining Raw Mix Fineness Level at PT XYZ

Keynobi, Fikri (2015) Optimization of Raw Mill Operating Parameters to Minimize SEEC While Maintaining Raw Mix Fineness Level at PT XYZ. S1 thesis, Universitas Andalas.

Abstract

Cement industry in Indonesia's manufacturing sector must continuously improve operational and cost efficiency. Energy consumption optimization is one of key strategy for cement companies to enhance efficiency while maintaining competitive product prices. Energy costs account for 47.05% of total Cost of Goods Manufactured (COGM) in the cement industry, including electricity and thermal energy. PT XYZ faces challenges in optimizing electricity consumption. At PT XYZ’s plant, electricity costs are distributed, with the raw mill consuming 40.26%. This study focuses on optimizing raw mill operating parameters to minimize Specific Electrical Energy Consumption (SEEC) while maintaining raw mix fineness quality. Factor variables analyzed include Airflow (X1), Separator Speed (X2), Hydraulic Ratio (X3), and Differential Pressure (DP) Mill (X4). Data for this research was collected from PT XYZ’s Technical Information System. Design of Experiments (DOE) approach was applied using Response Surface Methodology (RSM) combined with Box-Behnken Design (BBD) for experimental design. Optimization was performed using overlaid contour plots and the desirability function. Optimized raw mill operating parameters are Airflow (X1) at 340 Nm³, Separator Speed (X2) at 1250.5 rpm, Hydraulic Ratio (X3) at 0.127 bar/tph, and Differential Pressure (X4) at 39 mBar. Response variables obtained are SEEC (Y1) at 15.6 kWh/ton and Fineness Level (Y2) at 4%. Potential electricity cost savings from implementing these optimized parameters reach Rp1,677,503,968.12/month or 20% of the total cost of electrical energy consumed by the Raw Mill.

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