Practical Methods of Co-Benefit Diagnosis and Activity

Center for Agro – Based Industry (BBIA)

SEKRETARIAT SATGAS CITARUM

BANDUNG, FEBRUARY 12TH 2020

Introduction

79.2

16.5

2.7 1.5

Electricity Ceramic and cement

Pulp and Paper Others

Indonesian Coal Production and Consumption

(http://iesr.or.id/)

Coal Consumption by Industry in Indonesia

(quitcoal.info/consumption)

• Indonesia’s industry growth depends on long-term availability of energy

• Sugar, Canning Food, Noodle, Beverages are industries using coal energy

Boilers Efficiency on Agro-based Industries

Boilers is one of the Energy Cost Center in industry

The efficiency of boiler depend on the operational load

The inefficiency sources: Combustion system, excess air, flue gas, insulation, blowdown, etc.

Benefits effective energy savings on boiler

Environmental friendly, reduce CO2 emission

Reducing cost of energy

Reducing production costs

Heating loss in dry flue gas

Heating loss from H2 in flue gas

Heating loss because water content in fuel

Heating loss because water content in air

Heating loss in unburned material residue

Heating loss because radiation and uncountable

Heat inside steam

Fuel

ENERGY AUDIT

• Energy Audit is a technique used to

calculate energy consumption in buildings

and lend ways to save it.

• Energy audits are needed because we need

measured energy usage, It also monitors

energy usage on a time scale.

• Increase knowledge about energy efficiency,

identify energy costs used, identify and

minimize wasted things

CRITICAL POINTS

• Coal ;

• Blower volume;

• Oxygen temperature & concentration of

exhaust gases

• Steam pressure

• Feed water

• Blowdown water

Critical points in this coal boiler activities:

• Exhaust gas treatment

devices (use of filter in the

flue);

• Use of thermal insulation

material;

• Steam leaks from steam

traps.

Additional actions needed :

COAL

• Expected calorific value of coal: ± 6000 kcal/kg

• The actual calorific value measured by team: ± 5400

kcal/kg

• The difference of this value cause a decrease in the

effectiveness of the boiler to produce steam.

Study at PT . ABC President found that:

• Coal is a combustible black or brownish-black

sedimentary rock, formed as rock strata called coal

seams.

• Coal is mostly carbon with variable amounts of other

elements; chiefly hydrogen, sulfur, oxygen, and

nitrogen.

COAL

• The calorific value of coal is one of parameter which decide the quality of coal.

• The calorific value of coal used needs to be ascertained as to its accuracy

Recommendation :

• If possible, measure at least once or twice a year or, if there are problems with

costs, ask the supplier who supplies the coal to inform the value and use that

value.

Calorific

Value ?

Water Quality for Boiler

Water quality for boiler feed is

very important to note, because:

• Can prevent scaling, corrosion,

foaming, and priming

• Can affect the steam pressure

produced

• Main requirement conductivity

<200 µS

• Good quality feed water for boilers• Clean water does not contain salt• Condensate water conductivity: <10 µS /

cm, if >10 µS/cm then there is a possibility : The presence of contaminants in

boiling water There is a small hole or leak in the

heat exchange Equipment that uses steam, needs to

be checked

Steam condensate water:Feed water:

Water Quality for Boiler

water intentionally wasted from a boiler to avoid concentration of impurities during continuing evaporation of steam. If boiler feed water still contains impurities, as dissolved solids (TDS). The accumulation of TDS in the boiler causes blockage and over heating.

• Blowdown water TDS standard: < 7 µS/cm• Rasio Blowdown < 3 %

Blowdown water is

• Steam is a gas produced from a process called evaporation.

The raw material used to produce steam is clean water

• In the process sometimes there is a loss of heat in the

steam path / line steam, causing energy losses

HEAT LOSS

HEATING LOSS

•Steam loss is caused by two main

factors, namely:

1.Simultaneous transfer rate that

occurs in a distribution channel;

2.Steam trap leaks.

Need to check and

repair periodically so

that any damage that

occurs can be known early.

Oxygen

• Oxygen or acid is a chemical element in the periodic table system which has the

symbol O and atomic number 8. It is a class of elements of the chalkogen and

can easily react with almost all other elements (mainly oxide).

• Oxygen is needed for all combustion processes. By increasing the concentration

of oxygen in combustion air through the addition of relatively pure oxygen, the

flame temperature increases, the heat transfer rate increases, and overall

combustion efficiency increases.

Relationship between flue gas temperature and heat loss by oxygen concentration

OXYGEN

LATEST TECHNOLOGY FOR EFFICIENCY

STEAM PRESSURE GENERATOR

If the steam is not sufficient for production needs, then the steam is not flowed to the generator. Instead, steam is sent directly to the production line.

LATEST TECHNOLOGY FOR EFFICIENCY

High Performance Compressor Kobelco ALE65WⅢ-vH

HIGH PERFORMANCE COMPRESSOR

Conventional compressors always consume > 30 kW even when no compressed air is produced

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