COVERMILLOVERVIEW
POWER PLANTOVERVIEW
ENERGYCONSERVATIONEXPERIENCE and APPLICATIONofENERGY EFFICIENCYand CONSERVATIONinLECES PULP AND PAPER MILL

MAJORMINORPRESENTED BY

SUBAGYOCONCLUSION

COVERMILLOVERVIEWLocation
MillLECES PULP & PAPER MILLLOCATION
Leces-Probolinggo,
East Java, Indonesia

Production

POWER PLANTOVERVIEW
ENERGYCONSERVATIONCONCLUSIONLECESCOVERMILLOVERVIEW
Location
MillProduction

POWER PLANTOVERVIEW
ENERGYCONSERVATIONCONCLUSIONLECES PULP & PAPER MILLOVERVIEW
Consist of:a. Paper Machines
b. Bagasse Pulp Plant
c. Deinking Plant
d. Waste Water Treatment Plant
e. Steam Power Plant

COVERMILL MAIN PRODUCTIONMILLOVERVIEWLocation
MillProduction

POWER PLANTOVERVIEW
ENERGYCONSERVATIONCONCLUSION

Paper Machine

Kind of Product

Capacity

Paper Machine 1

Liner

30 ton/day

Paper Machine 2

Industrial paper,Writing paper

60 ton/day

Paper Machine 3

Writing & Printingpaper

Paper Machine 4

TissuePaper Machine 5

Newsprint, Writing& Printing paper

175

ton/day

30 ton day
275

ton/dayENERGY GENERATION AND
DISTRIBUTION DIAGRAM

COVERMILLOVERVIEW
5 unitPOWER PLANTOVERVIEW@ 90 ton/hour

PowerBoiler

Recovery
Boiler2 unit@ 40 ton/hour
44 BAR, 440oC

Diagram

HP Header
Demand27 MW

ENERGYCONSERVATIONMP Header19.4 MW

12.5 BAR, 200oC

Mill

LP Header
CONCLUSIONMill

6 BAR, 165oC

CTS

ECTS

EBPTS

Mill

19.4 MWCOVERMILL
OVERVIEW
POWER PLANTOVERVIEW

ENERGY GENERATIONand CONSUMPTION
HP Steam Generation

DiagramMill Operation

DemandMaximum264

Normal172

ENERGYCONSERVATION

ton/hourEnergy Consumption
MillElectricity
OperationMW

Steam (ton/hour)
6 barg

12 barg

33 barg

Maximum

33.87

100.1025.80

4.40Normal

24.55

65.00

2.20

4.40

CONCLUSION

COVER

ENERGY CONSERVATIONENERGYCONSERVATION
Aim

Aim :

Background

Decreasing excess energy usedPlanning
Implementation

CONCLUSION

Improved efficiency of the equipment

COVER

Background

ENERGYCONSERVATION
Aim
Background
Government
PolicyPower Plant
Performance

Planning
Implementation

CONCLUSION

1.
2.
3.
4.

Energy cost 24% of production cost
Government policy
Environment issue
Power Plant performance

COVER
ENERGYCONSERVATION
By PTKL

Government Policy
Indonesian Government Policy:
Decreased the subsidy of the fuel oil (since 2001)

AimBackground

FUEL PRICE
Government
Policy12Power Plant
Performance

Implementation

US$/MMBTu

Planning

109.66

9.66

8
5.014

64

3.67

2.96
2.67

3.2

20

1.07

4.18

3.3

4.36

2.2

1.9

1.3

1.4

1.6

1.7

1.9

2001

2002

2003

2004

2005

CONCLUSION
OIL

GAS

COAL

2006

COVER
ENERGYCONSERVATION
By PTKL
Aim
Background
Government
PolicyPower Plant
Performance
BoilerDeterioration
TurbineDeterioration
Low Power
FactorPlanning
Implementation
CONCLUSION

POWER PLANT PERFORMANCE
Efficiency Power Plant decrease,caused by:
1. Boiler Deterioation
2. Steam Turbine Deterioration3. Low Power factor

COVER
ENERGYCONSERVATION
By PTKLBOILER DETERIORATION

Aim
Background
Government
PolicyPower Plant
Performance
BoilerDeterioration
TurbineDeterioration
Low PowerFactor

1.

SLAG AND DEPOSIT
AT FIRE SIDE
DUE TO LOWQUALITY OF OIL

2. SCALE AND FLAKE AT
FIRESIDE
HIGH TEMPERATURE
CORROSION

Planning
Implementation
CONCLUSION

3. RUPTURE
OVERHEATINGCOVER
ENERGYCONSERVATION
By PTKL
Aim
Background
Government
PolicyPower Plant
Performance
BoilerDeterioration
TurbineDeterioration
Low Power
FactorPlanning
Implementation
CONCLUSIONSTEAM TURBINE
DETERIORATION
9 Capacity of Extraction Steam Turbine (ECT) is 27 MW.
9 Due to cracking at shaft of ECT, this turbine operate
maximum at 16 MW, so to fulfill electricity demand thePower Plant should operate ECT and CT
9 The operation of ECT and CT need more steam about
8 ton/hour
9 Potensial loss USD 1 million/year

COVER
ENERGYCONSERVATION
By PTKL
AimBackground

LOW POWER FACTOR
9 At 2000 the power factor at Power Plant was 0.74
(at power generation)

Government
Policy9 Operation steam turbine could not optimize

Power Plant
Performance
BoilerDeteriorationTurbine
Deterioration
Low Power
Factor

9 More motor and electricity equipment burnt

Planning
Implementation
CONCLUSION

COVER
ENERGYCONSERVATION
By PTKL
Aim
Background
Planning
Comparisonof Gas and Coal
Implementation
Major
Implementation
Minor

CONCLUSION

Planning
A. Major
1. Short term
1a. Modified from oil burner to gas burner(done, 2002-2003)
1b. Retubing (done, 2002)
2. Long term (future expansion, 2007-2009),
Changing the fuel from gas to coal
3. Repair Extraction Steam Turbine (ECT, 2007)
4. Install/adding capacitor (in progress)
B. Minor
1. Adding Economizer (done)2. Operation Pressure Reducing Valve (PRV, done)
3. Extract Steam Control (done)
4. Replace and or repair steam traps were not working
properly, piping system were leak (in progress)

COVER
ENERGYCONSERVATION
Aim

Comparison of the Gas Fired andCoal Fired Boiler
No

Description

Unit

Existing(Gas FiredBoiler)**

CoalFiredBoiler

1

Efficiencysystem%

54.2

51.6

2

Fuel cost

US$/year(million)

14

8.8

3

Saving

US$/year(million)

-

5.2

4

Investment

US$(million)-

17

Background
Planning
Comparison
Implementation

CONCLUSION** Initial, after modified from oil fired

COVERENERGYCONSERVATION
By PTKL
AimBackground
Planning
Implementation
Major
Gas FiredBoiler
Technical Aspect
Economic Aspect
Environment Aspect
Install/Adding
Capacitor
Implementation
Minor

CONCLUSION

IMPLEMENTATIONMAJORSHORT TERM
MODIFIED OIL FIRED BOILER
toGAS FIRED BOILER(Fuel Conversion, had been done)COVER

Gas Fired Boiler
ENERGYCONSERVATION
By PTKLTechnical Aspect

AimBackground
Planning
Implementation
Gas FiredBoiler
Technical Aspect
Economic Aspect
Environment Aspect
Minor

CONCLUSION

1.

No need atomizing and heater forgas
steam demand for no load decrease
from 50 ton/hour to 42.5 ton/hour
2. The superheater and evaporator moreclean- Efficiency the boiler increase- Maintenance cost decrease- Availability increase
3. The quality of gas remaining constantCOVER

Gas Fired Boiler
ENERGYCONSERVATION
By PTKL

Economic Aspect

Aim

Energy Cost

Background

Gas Fired

30

Planning

2520

Implementation
Gas FiredBoiler%

Economic Aspect
Environment Aspect

Minor

CONCLUSION

Oil Fired

15

17.0

14.5

105

Technical Aspect

24.0

6.502001

2002

2003

2004

Year

Investment :USD 1,600,000(5 power boilers)
Saving :USD 11,400,000/year
Payback period:± 2 months

COVER
ENERGYCONSERVATION
By PTKLAim

Gas Fired Boiler

Environment Aspect
1. Reduce energy consumption

Background

Energy Consumption
Planning
500

Implementation

Technical Aspect
Economic Aspect
Environment Aspect
Capacitor
Implementation
Minor(000) MMB T U /m on th450

Gas Fired
Boiler400

Oil350
Gas

300
250
200
150
5,000 6,000 7,000 8,000 9,000

10,000 11,000 12,000 13,000 14,000 15,000
Paper Production (ton/month)

CONCLUSION

COVER
ENERGYCONSERVATION
By PTKL

Environment Aspect

AimBackground
Planning
Implementation
Gas FiredBoiler
Technical Aspect
Economic Aspect
Environment Aspect

2. Reduce green house effect byreducing CO2 emission
Lesser CO2 emission occurred by;
1. Carbon content in gas is about 71%, otherwise
86% in oil
2. Increasing efficiency at steam generation
Paper production
ton/year
140,000
Fuel Consumption
Oil
Natural gas

Capacitor

MMBtu/ton

33.50

m3/ton0.87

MMBtu/ton

25.82(000)Nm3/ton

0.73

Fuel Consumption
Kind of Fuel
Oil

CONCLUSION

Gas Fired Boiler

Natural gas

m3(000)Nm3

CO2 emission
ton357,612

121,280
101,615

181,732
175,879COVER
ENERGYCONSERVATION
By PTKLINSTALL/ADDING CAPACITOR
POWER FACTOR AND HEAT RATECORELATION

Aim
9.0

Background

Implementation
Major
Gas Fired
BoilerCapacitor

HEAT RATE ,TON STEAM/MW

Planning

8.0
7.0
power factor 0.74

6.0
5.0
power factor 0.80

4.0
3.0
2.0
1.0

Implementation
Minor

10.0

10.5

11.0

11.5

12.0

12.5

13.0

13.5

14.0

POWER GENERATION (MW)CONCLUSION

Technical Aspect
1. Less steam consumption, less fuel2. Turbine operate optimum
3. Less Motor & equipment burn

Economic Aspect
Investment : USD 200,000
Saving: USD 800,000/year
Payback period: ± 3 months

COVER
ENERGYCONSERVATION
By PTKL
Aim
Background
Planning
Implementation

ENERGY CONSERVATION

Major

MINOR

Minor
Adding Economizer
Operation PRV
Extract SteamControl

CONCLUSION

COVER
ENERGYCONSERVATION
By PTKLAim

ADDING ECONOMIZER

Background
Planning
Implementation
Major
Minor
Adding Economizer
Operation PRV
Extract SteamControl

CONCLUSION

done at 5 power boiler
Stack temperature
Before: 180 oC
After
: 160 oC Efficiency increase: 1%
Each boiler
Investment USD 78,000
Saving
USD 28,600/year
Payback period 2.7 years

COVER
ENERGYCONSERVATION
By PTKL
Aim
Background
Planning
Implementation
Major
Minor

OPERATION PRV
Problem
9Valve slightly sticky and difficult to open once it is closed.
9
Kept manually opened ± 20%, higher than actual demand9
PRV MP to LP also opened 20% automatically
Program (done)
Repair PRV HP to MP
Result99

PRV MP to LP closed, efficiency of ECT improve
Save expected 1 ton steam HP/hour equal USD 12/hour

Adding Economizer
Recovery
BoilerPowerBoiler

Operation PRV

44 BAR,440oC

HP Header

Extract SteamControl

12.5 BAR,
200oC

MP HeaderMill

CONCLUSIONLP HeaderMill6 BAR,
165oC

CTSEC
TS

EBPTS

MillCOVERENERGYCONSERVATIONEXTRACT STEAM CONTROL
Problem

Aim
Background
Planning
Implementation
Major
Minor

99Extract steam controlled about 6.5 bar
Steam required at paper mill 2.5 bar; 140oC

Program (done)

Reduced pressure controlled to 6.0 bar
Result99Improve efficiency of ECTSave expected 1 ton steam HP/hour equal US$ 12/hour
Recovery
BoilerPowerBoiler

Adding Economizer

HP Header

Operation PRV
Mill

12.5 BAR,
200oC

MP HeaderMill

CONCLUSIONLP HeaderMill

6 BAR, 165oC

CTS

ECTS

EBPTS

Extract SteamControl

44 BAR,440oC

COVERMILLOVERVIEW
POWER PLANTOVERVIEW
ENERGYCONSERVATION
MAJOR
MINOR

CONCLUSIONCONCLUSION
1. Program in energy conversion from fuel oil to gas had
been done, apparently to reduce the energy cost from
USD 22.05 million/year to USD 11.45 million/year.
2. The future expansionis is changing the fuel from gasto coal
3. Increasing power factor from 0.74 to 0.80 reduce heatrate of power generator up to 6%.
4. Improve power factor by installing new capacitor,
target from 0.80 to 0.90 is still in progress.
5. Due to tight production and marketing schedule
repairing the shaft of ECT will be done after coal fired
boiler build.