Case Study Indonesian sugar industry : PRODUCTIVITY GAINS...

German-Indonesian Renewable Energy Days

Intercontinental Hotel Mid Plaza, Jakarta, 24th-26th 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)


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


Sugarcane Production global

Indonesia 418.259 70 29.278.130


Sugarcane Processes and Material Balance

Mill Station

Purification

Station

Evaporati

-on Station

Cooking and

Centrifuge

Station

sugarcane

WhiteSugar

MolassesFilterCakeBagasse

Imbibitionwater

Chemicals

300 Kg of Bagasse ~ 100 kWh

60-70 Kg Sugar

1 tonne

Steam Consumption : 0.55 Tonnes steam/Tonnes SugarcaneElectricity consumption : 16-21 Kwh/Ton Tebu


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?


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)


Bagasse as a Fuel


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


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, 325°C.

• The boiler fuel is mill bagasse, the fibrous residue of the cane milling process. Bagasse has 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)


Current situation in sugarmill industries


Existing Configuration COGEN

To Process

Bagasse + MFO + Moulding

Boiler Back pressure turbine

To Condenser

Turbines

G

Steam 20 Bar

Steam 2 bar


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


Bagasse Surplus

• The maximum commulative bagasse surplus which occured at the end of milling season is estimated around 94,000 ton at crushing capacity of7,200 TCD.


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


15

On-season 43,338 MWhOff-season 35,910 MWhTotal 79,248 MWh

Electricity generated for Grid


New Configuration operation mode

• Cogeneration system will operated continuously forthe entire year (330 days)

• on-season, existing boilers operate 63.8 TPH andexisting alternator turbine operates 3.97 MW. Whilenew boiler operate at 104.8 TPH, extraction steam 54TPH at 20 kg/cm2 and turbine alternator operating at10 MW

• off-season, existing boiler and turbine is not operated,while one unit of a new boiler operates at 47.4 TPHand new turbine operate with condensing mode at9.975 MW (10 MW).


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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Case Study Indonesian sugar industry : PRODUCTIVITY GAINS...

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