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EXPERIENCE and APPLICATION of
ENERGY EFFICIENCY and CONSERVATION
in LECES PULP AND PAPER MILL
SUBAGYO
PRESENTED BY
COVER
MILL OVERVIEW
POWER PLANTOVERVIEW
MAJOR
ENERGYCONSERVATION
MINOR
CONCLUSION
Location
LECES PULP & PAPER MILL LOCATION
LECES
Leces-Probolinggo, East Java, Indonesia
COVER
MILL OVERVIEW
Mill
Production
POWER PLANTOVERVIEW
ENERGYCONSERVATION
CONCLUSION
Consist of:a. Paper Machinesb. Bagasse Pulp Plantc. Deinking Plantd. Waste Water Treatment Plante. Steam Power Plant
LECES PULP & PAPER MILLOVERVIEW
Location
COVER
MILL OVERVIEW
Mill
Production
POWER PLANTOVERVIEW
ENERGYCONSERVATION
CONCLUSION
MILL MAIN PRODUCTION
275 ton/dayNewsprint, Writing & Printing paper
Paper Machine 5
30 ton dayTissuePaper Machine 4
175 ton/dayWriting & Printing paper
Paper Machine 3
60 ton/dayIndustrial paper, Writing paper
Paper Machine 2
30 ton/dayLinerPaper Machine 1
CapacityKind of ProductPaper Machine
Location
COVER
MILL OVERVIEW
Mill
Production
POWER PLANTOVERVIEW
ENERGYCONSERVATION
CONCLUSION
ENERGY GENERATION AND DISTRIBUTION DIAGRAM
Power Boiler
Recovery Boiler
MP Header
Mill
LP Header
Mill
HP Header44 BAR, 440oC
S S SMillCTECTEBPT
12.5 BAR, 200oC
6 BAR, 165oC
Diagram
Demand
COVER
MILL OVERVIEW
POWER PLANTOVERVIEW
ENERGYCONSERVATION
CONCLUSION
5 unit
@ 90 ton/hour
2 unit
@ 40 ton/hour
27 MW 19.4 MW19.4 MW
ENERGY GENERATION and CONSUMPTION
4.402.2065.0024.55Normal
4.4025.80100.1033.87Maximum
33 barg12 barg6 bargMW
Steam (ton/hour)ElectricityMill Operation
Energy Consumption
HP Steam Generation
172Normal
264Maximumton/hourMill OperationDiagram
Demand
COVER
MILL OVERVIEW
POWER PLANTOVERVIEW
ENERGYCONSERVATION
CONCLUSION
ENERGY CONSERVATION
Aim :
Decreasing excess energy used
Improved efficiency of the equipment
Aim
Background
Planning
Implementation
COVER
ENERGYCONSERVATION
CONCLUSION
Background
1. Energy cost 24% of production cost2. Government policy3. Environment issue4. Power Plant performancePlanning
Government Policy
Power PlantPerformance
Implementation
Aim
Background
COVER
ENERGYCONSERVATION
CONCLUSION
Government PolicyIndonesian Government Policy:
Decreased the subsidy of the fuel oil (since 2001)
Planning
Government Policy
Power Plant Performance
Implementation
Aim
Background
COVER
ENERGYCONSERVATION
By PTKL
CONCLUSION
FUEL PRICE
9.66 9.66
1.9
4.183.67
2.21.07
5.014
2.672.96
3.2 3.3 4.36
1.7 1.91.61.41.30
2
4
6
8
10
12
2001 2002 2003 2004 2005 2006
US$
/MM
BTu
OIL GAS COAL
POWER PLANT PERFORMANCE
1. Boiler Deterioation
2. Steam Turbine Deterioration
3. Low Power factor
Efficiency Power Plant decrease, caused by:
Planning
Government Policy
Power PlantPerformance
Implementation
Aim
Background
COVER
ENERGYCONSERVATION
By PTKL
CONCLUSION
BoilerDeterioration
Turbine DeteriorationLow Power
Factor
BOILER DETERIORATION
1. SLAG AND DEPOSIT AT FIRE SIDE
DUE TO LOW QUALITY OF OIL
Planning
Government Policy
Power PlantPerformance
BoilerDeterioration
Implementation
Aim
Background
COVER
ENERGYCONSERVATION
By PTKL
CONCLUSION
2. SCALE AND FLAKE AT FIRESIDE
HIGH TEMPERATURE CORROSION
3. RUPTURE
OVERHEATING
Turbine DeteriorationLow Power
Factor
STEAM TURBINE DETERIORATION
Capacity of Extraction Steam Turbine (ECT) is 27 MW.
Due to cracking at shaft of ECT, this turbine operate maximum at 16 MW, so to fulfill electricity demand the Power Plant should operate ECT and CT
The operation of ECT and CT need more steam about 8 ton/hour
Potensial loss USD 1 million/year
Planning
Government Policy
Power PlantPerformance
BoilerDeterioration
Implementation
Aim
Background
COVER
ENERGYCONSERVATION
By PTKL
CONCLUSION
Turbine DeteriorationLow Power
Factor
LOW POWER FACTOR
At 2000 the power factor at Power Plant was 0.74 (at power generation)
Operation steam turbine could not optimize
More motor and electricity equipment burnt
Planning
Government Policy
Implementation
Aim
Background
COVER
ENERGYCONSERVATION
By PTKL
CONCLUSION
Power PlantPerformance
BoilerDeterioration
Turbine DeteriorationLow Power
Factor
A. Major1. 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 coal3. Repair Extraction Steam Turbine (ECT, 2007)4. Install/adding capacitor (in progress)
Planning
Comparisonof Gas and Coal
Planning
ImplementationMajor
Aim
Background
COVER
ENERGYCONSERVATION
By PTKL
CONCLUSION
B. Minor1. 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)
ImplementationMinor
Comparison of the Gas Fired and Coal Fired Boiler
17-US$(million)
Investment4
5.2-US$/year(million)
Saving3
8.8 14US$/year(million)
Fuel cost2
51.654.2%Efficiency system
1
Coal Fired Boiler
Existing (Gas Fired Boiler)**
UnitDescriptionNo
** Initial, after modified from oil fired
Comparison
Planning
Implementation
Aim
Background
COVER
ENERGYCONSERVATION
CONCLUSION
MODIFIED OIL FIRED BOILER to
GAS FIRED BOILER(Fuel Conversion, had been done)
SHORT TERM
MAJOR
Gas Fired Boiler
ImplementationMinor
Technical Aspect
Economic Aspect
Environment Aspect
Planning
ImplementationMajor
Aim
Background
COVER
ENERGYCONSERVATION
By PTKL
CONCLUSION
IMPLEMENTATION
Install/AddingCapacitor
1. No need atomizing and heater for gassteam demand for no load decrease from 50 ton/hour to 42.5 ton/hour
2. The superheater and evaporator more clean- Efficiency the boiler increase- Maintenance cost decrease- Availability increase
3. The quality of gas remaining constant
Technical Aspect
Gas Fired Boiler
Minor
Technical Aspect
Economic Aspect
Environment Aspect
Planning
Implementation
Aim
Background
COVER
ENERGYCONSERVATION
By PTKL
CONCLUSION
Gas Fired Boiler
Energy Cost
6.5
14.5
24.0
17.0
0
5
10
15
20
25
30
2001 2002 2003 2004
Year
%
Gas Fired
Economic Aspect
Oil Fired
Investment : USD 1,600,000(5 power boilers)
Saving : USD 11,400,000/year
Payback period: ± 2 months
Gas FiredBoiler
Minor
Technical Aspect
Economic Aspect
Environment Aspect
Planning
Implementation
Aim
Background
COVER
ENERGYCONSERVATION
By PTKL
CONCLUSION
Gas Fired Boiler
Environment Aspect1. Reduce energy consumption
Energy Consumption
150
200
250
300
350
400
450
500
5,000 6,000 7,000 8,000 9,00010,000 11,000 12,000 13,000 14,000 15,000
Paper Production (ton/month)
(000
) MM
BTU/
mon
thOil
Gas
Gas Fired Boiler
ImplementationMinor
Technical Aspect
Economic Aspect
Environment Aspect
Planning
Implementation
Aim
Background
COVER
ENERGYCONSERVATION
By PTKL
CONCLUSION
Gas Fired Boiler
Capacitor
Environment Aspect2. Reduce green house effect by
reducing CO2 emissionLesser CO2 emission occurred by;1. Carbon content in gas is about 71%, otherwise
86% in oil2. Increasing efficiency at steam generation
181,732101,615Natural gas
ton(000)Nm3m3
175,879
357,612
CO2 emission
121,280Oil
Fuel ConsumptionKind of Fuel
33.50MMBtu/tonOil0.87m3/ton
0.73(000)Nm3/ton25.82MMBtu/tonNatural gas
Fuel Consumption140,000ton/yearPaper production
Gas Fired Boiler
Capacitor
Technical Aspect
Economic AspectEnvironment Aspect
Planning
Implementation
Aim
Background
COVER
ENERGYCONSERVATION
By PTKL
CONCLUSION
Gas Fired Boiler
INSTALL/ADDING CAPACITOR
Economic AspectInvestment : USD 200,000Saving : USD 800,000/yearPayback period: ± 3 months
Gas Fired Boiler
Planning
ImplementationMajor
Aim
Background
COVER
ENERGYCONSERVATION
By PTKL
CONCLUSION
-
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
10.0 10.5 11.0 11.5 12.0 12.5 13.0 13.5 14.0
power factor 0.74
power factor 0.80
POWER GENERATION (MW)
HE
AT
RA
TE ,T
ON
STE
AM
/MW
POWER FACTOR AND HEAT RATE CORELATION
Technical Aspect1. Less steam consumption, less fuel 2. Turbine operate optimum3. Less Motor & equipment burn
Capacitor
ImplementationMinor
ENERGY CONSERVATIONMINOR
Adding Economizer
Operation PRV
Extract Steam Control
Major
Minor
Implementation
Aim
Background
COVER
ENERGYCONSERVATION
By PTKL
CONCLUSION
Planning
ADDING ECONOMIZER
done at 5 power boilerStack temperatureBefore : 180 oCAfter : 160 oC Efficiency increase: 1%
Each boilerInvestment USD 78,000Saving USD 28,600/yearPayback period 2.7 years
Major
Minor
Implementation
Aim
Background
COVER
ENERGYCONSERVATION
By PTKL
CONCLUSION
Planning
Adding Economizer
Operation PRV
Extract Steam Control
OPERATION PRV
Major
Minor
Implementation
Aim
Background
COVER
ENERGYCONSERVATION
By PTKL
CONCLUSION
Planning
Power Boiler
Recovery Boiler
MP Header
Mill
LP Header
Mill
HP Header
44 BAR, 440oC
S S SMillCTEC
TEBPT
12.5 BAR, 200oC
6 BAR, 165oC
ProblemValve slightly sticky and difficult to open once it is closed.Kept manually opened ± 20%, higher than actual demandPRV MP to LP also opened 20% automatically
Program (done)Repair PRV HP to MP
ResultPRV MP to LP closed, efficiency of ECT improveSave expected 1 ton steam HP/hour equal USD 12/hour
Adding Economizer
Operation PRV
Extract Steam Control
EXTRACT STEAM CONTROL
Major
Minor
Implementation
Aim
Background
COVER
ENERGYCONSERVATION
CONCLUSION
Planning
Power Boiler
Recovery Boiler
MP Header
Mill
LP Header
Mill
HP Header
44 BAR, 440oC
S S SMillCTECTEBPT
12.5 BAR, 200oC
6 BAR, 165oC
ProblemExtract steam controlled about 6.5 barSteam required at paper mill 2.5 bar; 140oC
Program (done)Reduced pressure controlled to 6.0 bar
ResultImprove efficiency of ECTSave expected 1 ton steam HP/hour equal US$ 12/hour
Adding Economizer
Operation PRV
Extract Steam Control
CONCLUSION1. 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 gas to coal
3. Increasing power factor from 0.74 to 0.80 reduce heat rate 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.
COVER
MILL OVERVIEW
POWER PLANTOVERVIEW
MAJOR
ENERGYCONSERVATION
MINOR
CONCLUSION
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