Case Study Indonesian sugar industry : PRODUCTIVITY GAINS FROM EFFICIENT WASTE TO ENERGY SCHEMES

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1 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) Intercontinental Hotel Mid Plaza, Jakarta, 24 th -26 th Oct, 2011

2 Introduction Current Situation Sugarcane in Indonesia Total number of sugar-mill in Indonesia are 61 sugarmill, with crushing capacity ranging TCD, total crushing capacity is TCD *) Total sugar-mill plantation in Indonesia is 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

3 Sugarcane Production global Indonesia

4 Sugarcane Processes and Material Balance Imbibition water Chemicals 1 tonne sugar cane Mill Station Purifica tion Station Evaporati -on Station Cooking and Centrifuge Station White Sugar Kg Sugar Bagasse FilterCake Molasses 300 Kg of Bagasse ~ 100 kwh Steam Consumption : Electricity consumption : 0.55 Tonnes steam/tonnes Sugarcane Kwh/Ton Tebu

5 Primary Fuel Composition in Sugarmill How to make its zero? Additional fuel consumption is expected to be eliminated so that fuel can be met by bagasse

6 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)

7 Bagasse as a Fuel German-Indonesian Renewable Energy Days

8 Bagasse Analysis (Calorific value) Parameter Status Unit Bagasse1 Bagasse 2 Bagasse 3 Method Total Moisture ar % ASTM.D Gross Calorific Value (GCV) ar Kcal/Kg ASTM.D ar: as received

9 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)

10 Current situation in sugarmill industries

11 Existing Configuration COGEN Boiler Back pressure turbine Steam 20 Bar Bagasse + MFO + Moulding Steam 2 bar G To Condenser Turbines To Process

12 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

13 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.

14 New Configuration German-Indonesian Renewable Energy Days Boiler Steam 46 Bar Steam 20 Bar Extraction Condensing Turbine Back pressure turbine Bagasse G Steam 20 bar To Condenser Electric Motor Turbines To Process G Back pressure turbine Steam 2 bar

15 Electricity generated for Grid On-season Off-season Total 43,338 MWh 35,910 MWh 79,248 MWh 15

16 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 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 MW ( 10 MW).

17 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 billion base on electricity selling price of IDR 820/kWh

18 Terimakasih

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