PT.

LANGGENG CIPTALINDO

Webinar Series #2
“Future Business Opportunities in Steam and Energy Conservation Technology”

Program Studi Magister Teknik Kimia - Fakultas Teknik

Universitas Sriwijaya
28 November 2020
 Outline

• Company Profile
• Energy Conservation
• Steam User Overview
• Steam Application
• Steam System Audit
• Future Business Opportunity
• Success Story
• Conclusion
 Outline

• Company Profile
• Energy Conservation
• Steam User Overview
• Steam Application
• Steam System Audit
• Future Business Opportunity
• Success Story
• Conclusion
 Who we are

Welcome to LANGGENG GROUP

PT. LANGGENG CIPTALINDO is a proven engineering company that is capable in developing and
dealing with packaged implementation on a new plant design and improved steam system
performance to comply energy conservation, health and safety, and environmental friendly. We have
been focusing on many strategic industrial sectors such as Food & Beverages, Sugar Refinery,
Pharmaceuticals, Tobacco, Hotels, Feed Mill, Chemical, and other steam users. We have been also
exploring actively in other potential business sectors such as Mining and Cement. Having long
experience practically in application engineering and energy auditor mainly in steam system design,
piping and installation, and other pressure vessel fabrication, we believe that we are able to bring
more benefit and best solution to the customer.

A simple philosophical approach…

Developing and Implementing

that confirming clearly our strong commitment in delivering proper sustainable solutions for all customers.
 Our Capabilities

Engineering Services Construction & Steel Fabrication

• Design & build new steam plant system and • Supply and install for steam & process fluids
other utilities piping & insulation
• Improve and optimize steam system • Plate work (tank/vessel, hopper, ducting,
performance chimney, platform, and etc)
• Energy service company (ESCO) in energy • Installation of mechanical & electrical equipment
and cost saving turnkey project

Packaged System Products Audits & Training

• Heat exchange packaged solution with • Energy audits (thermal and electricity) with
worldwide heat exchanger brand certified energy auditor
• Heat recovery system (energy conservation in • Comprehensive steam audits and process fluids
boiler house and steam distribution) piping on existing plant
• Automation and system integrator for energy • Energy & water conservation training with
monitoring using HMI-PLC & SCADA certified energy auditor

www.langgengciptalindo.com
Energy Audit & Training

Gedung Inspektorat
Pemprov Jawa Tengah
Energy Efficiency Project
 Outline

• Company Profile
• Energy Conservation
• Steam User Overview
• Steam Application
• Steam System Audit
• Future Business Opportunity
• Success Story
• Conclusion
 Kebijakan dan Regulasi Konservasi Energi Nasional

1. Undang-Undang No. 30/2007 tentang Energi

2. Peraturan Pemerintah No. 70/ tahun 2009 tentang Konservasi Energi
3. Peraturan Presiden No. 5 tahun 2006 tentang Kebijakan Energi Nasional
4. Instruksi Presiden No. 13 tahun 2011 tentang Penghematan Energi dan Air
5. Peraturan Menteri ESDM No. 13 tahun 2012 tentang Penghematan Pemakaian Tenaga Listrik
6. Peraturan Menteri ESDM No. 14 tahun 2012 tentang Manajemen Energi
7. Peraturan Menteri ESDM No. 01 tahun 2013 tentang Pengendalian Penggunaan Bahan Bakar Minyak
8. Peraturan Menteri ESDM No. 6 tahun 2011 tentang Pembubuhan Label Tanda Hemat Energi Untuk Lampu Swabalast
9. Keputusan Menteri ESDM No. 4051K/07/MEM/2013 tentang Catur Dharma Energi

PERATURAN YANG TERKAIT DENGAN STANDAR KOMPETENSI MANAJER DAN AUDITOR ENERGI
10. Peraturan Menteri ESDM No. 13 dan No. 14 tahun 2010 tentang Standar Kompetensi Manajer Energi
11. Keputusan Menteri Nakertrans No. 321 dan 323/MEN/XII/2011 tentang Standar Kompetensi Kerja Indonesia untuk
Manajer Energi (SKKNI Manajer Energi)
12. Keputusan Menteri Nakertrans No. 614/MEN/IX/2012 tentang Standar Kompetensi Kerja Indonesia untuk Auditor
Energi (SKKNI Auditor Energi)
13.Peraturan Presiden No. 61 tahun 2011 tentang Rencana Aksi Nasional Penurunan Emisi Gas Rumah Kaca (RAN-GRK)
* Sumber: Ditjen EBTKE
 Definisi Konservasi Energi (PP No. 70/2009)
Konservasi energi adalah :
✓ upaya sistematis, terencana, dan terpadu;
✓ guna melestarikan sumber daya energi dalam negeri (nasional)
✓ serta meningkatkan efisiensi pemanfaatannya.

Ini merupakan program kerja yang harus dilaksanakan nasional, karena

menyangkut kelestarian (sustaianability) sumber daya energi dalam negeri/
strategis

Program KONSERVASI ENERGI ini diundangkan dalam UU No. 30/ 2007 tentang
ENERGI, yang didalamnya ada pasal 25 ayat (5) mengenai “KONSERVASI ENERGI”
dan dituangkan dalam PP No.70/2009
 Manajemen Energi (PP No. 70/2009)

PP No. 70/2009 Pasal 12 Mewajibkan pengguna energi > 6,000 TOE* per tahun untuk
menerapkan manajemen energi antara lain :

1. menunjuk manajer energi;

2. menyusun program konservasi energi;
3. melaksanakan audit energi secara berkala;
4. melaksanakan rekomendasi hasil audit energi;
5. melaporkan pelaksanaan konservasi energi kepada pemerintah

*) 6000 TOE setara dengan 251.208 Giga Joule (GJ) atau 69.780 Mega Watt hour (MWh).
 Audit Energi
PENGERTIAN AUDIT ENERGI, dari sudut pandang :
✓ REGULASI (PEMERINTAH):
Proses evaluasi pemanfaatan energi dan identifikasi peluang penghematan energi
serta rekomendasi peningkatan efisiensi pada pengguna energi dan pengguna
sumber energi dalam rangka konservasi energi.

✓ TEKNIK (ENGINEERING) :
Kegiatan mengevaluasi unjuk kerja suatu fasilitas pengguna energi guna
mengidentifikasi dimana dan berapa terjadi energy loss serta berapa potensi
penghematan (energy saving) yang mungkin diperoleh dalam suatu fasilitas
pengguna energi tersebut.
✓ EKONOMI (FINANSIAL) :
Proses evaluasi performa penggunaan biaya energi pada fasilitas pengguna energi
dan mengidentifikasi berapa losses biaya yang terjadi dan potensi penghematan
biaya dalam suatu fasilitas tersebut.
EnERGY MANAGEMENT SYSTEM

Terms to Understand

EnMS (Energy Management System)

A systematic approach to the management of energy use

EnMS Standard
Standarized approach to implementing an EnMS;
may be based on ISO 50001:2011

EnMS Certification
ISO 50001 or Self-Evaluation and Self-declaration of
conformance
 Audit Energi Menuju PROPER

1. Memenuhi kriteria penilaian sistem manajemen

lingkungan
2. Memenuhi kriteria penilaian pemanfaatan sumber daya,
antara lain dengan melakukan efisiensi energi dan
konservasi air
3. Memenuhi kriteria penilaian community development
* Sumber: PerMen LH No. 5 Tahun 2011
 Outline

• Company Profile
• Energy Conservation
• Steam User Overview
• Steam Application
• Steam System Audit
• Future Business Opportunity
• Success Story
• Conclusion
 Steam User Overview

• Heavy Steam Users

Other Facilities 8%
Petrochemicals, Chemicals, Petroleum 4%
Refining, Forest Products (Pulp & Paper), Electro-chemical
Food & Beverage, Plastics, Rubber, 2%
Textiles, Pharmaceuticals, Manufacturing
Assembly Process
Cooling
Steam
1%
• Medium Steam Users 35%
Large commercial heating, Laundries,
Bakeries, Cooking, Metal Fabrication, Motor
Large chiller systems Systems Process
12% Heating 38%
• Small Steam Users
Electronics, Paint booths, Humidification
systems
 Steam Advantages

❑ Steam is still the most efficient and cost effective way of transferring
heat
❑ Steam is easily and readily controllable, ensuring accurate and
repeatable operations
❑ Steam fills the heat transfer space evenly, ensuring consistent
product quality.
❑ Steam is ideally suited to clean and sterile products/environments
as it is inherently sterile
❑ Steam is extremely flexible, as it can be generated in central boiler
plant or localised boilers whichever suits the application.
❑ Steam can tie in with combined heat and power systems to provide
motive power, heating, and refrigeration.
❑ Steam and condensate pipe sizes are usually smaller and lighter than
liquid systems, minimising installation costs.
❑ Steam systems require no circulation pumps or circuit balancing,
reducing running costs and commissioning charges.
Grades of Steam

Contact product
Non
 Steam System in Food and Beverage

Plant steam

Clean steam
Steam System in Chemical/Petrochemical
Steam System in Oil Refinery
Steam System in Pharmaceutical
 Outline

• Company Profile
• Energy Conservation
• Steam User Overview
• Steam Application
• Steam System Audit
• Future Business Opportunity
• Success Story
• Conclusion
 Steam Application
Direct injection
Steam Product

Heat exchanger
Steam Product

Jacketed vessel
Steam Product

Steriliser
Steam Product

Heat exchanger Heat exchanger

Steam Hot water Product

Heat exchanger Dryer

Steam Hot air Product

Heat exchanger Dilution

Steam Hot water Product
 Plant Steam Process Application

Plant Steam Application

 Plant Steam Application
• Indirect product contact
• Indirect heating medium, such Heat Exchanger, Steam Coil, Jacketed Tank, and etc
 Filtered (Culinary) Steam Application

• Direct product contact

• Direct heating medium, such blenching, clean in place, direct steam cooking, direct steam
humidification, autoclave, direct steam conditioning, and etc
 Clean Steam Process Application

Clean Steam Application

Clean steam generator

 Clean Steam Process Application

Clean Steam Application

Clean steam generator

 Clean Steam Process Application
Aceptic Filling
Manufacturers go to great
lengths to ensure the sterility
of the product, process line,
bottles, etc., to ensure product
shelf life is not affected!
Food & Beverage

Every day steam sterilisers

from Central Sterile Supply
Department (CSSD) are
preparing medical devices for
patient
Hospital
 Clean Steam Process Application
Steam injected
2000 kg/h

Product capacity of
18,000 l/h

• UHT Milk: A large • Steam is often injected • Steam is used to

quantity of steam is directly injected into sterilise carbon
injected directly into soups and sauces activated filters used
the product under • Direct steam injection can for process water
controlled conditions potentially improve taste,
reduce fat, improves
colour, etc.
Pure Steam Process Application
 Sterilize In Place (SIP)

Pressure Control
Steam Quality Test

Pure Steam
Intake

Autoclave

Steam Separator

Sample Cooler
 Outline

• Company Profile
• Energy Conservation
• Steam User Overview
• Steam Application
• Steam System Audit
• Future Business Opportunity
• Success Story
• Conclusion
 Konservasi Energi Pengguna Steam
Konservasi energi adalah :
✓ upaya sistematis, terencana, dan terpadu;
✓ guna melestarikan sumber daya energi dalam negeri (nasional)
✓ serta meningkatkan efisiensi pemanfaatannya.

“Industri pengguna steam ingin

mengidentifikasi, merencanakan, dan
menerapkan perbaikan efisiensi dan konservasi
energi, agar dapat menurunkan biaya pokok
produksi sekaligus meningkatkan daya saing
serta memenuhi target keberlanjutan
penyediaan energi dengan tetap
memperhatikan keberlangsungan produksi,
standard keamanan, lingkungan, dan regulasi
yang berlaku”
 Steam System Components

✓ Generation ✓ End-use (Utilization)

• Boiler • Steam turbines
• Boiler auxiliaries • Heat exchangers
• Water treatment equipment • Live steam injection
• Deaerator • Hot Water Generator
• Feedwater Pumps • Evaporators, Drier, etc.
• Fuel storage and handling
equipment
✓ Recovery
• Steam traps
✓ Distribution • Condensate recovery and
• Steam piping return system
• Pressure reducing stations • Condensate pumps
• Flash steam recovery
 Steam and Energy Conservation Opportunities

❑ Boiler process control

❑ Distribution system
❑ Reduction of flue gas
insulation
quantities
❑ Steam trap improvement
❑ Reduction of excess air
❑ Steam trap maintenance
❑ Properly sized boiler
❑ Steam trap monitoring
systems
❑ Leak repair
❑ Boiler insulation
❑ Flash steam recovery
❑ Boiler maintenance
❑ Condensate return
❑ Flue gas heat recovery
❑ Preventive maintenance
❑ Blowdown steam
❑ Process integration and
recovery
pinch analysis
❑ Boiler replacement
 Steam and Energy Conservation Opportunities
Flue Gas Radiation
Losses Losses Distribution Flash
20% 3% Losses Losses
5% 5%

Fuel Input
100% Heat Output Heat To User
75% 55%

Boiler Distribution

Condensate
Blowdown Losses
Losses 10%
2%
 Steam System Audit

• Evaluasi terhadap kinerja sistem steam terpasang secara komprehensif

• Analisis steam supply and demand
• Identifikasi potensi perbaikan dan konservasi energi
• Analisis dampak perbaikan terhadap sistem steam
• Implementasi proyek konservasi energi
• Monitoring and verification terhadap proyek konservasi energi

Plant Survey Laporan Implementasi

Inventarisasi Presentasi Prioritas
Pengumpulan data Diskusi Biaya
Investigasi Rekomendasi Payback
Assesmen Potensi Monitoring
Identifikasi Kelayakan Verifikasi
 The Step of Steam System Audit

Kick off Meeting

Plant Survey
Final Presentation

Process & Instrumentation Diagram

Drawing
Reporting

Closing Field Survey Meeting

Tools of Steam System Audit
The Activities of Steam System Audit
The Activities of Steam System Audit
Ruang Lingkup Audit Steam
 KELUARAN STEAM SYSTEM AUDIT

• Laporan rekomendasi efisiensi dan konservasi energi, best practices, safety and
environment, maupun peluang perbaikan dari sistem distribusi steam yang terpasang
saat ini (existing vs improved steam system)

• Laporan rencana aksi (action plan) atas dasar biaya investasi konservasi energi,
penghematan biaya, dan payback period pada No/Low Cost, Medium Cost, dan High
Cost

No Rekomendasi Potensi Penghematan Biaya Investasi Payback Period Tingkat Pembiayaan

Energi (MJ/bulan) Biaya (Rp/bulan) (Rp) (bulan) (No/Low/Medium/High)
1
2
3
4
5
Total
 USAHA KONSERVASI ENERGI DI RUANG BOILER
3

1 Burner control
- Fully modulating control
- Use of variable speed fan
- O2 trim 2
…can save up to
2 % thermal energy
30 % electric energy 5
Boiler insulation…
5 6
- High density and thickness
2 Auto TDS control 7
insulation lagging
- Reduces amount of boiler blow down required - Elimination of heat bridges
- Reduces water carryover with steam 1 between hot vessel and cladding
-Use of air actuated valve instead of electric …can save up to
…can save up to 0,1 % thermal energy
0,4 % thermal energy
5 % salts and chemicals 6 Feed water control… 7
Water treatment…
- Use of multistage high efficiency pumps - Reduces amount of boiler blow down required
4 Deaerator…
3 Waste heat recovery… - Use of variable speed feed water pumps - Avoids scaling inside the boiler which affect
- High density and thickness
- Use of flue gas economizer - Use of modulating feed water system for heat transfer rate between the water and the hot
insulation lagging
- Use of flues / air pre heater feed water rating matched to steam gases
…can save up to
…can save up to demand …can save up to
0,45 % thermal energy
5 % thermal energy …can save up to 5 % thermal energy
70 % salts and chemicals
15 % electric energy
 Steam Distribution Improvement

Existing steam system Improved steam system

 PROYEK IMPLEMENTASI KONSERVASI ENERGI DI BOILER

Flue Gas
Losses
20%
Radiation Distribution Flash
Losses Losses Losses
3% 5% 5%

Fuel Input
100% Heat Output Heat To User
75% 55%

Boiler Distribution

Condensate
Blowdown Losses
Losses 10%
2%
RETROFIT BURNER CONTROL SYSTEM
dan
DAUR ULANG PANAS GAS CEROBONG
 Mechanical vs Electronic Burner Control System

Boiler di pabrik secara umum masih menggunakan teknologi mechanical linkage burner
control system sebagai kontrol pembakaran. Teknologi terbaru adalah electronic
modulating burner control system yang lebih presisi.

Mechanical Burner Control System Electronic Burner Control System

 Kinerja Boiler Saat Audit Steam

Parameter Value Unit Keterangan

Flue gas analyser: High firing Low firing Unit
O2 11,8 16,0 %
CO2 5,2 2,8 %
o
Tstack 204 190 C
o
Tudara ambient 33,8 35 C
Excess Air 128,3 320,0 %
Basis = 1 Nm3 /jam gas 1,0 1,0 Nm3 /jam gas
Udara stoikiometrik 9,65 9,65 Nm3 /jam udara
Udara nyata 22,02 40,5 Nm3 /jam udara
25,76 47,4 kg/jam udara
Wet gas 1,18 1,18 kg/jam
Dry gas (air+gas-WG) 25,43 47,06 kg/jam
Q DFG losses 995,35 1.683,2 kcal/jam
4.167 7.046,1 kJ/jam
10,8 18,3 %
Q WG losses 730,21 722,39 kcal/jam
3.056,64 3.023,94 kJ/jam
7,9 7,8 %
Rad & Conv Losses (1%) 385,47 385,47 kJ/jam
Blowdown losses 1,8 1,8 %
680,83 680,83 kJ/jam
Total losses 8.289,46 11.136,30 kJ/jam
21,5 28,9 %
Efisiensi 78,5 71,1 % (Metode Tak Langsung ASME PTC4.1)
Benchmark Efisiensi Design : 90%

Fuel Target Flue Gas Concentrations Excess Air Dampak excess air yang berlebihan adalah energi panas
O2 CO2 pembakaran dibawa oleh udara keluar cerobong dan tidak
terserap oleh air boiler. Pengendalian udara berlebih pada
Natural Gas 1- 2 11.9 – 12.3 5 – 10 %
tingkat yang optimal mampu mencegah rugi-rugi panas gas
Fuel Oil 2–3 15.4 -15.8 10 – 15 % buang.
Coal (Stoker) 3.5 - 5 17.2 – 17.4 30 – 60 %
 Implementasi Electronic Burner Control System

Metode untuk mengendalikan udara berlebih dengan cara :

• Retrofit burner control system dengan sistem modulating berbasis microprosesor
untuk mengatur rasio udara dan bahan bakar secara akurat sekaligus mengatur
putaran FD fan dan burner sesuai dengan beban dengan sensor oksigen pada gas
cerobong.
PROJECT ON RETROFIT BURNER CONTROL SYSTEM
 Sistem Daur Ulang Panas Gas Cerobong
Setiap kenaikan air umpan sebesar 6 oC, memberikan penghematan BB 1%

No Parameter Boiler 1, 10 TPH Boiler 2, 10 TPH

1 Efisiensi awal, % 77,3 78,1
o
2 Temperatur awal gas cerobong, C 231 215
o
3 Temperatur akhir gas cerobong, C 130 130
4 Efisiensi target, % 81,9 82,0
5 Kenaikan efisiensi boiler, % 4,6 3,9
3
6 Konsumsi gas awal, m /jam 495 489
3
7 Konsumsi gas target, m /jam 461 460
3
8 Penghematan gas, m /jam 34 29
3
9 Penghematan gas, m /bulan 19.323 16.877
3
10 Penghematan biaya, m /bulan 90.471.394 79.017.519
11 Instalasi economiser c/w mod level 1.294.000.000 1.294.000.000
12 Payback period (bulan) 14 16
13 Payback period (tahun) 1,2 1,4
o
14 Temperatur awal air umpan, C 72 72
o
15 Temperatur akhir air umpan, C 99 106
Sistem Daur Ulang Panas Gas Cerobong
Hot Water Generator
Sistem Daur Ulang Panas Gas Cerobong

Hot Water Generator

Setiap penurunan temperatur gas cerobong 22 oC, akan meningkatkan efisiensi 1%
No Parameter Boiler 03, 7 TPH
1 Efisiensi awal, % 84,1
o
2 Temperatur awal gas cerobong, C 130
o
3 Temperatur akhir gas cerobong, C 90
4 Efisiensi target, % 85,9
5 Kenaikan efisiensi boiler, % 1,8
6 Konsumsi gas awal, m3/bulan 190.066
3
7 Konsumsi gas target, m /bulan 186.023
3
8 Penghematan gas, m /bulan 4.043
3
9 Penghematan biaya, m /bulan 17.462.880
10 Instalasi condensing economiser 1.500.000.000
11 Payback period (bulan) 86
12 Payback period (tahun) 7,2
o
13 Temperatur awal make up water, C 30
o
14 Temperatur akhir make up water, C 48
 Konservasi Energi pada Blowdown

Flue Gas
Losses Radiation Distribution Flash
17% Losses Losses Losses
3% 5% 5%

Fuel Input
100% Heat Output Heat To User
78% 58%

Boiler Distribution

Condensate
Blowdown Losses
Losses 10%
2%
 Boiler Blowdown

Steam

Padatan terakumulasi dalam air

karena penguapan, jadi
TDS diperlukan boiler blowdown

TDS : total dissolved solid

TSS : total suspended solid

Air umpan
TSS
Kandungan
Padatan Terlarut
Blowdown
 TDS control system dan Daur Ulang Panas Blowdown

Blowdown Heat
Boiler TDS Control System
Recovery System

Automatic Bottom
Blowdown
TDS/Blowdown Control System
TDS/Blowdown Control System Project
 Daur Ulang Panas Blowdown dan Flash Steam
Blowdown Heat Recovery

Flash steam recovery

Flash steam recovery
from Exhaust Hot Process Gas
Mixing Tank

Boiler
 RE-INSULATION BOILER BODY
MENCEGAH
PANAS RADIASI DAN KONVEKSI
 Konservasi Energi pada Boiler

Flue Gas
Radiation Distribution Flash
Losses
Losses Losses Losses
17%
3% 5% 5%

Fuel Input
100% Heat Output Heat To User
78% 58%

Boiler Distribution

Condensate
Blowdown Losses
Losses 10%
2%
Laporan Thermal Imager
 Penghematan Energi dan Biaya
Hilang Panas pada Boiler karena Konveksi dan Radiasi Hilang Panas pada Boiler karena Konveksi dan Radiasi
Boiler, 10 TPH, Perbaikan insulasi
Parameter Value Unit Keterangan Parameter Value Unit Keterangan
D 3 m Diameter Boiler D 3 m Diameter Boiler
L 6 m Panjang body boiler L 6 m Panjang body boiler
A1 52,8 m2 Luas permukaan boiler A1 52,8 m2 Luas permukaan boiler
Ts, 1 44 oC Temperatur permukaan panas rata2 Ts, 1 44 oC Temperatur permukaan panas rata2
o o
Ta, 1 30 C Ambient temperature Ta, 1 30 C Ambient temperature
S,1 146 kcal/h m2 S = [10+(Ts–Ta)/20] x (Ts–Ta) S,1 146 kcal/h m2 S = [10+(Ts–Ta)/20] x (Ts–Ta)
Hs,1 7.722 kcal/h Hs = S x A Hs,1 7.722 kcal/h Hs = S x A
32.433 kJ/h 32.433 kJ/h
A2 12,3 m2 Luas permukaan boiler A2 12,3 m2 Luas permukaan boiler
Ts,2 105 oC Temperatur permukaan panas rata2 Ts,2 50 oC Temperatur permukaan panas rata2
Ta,2 30 oC Ambient temperature Ta,2 30 oC Ambient temperature
S,2 1.026 kcal/h m2 S = [10+(Ts–Ta)/20] x (Ts–Ta) S,2 216 kcal/h m2 S = [10+(Ts–Ta)/20] x (Ts–Ta)
Hs,2 12.629 kcal/h Hs = S x A Hs,2 2.664 kcal/h Hs = S x A
53.041 kJ/h 11.187 kJ/h
Convection Losses 85.474 kJ/h 43.620
Convection Losses 1,5 % Panas hilang karena konveksi Convection Losses 0,7 % Panas hilang karena konveksi
e 0,8 emisivitas e 0,8 emisivitas
s 5,67E-08 W/m2K4 konstanta Stefan-Boltzman s 5,67E-08 W/m2K4 konstanta Stefan-Boltzman
A1 52,8 m2 Luar permukaan boiler A 52,8 m2 Luar permukaan boiler
T1 317,0 K Temperatur permukaan panas (K) T1 317,0 K Temperatur permukaan panas (K)
T2 303,3 K Ambient temperature (K) T2 303,3 K Ambient temperature (K)
Qrad, 1 3.914,0 Watt Qrad = e x s x A x (T1^4-T2^4) Qrad, 1 3.914,0 Watt Qrad = e x s x A x (T1^4-T2^4)
14.090,4 kJ/h 14.090,4 kJ/h
A2 12,3 m2 Luar permukaan boiler A2 12,3 m2 Luar permukaan boiler
T1 378,0 K Temperatur permukaan panas (K) T1 323,0 K Temperatur permukaan panas (K)
T2 303,3 K Ambient temperature (K) T2 303,3 K Ambient temperature (K)
Qrad,2 6.674,0 Watt Qrad = e x s x A x (T1^4-T2^4) Qrad,2 1.352,4 Watt Qrad = e x s x A x (T1^4-T2^4)
24.026,3 kJ/h 4.868,6 kJ/h
Radiation Losses 38.116,7 kJ/h 18.959,0
Radiation Losses 0,6 % Panas hilang karena radiasi Radiation Losses 0,3 % Panas hilang karena radiasi
Total C & R losses 2,1 % Panas hilang karena radiasi dan konveksi Total C & R losses 1,1 % Panas hilang karena radiasi dan konveksi
 TEKNIK KONSERVASI ENERGI PADA DISTRIBUSI STEAM

Flue Gas Radiation

Losses Losses Distribution Flash
20% 3% Losses Losses
5% 5%

Fuel Input
100% Heat Output Heat To User
75% 55%

Boiler Distribution

Condensate
Blowdown Losses
Losses 10%
2%
 Waterhammer pada Distribusi Steam
 Flow Induced Waterhammer
Akibat kondensat terbawa oleh laju
aliran steam
 Condensation Induced Waterhammer
Akibat kondensasi tiba-tiba dari steam
yang terjebak dalam genangan
kondensat dingin
 Best Practices Instalasi Distribusi Steam

Aliran steam Kemiringan 1/100-1/500

Rising
Steam pipe
30 – 50 m

Titik pembuangan
Best Practices Instalasi Distribusi Steam
RUGI-RUGI PANAS PADA DISTRIBUSI
DAN
TEKNIK KONSERVASI ENERGI
 Menutup Kebocoran Steam

PANJANG
FLUME

Contoh : Kebocoran uap dari gasket pada sambungan pipa = 4 kg/jam

dengan panjang ‘Plume’ 300 mm

Kerugian biaya = 4 kg/jam x Rp 367/kg x 16 x 25 x 12 = Rp 7 juta/tahun

Thermal Imager Distribusi Steam
 Insulasi Perpipaan Steam dan Kondensat

Rugi-rugi energi distribusi umumnya berkisar 1-3% meskipun telah diinsulasi

 Insulasi Tangki Kondensat dan Jalur Pipa

Kondisi Saat Ini :

Tangki kondensat tidak terinsulasi
Pipa kondensat 4” tidak terinsulasi dari tangki kondensat ke deaerator sepanjang 50 m
Pipa air umpan dari deaerator ke boiler 4” sepanjang 15 m, 6” 20 m
Pipa steam 1” sepanjang 15 m
 Steam Trapping and Monitoring
Steam trap adalah peralatan otomatis untuk membuang kondensat
dan udara dari distribusi dan proses, tetapi menahan steam agar
tidak terjadi kebocoran steam ke jalur kondensat.
 Steam Trap Monitoring

1. Uji kinerja steam trap dengan bantuan ultrasonic trap

tester dan peralatan pendukung seperti infrared
temperature gun sensor
2. Uji kebocoran lain, seperti valve steam trap set
3. Tagging and numbering steam trap
4. Tabulasi steam trap
5. Pengambilan gambar setiap steam trap setMengolah
dan menampilkan data tabel steam trap audit
6. Perhitungan kebocoran steam dan emisi karbon
7. Laporan steam trap survey
Steam Trapping and Monitoring
Hasil Steam Trap Audit

Total kebocoran = 18 kg/jam

Kerugian = Rp 31,7 juta/tahun
Penggantian trap = Rp 10 juta
Payback = 4 bulan
 SISTEM DAUR ULANG PANAS
KONDENSAT DAN FLASH STEAM
 TEKNIK KONSERVASI ENERGI PADA DISTRIBUSI STEAM

Flue Gas Radiation

Losses Losses Distribution Flash
20% 3% Losses Losses
5% 5%

Fuel Input
100% Heat Output Heat To User
75% 55%

Boiler Distribution

Condensate
Blowdown Losses
Losses 10%
2%
 Pembentukan Kondensat & Flash Steam
Flash steam is a natural occurrence when condensate drops in pressure after leaving a steam trap. The
condensate is at steam temperature and cannot maintain this temperature at a lower pressure. This
results in the condensate flashing off into steam to lose the excess heat.

Steam supply
4 to 0,2 Flash steam umumnya
barg belum dimanfaatkan

0,2 bar g
% Flash Steam = 8,9%
Flash steam = 60 kg/h
Kondensat = 609 kg/h
669 kg/h
Kondensat
Pembuangan Kondensat Panas

Condensate Drain
Daur Ulang Kondensat Panas

Condensate Recovery
 Pompa Elektrik vs Mekanik

- Pompa elektrik sentrifugal kondensat panas

- Kavitasi, karena efek penguapan kondensat panas
- Biaya perawatan lebih mahal
- Membutuhkan energi listrik
- Sering diperlukan penggantian seal

- Pompa mekanik (motive pressure pump, Ogden Pump)

- Tidak ada kavitasi, bahkan dapat bekerja pada
kondisi vakum
- Biaya perawatan lebih murah
- Membutuhkan steam sebagai pendorong, 20 kg/h
- Tidak perlu level probe, panel listrik, dan controller
- Tidak diperlukan seal mekanik
 Sistem Daur Ulang Panas Kondensat

Design, supply and installation of condensate

pump and piping return for energy recovery
Before …..
Electric centrifugal pump is installed with hot
condensate tank, unable to pump high
temperature fluids, because of cavitation
After …..
Mechanical pump c/w receiver was installed
successfully and working excellently to return
back hot condensate to feed water tank

Sentrifugal pump and bigger condensate tank Mechanical Pump with compact condensate receiver tank
Removed bigger condensate tank, less space
 Rugi-rugi Flash Steam

Problema terbentuknya flash steam :

• Rugi-rugi panas terbawa flash steam Flash Steam

Venting
• Rugi-rugi air terbawa flash steam
• Isu safety dan isu lingkungan
• Berdampak pada kenaikan tekanan jalur
Condensate
kondensat from process

Condensate from
Process
Receiver Overflow

Condensate To Boiler
House
Condensate Pump c/w receiver
 Pembuangan Panas Flash Steam

Potensi pemanfaatan flash steam sebagai pemanas

Flash Steam awal (pre-heat) water make up dengan bantuan flash
steam condenser

Venting
Air panas

Vent Condenser
Flash Steam

Air dingin

Sumber
Flash steam
 BEST from BOTH WORLDS !

+ Compact + High pressure

+ Low fouling + High temperature Shell & Tube HE (Tubular)
+ Close approach temps + No gaskets

- Low pressure - Large size /weight

- Low temperature - High fouling
- Gasket

Plate HE (PHE)

+ High pressure
+ High temperatures
+ No gaskets
+ Compact
+ Low fouling
+ Close approach temps

Plate and Shell HE (PSHE)

 Sistem Daur Ulang Flash Steam

• Flash steam generated from Thermocompressor

frying oil heater unit during Medium
heat process is recovered High Pressure Pressure
Team to
before it’s lost via the Steam from Mains
Steam Box
receiver vent using
Flash Steam
thermocompressor
• A jet of high pressure steam
(called the Motive pressure) Condensate From Frying
Flash Tank Oil Heater
to entrain Flash steam from Oil
(called the Suction Heater
pressure).
Receiver Overflow
• Steam saving opportunity
• No unsightly loss of flash To Boiler House
steam from the vent pipe
Condensate Pump c/w receiver
• Less likelihood of receiver
overflowing
 Thermocompressor

Sistem Daur Ulang Panas Flash Steam sebagai Sumber Steam Tekanan
Rendah pada Steam Box menggunakan Thermocompressor

A. Steam 8-9 bar from main header

C. Steam 2-3 barg

supplied to steam box
Thermocompressor

B. Flash Steam < 0.2 bar Using PRV to reduce

from oil heaters Pressure down to 0.2-0.5 bar
Condensate from
Oil Heater

Flash Tank

STEAM BOX
 Teknik Pemanfaatan Flash Steam

Pressure controls Motive steam Motive steam

Thermocompressor
Thermocompressor

Dryers: Dryers Dryers

wet end

Condenser Motive
steam Level Level
control control
Pump
Pressure
control of
first
separating Separating vessel Separating vessel
vessel
 Spray Condensing

atmospheric pressure
 Pemanfaatan Flash Steam dan Kondensat
Flash exchanger

Flash vessel

• Heat Recovery System Pressurised

• Minimise vent flash losses returns
• Carbon reduction targets 128 °C approx 3 barg
• Real Savings (fuel, water, chemicals) to boiler
• Mechanical solution
• Optimise system heat balance
• Increase boiler efficiency
• Reduce safety concerns with vented steam
• Reduce environmental concerns with vented steam Deaeration system
• Feasible at affordable investment
• Energy savings = 20% Condensate exchanger

Spillback
line Recirculation line
Feedtank

97 °C feedwater BEFORE
Boiler
…
Feedpump

By-pass valve
 Daur Ulang Panas Flash Steam

Before…

Hot water temp.

Heat Exchanger
Flash steam line After…
Installation result No more venting steam
 Before and After Project Implementation

BEFORE…
BEFORE… …AFTER
BEFORE…

…AFTER

…AFTER

BEFORE… …AFTER
 Contoh Keluaran Rekomendasi Audit Steam

Boiler 10 ton/jam, tekanan kerja 10-12 barg

No Rekomendasi Potensi Penghematan Biaya Investasi Payback Period Tingkat Pembiayaan No Rekomendasi Potensi Penghematan Biaya Investasi Payback Period Tingkat Pembiayaan
Gas (m3/bulan) Biaya (Rp/bulan) Biaya % (Rp) (Tahun) (No/Low/Medium/High) Energi (MJ/bulan) Biaya (Rp/bulan) (Rp) (bulan) (No/Low/Medium/High)
Retrofit Burner dari Mechanical
Daur ulang flash steam dari Tangki
1 Linkage Control System menjadi
Electronic Burner Control System 1.975 14.934.336 1,2% 884.000.000 4,9 Medium Cost 1 Kondensat Area A sebagai pemanas
Daur ulang gas buang boiler dengan awal Hot Water Generator 122.620 29.109.287 600.000.000 21 Low Cost
2 economiser c/w modulating feed Daur ulang flash steam dari Tangki
water control system + retubing 8.887 41.608.283 3,2% 1.028.000.000 2,1 Medium Cost 2 Kondensat Area B sebagai pemanas
3 Penggantian Steam Trap yang Bocor 821 3.845.357 0,3% 55.000.000 1,2 Low Cost
awal Hot Water Generator 98.828 23.461.217 300.000.000 13 Low Cost
4 TDS control system 2.131 9.978.278 0,8% 200.000.000 1,7 Low Cost
5 Blowdown Heat Recovery System 3.802 17.799.091 1,4% 500.000.000 2,3 Medium Cost Daur ulang flash steam dari Tangki
6 Re-insulation body boiler 3.127 14.639.963 1,1% 300.000.000 1,7 Low Cost 3 Kondensat Area C sebagai pemanas
Total 20.743 102.805.308 8,0% 2.967.000.000 2,4 Medium Cost awal Hot Water Generator 140.263 33.566.613 500.000.000 15 Low Cost
Daur ulang panas dan air dari
a Konsumsi gas, MMBTU/bulan 9.632
4 pengembalian kondensat dari semua
b Konsumsi gas, m3/bulan 274.423
c Tagihan gas, Rp/bulan 1.284.847.835 area A dan B 235.075 46.136.163 300.000.000 7 Low Cost
d Tagihan gas, Rp/tahun 15.418.174.014 5 Penggantian Steam Trap yang Bocor 78.324 18.727.200 101.961.000 5 Low Cost
Total 675.109 151.000.481 1.801.961.000 12 Low Cost
 Typical Losses
Flue Losses Radiation Losses Distribution
17% Losses Flash Losses
3%
5% 5%

Fuel Input
100% Heat Output Heat To User
78% 58%

Boiler Distribution

Condensate
Blowdown Losses
Losses 10%
2%
 Ideal System
Flue Losses Radiation Losses Distribution
20% Losses Flash Losses
9% 2%
3% 0%

Fuel Input
100% Heat Output Heat To User
75%
88% 55%
84%

Boiler Distribution

Condensate
Blowdown Losses
Losses 10%
<1%
<1%
2%
 Outline

• Company Profile
• Energy Conservation
• Steam User Overview
• Steam Application
• Steam System Audit
• Future Business Opportunity
• Success Story
• Conclusion
 Future Business Opportunity
Kebijakan Perusahaan
Top Management

Audit Energi
Internal/Eksternal

Rekomendasi Potensi
Proyek Konservasi Energi

Prioritas Implementasi
Proyek Konservasi Energi

Monitoring & Verifikasi

Studi Kasus 1 unit x Boiler 10 TPH
Hemat Energi dan Biaya Audit Boiler dan Distribusi Steam
ESCO PEMERINTAH
Penurunan Emisi Karbon Peluang Rp 4,7 M 1,543 GJ 62 ton CO2e
 Future Trend Business in Energy Conservation
Energy Service Company (ESCO)
An energy service company (ESCO) is a business that
provides a broad range of energy solutions including designs
and implementation of energy savings projects,
retrofitting, energy conservation, energy infrastructure
outsourcing, power generation and energy supply, and risk
management.
A newer breed of ESCO includes
innovative financing methods, such as off-balance sheet
mechanisms which own a range of applicable equipment
configured in such a way as to reduce the energy cost of a
building. The ESCO starts by performing an analysis of the
property, designs an energy efficient solution, installs the
required elements, and maintains the system to ensure
energy savings during the payback period. The savings in
energy costs are often used to pay back the capital
investment of the project over a five- to twenty-year period, or
reinvested into the building to allow for capital upgrades that
may otherwise be unfeasible. If the project does not provide
returns on the investment, the ESCO is often responsible to
pay the difference.
 SKEMA ESCO (ENERGY SERVICES COMPANY)

Keuntungan
Client
Keuntungan
ESCO Dampak Keuntungan
Penghematan Client

Repayment
Bunga
Biaya Energi
Pemakaian
Cicilan
Energi Client
Investasi

Biaya Biaya
Pemakaian Pemakaian
Energi Client Energi
Client

Sebelum Pengenalan Selama Pelaksanaan Sesudah Kontrak

Bisnis ESCO Bisnis ESCO dengan Bisnis ESCO
 ESCO Project’s Process Flow
STEP 1 Selection of Target Facilities

STEP 2 Preliminary analysis (walk through survey)

Check of the Proposal Content

NO
Agreement Project Cancelled
yes

Detailed Energy Audit

STEP 3
Check of Proposal Content ( Comprehensive Modiffication Plan)
NO
Agreement Project Cancelled
yes

Signing a contract
STEP 4
Installation

Measurement, examination, operation management, maintenance and inspection

STEP 5 End of ESCO Project

 Hambatan Pelaksanaan Proyek Konservasi Energi

Hambatan Finansial:
1. Harga Bahan Bakar yang masih disubsidi
oleh Pemerintah
Finansial 2. Mekanisme pendanaan proyek ESCO di
Indonesia
Hambatan Teknikal:
3. Nilai bunga bank yang cukup tinggi
1. Kurang familiarnya Program
untuk pendanaan proyek efisiensi
Efisiensi Energi di kalangan
energi
industri
2. Terbatasnya jumlah personel
untuk implementasi efisiensi
energi Hambatan
3. Terbatasnya teknologi dan
supplier peralatan hemat ESCO
energi di Indonesia

Teknikal Manajemen

Hambatan Manajemen:
1. Belum adanya kebijakan perusahaan
mengenai program efisiensi energi
2. Kurangnya kemampuan tim internal untuk
melihat peluang efisiensi energi
 Outline

• Company Profile
• Energy Conservation
• Steam User Overview
• Steam Application
• Steam System Audit
• Future Business Opportunity
• Success Story
• Conclusion
 Implementation on Boiler Efficiency Projects

Deaerator Tank
Flue Gas Economiser
PROJECT ON RETROFIT BURNER CONTROL SYSTEM
 Sistem Daur Ulang Panas Gas Cerobong
Success Story
 Daur Ulang Panas Blowdown dan Flash Steam

Blowdown Heat Recovery

Flash steam recovery

from Exhaust Hot Process Gas
Flash steam recovery

Mixing Tank

Boiler
 Vented Steam Recovery Project

Before …

After …
 Daur Ulang Panas Flash Steam

Before…

Hot water temp.

Heat Exchanger
Flash steam line After…
Installation result No more venting steam
 Excess Steam Recovery

After… Steam to Water

Exhaust Temp In/Out 110 C/ 100 C
Water Temp In/Out 30 C/ 83 C
Exhaust Mass Flow 7,000 Kg/h
Water Mass Flow 70,000 Kg/h
Weight of unit 1,500 Kg
Exhaust pressure drop 2,500 Pa
Energy Recovered 4,378 KW
Recovered Energy Value IDR 3,849M p.a.

The utilization of excess steam exhausted

from process as heat source to generate
hot water or other liquid or gas using steam
condenser.
 Engineering Design, Supply, and Construction
Blowdown Tank System

Scope of project :
1. Engineering Design of Blowdown Tank System & Shop Drawing
2. Boiler capacity up to 10 ton/h at 20 barg
3. Full Installation, Testing, and Commissioning to comply safety and environment regulation
 Engineering Design, Supply, and Construction
Installalation of Pressure Reducing Desuperheater Station (PRDS)

Scope of project :
1. Engineering Design of PRDS and Isometric & Shop Drawing
2. Installation of Pressure Reducing Desuperheater Station from 32 down to 3 barg
3. Project Management
 Engineering Design, Supply, and Construction
Installalation of Steam and Condensate Piping System in the New Plant

Scope of project :
1. Detailed Engineering Design (DED) of Steam System and Isometric & Shop Drawing
2. Installation of Steam Piping System at 22 barg
3. Project Management
 Engineering Design, Supply, and Construction
Utility & Product Piping System for New Plant

Scope of project :
1. Detailed Engineering Design (DED) of Utility & Product Piping
2. 3D drawing of Product Tank System
3. Design and Project Management
 Engineering Design, Supply, and Construction
Deaerator/Feed Water/Condensate Tank System

Scope of project :
1. Detailed Engineering Design (DED) of Feed Water Tank System & Shop Drawing
2. 3D drawing of Feed Water Tank System
3. Project Management
Engineering Design, Supply, and Construction
Fabrication, Supply, and Installation of Condensate Tank 60 m3 for Powerplant

Fabrication Ready to Install Loading Aligning Finishing

Testing & Commissioning Project Accomplish

 Engineering Design, Supply, and Construction
Installation of 38” Vapor Piping during Shutdown Project
Loading Start …………… Fabrication……………. Installation………………..

Teamwork……………….

Loading Progress………
 Outline

• Company Profile
• Energy Conservation
• Steam User Overview
• Steam Application
• Steam System Audit
• Future Business Opportunity
• Success Story
• Conclusion
 Conclusion
1. Peluang bisnis proyek konservasi energi pada boiler dan
distribusi steam masih sangat menjanjikan dan terbukti
memberikan penghematan energi sebesar 5-20%.

2. Diperlukan langkah nyata secara sinergi (ESCO, Industri,

Lembaga Keuangan, dan Pemerintah, bersifat segera, dan
berkelanjutan dalam rangka mendukung program
pengembangan konservasi energi secara nasional

3. Rencana revisi PP 70/2009 dari 6000 menjadi 3000-4000 TOE

akan memperluas objek audit energi dan peluang bisnis
konservasi energi

4. Kolaborasi antara Langgeng dan Universitas Sriwijaya untuk

ikut ambil bagian peluang proyek konsultasi energi dan
implementasi konservasi energi
Contact Us

Rusmanto, ST. MT.

Marketing Director

M : +62-8156159711
Developing & Implementing
E : rusmanto@langgengciptalindo.com

Website : www.langgengciptalindo.com
www.langgeng-institute.com

Certified Energy Auditor on Industry by :

Keep Your Balance

Central Java Office: West Java Office: East Java Office:

Jl. Taman Giri Mukti Barat II/351A Bumi Sentosa Blok A6/12B, Ruko Bukit Permata Sukodono, Blok A No. 4
Tlogosari Kulon, Semarang 50196 Nanggewer Mekar, Cibinong, Bogor 16912 Jl. Raya Sukodono, Sidoarjo 61258,
HP. +62-815-8404-5025 HP. +62-81-5615-9711 Phone/Fax : +62-31-99037230
Mr. Hendar Wirawan Mr. Rusmanto Mr. Kristiyono