German-Indonesian Renewable Energy Days

Intercontinental Hotel Mid Plaza, Jakarta, 24

th
-26
th
Oct, 2011
Case Study Indonesian sugar industry :
PRODUCTIVITY GAINS FROM EFFICIENT
WASTE TO ENERGY SCHEMES
Hariyanto
Energy Technology Center, Agency for The Assessment and
Application of Technology (BPPT)
German-Indonesian Renewable Energy Days
Introduction
Current Situation Sugarcane in Indonesia
Total number of sugar-mill in Indonesia are 61 sugar-
mill, with crushing capacity ranging 1000-12000 TCD,
total crushing capacity is 225.018 TCD *)
Total sugar-mill plantation in Indonesia is 418.259 ha
(2010) which is concentrated in east java (45%) and
Lampung (25%)
Total Sugar production (2010) :2.214 Mio Tonnes Sugar,
while the sugar demand is 5.4 Mio Tonnes *)
Indonesian sugarmill Factories: mostly were old
factories need to improve performance
*)Sources: Kompas Daily 29 July 2011
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Sugarcane Production global
Indonesia 418.259 70 29.278.130
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Sugarcane Processes and Material Balance
Mill
Station
Purifica
tion
Station
Evaporati
-on Station
Cooking
and
Centrifuge
Station
sugar
cane
White
Sugar
Molasses FilterCake Bagasse
Imbibition
water
Chemicals
300 Kg of Bagasse ~ 100 kWh
60-70 Kg Sugar
1 tonne
Steam Consumption : 0.55 Tonnes steam/Tonnes Sugarcane
Electricity consumption : 16-21 Kwh/Ton Tebu
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Primary Fuel Composition in Sugarmill
Additional fuel consumption is expected to be eliminated so that fuel
can be met by bagasse
How to make its zero?
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How to make money from the bagasse?
Thermal energy (steam) Processes ,turbine
drive, drying, heating
Electricity motor, pump, Fan
1. Plant Modernization & Improving efficiency
2. Utilizing bagasse surplus to generate electricity
(new configuration of COGEN)
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Bagasse as a Fuel
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Bagasse Analysis (Calorific value)
Parameter Status Unit Bagasse1 Bagasse 2 Bagasse 3 Method
Total Moisture ar % 54 50 38.8 ASTM.D 3302-10
Gross Calorific
Value (GCV)
ar Kcal/Kg 2160 2377 2986 ASTM.D 5865-10
ar: as received
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Case Study: Bagasse Utilization for Electricity
Production
Existing Plant Performance:
Sugarmill capacity 6000 TCD
The average mechanical downtime of the mills per milling season
has been found to be 5.09 %.
Steam is generally produced at medium pressures of 20 kg/cm2,
325C.
The boiler fuel is mill bagasse, the fibrous residue of the cane
milling process. Bagassehas a moisture content of 52
Fiber Content of the cane averages 10-11% on cane. This is
equivalent to 29.2% of bagasse.
Thermal and Electrical energy requirements average between 55
Ton Steam and 21 kWh per ton of cane crushed
Power generated : 3.97 MW (House load)
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Current situation in sugarmill industries
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Existing Configuration COGEN
To Process
Bagasse +
MFO +
Moulding
Boiler Back pressure turbine
To Condenser
Turbines
G
Steam 20 Bar
Steam 2 bar
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Modernization and Improving Efficiency
Improving Capacity 6000 TCD to 7200 TCD
Steam consumption become 0.5 TS/TCD
Replacement of milling turbine to electric motor
Increase Bagasse Surplus
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Bagasse Surplus
The maximum commulative bagasse surplus which occured at the end
of milling season is estimated around 94,000 ton at crushing capacity of
7,200 TCD.
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New Configuration
To Process
Bagasse
Boiler
Extraction Condensing Turbine
Back pressure turbine
To Condenser
Electric Motor
Turbines
G
Steam 46 Bar
Steam 20 Bar
Steam 20 bar
G
Steam 2 bar
Back pressure turbine
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15
On-season 43,338 MWh
Off-season 35,910 MWh
Total 79,248 MWh
Electricity generated for Grid
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New Configuration operation mode
Cogeneration system will operated continuously for
the entire year (330 days)
on-season, existing boilers operate 63.8 TPH and
existing alternator turbine operates 3.97 MW. While
new boiler operate at 104.8 TPH, extraction steam 54
TPH at 20 kg/cm
2
and turbine alternator operating at
10 MW
off-season, existing boiler and turbine is not operated,
while one unit of a new boiler operates at 47.4 TPH
and new turbine operate with condensing mode at
9.975 MW(10 MW).
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Conclusion
Bagasse Surplus can be utilize to produce electricity
through cogeneration system in sugarmill (send to grid)
, (7200 TCD 71.5 GWhr/year)
The net electricity production will be of about 71.5
GWh will distributed to the grid as electricity sales that
generate revenue annually about IDR 58.648 billion
base on electricity selling price of IDR 820/kWh
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Terimakasih