Reducing Electrical Power Consumption SEEC by 2 kWh/ton Cement and Increasing Production Rate by 10-15 TPH through Diaphragm Slot Cleaning and Grinding Ball Addition in Chambers 1 and 2
Moh. Abdul Aziz, ST. IPU (a*), Dr. Ir. Rosalendro Eddy Nugroho, MM. (b)

Universitas Mercubuana UMB in Faculty Business & Economy Jakarta Indonesia

Abstract

This study focuses on enhancing the efficiency of cement production by implementing strategic maintenance and optimization measures, with the aim of reducing power consumption SEEC by 2 kWh per ton of cement while increasing the production rate by 10-15 tons per hour (TPH). The approach involves cleaning the diaphragm slots and adding grinding balls in chambers 1 and 2 of the cement mill. Data collection was conducted through a forum group discussion (FGD) and questionnaires to gather insights from various stakeholders. The results were analyzed using a fishbone diagram to identify root causes and a SWOT analysis to evaluate the strengths, weaknesses, opportunities, and threats associated with the proposed changes. Diaphragm slot cleaning reduces blockages and improves material flow, enhancing grinding efficiency. Additionally, adding grinding balls in the first and second chambers increases impact and attrition forces, resulting in finer grinding of raw materials. These measures collectively contribute to lower energy consumption and higher production rates. The study demonstrates that these modifications can achieve the desired outcomes without compromising cement quality, highlighting the importance of regular maintenance and strategic upgrades in achieving operational excellence and sustainability in cement manufacturing.

Keywords: Fishbone Diagram, Forum Group Discussion, Waste Management, Lean Production

Topic: Energy Efficiency in Business Operations