peningkatan daya saing industri tekstil melalui konservasi energi bppt (full)

CENTER FOR ENERGY CONVERSION AND CONSERVATION TECHNOLOGY

DR EDI HILMAWAN PUSAT TEKNOLOGI KONVERSI DAN KONSERVASI ENERGI, BPPT

PENINGKATAN DAYA SAING INDUSTRI TEKSTIL MELALUI KONSERVASI ENERGI

DISAMPAIKAN PADA SEMINAR NASIONAL TEKSTIL DAN BUSINESS GATHERING 2014

BALAI BESAR TEKSTIL BANDUNG, 24 MARET 2014

PUSAT TEKNOLOGI KONVERSI DAN KONSERVASI ENERGI

OUTLINE

• Kondisi Keenergian Nasional

• Industri Tekstil dan Penggunaan Energinya

• Konservasi Energi di Industri Tekstil

• Manajemen Energi di Industri Tekstil

• Teknologi Konservasi Energi di Industri Tekstil

• Penutup


KONDISI KEENERGIAN NASIONAL ENERGY SUPPLY - DEMAND

• Laju Pertumbuhan Kebutuhan Energi Primer 6,2%/yr • Ketergantungan terhadap Bahan Bakar Fosil (95%)

(Diolah dari data Pusdatin - KESDM, 2011)

• Peningkatan Energi Final 5,6%/yr • Sektor Industri dan Transportasi adalah

Pengguna Energi Terbesar

-

200

400

600

800

1.000

1.200

1.400

2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010

Mill

ion

s

Geothermal Hydro Gas Oil Coal

-

100

200

300

400

500

600

700

800

900

Mill

ion

s Other Transportation Commercial

Households Non-Energy Industry

24%

47%

24%

4% 1%

Primary Energy Composition

Coal

Oil

Gas

Hydro

Geothermal

39%

11% 10% 4%

32%

4% Final Energy User

Industry

Non-Energy

Households

Commercial

Transportation

Other


KONSUMSI ENERGI FINAL DI SEKTOR INDUSTRI

2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010

Listrik 20850 21819 22578 22373 24719 26021 26736 28077 29405 28323 31254

LPG 1073 972 1093 808 1101 1131 1453 1242 1124 955 1045

BBM 74979 78033 75690 68493 74718 64239 57203 52418 48856 49952 57602

Gas Bumi 59868 59050 54662 65127 60416 61537 58982 54837 62925 89101 85729

Briket 85 78 83 77 80 94 94 89 155 219 285

Batubara 36060 37021 38698 68264 55344 65744 89043 121904 74939 80466 136540

Biomasa 58981 55186 52305 50167 46917 43920 46676 42108 44235 44496 43302

0

50.000

100.000

150.000

200.000

250.000

300.000

350.000

400.000

Sumber: Pusdatin, KESDM

(R

ibu

SB

M)

pertumbuhan 2000-2010

50%

-3%

-23%

43%

235%

279%

-27%


5


PROYEKSI KEBUTUHAN ENERGI KE DEPAN Konsumsi energi final tahun 2011 mencapai 1.044 juta SBM. Dengan

laju pertumbuhan GDP rata-rata 7,1% per tahun, kebutuhan energi meningkat sekitar 4,7% per tahun Perkiraan kebutuhan energi final nasional tahun 2025 sekitar 1960 juta SBM (2 kali lipat dalam kurun waktu

15 tahun) dan 2518 juta SBM di tahun 2030 (2,5 kali lipat dalam kurun waktu 20 tahun).

Ketergantungan terhadap Bahan Bakar Fosil masih tinggi

Sumber: BPPT Outlook Energi Indonesia 2013

Konsumsi energi terbesar ada di sektor industri. Meningkat dari 37% pada tahun 2011, menjadi 41% di tahun 2015 dan 42% di tahun 2025.

Proyeksi kebutuhan energi final per sektor pengguna

Proyeksi kebutuhan energi final per sektor pengguna

Sumber: BPPT Outlook Energi Indonesia 2013


INTENSITAS ENERGI INDUSTRI

Besi dan Baja

–Indonesia: 650 kWh/Ton

–India: 600 kWh/Ton

–Japan: 350 kWh/Ton

Semen

–Indonesia: 800 Kcal/kg clinker

–Jepang: 773 Kcal/kg clinker

Keramik

–Indonesia: 16,6 GJ/Ton

–Vietnam: 12,9 GJ/Ton

Gelas

Indonesia: 12 MJ/ton

Korea: 10 MJ/ton

Tekstil

Spinning

Indonesia: 9,59 GJ/Ton

India: 3,2 GJ/Ton

Weaving

Indonesia: 33 GJ/Ton

India: 31 GJ/Ton

Sumber: BPPT, Kemenperin


POHON INDUSTRI TPT


KONDISI INDUSTRI TPT NASIONAL

Tahun 2010

Tahun 2010


JUMLAH MESIN INDUSTRI USIA 20 TAHUN

Pemintalan Pertenunan Perajutan Finishing PakaianJadi

64,40%

82,10% 84,10% 93,20%

78,00%

Jumlah Mesin Industri Usia 20 tahun


11


ENERGY FOOTPRINT INDUSTRI (EXP. INDUSTRI TEKSTIL)

Sumber: DOE – USA

Machine

Drives

Process

Cooling

Process

Heating


DISTRIBUSI PENGGUNAAN ENERGI DI INDUSTRI

Subsektor

Process

Heating

(%)

Process

Cooling

(%)

Machine

Drives

(%)

Makanan dan Minuman 75,0 8,5 16,5

Tekstil dan Pakaian 59,0 6,8 34,2

Kayu dan Mebel 80,4 0,5 19,1

Pulp dan Kertas 80,4 0,5 19,1

Pupuk dan Kimia 76,7 7,2 16,1

Karet dan Plastik 49,6 7,5 42,9

Keramik dan Gelas 90,5 0,9 8,6

Semen 87,8 0,3 11,9

Besi dan Baja 91,8 0,6 7,6

Peralatan dan Permesinan 51,9 4,8 43,3

Industri Lainnya 61,3 3,9 34,8

Sumber: DOE


POLA PEMAKAIAN ENERGI

Facilities 18%

Steam 28%

Motor driven

systems 28%

Process cooling

4%

Fired heater

20%

Other 2%

Final Energy End-Use in the U.S. Textile Industry

Pump; 19%

Fan; 14%

Compressed; 15%

Refrigeration; 7%

Materials Handling;

11%

Materials Processing;

31%

Other Systems; 3%

Motor Systems Energy Use in the U.S. Textile Industry


TYPICAL FINAL ENERGY USE IN SPINNING PLANT

78%

3% 3%

16%

Machines Compressors Lighting Humidification plant

7%

1%

5%

12% 11%

7%

20%

37%

0%

5%

10%

15%

20%

25%

30%

35%

40%


THERMAL ENERGY USE IN DYEING PLANT, AND WET PROCESS

Product heating

16%

Product drying 17%

Waste water loss

25%

Heat released

from equipment

12%

Exhaust gas loss 9%

Idling 4%

Evaporation from liquid

surface 5%

Un-recovered

condensate 4%

Loss during condensate

recovery 1%

Others 7%

Breakdown of Thermal Energy Use in Dyeing Plant

Product form / Machine type

Process Energy requirement

(GJ/ton output) Desize unit Desizing 1.0–3.5

Kier Scouring/bleaching 6.0–7.5 J-box Scouring 6.5–10.0

Open width range Scouring/bleaching 3.0–7.0 Low energy steam

purge Scouring/bleaching 1.5–5.0 Jig/winch Scouring 5.0–7.0 Jig/winch Bleaching 3.0–6.5

Jig Dyeing 1.5–7.0 Winch Dyeing 6.0–17.0

Jet Dyeing 3.5–16.0 Beam Dyeing 7.5–12.5

Pad/batch Dyeing 1.5–4.5 Continuous/thermosol Dyeing 7.0–20.0

Rotary Screen Printing 2.5–8.5 Steam cylinders Drying 2.5–4.5

Stenter Drying 2.5–7.5 Stenter Heat setting 4.0–9.0

Package/yarn Preparation/dyeing

(cotton) 5.0–18.0

Package/yarn Preparation/dyeing

(polyester) 9.0–12.5 Continuous hank Scouring 3.0–5.0

Hank Dyeing 10.0–16.0 Hank Drying 4.5–6.5


TYPICAL ELECTRICITY AND THERMAL ENERGY USED IN A COMPOSITE TEXTILE PLANT

Spinning (ring spinning);

41%

Weaving preparation;

5%

Weaving preparation;

13%

Humidification; 19%

Wet-processing;

10%

Lighting; 4% Others; 8%

Typical Electricity Use in a Composite Textile Plant

Bleaching and

finishing; 35%

Dyeing and printing;

15%

Humidification, sizing

and others; 15%

Boiler plant losses; 25%

Steam distribution losses; 10%

Typical Thermal Use in a Composite Textile Plant


PENDEKATAN KONSERVASI ENERGI TERINTEGRASI

Energy Conservati

on

Energy Managem

ent

Energy Efficiency Improvem

ent

Energy Efficient Design

EXISTING SYSTEM NEW SYSTEM

Monitoring and Control System

Operation and Maintenance

Energy Efficiency Standard

Low Energy System Design

Energy Efficient Technology

System Optimization


PENDEKATAN KONSERVASI ENERGI TERINTEGRASI

Energy Conservati

on

Energy Managem

ent

Energy Efficiency Improvem

ent

Energy Efficient Design

NEW SYSTEM

Monitoring and Control System

Operation and Maintenance

Energy Efficiency Standard

Low Energy System Design

Energy Efficient Technology

System Optimization

Energy Management Information System

Implementation of ISO 50001 EnMS

Advanced Control System

Low Energy Process High Eff Furnace Cogeneration Regenerative Burners Material Preheater VSD for motors etc ....

Pump System Steam System Waste heat Recovery Compressed Air Water Suppy System

Process Integration COGENERATION

High eff Boiler High eff Cooling System High Eff Burner High Eff Compressor Green Industry


ISO 50001 ENERGY MANAGEMENT

• Management Participation – Management Representative

– Energy Policy

– Management Review

• Energy Planning Energy review, Significant Energy User, EnPI, Baseline and Target, Action Plan

20

• Control and Monitoring –Nonconformities,

–correction, corrective and preventive action

• Implementation and Operation –Operational Control

–Maintenance Control

–Training and Socialization

–Energy Efficient Design

–Procurement


0 5 Years

-25%

-20%

-15%

-10%

-5%

0

+5%

Costs

Biaya Tinggi Audit Energi

Tindakan Penghematan

Terkendali

Biaya naik lagi: Kapan audit terakhir ?

Mulai sekali lagi!

Manajemen Energi : Pendekatan Konvensional vs Pendekatan Sistemik


PENDEKATAN SISTEMATIS

Komitmen Senior Manajemen

0 3 Years

-20%

-25%

-15%

-10%

-5%

0

+5%

Costs

Investment

Penghematan Awal Terjaga

Mulai dari housekeeping Investasi tinggi

Menjadi Budaya Perusahaan


MANAJEMEN ENERGI : AUDIT ENERGI

• Audit energi adalah aktifitas yang dilakukan untuk mengevaluasi pola penggunaan energi sebuah sistem, baik itu berupa industri maupun bangunan, guna mengidentifikasi peluang-peluang penghematan yang dapat dilakukan.

• Audit Energi adalah bagian dari Manajemen Energi • Sasaran – Memperoleh Gambaran Pola Penggunaan Energi

• Fluktuasi Penggunaan Energi (faktor berpengaruh • Neraca/Distribusi energi (input = output ?) • Efisiensi Penggunaan Energi

– Mengidentifikasi sumber-sumber pemborosan energi dan menyusun langkah-langkah pencegahannya • Waste Energy (reduce, reuse, recycle) • Rasionalisasi dan optimalisasi penggunaan energi

– Dasar untuk melakukan peningkatan efisiensi penggunaan energi • Perbaikan manajemen operasi dan perawatan

peralatan konversi energi • Reparasi alat dan retrofit • Instalasi peralatan baru/teknologi hemat energi

PRELIMINARY AUDIT

EFISIEN ?

MONITORING

DETIL AUDIT

REKOMENDASI NO/LOW

COST

MEDIUM COST

HIGH COST

Implementasi

Feasibility Study

REKOMENDASI AWAL

Tidak

Ya


MANAJEMEN ENERGI: OPERATION AND MAINTENANCE

24

Fan masih menyala pada saat mesin tidak beroperasi

Contoh Kasus: Stenter Machine

Motor beroperasi hanya setengah dari daya terpasangnya Pemasangan inverter

Sumber: JICA – BPPT Study (2008)

Pabrik A Pabrik B



25

Contoh Kasus: Cylinder Dryer


Temp Silinder rendah, distribusi uap tidak merata, kondensat tidak terbuang dengan baik

Temp kain turun, Pemanasan kurang efektif, Pemborosan Uap



26

Contoh Kasus: Washing Machine


TDS di bak 2 rendah, Indikasi kebanyakan air, Temp rendah, PH terjaga tinggi

Sistem individu, air limbah dibuang

Sistem Counterflow Kontrol temperatur


MANAJEMEN ENERGI: PERFORMANCE MONITORING • Regresi Linier : Konsumsi energi vs faktor yang mempengaruhi

(ex. Produksi vs Electricity)

y = 3,3272x + 4784,8 R² = 0,71

0

20.000

40.000

60.000

80.000

100.000

120.000

140.000

160.000

0 10.000 20.000 30.000 40.000

Ele

ctri

city

[kW

h]

Production

Electricity vs Production Y = 3,3272 X + 4784,8

Slope

Intercept = Baseload

Baseload menunjukkan konsumsi energi

ketika tidak ada produksi

Seharusnya nol !

Hindari penggunaan energi saat tidak

berproduksi

Persamaan regresi dapat juga digunakan sebagai :

• baseline untuk menentukan target (persamaan baru)

• Tool untuk monitor kinerja energi,

baseline

target

Regresi lainnya : Multivariable regression (Y = b + a1 X1 + a2 X2 + ...)

Polynomial regression, Non Linier Regression

Gunakan metoda paling sederhana dan mudah diterapkan


MANAJEMEN ENERGI: PERFORMANCE MONITORING (SPINNING PLANT)

Annual Electricity Consumption

- 2011 : 25.061.873

- 2012 : 26.169.520

Cummulative Saving

- Baseline 2011 :

- Per Des 2012 : 1.551.140 (5,6%)

- Per Agustus 2013 : 3.056.024 (6,4%)

- Baseline 2012 :

- Per Agustus 2013 : 441.099

(2,4%)


MANAJEMEN ENERGI: PERFORMANCE MONITORING (FINISHING PLANT)

Annual Steam Consumption (ton)

- 2011 : 111.311

- 2012 : 114.552

Cummulative Saving

- Baseline 2011 :

- Per Des 2012 : 38.140 (25,0%)

- Per Agustus 2013 : 105.796 (37,8%)

- Baseline 2012 :

- Per Agustus 2013 : 9.089

(13,2%) Sumber: UNIDO Pilot Project (2013)


ENERGY EFFICIENCY IMPROVEMENT A. Application of Energy Efficient Technology • High Efficiency Energy Conversion Technology

– Boiler, Power Generation, Air Compressor, Cogeneration System, etc

• Low Energy Consumption Process Equipment – (Process Specific for each industries)

• Waste Heat Recovery Equipment – WHRB, Economizer, Preheater, etc

• Energy and Process Management – Process Automation – Energy Monitoring and Control System • Renewable Energy – Biomass – Geothermal

B. System Optimization • Electrical System, HVAC System, Steam System,

Pump System, Compressed Air system, etc • Process Integration

30


EE TECHNOLOGY IN SPINNING AND WEAVING PROCESS

no Technologies Electricity Saving Installation Cost

Preparasi

1 High Speed Carding Machine

Ring Frame

2 The use of lighter spindle 23 MWh/year/ring frame 13,500 /ring frame

3 Installation of energy-efficient motor 6.3 -18.83 MWh/year/motor 1950 - 2200 /motor

4 The use of light weight bobbins 10.8 MWh/year/ring frame 660 /ring frame

Windings, Doubling, and finishing process

5 Installation of Variable Frequency Drive on Autoconer machine

331.2 MWh/year/plant

19500/plant

6 Replacing the Electrical heating system with steam heating system for the yarn polishing machine

19.5 MWh/year/machine

980/ humidification plant

Air conditioning and Humidification system

7 Installation of Variable Frequency Drive (VFD) for washer pump motor, Humidification System Fan Motor, Humidification system Pumps

20 MWh/year/humidification plant

1100/ humidification plant


EE TECHNOLOGY IN SPINNING AND WEAVING PROCESS

no Technologies Electricity Saving Installation Cost

8 Replacement of the existing Aluminium alloy fan impellers with high efficiency F.R.P (Fiberglass Reinforced Plastic) impellers in humidification fans and cooling tower fans

55.5 MWh/year/fan 650/ fan

General

9 Replacement of Ordinary ‘V – Belts’ by Cogged ‘V – Belts’

1.5 MWh/year/belt 12.2/belt

Weaving Process

10 Energy efficiency of compressed air system in the Air-jet weaving plant

US$440,000 /year (for 500 air jet looms)


EE TECHNOLOGY IN WET PROCESS

no Technologies Energy Saving Installation Cost

Preparasi

Cold-Pad-Batch pretreatment 38% of fuel use 50% of electricity use

Bleach bath recovery system ** US$38,500 -US$118,400 saving 80000 -246,000

Use of Counter-flow Current for washing 41% - 62% of washing energy use

Dyeing and Printing Process

Installation of Variable Frequency Drive on pump motor of Top dyeing machines

26.9 MWh/year/machine 3100 /machine

Cold-Pad-Batch dyeing system 1215000/ system

Single-rope flow dyeing machines 2.5 kg steam /kg fabric 0.16 - 0.20 kWh/kg fabric

Microwave dyeing equipment 96% fuel saving 90% electricity saving

450000/ machine

Use of steam coil instead of direct steam heating in batch dyeing machines (Winch and Jigger)

4580 GJ/year/plant 165500/plant

Heat recovery of hot waste water in Autoclave 554 MJ/batch product


EE TECHNOLOGY IN DRYING AND FINISHING

no Technologies Energy Saving Installation Cost

Drying

Introduce Mechanical Pre-drying Avoid Overdrying, intermediate drying Recover Condensate and Flash Steam

The use of Low Pressure Microwave drying machine for bobbin drying instead of dry-steam heater

107 kWh/tonne yarn 500000/plant

High-frequency reduced-pressure dryer for bobbin drying after dyeing process

200 kWh/tonne product 500000/machine

Finishing

Conversion of Thermic Fluid heating system to Direct Gas Firing system in Stenters and dryers

11000 GJ/year/plant 120 MWh/year/plant

50000/plant

Introduce Mechanical De-watering or Contact Drying Before Stenter

13% - 50% of stenter energy use

Optimize exhaust humidity in stenter 670 GJ/year US$600

Install heat recovery equipment in stenter 30% energy saving US$77,000 to US$460,000

General

The recovery of condensate in wet-processing plants Heat recovery from the air compressors for use in drying woven nylon nets


CROSS CUTTING TECHNOLOGY

• Electrical demand control • Energy-efficiency improvement opportunities in electric

motors • Energy-efficiency improvement opportunities in

compressed air systems • Energy-efficiency improvement opportunities in pumping

systems • Energy-efficiency improvement opportunities in fan

systems • Energy-efficiency improvement opportunities in lighting

system • Energy-efficiency improvement opportunities in steam

systems


CONTOH KASUS : PENERAPAN HIGH EFFICIENT COMPRESSOR DI INDUSTRI TEKSTIL

36

Investment Cost (Rp) 180.000.000,-

Equipment & Installation 180.000.000,-

Benefit (Rp/Year) 580.500.000,-

Net Electricity Saving 580.500.000,-

Simple Pay Back (year) 0,31

Electricty Consumption

Old : 32 kWh/bale

New : 19 kWh/bale


CONTOH KASUS : PENERAPAN TEKNOLOGI MICROTURBIN COGENERATION DI PABRIK LAMPU

* Operasi 8 jam/hr

before

after


Equipment Installation

498.750.000,- 142.500.000,-


Net Electricity Saving* 116.000.000,-



OPTIMASI SISTEM : PUMP SYSTEM OPTIMIZATION

38

Sumber (UNIDO)


ENERGY EFFICIENT DESIGN : ENERGY EFFICIENCY STANDARD

• Energy Performance Standard for Equipments (High Energy Perfomance Standard, Minimum Energy Performance Standard)

– Boiler

– Motor

– Air Conditioner

– Compressor

– Pumps

– Lamps

• Energy Performance Standard for System

– Green Industry

– Green Building

39

EU

Thailand

Cina

Hong kong

India

Malaysia

Using Energy Efficiency Standard as

reference to purchase new equipments

and/or design new system


ENERGY EFFICIENT DESIGN : COGENERATION • Cogeneration is a thermal energy

conversion system that simultaneously produce electricity and heat at the same time

• Another term: Combined Heat and Power, CHP

C65

C65

C65

C65

C65

C65

C65

C65

C65

C65

C65

C65

C65

C65

C65

C65

Ads Chiller

180 TR

Ads Chiller

180 TR

Ads Chiller

180 TR

ELECTRICAL LOAD

COOLING LOAD

HOT WATER

C65

C65

Microturbine

MT + CHP module

Electrical Line

Flue Gas Line

Hot Water Line

Chilled Water Line

Multi Pack

Eff 35%

Eff 80%

Trigeneration Application of Microturbine

Cogenerations in a Commercial Building


ENERGY EFFICIENT DESIGN : PROCESS INTEGRATION IN INDUSTRY

Process Integration Optimizing waste heat

utilization to minimize needs of hot and/or cold utilities


PENDEKATAN LIFE CYCLE COST UNTUK PENILAIAN INVESTASI

Proyek Efisiensi Energi harus mampu menghitung semua keuntungan/penghematan yang diperoleh terhadap biaya-biaya yang timbul akibat proyek tersebut. Keuntungan (benefit) dalam proyek efisiensi energi mencakup •Keuntungan secara finansial •Keuntungan dalam penghematan penggunaan energi •Keuntungan secara lingkungan (biaya eksternal) •Peningkatan produktifitas akibat meningkatnya efisiensi dan manajemen operasi dan perawatan peralatan yang optimal Biaya-biaya dalam proyek efisiensi energi mencakup •Biaya Langsung Proyek (Direct project cost) •Biaya tambahan Operasi dan Perawatan (Additional operations and maintenance cost) •Capacity Building Cost (Training of personnel on new technology etc.) Penilaian Investasi mencakup : •Simple Payback Period (PBP) •Return on Investmen (RoI) •Net Present Value (NPV) •Internal Rate of Return (IRR)

Investasi

Ops

Ops

Ops

Ops

Disposal

Investasi

Ops

Disposal

Ops Ops

Ops

Live Cycle Cost Analysis

benefit

Tota

l C

ost

Existing New


PENUTUP

• Pendekatan Konservasi Energi di Industri tekstil harus dilakukan secara sistematik dan terintegrasi, mulai dari manajemen energi, penerapan teknologi efisien dan optimasi sistem, disain dan pengadaan sistem baru yang hemat energi

• Penerapan Manajemen Energi berbasis SNI ISO 50001 terbukti mampu mengendalikan dan menurunkan konsumsi energi secara berkelanjutan, dimulai dari pembenahan manajemen operasional dan perawatan peralatan

• Penerapan standard minimum efisiensi dan pendekatan Life Cycle Cost Analysis perlu dilakukan untuk pengadaan peralatan-peralatan baru untuk pabrik

43


TERIMA KASIH Contact

Dr Edi Hilmawan

Ka Bidang Konservasi Energi, Pusat Teknologi Konversi dan Konservasi Energi, BPPT

HP : 081380731007

Email : [email protected]


REFERENSI


Name : Dr Edi Hilmawan . Place/Date of Birth : Malang, 10 Maret 1974 Contact : 081380731007 (HP) [email protected] Current Job : Head of Energy Conservation Division,

Center for Energy Conversion and Conservation Technology, Agency for Assessment and Application of Technology (PTKKE-BPPT)

Expertise/Specialization :

Process and Chemical Engineer, Heat Transfer and Energy Analyst, Thermodynamics, System Analysis and Optimization

Last Academic Achievement :

Doctor of Engineering from Graduate School of Natural Science and Technology, Kanazawa University, Japan (2001)

Work Experiences (2002-now)

• Project Director/Chief Engineer/Engineer in several energy related projects

• Instructur of Energy Management Trainings

• Lead Consultant on Energy Efficiency Consultation Projects

• Lead Energy Auditors on Industries and Commercial Buildings


CONTOH KASUS : PENERAPAN HIGH EFFICIENT COMPRESSOR DI INDUSTRI TEKSTIL

48


Equipment & Installation 180.000.000,-


Net Electricity Saving 580.500.000,-


Electricty Consumption

Old : 32 kWh/bale

New : 19 kWh/bale


CONTOH KASUS : PENERAPAN TEKNOLOGI MICROTURBIN COGENERATION DI PABRIK LAMPU

* Operasi 8 jam/hr

before

after


Equipment Installation

498.750.000,- 142.500.000,-


Net Electricity Saving* 116.000.000,-



ENERGY EFFICIENT DESIGN : COGENERATION • Cogeneration is a thermal energy

conversion system that simultaneously produce electricity and heat at the same time

• Another term: Combined Heat and Power, CHP

C65

C65

C65

C65

C65

C65

C65

C65

C65

C65

C65

C65

C65

C65

C65

C65

Ads Chiller

180 TR

Ads Chiller

180 TR

Ads Chiller

180 TR

ELECTRICAL LOAD

COOLING LOAD

HOT WATER

C65

C65

Microturbine

MT + CHP module

Electrical Line

Flue Gas Line

Hot Water Line

Chilled Water Line

Multi Pack

Eff 35%

Eff 80%

Trigeneration Application of Microturbine

Cogenerations in a Commercial Building


ENERGY EFFICIENT DESIGN : PROCESS INTEGRATION IN INDUSTRY

Process Integration Optimizing waste heat

utilization to minimize needs of hot and/or cold utilities


POTENSI PENGHEMATAN ENERGI DI INDUSTRI

52


PENGHEMATAN ENERGI SEKTOR INDUSTRI (SKENARIO RENDAH DAN TINGGI)

Skenario Penghematan (juta SBM)

2010 2015 2020 2025 Konservasi Rendah 2.05 17.48 46.45 99.74

Konservasi Sedang 4.09 34.95 92.90 199.48 Konservasi Tinggi 6.14 52.43 139.34 299.22

(BPPT, 2011)


POTENSI PENGHEMATAN ENERGI INDUSTRI TEKSTIL

• Penghematan energi industri tekstil sebesar 40 juta SBM pada tahun 2030 atau sebesar38%.

• Total Listrik yang bisa dihemat 2010 – 2030 adalah 19,6 TWh atau setara dengan daya pembangkit 2,8 GW pada tahun 2030.

• Kumulatif penghematan energi final non listrik 2010 – 2030 adalah sebesar 170 juta SBM atau setara dengan 6,5 bulan lifting minyak sebesar 0,9 juta SBM per hari


ISO 50001 ENERGY MANAGEMENT STANDARD • Based on the PDCA concept Source ISO50001:2011


MANAGEMENT RESPONSIBILITY • Is the top management really

comitted?

• Will you support the system?

• This is a decision point!

• If not, we can all go for more coffee now!

• Will you make the necessary resources available (technical, financial and human)

• We assume you will if you believe there is an adaquate return on your effort or investment


POLICY

• Management commitment

• Not just a signature!

• Define scope of EnMS

• Appropriate to scale

• Commitment to continual improvement

• Make resources available

• Framework for target setting and review organizations


PLANNING • How much energy are you using?

• Where are you using it?

– Which are the biggest users?

• What is driving this use?

• What is your baseload?

• Who is influencing its use?

• Is an energy audit required – focus it?

• System Optimization

• Renewable energy options

• Develop baseline & indicators

• Set objectives and targets

• Action Plan


IMPLEMENTATION & OPERATION • Competence, training and awareness

• Documentation

• Operational control

• KEY AREA

• Operation & Maintenance

• Service contractors

• Training

• Implement your action plan

• Communication

• Design

– Energy Efficient Design (EED)

• Purchasing energy, services, goods


CHECKING

Technical checking

• Monitoring and targeting

(software may be justifiable?)

• Equipment checking

System checking

• Is everyone doing what is

required?

• Corrective and preventive action

• Non-conformities

Performance checking

• Check Energy Performance

Indicators (EnPIs)


MANAGEMENT REVIEW • Regular presentation

• Frequency based on requirements

• How are we getting on? • Is performance improving as

targeted?

• Problems and barriers to overcome?

• Achievements

• What is the plan for next year? • What do we need to achieve

this plan?


YOU’RE NOT FINISHED – THIS IS NOT A PROJECT!

• Then

• you

• start

• all

• over

• again!!

PUSAT TEKNOLOGI KONVERSI DAN KONSERVASI ENERGI ENERGY MANAGEMENT SYSTEM ISO 5001

STEP 1. TOP MANAGEMENT COMMITMENT

Komitmen manajemen

• Menunjuk MR

• Membentuk tim

• Membuat policy


STEP 2. PLANNING

Planning:

•Analisis Data Energi

•Identifikasi Pengguna Energi

Signifikan (SEUs)

•Tetapkan Faktor Pendorong

•Tetapkan Indikator Kinerja Energi,

Baseload, Baseline

•Identifikasi Peluang Perbaikan

•Tetapkan Tujuan dan Target

•Susun Rencana Aksi


STEP 3. IMPLEMENTATION OPERATION & CHECKING

Implementation:

•Competence, training and awareness

•Documentation

•Operational Control

•Communication

•Design

•Purchasement

Checking:

•Check Operations

• Operator record, maintenance

record, equipment checking

•Check the System

•Check Performance

• EnPIs, Trends, cost

•Check Progress

• Against plans

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