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pt maxxtec teknologi indonesia

Celsi

Cost efficient and environmental friendly Energy

generation from production residues

Tuesday, April 9th 2019

by PT MaxxtecTeknologi Indonesia

pt maxxtec teknologi indonesiaCelsiNRGgroup technologies

Engineering, design, R&D(NRGgroup & customers)

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by PT Maxxtec Teknologi Indonesia

Material storage, handling and

dosing systemsfor any kind of

bulky and dustymaterials-

German technology adapted to the needs in the Southeast Asia

German technologies for efficient

energy generation and utilization

brought to South-East Asia

Since 1995 Maxxtec delivered more

than 3000 plants to more than 50

countries all over the world

Efficient Energy for South-East Asia

Thermal process

technology, heat exchangers, heat recovery, biogas

utilization, ORC technology

Standardized

Biomass Combustion Systems, Hot

Water and Steam Boilers,

50kW to 5MW

Steam, electricity production from

solid fuels (biomass, waste,

coal, tires ) water/steam technology, 5-50 MWth

2

In Europe there are more than 150

biomass heat and power plants with

ORC-process installed for biomass

utilization

http://www.wvterm.si/

http://www.wvterm.si/

pt maxxtec teknologi indonesiaCelsi

With our wide range of firing systems, any kind of solid fuels can be used for energy generation

Capacities

Charact-

eristics

Applica-

tion areas

“Workaholics”

for saturated

steam generation

out of any kind of

solid fuels

High-end gene-

ration of super-

heated steam out

of any kind of solid

fuels

Process

steam and CHP

Reciprocating Grate Stoker

Combustor

Flame tube &

pre chamber

Boiler

Water Tube

Boiler

Thermal Oil

Heater for Solid

FuelFlat Declining

CHP and

power generation

only

Efficient and

safe heat transfer

with organic heat

carriers for all Kind

of solid fuels

Process Heat,

CHP and power

generation only

Products for efficient use of any solid fuels

up to 35 MWth 500 kWth

to 20 MWth 5000 kWth

to 50 MWth 200 kWth

to 50 MWth

For dry and wet

chippings and

wood chips, any

other residues

Power Generation

and Industrial process

in general with

complex fuels

up to 12 MWth

Standard designed

for dry and wet

chippings and

wood chips, any

other residues

Industrial process heat

in general with

standard fuels

up to10 MWth

For dry and wet

chippings and

wood chips, coal

Small to

medium-sized

furniture industry,

timber industry

3


Waste Heat

Thermal Oil

Systems

Heating Surface

Cleaning Systems

Indirect steam

generator

Steam Power

Plants

ORC – Power

Plants

Capacities

Charact-

eristics

Application-

areas

200 kWth to 50 MWth

Consisting of a wood

firing system and a heat

transfer system with

Thermal Oil

Power stations de

centralized, recycling

Industry, wood industry,

etc.

to 30 MW, 30barg 300 kWth to 2,5 MWth 300 kWth to 2,5 MWel

Recovering heat from

hot flue gases into water,

thermal-oil or steam

Diesel power generators,

cement industry, steel mills,

any other waste heat

producing industries

Palm oil industry, food

& beverages, wood

industry, power stations

decentralized etc.

Palm oil industry, food

& beverages, wood

industry, power stations

decentralized etc.

Power generation from

waste heat or thermal

energy from a wood-fired

Consisting of a

transmission system for

heat and an ORC module

Fully automatic

cleaning of heating

surfaces of boilers and

heat exchanges for waste

heat and solid fuels

For all Kind of Boiler,

Heat Exchanger and

Heaters

Since 23 years Maxxtec has build more than 100 ORC power plants for CHP with solid fuels!

Patented technology

for all capacities

Energy Efficiency

4


With our wide range of firing systems and boilers, any kind of solid fuels can be used for energy generation

Capacities

Application-

areas

Up to 5000Nm³/h 2.000Nm³/h / unit Up to 5.000Nm³/h According to

Demand

Up to DN 1.500

Used to remove

relative humidity of

biogas by cooling

water/combined system

with low energy

Characte-

ristics Reduction of Hydrogen

Sulphide (H2S) in

Biogas to 0 ppm helps

to significantly reduce

operative cost of Engine

Safe and environ-

mentally friendly

utilization of access

gas. Including engine-

ering and controls.

Automation of

industrial processes and

machines. Control

panel, PLC and Scada

systems. PLC Software.

Control flaps for

exhaust gases and

industrial process

gases. Basket strainers,

pump monitoring etc.

Agroindustry, Sugar,

Breweries, Biofuel,

wherever Biogas is

utilized.

Agroindustry, Sugar,

Breweries, Biofuel,

wherever Biogas is

utilized.

Biogas, waste water

treatment, chemical

plants, oil and gas etc.

Mainly for process

industry, food industry

and machining

industry

For any kind

industrial

application

Biogas technology

Dewatering Fine

DesulphurizationFlare System

Process

Automation &

Control

Instrumentation

& Control

Armatures

5


Capacities

Charact-

eristics

Application-

areas

100 kWth

to 20 MWth

Use of gaseous &

liquid fuels to

generate process

heat. Solutions for

food processing

Chemical plants,

textile industry,

drying plants,

reaction proces-

ses, food, oil & gas

etc.

200 kWth

to 20 MWth

50MW / unit

Use of waste heat

from engines & indus-

trial processes for heat

generation

Waste heat

recovery, deodorizing

plants, large engines

Liquid - air / liquid –

gas, air coolers,

condensers, gas / gas,

steam / liquid etc.

For any kind of

industrial application

Technology available for industrial processes & biogas plants. Innovative and efficient solutions for process heat generated

from waste heat, and fossil fuels

Thermal Oil HeatersHigh Pressure

Steam Boiler

Heat ExchangersHeat Transfer

FluidsFor liquid and

gaseous fuels

For waste heat

recovery

Register Heat

Exchanger

Shell & Tube Heat

Exchanger

Food, refinery,

energy plants,

textile, cemical.

etc.

Synthetic and

mineral oils with food

grade, Halal and

Kosher cert.

Temperatures -

-110 C to 400 C° °

Industrial Process Heat

Up to DN 1.500

Liquid - air / liquid –

gas, air coolers,

condensers, gas / gas,

steam / liquid etc.

For any kind of

industrial application

232kWth

to 2.615kWth

P-Design 110bar

Closed cycle natural

circulation for high

pressure saturated

steam. Fully automatic

operation.

Food processing,

edible oil refineries,

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As the largest Palm oil producer in the world and with

extensive agriculturally used land has Indonesia a considerable

potential for power plants that run on waste

The diverse possibilities for conversion of energetic existing

residual materials for energy and electricity generation and the

huge volume (100 bil.) of this materials in Indonesia open up

opportunities to commercialize this type of use

Also on the part of the Indonesian government this potential is

increasingly taken into account with increase in

compensation.

POTENTIAL

Power Generation from Palm Oil Residues - Potential, Fuels, Advantages

Key arguments for the usage and conversion of energetic

existing residual materials for energy and electricity

generation:

replacement of fossil oil, -gas and etc.

free primary energy

additional income by feeding into the public grid

high feed-in tariffs from government

no additional CO2 emissions

optimization of the complete energy efficiency

ADVANTAGES

FUELS

Potentials in the Agroindustry

Palm FibresEmpty Fruit Bunches

Palm Kernel Shells Palm Oil Mill EffluentTable 1* : Forecast of energy demand and the electrification 2013-2022**:

Energy demand TWh

2013 2014 2016 2018 2020 2022

IDN 189,0 207,8 246,4 287,7 334,2 386,6

* A forecast of the state electricity utility PLN

** (Perusahaan Listrik Negara, 2013)

Electrification Rate

2013 2014 2015 2016 2017 2018 2019

IDN 80.5 84.35 88.3 91.16 95.35 98.3 99.9

Utilization of existing residue can provide a major contribution to the energy supply, offer economically interesting perspectives and

contribute to environmental protection. Therefore it is a WIN – WIN – WIN situation.7

pt maxxtec teknologi indonesiaCelsiSteam and thermal oil process heating plant with solid fuels:

Process heat from solid fuels

Celsicorp products, for any kind of solid fuel the perfect solution

SUPPLY STEAM AND THERMAL OIL PLANTS FOR PROCESS HEAT

Steam and thermal oil process heating system for

any kind of solid fuels, including the flue gas handling

and cleaning systems, material storage and handling

systems as well as the surface cleaning system.

Capacities up to 50MW

Temperature range up to 450°C

Usable energy sources:

Solid fuels like: Empty fruit bunches, waste wood,

rice shells, coal etc.

Complete plant from one hand

Many different kind of fuels can be used

High efficiency, easy to operate

Long lifetime

Long operating periods due to patented

airmaxx surface cleaning system

High local content

SUPPLY

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For any challenge the perfect solution. Single fuels as well as multifuel systems offer a wide field of applications.

Technical Parameters: The LAMBION grate Systems are

extremely robust and can be used for a wide range of fuels.

Ash content 1 to 25 %

Water content 0 to 60 % (weight)

Fuel diameter 0,2 to 50 cm

Fuel length 5 to 100 cm

Other parameters can be used with additional adjustments

Mixtures of bulk an pulverized fuels can be used with the standard

configuration

Due to the innovative LAMBION control system a wide range of fuels with different onditions can be used on any grate system

Multi fuel operation with solid, dusty, liquid and gaseous fuels

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10Development of reciprocating grate technology for more than 100 Years for your advantage!

Innovative combustion technology

Primary air infeed under the grate,

pressurized to boost into the fuel layer

Each zone has an individual fan,

automatically by the control system

Control system enables grate to

combust a wide range of fuels (humidity, size, energy content etc.)

Open grate area:

evenly distributed air flow →

no local excessive forge

phenomena

straight grate bars; easy

replaceable without special tools or welding equipment

large air path cross sections

→ low air velocity minimizes

carry over of ash particles

Comparison:

closed grate area of an

competitor

Our flat reciprocating grate, a standardized and cost effective

solution offering the advantages of

a reciprocating grate for standard

fuels already at low investment

cost.

Up to 5 individually controlled

combustion zones

Automatic fuel feeding, efficient

dust separation, automatic ash

discharge and a highly developed, state of the art PLC control offers

highest efficiency, availability and

low effort for operation.

pt maxxtec teknologi indonesiaCelsiThe steam process is economically & technologically a very common solution for power generation and CHP

Power generation with steam turbine

Our Technology is suitable for optimal converting of the primary energy into electrical power

SIMPLIFIED COMBINED POWER GENERATION PROCESS WITH STEAM CYCLE STEAM BENEFITS

The necessary

amount of heat is automatically uncoupled forward

of the low pressure of the turbine.

An optimal current efficiency is

achieved, when no heat is required.

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pt maxxtec teknologi indonesiaCelsiTechnical scheme of the steam process

Biomass

G

2

7

8

1311

12

14

9

15

16

10

19

17

18

1

3

4

5

6

C B

B

A

D

Combustion Condensate System Water Treatment

1 Firing

2 Steam boiler

3 Steam drum

4 Superheater

5 Economizer

6 LUVO

7 High pressur

vapour

distributor

8 Pressure reduction

station

9 Low pressure

vapour distributor

10 Degassers / Feed

water tank

11 Turbine

12 Generator

13 Steam by-pass

14 Heat consumer

15 Air condenser

16 Condensate tank

17 Condensate Pump

18 Feed water pump

19 Water treatment

A Combustion air

C for

flue gas cleaning

Steam System Steam Turbine

Steam cycles are the most common process to produce electrical power

Steam process for electricity production with biomass

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pt maxxtec teknologi indonesiaCelsiElectricity power generation with organic rankine cycle (ORC)

More than 120 ORC-Modules for high temperature applications are successful in operation

DESCRIPTION ORC MODULE

Use your energy and convert them into electricity:

The ORC systems make use of medium

temperatures around 300 °C and transfers them into

electricity up to 2,5 MW.

YOUR BENEFITS

Primary energy consumption can be

reduced by 10 %

Use of free primary energy

Low operating costs

Short payback times

No additional CO2 emission

Improving the energy efficiency

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pt maxxtec teknologi indonesiaCelsiTechnical scheme of combined ORC heat and power generation process

Combustion

Thermal Oil System

Heating Water System

G

270 °C / 10 bar

230 °C / 0,2 bar

320 °C / 10 bar

240 °C

95 °C / 0,2 bar

80 °C

60 °C170 °C

370 °C

80 °C

Biomass

1

2

3

4

6

5

8

9

10

11

7

12

14

B

B

C

D

E

A

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1 Firing2 Thermal oil heater3 Economizer TO

4 Economizer Water5 LUVO

6 ORC Vaporizer7 Primary pump8 Turbine

9 Generator10 Regenerator

11 Condenser12 ORC circulation pump13 Heating water pump

14 Heat consumer

A Combustion airC for flue gas cleaningD of

heating water returnE for heating water flow

ORC - Process

Simple process for modulating operation with low pressures and low temperatures 14

pt maxxtec teknologi indonesiaCelsiHeat recovery from any heat source

offers many different solutions HEATERS, BOILERS & ECONOMIZERS

Almost every industrial process offers potential

for waste heat recovery.

Our units are available with capacities from 0,01

to 50 MW; depending on the application

In the temperature range up to 1500°C

If required, surface cleaning during full operation

In many cases very short payback

Usable energy sources:

Flue gases from burners, ovens, dryers, printing

machines

Waste heat from the engines, gas turbines

Exhaust gas from steel production, cement

manufacturing.

Any other industrial waste heat.

Helical coil boilers are perfect in combination with organic heat carriers 15

pt maxxtec teknologi indonesiaCelsiFully automatic surface cleaning systems

OUR SUPPLY CLEANING SYSTEMS

We have different cleaning systems :

Ball cleaning systems

Soot blower systems

Shaking systems

airmaxx – Fully automatic pressure pulse

cleaning systems

Deposits work in heating surface linke an

Isulating layer - the heat transfer is hindered and

the flue gas temperature rises

The efficiency drop down and causes an increase

in fuel consumption

Excessive flue gas temperatures can lead to

overstrain and damage

CLEANING FOR CONSTANT EFFICIENCY

Constant energy efficiency and long operation periodes by the patented airmaxx technology 16

pt maxxtec teknologi indonesiaCelsiORC can use low temperature heat

The ORC process allows to exploit efficiently low temperature heat sources to produce electricity in a wide range of power outputs (from few kW to some 2.5 MW electric power per unit).

SIMPLIFIED COMBINED HEAT AND POWER GENERATION PROCESS ORC BENEFITS

Economic viability

• Higher efficiency

• Reduction of operating personnel

• Reduced installation costs/time

• Automatic start-up & shut-down

Technological advantages

• No use of chemicals

• Low temperatures for electricity

generation

• No super heater is required

• Better part load efficiency

Flexibility

• Reduced project-engineering

• Standardized systems

• Flexibility for primary

temperatures and energy

sources

1

2

3

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Environmental friendly and cost effective Energy from organic and low calorific production residue.

Integrated Biogas treatment

Integrated Biogas treatment offers

various advantages in terms of energy

efficiency.

Using of existing cooling water instead of installing an expensive chiller

Providing individual Biogas quality in relation with the Consumer (Engines have other requirements then Burners)

Combinations of fuel, for example for process heating plants, allow flexible operation in relation to fuel availability and cost. Multifuel burners and synchronous operation with different fuels are reducing operation cost.

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Lower investment and operation costs

Biogas Dewatering

Conventionel Biogas Dryer (Cooler)Biogas Dryer

45 °C 15 °CBiogas Biogas

7 °C15 °C

79 °C

34 °C

40 °C

29 °C

Biogas

Biogas

Cooling WaterCooling Water

Cooling Water

Cooling Water

Advantages of the Biogas Dryer?

Significant energy saving

Lower opex (often existing cooling water

can be used.

Lower capex (maintenance)

Better condensate separation

Lower space required (vertical design)

40 °C

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Extended lifetime of engines and reduced maintenance by fine - desulfurisation

Biogas Fine Desulphurization

Doted activated carbon allows to absorb large

quantities of hydrogen sulfide

Even in fluctuating conditions, the sulfur can be deduced constantly below 1ppm

Operation time of the lubrication oil in Biogas

Engines can be doubled

Reduced downtime and maintenance costs for

the engines

cartridge absorbers make

replacement of the active coal very easy.

Removable cartridges can be filled externally

Silica gel indicators indicate the condition of the

filling and avoid unnecessary change.

Fine – Desulfurization with doted

activated carbon

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Integration of both liquid and solid biogenic residues with one system

21

SIMPLIFIED SCHEME OF A COMBINED POWER GENERATION PROCESS

WITH STEAM AND BIOGAS CYCLE

STEAM AND BIOGAS

BENEFITS

Highest efficiency

• Most complete use of

solid and liquid residue

• Integrated system allows

almost complete use of

the energy potential.

• Power generation for

internal consumption and

for feeding into the public

grid.

• Waste water treatment

included.

• Reduction of methane

emission to protect the

environment.

Heat & Power from solid residues and effluent

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Complete utilization of the energy potential at highest efficiency.

Coal fired steam boiler Karawang

Indonesian coal contains a high content of volatile matters.

Travelling grates often cannot use the full energy content,

since there is only one single combustion zone.

Declined reciprocating grate systems offer full

combustion and therefore fast return on investment.

Long lifetime, high efficiency and low operating cost and low

emissions make the difference on the long run.

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Declined reciprocating grate. Fully automatic

fuel feeding and ash discharge. Combi-Steam

Boiler with Economiser, high efficient dust separator (Multi Cyclone)

with Big Bag collection system, Fully automatic PLC – Control

system with O2 sensor for highest efficiency and lowest emissions.

Steam capacity: 10.5 t/h at 10barg

Fuel: Low caloric coal


Complete utilization of all available energy potentials with highest flexibility.

PKS fired TO-Heater, Bangka

23

Flat reciprocating grate systems offer complete

combustion, especially for dry materials.

Standardized unity offer long lifetime, high efficiency, low investment

and low operating cost at low emissions.

Thermal Oil Process

heating Plant. Installed in

Bangka Island.

Th. capacity 3000kW

Oil Temp: 300 / 185°C

Fuel: Palm Kernel Shell

delivery:

-Fuel feeding system

-Furnace with deashing

-Multicyclone dust

separator

-Automatic deashing

-TO Heater system with

cooling shield, 3-pass

Thermal Oil Heater and

Economiser

-Thermal Oil system

-3 Oil-Air Heat exchanger

pt maxxtec teknologi indonesiaCelsiProcess heat for drying of the tapioka starch replacing coal

combustion

Utilize Biogas in the best possible way requires an integrated view of all related systems

OVERVIEW PROJECT SIMPLIFIED SCHEME

Requirement: Complete substitution of coal combustion

through the use of excess biogas and waste heat from the

gas engines.

Solution:

• Significantly reduced power consumption by highly

efficient process heating plant.

• Installation of a biogas -fired thermal oil heater to

replace the existing high-temperature heaters.

• Installation of an additional low-temperature air

preheater with associated low-temperature

thermal oil circuit. The engine waste heat can be

optimally utilized in this manner to pre-heat the

process air

Result: The amortization is taken place by the saved fuel

costs in less than 12 months

Efficient utilization of Biogas

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Application of vertical EGHE

Energy generation for Tapioka productionEnergy plant for Tapioka Production

installed in 6 different locations in Indonesia. Thermal capacity: up to 10MW Fuel: Biogas and Engine exhaust gas.

Oil Temperature: 280 / 120°CDelivery range: Thermal Oil Heater with biogas burner, Exhaust Gas Heat exchangers, Thermal Oil System, Oil / Air Heat exchangers,

Biogas dryers

In several realized projects it is approved, that the consumption of fossil fuels could be reduced significantly and the investment is paid back in less than 2 years.

High temperature cycle with Maxxtec Biogas Heater

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Multi fuel burners offer better flexibility and therefore reducing energy cost

Liquid, gaseous or dusty production residues can be valuable energy

sources.

• Process heaters with multi fuel burners for high and medium calorific production residues in liquid or gaseous condition.

• Synchronous operation of 2 different fuels

• Fuel treatment systems to adjust viscosity and to remove particles and other contaminations.

• Fuel control systems to ensure emission free combustion and safe operation.

• Seamless integration into existing plants and processes

• Remote control systems for centralized plant monitoring, information processing and process control.

Multifuel combustion for highest flexibility

Thermal Oil Process Heating Plant in Kisaran, Thermal capacity 9MW, fired by Biogas, Diesel Oil and Palm Crude oil,

Delivery range: Thermal Oil System with Oil / Air heat exchanger, Warm Water System with Water / Air heat exchanger,

3 Exhaust gas / Thermal Oil Heat exchangers, 3 Water / Water Heat Exchangers, Biogas Treatments System with Biogas Dryer

and Fine Desulphurisation, Biogas Flare, Process Automation.

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Instead of making bad experience, trust in quality and reliability

Contact us:PT Maxxtec Teknologi IndonesiaPhone +62 21 [email protected]

Mobile: +62 857 437 56 221www.maxxtec.co.id

mailto:[email protected]

powerpoint-präsentation - titel · industry, wood industry, etc. to 30 mw, 30barg 300 kwthto 2,5...

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