bab 2
May 7, 2019 | Author: Muhammad Zaqzulkan | Category: N/A
Short Description
bab 2 yes bos yeah...
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BAB II DIAGRAM ALIR DAN MATERIAL BALANCE
Dalam pengolahan batugamping diperlukan ukuran sesuai dengan produk yang diinginkan. Untuk itu diperlukan peremukan sebagai tahap kominusi untuk menyesuaikan dengan target produksi dalam pengolahan batugamping.
Produk dari Penambangan Penambangan Didapatkan Didapatkan :
-800+500
mm = 12%
-500+250
mm = 18%
-250+75
mm = 32%
-75+25
mm = 25%
-25
mm = 13% 100%
Kapasitas
= 80 ton/jam
1 hari alat beroperasi
= 7 jam
1 minggu beroperasi
= 6 hari kerja
Target produksi
= 80 ton/jam x 7 jam/hari = 560 ton/hari x 6 hari/minggu = 3360 ton/minggu
2.1.
Densitas batugamping = 2.35 ton/m 3
Ukuran umpan terbesar = 800 mm
Produk yang diinginkan = -600 mm
Diagram Alir
Rencana Proses pengolahan batugamping pada rancangan pabrik ini akan dijelaskan dalam diagram alir berikut ini, sehingga dapat diketahui dan dipahami alur peremukan batugamping di PT. Javalimestone, berikut merupakan diagram alir tahap kominusi di PT. Javalimestone Crusher :
I Gede Sathya Vidyana/112140076 Ardhiansyah Fitria Sukma P/112140104 P /112140104
1
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ROM Dump Truck
WHEEL LOADER Kapasitas Bucket : 9,3 m³ Lebar Bucket : 4,815 m
STOCKYARD Wheel Loader HOPPER
FEEDER
IMPACT CRUSHER
METSO (PAN FEEDER PF525) Capacity : 500 Tph
IMPACT CRUSHER Setting :60 mm RR :800/100 = 8 NP 1210 (Metso Mineral) Mineral)
BELT CONVEYOR Lebar belt : 16 inch
VERTICAL ROLLER MILL
VERTICAL ROLLER MILL Clirik HRM 53 End Product :30-1000 mesh
BLOWER
CYCLONE
2.2
Underflow -30 +600 Mesh
Overflow -600 Mesh
TAILING
PACKING
Material Balance
1. Material Dari ROM
Bongkah-bongkah hasil peledakan di pit penambangan batugamping yang ditempatkan pada tempat penampungan sementara (Stock Yard) sebelum masuk ke preparasi dinamakan dengan ROM (Raw of Material). Dimana perlu dilakukan proses peremukan untuk mendapatkan hasil yang sesuai dengan target produksi. Bongkah – bongkah bongkah hasil peledakan di kuari penambangan dibawa ke stock yard menggunakan Dumptruck.
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Distribusi partikel umpan dari ROM :
- 800 + 500 mm
= 12 % x 80 ton/jam
= 9,6
- 500 + 250 mm
= 18 % x 80 ton/jam
= 14,4 ton/jam
- 250 + 75 mm
= 32 % x 80 ton/jam
= 25,6 ton/jam
- 75 + 25mm
= 25 % x 80 ton/jam
= 20
- 25 mm
= 13 % x 80 ton/jam
= 10,4
= 100 %
= 80 ton/jam
Total
2.
ton/jam
ton/jam ton/jam
Back Hoe
Untuk melakukan pemuatan ke alat pengangkutan digunakan alat muat yaitu back hoe dengan spesifikasi sebagai berikut:
Merk
: Komatsu
Type
: PC800LC-8
Bucket Capacity
: 6 M3
Overall Length
: 13,995m
Overall Width
: 4,335 m
Overall Height
: 4,85 m
3.
Dump Truck
Untuk memindahkan material dari tambang ke stock ke stock yard digunakan digunakan dump truck dengan spesifikasi :
Merk
: Komatsu
Type
: Komatsu HD 326-8
Capacity
: M3
Overall Length
: 9,355 m
Overall Width
: 5,395 m
Overall Height
: 4,4 m
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Kecepatan 40 km/jam untuk dump truk dalam keadaan isi.
4. Stock Yard
Untuk menyimpan bongkahan batu andesit hasil peledakan diperlukan sebuah tempat untuk menyimpanan sementara sebelum dilakukan pengolahan terhadap material dari tambang tersebut. Tempat penyimpanan sementara tersebut biasa disebut dengan Stock Yard. 3.1 Dimensi Stock Yard
Kapasitas Stockyard dirancang untuk 7 hari
Umpan dari ROM
: 80 ton/jam
Densitas batugamping
: 2,35 ton/m 3
Kapasitas stock yard (yang dibutuhkan) dalam 7 hari : = 7 jam/hari x 7 hari x
/ , /
= 1668 m 3
Diketahui : Tinggi
=1m
Ɵ
= 36⁰
Dimisalkan stockyard berbentuk balok V
=pxlxt
P
= 2l
V
= 2l x l x t
1668 m 3 = 2l2 x 1,5
L=
= 28,88 ≈ 29 m 29 m
P = 2l = 2x29 = 58 m
Untuk dimensi persegi panjang atas
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DD’= CC’= 1,4 m 1,4 m CD
= AB + CC’ + DD’ = 30 m + 1,4 m + 1,4 m = 32,8 m
GG’ =
′ = = 1,38 ≈ 1,4 tn° tn°
CC’= GG’= 1,4 m 1,4 m CG
= BF + GG’ + CC’ = 60 m + 1,4 m + 1,4 m = 62,8 m
Jadi dimensi Stockyard sebagai berikut :
Luas Atas
= 29 m x 58 m = 1682 m 2
Luas Bawah
= 32,8 m x 62,8 m
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=
+ 1
= 1871 m 3 (lebih besar dari kapasitas yang dibutuhkan)
58m
62,8m 29m
32,8m
Gambar 2.2 Sketsa Stock Yard
Adapun distribusi Material dalam Stockyard Sebagai Berikut - 800 + 500 mm
= 12 % x 80 ton/jam
= 9,6
- 500 + 250 mm
= 18 % x 80 ton/jam
= 14,4 ton/jam
- 250 + 75 mm
= 32 % x 80 ton/jam
= 25,6 ton/jam
- 75 + 25mm
= 25 % x 80 ton/jam
= 20
- 25 mm
= 13 % x 80 ton/jam
= 10,4
= 100 %
= 80 ton/jam
Total 5.
ton/jam
ton/jam ton/jam
Wheel Loader
Untuk menumpahkan material dari stockyard ke hopper digunakan digunakan wheel loader
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Merk
: KOMATSU
Type
: WA 300L-3
Bucket Type
: General Purpose (Stock yard)
Maksimal Speed
: 34 km/jam
Jumlah Gears Maju
: 4
Jumlah Gears Mundur
: 4
Waktu Dump
: 2,5 detik
Lebar Bucket
: 2.740mm
Kapasitas Bucket
: 2,5 m32,1 m3 ( fill factor 80%)
Max Speed
: 34 km/jam
6. Hopper
Bongkahan-bongkahan Bongkahan-bongkahan batugamping dari stock yard dimuat dengan menggunakan wheel loader dan ditumpahkan ke dalam tempat/bak penampungan sementara sebelum masuk ke feeder. Bak tersebut dinamakan Hopper , dimana hopper didisign untuk memudahkan penumpahan material ke feeder yang dibentuk seperti corong. Hopper dibuat harus memperhatikan aspek
Dimensi hopper bagian atas lebih besar dari lebar l ebar bucket wheel loader
Dimensi hopper bagian bawah lebih kecil dari feeder
Menentukan ukuran hooper h ooper Kapasitas wheel wheel loader Perencanaan hooper
: 2,1 m³
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Volume hooper (V)
(La x Lb)] ) √ (La (11,375x3)] ) = (⅓ x 1,5 [ 11,375 + 3 + √ (11,
V
= (⅓ x T [ La + Lb +
= 10,108 m 3 3,25m
3,5 m 0,5 m 1m
1,2 m
2,5 m
Gambar 2.3 Dimensi Hopper Adapun distribusi material sebagai berikut : - 800 + 500 mm
= 12 % x 80 ton/jam
= 9,6
- 500 + 250 mm
= 18 % x 80 ton/jam
= 14,4 ton/jam
- 250 + 75 mm
= 32 % x 80 ton/jam
= 25,6 ton/jam
- 75 + 25mm
= 25 % x 80 ton/jam
= 20
- 25 mm
= 13 % x 80 ton/jam
= 10,4
= 100 %
= 80 ton/jam
Total
ton/jam
ton/jam ton/jam
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Merk
= Metso
Type
= Pan Feeder PF525
Lebar
= 1300 mm
Panjang
= 2500 mm
Power
= 11 kW
Capacity
= 500 tph
Maximum Feed size
= 900 mm
Adapun distribusi ukuran umpan feeder sebagai berikut - 800 + 500 mm
= 12 % x 80 ton/jam
= 9,6
- 500 + 250 mm
= 18 % x 80 ton/jam
= 14,4 ton/jam
- 250 + 75 mm
= 32 % x 80 ton/jam
= 25,6 ton/jam
- 75 + 25mm
= 25 % x 80 ton/jam
= 20
- 25 mm
= 13 % x 80 ton/jam
= 10,4
= 100 %
= 80 ton/jam
Total
ton/jam
ton/jam ton/jam
8. Corong
Corong digunakan karena lebar feeder lebih besar dari lebar mulut impact crusher Dimensi Feeder
= 1300 x 2500 mm
Dimensi mulut impact crusher= 1020 x 1080 mm
1. Bagian atas disesuaikan dengan lebar feeder lebar feeder
Panjang
: 2,5 m
Lebar
: 1,3 m
Luas atas (LA)
3,25 m²
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= (⅓ x 0,5 [ 3,25+ 1,1016 +
(3,25x1,1016)] ) √ (3,
= 1,0406 m 3 9. Impact Crusher
Peremukan batugamping menggunakan alat Impact Crusher mengingat material adalah batugamping yang memiliki sifat lengket. Adapun tujuan dari peremukan ini adalah untuk memperkecil ukuran butir sesuai dengan yang diinginkan. Umpan terbesar yang berasal dari tambang adalah 800 mm dengan produk terbesar dari hasil peremukan 100 mm sehingga didapatkan RR 8.
RRtotl = = 8 = Adapun jaw crusher yang digunakan adalah : Merk
= Metso
Type
= NP 1210
Setting
= 60 mm
Kapasitas
= 250 mtph
Produk terbesar
= 100 mm
Power
= 160 ku/220 HP
Distribusi ukuran umpan yang yang masuk ke ke Impact Crusher :
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Setelah dilakukan peremukan didapat distribusi ukuran produk (bersarkan grafik) sebagai berikut: - 100 + 80 mm
= 2 % x 80 ton/jam
= 1,6 ton/jam
- 80 + 60 mm
= 8 % x 80 ton/jam
= 6,4 ton/jam
- 60 + 40 mm
= 17 % x 80 ton/jam
= 13,6 ton/jam
- 40 + 20 mm
= 27 % x 80 ton/jam
= 21,6 ton/jam
- 20 + 10 mm
= 17 % x 80 ton/jam
= 13,6 ton/jam
- 10 + 5
mm
= 11 % x 80 ton/jam
= 8,8 ton/jam
-5
mm
= 18 % x 80 ton/jam
= 14,4 ton/jam
= 100 %
= 80 ton/jam
Total
10. Belt Conveyor
Densitas batugamping = 2,35 ton/m 3 = 146 lb/cuft Berdasarkan diagram alir yang dibuat, belt conveyor yang direncanakan pada ragkaian unit pengolahan batugamping adalah sebanyak 1 unit. Belt conveyor dengan spesifikasi alat sebagai berikut : -
Produk terbesar
= 100 mm = 3,93"
-
Merk
= Nordberg
-
Type
= TBC 500
-
Lebar belt
= 16"
-
Kapasitas belt
= 84 ton/jam
-
Kemiringan Idler
= 20
-
Kemiringan belt
= 15
°
°
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-
Capacity
= 350-510 tph
-
Fineness
= 30-1000 mesh
Dengan menggunakan spesifikasi alat tersebut maka didapatkan distribusi ukuran produk 30-1000 mesh, sehingga dipenuhi produk yang diinginkan yaitu -600 mesh dan dibutuhkan alat vertical roller mill 1 buah. Distribusi produk vertical roller mill adalah sebagai berikut : -
-30+600 mesh = 0% x 80 ton/jam
-
-600 mesh
=
0 ton/jam
= 100% x 80 ton/jam = 80 ton/jam
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BAB III PEMILIHAN ALAT
3.1 Dasar Pemilihan Alat
Data-data yang didapat, kamudian diolah sehingga dapat dibuat material balancenya dan pemilihan spesifikasi alatnya yang sesuai sehingga s ehingga nantinya dapat tercapai target produksi yang diinginkan. Sebelum melakukan pengolahan data, terdapat tinjauan umum dan tahapan-tahapan yang harus dilakukan.Tinjauan umum dan tahapan-tahapan pengelolaan itu adalah sebagai berikut : Tinjauan Umum :
Lokasi cadangan bahan galian
Besar cadangan bahan galian yang akan diolah
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Penentuan lokasi dan perhitungan luas area pabrik pengolahan serta area lain yang dibutuhkan seperti : stockpile, stockyard, kantor dsb. Beberapa hal yang perlu dipertimbangkan dalam pemilihan alat yang akan digunakan dalam peremukanandesit adalah sebagai berikut : 1. Pertimbangan segi teknis Pertimbangan secara teknis berguna untuk mengetahui alat yang akan dipilih agar sesuai dengan kondisi yang ada, baik masalah material, lokasi, kapasitas serta produksi yang diharapakan. diharapakan. Data-data yang diketahui di lapangan : a. Densitas Batu Andesit
= 2,5 ton / m3
b. Jumlah jam kerja aktif
= 8 jam / hari ( 1 shift )
c. Target produksi
= 120 ton/jam
d. Kapasitas umpan dari tambang = 120 120 ton/jam 3.2. Pemilihan Alat A. Back Hoe (ROM – Dump Dump Truck)
Untuk memindahkan material dari tambang ke dump truck dibutuhkan dibutuhkan alat muatdengan spesifikasi :
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45 s Produksi Back Hoe
= Capasitas Back Hoe x MA x EU = 3,29m3 x 0,8 x 0,8 = 2,1056 m3
Kapasita Dump Truck
= 16,8m3
Jumlah Pemuatan
=
16,8 m3 2,1056m3
= 7,97 = 8 kali Waktu Muat
= 8 x 45s = 360 s
Back Hoe yang dibutuhkan
=
80,64 ton / Jam 168ton / Jam
=
Taerget / Jam Pr odukDT / Jam
= 1 buah Back Hoe
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Capacity
: 60 Ton atau 23 M 3
Overall Length : 8,365m
Overall Width
: 4,515m
Overall Height : 3,380m
Kecepatan maksimum dumptruck adalah 70 km/jam. Jarak quary ke Stock yard adalah 4 km. Dalam pengangkutan pengangkutan dipilih :
Kecepatan 30 km/jam untuk dumptruk dalam keadaan isi
Kecepatan 40 km/jam untuk dump truck dalam keadaan kosong
Waktu yang dibutuhkan :
Waktu untuk mengisi bak truk, memutar truk dll
= 6 menit
Waktu berangkat dari tambang ke stockyard (pengangkutan)
= 6menit
Waktu menukar, menumpahkan
= 2 menit
Waktu kembali ke tambang
= 6menit
20menit Jumlah jam kerja aktif = 8 jam/ hari ( 1 shift ) Efisiensi kerja = 70% Produksi per hari = 120 ton/jam x 8 jam/hari = 960 ton/hari
+
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Gambar 3.2 Dump Truck C. Wheel Loader
Untuk menumpahkan material dari stockyard dari stockyard ke hopper digunakan digunakan wheel
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: ( 70 + 27 + 20 + 3 ) detik deti k = 120 detik
= 30 / = 48 / /3 3 Target produksi 120 ton/jam : , ton/m
Banyak pengangkutan dalam 1 jam :
Kapasitas Wheel Loader : : 5,25 ton/jam x 80% = 4,2 ton Kapasitas Wheel Loader = = 4,2 ton/trip x 30 trip/ jam = 126 ton/jam
Wheel Loader yang Loader yang dibutuhkan
:
=0,95 ≈1 ℎ j
≈ 2 menit
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Gambar 3.4
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P an F eeder
Dengan spesifikasi seperti berikut: berikut:
Pan Feeder :
- Merk
: METSO
- Type
: PF525
-
Length
: 2500 mm
-
width
: 1300 mm
- Power
: 11 kW
- Max. feed
: 900 mm
- Capacity
: 500ton/jam
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Jumlah yang dibutuhkan
: 1 jaw crusher
Gambar 3.6
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Jenis
: Cone Crusher
Type
: HP400
Feed opening
: 252 mm
Kapasitas
: 295-370 Stph
Setting
: 26 mm
Speed
: 700-1000 rpm
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Cone Crusher HP
G. Screening
Pemilihan alat Screen didasarkan pada Luas setiap screen Luas Screen =
()
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A
= Deck Terluas x F1 X F2 = 5,896ft2 x 1,1 x 1,1 = 7,1341ft2
Sehingga, digunakan ayakan dengan ukuran 2x4 ft (8ft2)
DDVS II
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Width
= 661mm
Length
= 1282 mm
Size
= 2x6 ft2
Luas
= 8 m2
Deck
=2
Power
= 2 x 30 kW
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Berat material yang diangkut = 120 ton/jam Sehingga dipilih mixed with 90% fines = 11, belt width 30” = 762 mm Dari dasar tersebut dipilih alat : Merk
: Metso
Model
: TBC 800
Widths x height
: 1030 x 505 mm
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The world's largest digital library
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The world's largest digital library
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The world's largest digital library
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The world's largest digital library
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The world's largest digital library
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The world's largest digital library
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The world's largest digital library
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The world's largest digital library
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The world's largest digital library
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The world's largest digital library
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The world's largest digital library
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The world's largest digital library
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The world's largest digital library
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The world's largest digital library
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The world's largest digital library
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The world's largest digital library
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The world's largest digital library
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The world's largest digital library
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The world's largest digital library
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The world's largest digital library
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The world's largest digital library
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The world's largest digital library
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The world's largest digital library
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The world's largest digital library
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The world's largest digital library
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The world's largest digital library
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The world's largest digital library
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The world's largest digital library
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The world's largest digital library
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The world's largest digital library
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