PERSENTASI ASOSIASI SEMEN INDONESIA BIDANG TEKNIK

PT INDOCEMENT TUNGGAL PRAKARSA ,TBK

UNIT OPERASI CITEUREUP
2018

“ Kedepan, diversifikasi dan konservasi energi tidak lagi menjadi alternatif. Mulai sekarang,
Akan dilakukan hal hal besar yang membuat energi baru terbarukan dan Efisiensi energi menjadi

mainstream” – Mentri ESDM Republik Indonesia

“ Energy and Climate Protection are a core element of HEIDELBERGCement’s environmental Policy”

– HEIDELBERGCement Group
Kebijakan Energi Nasional
Peraturan Pemerintah No. 79/2014

Sumber : Handbook of Energy and Economic Statistics,KESDM

Sektor Industri adalah Pengguna Energi Utama

Sumber : Handbook of Energy and Economic Statistics,KESDM

 Pengelolaan Energi Nasional
Definisi Konservasi Energi (UU No. 30 Tahun 2007 dan PP No. 70 Tahun 2009)

Presentation
Background – Where Energy Uses at Cement Plant

Lighting
Utility
2%
2%
Mechanical
Energy
25%

Process Heat
71%
Source : drucklufttechnik/aircompressed – HZ Electrical Energy Efficiency Seminar
 Legal Background

Undang Undang No.30

Tahun 2007 Tentang Energi

Peraturan Pemerintah No.70

Tahun 2009 Tentang Konservasi Energi

Presentation
 PLANNING

Operational and Capex Budgeting

CSR issue (Project)

ENERGY
PLANNING
Improvement
QC Project
(CIP,GKM,etc)

Example
Energy Efficiency
Group Project
 Energy Efficiency (Group Project)

1. Project Tittle : Conversion of Electrostatic Precipitator (ESP) to Bag House Filter Plant 4
2. Implementation : November 2017 to January 2018
3. Step Implement :
• Project Study
• Schedulling and Preparation
• Execution
• Evaluation
4. Execution :
 Flow Sheet Plant 4

Production Suspension
Preheater
Kiln Line 4
ESP
Chimney Cooler

Gas
Air Compressed Condition
System Tower Chimney

ESP EP Fan 1

Separator

Mill
EP Fan 2
Fan

Clinker
Cooler

Mill
Drive
Impact Ball Mill
Hot Gas
Hammer Mill Clinker
Material Silos
Raw Mill
Silos
 Flow Sheet Plant 4

Production Suspension
Preheater
Kiln Line 4
ESP
Chimney Cooler

Gas
Air Compressed Condition
System Tower Chimney

Bag FIlter
BF Fan
Separator

Mill
Fan

Clinker
Cooler

Mill
Drive
Impact Ball Mill
Hot Gas
Hammer Mill Clinker
Material Silos
Raw Mill
Silos
 How’s Energy Efficiency ?
Electrical Line Diagram
Incoming 33 KV Incoming 33 KV

Outgoing 3KV Outgoing 3KV

Load to Kiln

Load to FM
Load To Coal Mill Load To PH

Trafo T2

Motor Motor Raw Mill Load

Trafo T6 Bag Filter fan
Kiln Bag Filter
(Water Pump)

LV 400V
ESP Transformator (400V/110kv)
Load Comp
 What’s Change?
1. Absolute Energy Decrease more than 70kw
Compressor ESP Water Pump Fan
Name Power
Before After Before After Before After Before After
Specificatio
320 584 720 0 180 330 700 1850 KW
n
Operation 192 350,4 432 0 108 60 650 900 KW
Delta 158,4 -432 -48 250 KW
Total -71,6 KW

70 KW Calculation :
1400
1380 Energy Electricity Saving/year
1360 = Power x Operating Hours x Electricity Cost
1340 = 70 KW x (24 H x 300d) x Rp. 1200
1320
1300
= Rp. 604,800,000/year
1280
1260
Before After

2. Specific Energy Consumption Decrease

0,55 kwh/ton
23,8

23,6 Calculation : Decrease 0,5 kwh/ton(raw mill)

23,4
Energy Electricity Saving/year
= 0,55 kwh/ton x 2,500,000 ton RM x Elect Cost
23,2
= Rp. 1,500,000,000/year
23

22,8
2017 2018
 What’s Change?
3. Eliminate Stop Due to CO Max

Calculation :
RM Power x Recovery Time (h) x Frequency
Recovery Time 45 - 60 Minute 3456 KW x 1 h x 20
Frequency/year 10 - 20 Times 69,120 KWh

Raw Mill Area Power Saving/year

= 3456 KW 69,120 KWh x Rp.1200
Rp. 84,944,000

4. Reduce Water Consumption and Water Pump Electricity

600 – 800 m3/day
4,3 kwh/m3
300 – 400 m3/day 3,06 kwh/m3
600 5
4,5
500 4
400 3,5
3
300 2,5
2
200 1,5
100 1
0,5
0 0
Before After Before After
 Energy Efficiency (GKM/CIP)

1. Project Tittle : Water Consume at GCT Optimization at Raw Mill Plant 14

2. Implementation : March 2017
3. Step Implement :
• Project Study
• Schedulling and Preparation
• Execution
• Evaluation
4. Execution :
 How’s Energy Efficiency ?

To Chimney Quarrying

Clinker Silo
Stacking and
Raw Coal
Reclaiming
To Chimney

Raw Mill Cement Mill

Clinker
(Grinding)
Coal Mill
GCT
Cement Silo
Hot Gas

Raw Meal

Coal
Hot Gas

Silos

Packing
House
Preheater Precalciner
Tertiary
Air

Secondary Air

Kiln Grate Cooler

Clinker
 How’s Energy Efficiency ?

Small Changes Big Leap

To Chimney 325 degC
Temp Preheater

Raw Mill
(Grinding)
260 - 320 degC 320 degC
GCT GCT
Raw Meal Hot Gas
130 degC
Hot Gas

Silos 250 degC

210 degC Bag
Inlet Mill
House To Chimney
Preheater Precalciner 90 - 99 degC
75 degC Outlet
Mill
Secondary Air

Kiln Red : Before Improvement

Clinker Grey : After Improvement
 What’s Change?
1. Absolute Energy Decrease 100-115 KW During Operation

120
Calculation : Motor Water Pump (160KW)
During Normal Operation 110 – 115Kw
100
Electric Energy Save :
80 115 Kw 115 KW x Operation Hours (Year) x Elect Cost
60 Rp. 966,000,000,000
40
Note:
20 Pump only run during Preventive Maintenance
For raw mill area (832 h/year)
0
Before After

2. Can increase raw mill feed due to temperature inlet increase

15 degC
To Chimney 90
Raw Mill
(Grinding) 85
GCT

Raw Meal
80
Hot Gas

degC
Silos
Hot Gas

75
Precalcine
Preheater r 70
Secondary Air

Kiln 65
Clinker Before After
 What’s Change?
3. Reduce Water Consumption

16 120000
14
100000
12 10 – 15 m3/h 92520 m3/year
10 80000
8 60000
6
40000
4
2 20000
0
0
Before After
Before After

4. Reduce Water Pump Electricity

8
700000
7
600000
6
500000
5 7,4 kwh/m3 684.648 Kwh/Year
400000
4
3 300000

2 200000

1 100000

0 0
Before After Before After
 Conclusion
Indonesian Government Regulation :
Ministry of environment and forestry : No.19 Year 2017
Category A : Operation Before 1990
Category B : Operation 1990 – 2013
Category C : Operation after 2014
Corporate Policy :
...”We will operate our company in
compliance with applicable Indonesian
Laws,
Regulations and relevant standards “....
...”We will prevent accident, occupational
disease and operate our company by
managing
Potential hazard and risk to create a secure,
safe, healthy and friendly environment

Conclusion:
Conversion Electrostatic Precipitator (ESP) to Bag House Filter not only make lower clean gas dust
emission but also has potential energy saving such as :
1. Absolute energy decrease
2. Has potential increase feed due to increase temperature inlet mill (specific energy)
3. Eliminate stop due to CO Max
4. Reduce Water consumption
5. Reduce Water Pump Operation
THANK YOU