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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
PUSAT TEKNOLOGI KONVERSI DAN KONSERVASI ENERGI
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
PUSAT TEKNOLOGI KONVERSI DAN KONSERVASI ENERGI
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%
CENTER FOR ENERGY CONVERSION AND CONSERVATION TECHNOLOGY
5
PUSAT TEKNOLOGI KONVERSI DAN KONSERVASI ENERGI
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
PUSAT TEKNOLOGI KONVERSI DAN KONSERVASI ENERGI
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
PUSAT TEKNOLOGI KONVERSI DAN KONSERVASI ENERGI
POHON INDUSTRI TPT
PUSAT TEKNOLOGI KONVERSI DAN KONSERVASI ENERGI
KONDISI INDUSTRI TPT NASIONAL
Tahun 2010
Tahun 2010
PUSAT TEKNOLOGI KONVERSI DAN KONSERVASI ENERGI
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
CENTER FOR ENERGY CONVERSION AND CONSERVATION TECHNOLOGY
11
PUSAT TEKNOLOGI KONVERSI DAN KONSERVASI ENERGI
ENERGY FOOTPRINT INDUSTRI (EXP. INDUSTRI TEKSTIL)
Sumber: DOE – USA
Machine
Drives
Process
Cooling
Process
Heating
PUSAT TEKNOLOGI KONVERSI DAN KONSERVASI ENERGI
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
PUSAT TEKNOLOGI KONVERSI DAN KONSERVASI ENERGI
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
PUSAT TEKNOLOGI KONVERSI DAN KONSERVASI ENERGI
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%
PUSAT TEKNOLOGI KONVERSI DAN KONSERVASI ENERGI
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
PUSAT TEKNOLOGI KONVERSI DAN KONSERVASI ENERGI
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
PUSAT TEKNOLOGI KONVERSI DAN KONSERVASI ENERGI
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
PUSAT TEKNOLOGI KONVERSI DAN KONSERVASI ENERGI
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
PUSAT TEKNOLOGI KONVERSI DAN KONSERVASI ENERGI
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
PUSAT TEKNOLOGI KONVERSI DAN KONSERVASI ENERGI
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
PUSAT TEKNOLOGI KONVERSI DAN KONSERVASI ENERGI
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
PUSAT TEKNOLOGI KONVERSI DAN KONSERVASI ENERGI
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
PUSAT TEKNOLOGI KONVERSI DAN KONSERVASI ENERGI
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
PUSAT TEKNOLOGI KONVERSI DAN KONSERVASI ENERGI
MANAJEMEN ENERGI: OPERATION AND MAINTENANCE
25
Contoh Kasus: Cylinder Dryer
Sumber: JICA – BPPT Study (2008)
Temp Silinder rendah, distribusi uap tidak merata, kondensat tidak terbuang dengan baik
Temp kain turun, Pemanasan kurang efektif, Pemborosan Uap
PUSAT TEKNOLOGI KONVERSI DAN KONSERVASI ENERGI
MANAJEMEN ENERGI: OPERATION AND MAINTENANCE
26
Contoh Kasus: Washing Machine
Sumber: JICA – BPPT Study (2008)
TDS di bak 2 rendah, Indikasi kebanyakan air, Temp rendah, PH terjaga tinggi
Sistem individu, air limbah dibuang
Sistem Counterflow Kontrol temperatur
PUSAT TEKNOLOGI KONVERSI DAN KONSERVASI ENERGI
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
PUSAT TEKNOLOGI KONVERSI DAN KONSERVASI ENERGI
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%)
PUSAT TEKNOLOGI KONVERSI DAN KONSERVASI ENERGI
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)
PUSAT TEKNOLOGI KONVERSI DAN KONSERVASI ENERGI
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
PUSAT TEKNOLOGI KONVERSI DAN KONSERVASI ENERGI
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
PUSAT TEKNOLOGI KONVERSI DAN KONSERVASI ENERGI
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)
PUSAT TEKNOLOGI KONVERSI DAN KONSERVASI ENERGI
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
PUSAT TEKNOLOGI KONVERSI DAN KONSERVASI ENERGI
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
PUSAT TEKNOLOGI KONVERSI DAN KONSERVASI ENERGI
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
PUSAT TEKNOLOGI KONVERSI DAN KONSERVASI ENERGI
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
PUSAT TEKNOLOGI KONVERSI DAN KONSERVASI ENERGI
CONTOH KASUS : PENERAPAN TEKNOLOGI MICROTURBIN COGENERATION DI PABRIK LAMPU
* Operasi 8 jam/hr
before
after
Investment Cost (Rp) 641.250.000,-
Equipment Installation
498.750.000,- 142.500.000,-
Benefit (Rp/Year) 116.000.000,-
Net Electricity Saving* 116.000.000,-
Simple Pay Back (year) 5,53
PUSAT TEKNOLOGI KONVERSI DAN KONSERVASI ENERGI
OPTIMASI SISTEM : PUMP SYSTEM OPTIMIZATION
38
Sumber (UNIDO)
PUSAT TEKNOLOGI KONVERSI DAN KONSERVASI ENERGI
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
PUSAT TEKNOLOGI KONVERSI DAN KONSERVASI ENERGI
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
PUSAT TEKNOLOGI KONVERSI DAN KONSERVASI ENERGI
ENERGY EFFICIENT DESIGN : PROCESS INTEGRATION IN INDUSTRY
Process Integration Optimizing waste heat
utilization to minimize needs of hot and/or cold utilities
PUSAT TEKNOLOGI KONVERSI DAN KONSERVASI ENERGI
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
PUSAT TEKNOLOGI KONVERSI DAN KONSERVASI ENERGI
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
PUSAT TEKNOLOGI KONVERSI DAN KONSERVASI ENERGI
TERIMA KASIH Contact
Dr Edi Hilmawan
Ka Bidang Konservasi Energi, Pusat Teknologi Konversi dan Konservasi Energi, BPPT
HP : 081380731007
Email : [email protected]
PUSAT TEKNOLOGI KONVERSI DAN KONSERVASI ENERGI
REFERENSI
PUSAT TEKNOLOGI KONVERSI DAN KONSERVASI ENERGI
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
PUSAT TEKNOLOGI KONVERSI DAN KONSERVASI ENERGI
PUSAT TEKNOLOGI KONVERSI DAN KONSERVASI ENERGI
CONTOH KASUS : PENERAPAN HIGH EFFICIENT COMPRESSOR DI INDUSTRI TEKSTIL
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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
PUSAT TEKNOLOGI KONVERSI DAN KONSERVASI ENERGI
CONTOH KASUS : PENERAPAN TEKNOLOGI MICROTURBIN COGENERATION DI PABRIK LAMPU
* Operasi 8 jam/hr
before
after
Investment Cost (Rp) 641.250.000,-
Equipment Installation
498.750.000,- 142.500.000,-
Benefit (Rp/Year) 116.000.000,-
Net Electricity Saving* 116.000.000,-
Simple Pay Back (year) 5,53
PUSAT TEKNOLOGI KONVERSI DAN KONSERVASI ENERGI
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
PUSAT TEKNOLOGI KONVERSI DAN KONSERVASI ENERGI
ENERGY EFFICIENT DESIGN : PROCESS INTEGRATION IN INDUSTRY
Process Integration Optimizing waste heat
utilization to minimize needs of hot and/or cold utilities
PUSAT TEKNOLOGI KONVERSI DAN KONSERVASI ENERGI
POTENSI PENGHEMATAN ENERGI DI INDUSTRI
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PUSAT TEKNOLOGI KONVERSI DAN KONSERVASI ENERGI
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)
PUSAT TEKNOLOGI KONVERSI DAN KONSERVASI ENERGI
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
PUSAT TEKNOLOGI KONVERSI DAN KONSERVASI ENERGI
ISO 50001 ENERGY MANAGEMENT STANDARD • Based on the PDCA concept Source ISO50001:2011
PUSAT TEKNOLOGI KONVERSI DAN KONSERVASI ENERGI
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
PUSAT TEKNOLOGI KONVERSI DAN KONSERVASI ENERGI
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
PUSAT TEKNOLOGI KONVERSI DAN KONSERVASI ENERGI
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
PUSAT TEKNOLOGI KONVERSI DAN KONSERVASI ENERGI
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
PUSAT TEKNOLOGI KONVERSI DAN KONSERVASI ENERGI
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)
PUSAT TEKNOLOGI KONVERSI DAN KONSERVASI ENERGI
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?
PUSAT TEKNOLOGI KONVERSI DAN KONSERVASI ENERGI
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
PUSAT TEKNOLOGI KONVERSI DAN KONSERVASI ENERGI ENERGY MANAGEMENT SYSTEM ISO 5001
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
PUSAT TEKNOLOGI KONVERSI DAN KONSERVASI ENERGI ENERGY MANAGEMENT SYSTEM ISO 5001
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