EXPERIENCE and APPLICATION of

ENERGY EFFICIENCY and CONSERVATION

in LECES PULP AND PAPER MILL

SUBAGYO

PRESENTED BY

COVER

MILL OVERVIEW

POWER PLANTOVERVIEW

MAJOR

ENERGYCONSERVATION

MINOR

CONCLUSION

Location

LECES PULP & PAPER MILL LOCATION

LECES

Leces-Probolinggo, East Java, Indonesia

COVER

MILL OVERVIEW

Mill

Production

POWER PLANTOVERVIEW

ENERGYCONSERVATION

CONCLUSION

Consist of:a. Paper Machinesb. Bagasse Pulp Plantc. Deinking Plantd. Waste Water Treatment Plante. Steam Power Plant

LECES PULP & PAPER MILLOVERVIEW

Location

COVER

MILL OVERVIEW

Mill

Production

POWER PLANTOVERVIEW

ENERGYCONSERVATION

CONCLUSION

MILL MAIN PRODUCTION

275 ton/dayNewsprint, Writing & Printing paper

Paper Machine 5

30 ton dayTissuePaper Machine 4

175 ton/dayWriting & Printing paper

Paper Machine 3

60 ton/dayIndustrial paper, Writing paper

Paper Machine 2

30 ton/dayLinerPaper Machine 1

CapacityKind of ProductPaper Machine

Location

COVER

MILL OVERVIEW

Mill

Production

POWER PLANTOVERVIEW

ENERGYCONSERVATION

CONCLUSION

ENERGY GENERATION AND DISTRIBUTION DIAGRAM

Power Boiler

Recovery Boiler

MP Header

Mill

LP Header

Mill

HP Header44 BAR, 440oC

S S SMillCTECTEBPT

12.5 BAR, 200oC

6 BAR, 165oC

Diagram

Demand

COVER

MILL OVERVIEW

POWER PLANTOVERVIEW

ENERGYCONSERVATION

CONCLUSION

5 unit

@ 90 ton/hour

2 unit

@ 40 ton/hour

27 MW 19.4 MW19.4 MW

ENERGY GENERATION and CONSUMPTION

4.402.2065.0024.55Normal

4.4025.80100.1033.87Maximum

33 barg12 barg6 bargMW

Steam (ton/hour)ElectricityMill Operation

Energy Consumption

HP Steam Generation

172Normal

264Maximumton/hourMill OperationDiagram

Demand

COVER

MILL OVERVIEW

POWER PLANTOVERVIEW

ENERGYCONSERVATION

CONCLUSION

ENERGY CONSERVATION

Aim :

Decreasing excess energy used

Improved efficiency of the equipment

Aim

Background

Planning

Implementation

COVER

ENERGYCONSERVATION

CONCLUSION

Background

1. Energy cost 24% of production cost2. Government policy3. Environment issue4. Power Plant performancePlanning

Government Policy

Power PlantPerformance

Implementation

Aim

Background

COVER

ENERGYCONSERVATION

CONCLUSION

Government PolicyIndonesian Government Policy:

Decreased the subsidy of the fuel oil (since 2001)

Planning

Government Policy

Power Plant Performance

Implementation

Aim

Background

COVER

ENERGYCONSERVATION

By PTKL

CONCLUSION

FUEL PRICE

9.66 9.66

1.9

4.183.67

2.21.07

5.014

2.672.96

3.2 3.3 4.36

1.7 1.91.61.41.30

2

4

6

8

10

12

2001 2002 2003 2004 2005 2006

US$

/MM

BTu

OIL GAS COAL

POWER PLANT PERFORMANCE

1. Boiler Deterioation

2. Steam Turbine Deterioration

3. Low Power factor

Efficiency Power Plant decrease, caused by:

Planning

Government Policy

Power PlantPerformance

Implementation

Aim

Background

COVER

ENERGYCONSERVATION

By PTKL

CONCLUSION

BoilerDeterioration

Turbine DeteriorationLow Power

Factor

BOILER DETERIORATION

1. SLAG AND DEPOSIT AT FIRE SIDE

DUE TO LOW QUALITY OF OIL

Planning

Government Policy

Power PlantPerformance

BoilerDeterioration

Implementation

Aim

Background

COVER

ENERGYCONSERVATION

By PTKL

CONCLUSION

2. SCALE AND FLAKE AT FIRESIDE

HIGH TEMPERATURE CORROSION

3. RUPTURE

OVERHEATING

Turbine DeteriorationLow Power

Factor

STEAM TURBINE DETERIORATION

Capacity of Extraction Steam Turbine (ECT) is 27 MW.

Due to cracking at shaft of ECT, this turbine operate maximum at 16 MW, so to fulfill electricity demand the Power Plant should operate ECT and CT

The operation of ECT and CT need more steam about 8 ton/hour

Potensial loss USD 1 million/year

Planning

Government Policy

Power PlantPerformance

BoilerDeterioration

Implementation

Aim

Background

COVER

ENERGYCONSERVATION

By PTKL

CONCLUSION

Turbine DeteriorationLow Power

Factor

LOW POWER FACTOR

At 2000 the power factor at Power Plant was 0.74 (at power generation)

Operation steam turbine could not optimize

More motor and electricity equipment burnt

Planning

Government Policy

Implementation

Aim

Background

COVER

ENERGYCONSERVATION

By PTKL

CONCLUSION

Power PlantPerformance

BoilerDeterioration

Turbine DeteriorationLow Power

Factor

A. Major1. Short term

1a. Modified from oil burner to gas burner (done, 2002-2003)

1b. Retubing (done, 2002)2. Long term (future expansion, 2007-2009),

Changing the fuel from gas to coal3. Repair Extraction Steam Turbine (ECT, 2007)4. Install/adding capacitor (in progress)

Planning

Comparisonof Gas and Coal

Planning

ImplementationMajor

Aim

Background

COVER

ENERGYCONSERVATION

By PTKL

CONCLUSION

B. Minor1. Adding Economizer (done)2. Operation Pressure Reducing Valve (PRV, done)3. Extract Steam Control (done)4. Replace and or repair steam traps were not working

properly, piping system were leak (in progress)

ImplementationMinor

Comparison of the Gas Fired and Coal Fired Boiler

17-US$(million)

Investment4

5.2-US$/year(million)

Saving3

8.8 14US$/year(million)

Fuel cost2

51.654.2%Efficiency system

1

Coal Fired Boiler

Existing (Gas Fired Boiler)**

UnitDescriptionNo

** Initial, after modified from oil fired

Comparison

Planning

Implementation

Aim

Background

COVER

ENERGYCONSERVATION

CONCLUSION

MODIFIED OIL FIRED BOILER to

GAS FIRED BOILER(Fuel Conversion, had been done)

SHORT TERM

MAJOR

Gas Fired Boiler

ImplementationMinor

Technical Aspect

Economic Aspect

Environment Aspect

Planning

ImplementationMajor

Aim

Background

COVER

ENERGYCONSERVATION

By PTKL

CONCLUSION

IMPLEMENTATION

Install/AddingCapacitor

1. No need atomizing and heater for gassteam demand for no load decrease from 50 ton/hour to 42.5 ton/hour

2. The superheater and evaporator more clean- Efficiency the boiler increase- Maintenance cost decrease- Availability increase

3. The quality of gas remaining constant

Technical Aspect

Gas Fired Boiler

Minor

Technical Aspect

Economic Aspect

Environment Aspect

Planning

Implementation

Aim

Background

COVER

ENERGYCONSERVATION

By PTKL

CONCLUSION

Gas Fired Boiler

Energy Cost

6.5

14.5

24.0

17.0

0

5

10

15

20

25

30

2001 2002 2003 2004

Year

%

Gas Fired

Economic Aspect

Oil Fired

Investment : USD 1,600,000(5 power boilers)

Saving : USD 11,400,000/year

Payback period: ± 2 months

Gas FiredBoiler

Minor

Technical Aspect

Economic Aspect

Environment Aspect

Planning

Implementation

Aim

Background

COVER

ENERGYCONSERVATION

By PTKL

CONCLUSION

Gas Fired Boiler

Environment Aspect1. Reduce energy consumption

Energy Consumption

150

200

250

300

350

400

450

500

5,000 6,000 7,000 8,000 9,00010,000 11,000 12,000 13,000 14,000 15,000

Paper Production (ton/month)

(000

) MM

BTU/

mon

thOil

Gas

Gas Fired Boiler

ImplementationMinor

Technical Aspect

Economic Aspect

Environment Aspect

Planning

Implementation

Aim

Background

COVER

ENERGYCONSERVATION

By PTKL

CONCLUSION

Gas Fired Boiler

Capacitor

Environment Aspect2. Reduce green house effect by

reducing CO2 emissionLesser CO2 emission occurred by;1. Carbon content in gas is about 71%, otherwise

86% in oil2. Increasing efficiency at steam generation

181,732101,615Natural gas

ton(000)Nm3m3

175,879

357,612

CO2 emission

121,280Oil

Fuel ConsumptionKind of Fuel

33.50MMBtu/tonOil0.87m3/ton

0.73(000)Nm3/ton25.82MMBtu/tonNatural gas

Fuel Consumption140,000ton/yearPaper production

Gas Fired Boiler

Capacitor

Technical Aspect

Economic AspectEnvironment Aspect

Planning

Implementation

Aim

Background

COVER

ENERGYCONSERVATION

By PTKL

CONCLUSION

Gas Fired Boiler

INSTALL/ADDING CAPACITOR

Economic AspectInvestment : USD 200,000Saving : USD 800,000/yearPayback period: ± 3 months

Gas Fired Boiler

Planning

ImplementationMajor

Aim

Background

COVER

ENERGYCONSERVATION

By PTKL

CONCLUSION

-

1.0

2.0

3.0

4.0

5.0

6.0

7.0

8.0

9.0

10.0 10.5 11.0 11.5 12.0 12.5 13.0 13.5 14.0

power factor 0.74

power factor 0.80

POWER GENERATION (MW)

HE

AT

RA

TE ,T

ON

STE

AM

/MW

POWER FACTOR AND HEAT RATE CORELATION

Technical Aspect1. Less steam consumption, less fuel 2. Turbine operate optimum3. Less Motor & equipment burn

Capacitor

ImplementationMinor

ENERGY CONSERVATIONMINOR

Adding Economizer

Operation PRV

Extract Steam Control

Major

Minor

Implementation

Aim

Background

COVER

ENERGYCONSERVATION

By PTKL

CONCLUSION

Planning

ADDING ECONOMIZER

done at 5 power boilerStack temperatureBefore : 180 oCAfter : 160 oC Efficiency increase: 1%

Each boilerInvestment USD 78,000Saving USD 28,600/yearPayback period 2.7 years

Major

Minor

Implementation

Aim

Background

COVER

ENERGYCONSERVATION

By PTKL

CONCLUSION

Planning

Adding Economizer

Operation PRV

Extract Steam Control

OPERATION PRV

Major

Minor

Implementation

Aim

Background

COVER

ENERGYCONSERVATION

By PTKL

CONCLUSION

Planning

Power Boiler

Recovery Boiler

MP Header

Mill

LP Header

Mill

HP Header

44 BAR, 440oC

S S SMillCTEC

TEBPT

12.5 BAR, 200oC

6 BAR, 165oC

ProblemValve slightly sticky and difficult to open once it is closed.Kept manually opened ± 20%, higher than actual demandPRV MP to LP also opened 20% automatically

Program (done)Repair PRV HP to MP

ResultPRV MP to LP closed, efficiency of ECT improveSave expected 1 ton steam HP/hour equal USD 12/hour

Adding Economizer

Operation PRV

Extract Steam Control

EXTRACT STEAM CONTROL

Major

Minor

Implementation

Aim

Background

COVER

ENERGYCONSERVATION

CONCLUSION

Planning

Power Boiler

Recovery Boiler

MP Header

Mill

LP Header

Mill

HP Header

44 BAR, 440oC

S S SMillCTECTEBPT

12.5 BAR, 200oC

6 BAR, 165oC

ProblemExtract steam controlled about 6.5 barSteam required at paper mill 2.5 bar; 140oC

Program (done)Reduced pressure controlled to 6.0 bar

ResultImprove efficiency of ECTSave expected 1 ton steam HP/hour equal US$ 12/hour

Adding Economizer

Operation PRV

Extract Steam Control

CONCLUSION1. Program in energy conversion from fuel oil to gas had

been done, apparently to reduce the energy cost from USD 22.05 million/year to USD 11.45 million/year.

2. The future expansionis is changing the fuel from gas to coal

3. Increasing power factor from 0.74 to 0.80 reduce heat rate of power generator up to 6%.

4. Improve power factor by installing new capacitor, target from 0.80 to 0.90 is still in progress.

5. Due to tight production and marketing schedule repairing the shaft of ECT will be done after coal fired boiler build.

COVER

MILL OVERVIEW

POWER PLANTOVERVIEW

MAJOR

ENERGYCONSERVATION

MINOR

CONCLUSION