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pt maxxtec teknologi indonesia
Celsi
Cost efficient and environmental friendly Energy
generation from production residues
Tuesday, April 9th 2019
by PT MaxxtecTeknologi Indonesia
pt maxxtec teknologi indonesiaCelsiNRGgroup technologies
Engineering, design, R&D(NRGgroup & customers)
zz
by PT Maxxtec Teknologi Indonesia
Material storage, handling and
dosing systemsfor any kind of
bulky and dustymaterials-
German technology adapted to the needs in the Southeast Asia
German technologies for efficient
energy generation and utilization
brought to South-East Asia
Since 1995 Maxxtec delivered more
than 3000 plants to more than 50
countries all over the world
Efficient Energy for South-East Asia
Thermal process
technology, heat exchangers, heat recovery, biogas
utilization, ORC technology
Standardized
Biomass Combustion Systems, Hot
Water and Steam Boilers,
50kW to 5MW
Steam, electricity production from
solid fuels (biomass, waste,
coal, tires ) water/steam technology, 5-50 MWth
2
In Europe there are more than 150
biomass heat and power plants with
ORC-process installed for biomass
utilization
pt maxxtec teknologi indonesiaCelsi
With our wide range of firing systems, any kind of solid fuels can be used for energy generation
Capacities
Charact-
eristics
Applica-
tion areas
“Workaholics”
for saturated
steam generation
out of any kind of
solid fuels
High-end gene-
ration of super-
heated steam out
of any kind of solid
fuels
Process
steam and CHP
Reciprocating Grate Stoker
Combustor
Flame tube &
pre chamber
Boiler
Water Tube
Boiler
Thermal Oil
Heater for Solid
FuelFlat Declining
CHP and
power generation
only
Efficient and
safe heat transfer
with organic heat
carriers for all Kind
of solid fuels
Process Heat,
CHP and power
generation only
Products for efficient use of any solid fuels
up to 35 MWth 500 kWth
to 20 MWth 5000 kWth
to 50 MWth 200 kWth
to 50 MWth
For dry and wet
chippings and
wood chips, any
other residues
Power Generation
and Industrial process
in general with
complex fuels
up to 12 MWth
Standard designed
for dry and wet
chippings and
wood chips, any
other residues
Industrial process heat
in general with
standard fuels
up to10 MWth
For dry and wet
chippings and
wood chips, coal
Small to
medium-sized
furniture industry,
timber industry
3
pt maxxtec teknologi indonesiaCelsi
Waste Heat
Thermal Oil
Systems
Heating Surface
Cleaning Systems
Indirect steam
generator
Steam Power
Plants
ORC – Power
Plants
Capacities
Charact-
eristics
Application-
areas
200 kWth to 50 MWth
Consisting of a wood
firing system and a heat
transfer system with
Thermal Oil
Power stations de
centralized, recycling
Industry, wood industry,
etc.
to 30 MW, 30barg 300 kWth to 2,5 MWth 300 kWth to 2,5 MWel
Recovering heat from
hot flue gases into water,
thermal-oil or steam
Diesel power generators,
cement industry, steel mills,
any other waste heat
producing industries
Palm oil industry, food
& beverages, wood
industry, power stations
decentralized etc.
Palm oil industry, food
& beverages, wood
industry, power stations
decentralized etc.
Power generation from
waste heat or thermal
energy from a wood-fired
Consisting of a
transmission system for
heat and an ORC module
Fully automatic
cleaning of heating
surfaces of boilers and
heat exchanges for waste
heat and solid fuels
For all Kind of Boiler,
Heat Exchanger and
Heaters
Since 23 years Maxxtec has build more than 100 ORC power plants for CHP with solid fuels!
Patented technology
for all capacities
Energy Efficiency
4
pt maxxtec teknologi indonesiaCelsi
With our wide range of firing systems and boilers, any kind of solid fuels can be used for energy generation
Capacities
Application-
areas
Up to 5000Nm³/h 2.000Nm³/h / unit Up to 5.000Nm³/h According to
Demand
Up to DN 1.500
Used to remove
relative humidity of
biogas by cooling
water/combined system
with low energy
Characte-
ristics Reduction of Hydrogen
Sulphide (H2S) in
Biogas to 0 ppm helps
to significantly reduce
operative cost of Engine
Safe and environ-
mentally friendly
utilization of access
gas. Including engine-
ering and controls.
Automation of
industrial processes and
machines. Control
panel, PLC and Scada
systems. PLC Software.
Control flaps for
exhaust gases and
industrial process
gases. Basket strainers,
pump monitoring etc.
Agroindustry, Sugar,
Breweries, Biofuel,
wherever Biogas is
utilized.
Agroindustry, Sugar,
Breweries, Biofuel,
wherever Biogas is
utilized.
Biogas, waste water
treatment, chemical
plants, oil and gas etc.
Mainly for process
industry, food industry
and machining
industry
For any kind
industrial
application
Biogas technology
Dewatering Fine
DesulphurizationFlare System
Process
Automation &
Control
Instrumentation
& Control
Armatures
5
pt maxxtec teknologi indonesiaCelsi
Capacities
Charact-
eristics
Application-
areas
100 kWth
to 20 MWth
Use of gaseous &
liquid fuels to
generate process
heat. Solutions for
food processing
Chemical plants,
textile industry,
drying plants,
reaction proces-
ses, food, oil & gas
etc.
200 kWth
to 20 MWth
50MW / unit
Use of waste heat
from engines & indus-
trial processes for heat
generation
Waste heat
recovery, deodorizing
plants, large engines
Liquid - air / liquid –
gas, air coolers,
condensers, gas / gas,
steam / liquid etc.
For any kind of
industrial application
Technology available for industrial processes & biogas plants. Innovative and efficient solutions for process heat generated
from waste heat, and fossil fuels
Thermal Oil HeatersHigh Pressure
Steam Boiler
Heat ExchangersHeat Transfer
FluidsFor liquid and
gaseous fuels
For waste heat
recovery
Register Heat
Exchanger
Shell & Tube Heat
Exchanger
Food, refinery,
energy plants,
textile, cemical.
etc.
Synthetic and
mineral oils with food
grade, Halal and
Kosher cert.
Temperatures -
-110 C to 400 C° °
Industrial Process Heat
Up to DN 1.500
Liquid - air / liquid –
gas, air coolers,
condensers, gas / gas,
steam / liquid etc.
For any kind of
industrial application
232kWth
to 2.615kWth
P-Design 110bar
Closed cycle natural
circulation for high
pressure saturated
steam. Fully automatic
operation.
Food processing,
edible oil refineries,
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pt maxxtec teknologi indonesiaCelsi
Page 7
As the largest Palm oil producer in the world and with
extensive agriculturally used land has Indonesia a considerable
potential for power plants that run on waste
The diverse possibilities for conversion of energetic existing
residual materials for energy and electricity generation and the
huge volume (100 bil.) of this materials in Indonesia open up
opportunities to commercialize this type of use
Also on the part of the Indonesian government this potential is
increasingly taken into account with increase in
compensation.
POTENTIAL
Power Generation from Palm Oil Residues - Potential, Fuels, Advantages
Key arguments for the usage and conversion of energetic
existing residual materials for energy and electricity
generation:
replacement of fossil oil, -gas and etc.
free primary energy
additional income by feeding into the public grid
high feed-in tariffs from government
no additional CO2 emissions
optimization of the complete energy efficiency
ADVANTAGES
FUELS
Potentials in the Agroindustry
Palm FibresEmpty Fruit Bunches
Palm Kernel Shells Palm Oil Mill EffluentTable 1* : Forecast of energy demand and the electrification 2013-2022**:
Energy demand TWh
2013 2014 2016 2018 2020 2022
IDN 189,0 207,8 246,4 287,7 334,2 386,6
* A forecast of the state electricity utility PLN
** (Perusahaan Listrik Negara, 2013)
Electrification Rate
2013 2014 2015 2016 2017 2018 2019
IDN 80.5 84.35 88.3 91.16 95.35 98.3 99.9
Utilization of existing residue can provide a major contribution to the energy supply, offer economically interesting perspectives and
contribute to environmental protection. Therefore it is a WIN – WIN – WIN situation.7
pt maxxtec teknologi indonesiaCelsiSteam and thermal oil process heating plant with solid fuels:
Process heat from solid fuels
Celsicorp products, for any kind of solid fuel the perfect solution
SUPPLY STEAM AND THERMAL OIL PLANTS FOR PROCESS HEAT
Steam and thermal oil process heating system for
any kind of solid fuels, including the flue gas handling
and cleaning systems, material storage and handling
systems as well as the surface cleaning system.
Capacities up to 50MW
Temperature range up to 450°C
Usable energy sources:
Solid fuels like: Empty fruit bunches, waste wood,
rice shells, coal etc.
Complete plant from one hand
Many different kind of fuels can be used
High efficiency, easy to operate
Long lifetime
Long operating periods due to patented
airmaxx surface cleaning system
High local content
SUPPLY
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pt maxxtec teknologi indonesiaCelsi
For any challenge the perfect solution. Single fuels as well as multifuel systems offer a wide field of applications.
Technical Parameters: The LAMBION grate Systems are
extremely robust and can be used for a wide range of fuels.
Ash content 1 to 25 %
Water content 0 to 60 % (weight)
Fuel diameter 0,2 to 50 cm
Fuel length 5 to 100 cm
Other parameters can be used with additional adjustments
Mixtures of bulk an pulverized fuels can be used with the standard
configuration
Due to the innovative LAMBION control system a wide range of fuels with different onditions can be used on any grate system
Multi fuel operation with solid, dusty, liquid and gaseous fuels
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pt maxxtec teknologi indonesiaCelsi
10Development of reciprocating grate technology for more than 100 Years for your advantage!
Innovative combustion technology
Primary air infeed under the grate,
pressurized to boost into the fuel layer
Each zone has an individual fan,
automatically by the control system
Control system enables grate to
combust a wide range of fuels (humidity, size, energy content etc.)
Open grate area:
evenly distributed air flow →
no local excessive forge
phenomena
straight grate bars; easy
replaceable without special tools or welding equipment
large air path cross sections
→ low air velocity minimizes
carry over of ash particles
Comparison:
closed grate area of an
competitor
Our flat reciprocating grate, a standardized and cost effective
solution offering the advantages of
a reciprocating grate for standard
fuels already at low investment
cost.
Up to 5 individually controlled
combustion zones
Automatic fuel feeding, efficient
dust separation, automatic ash
discharge and a highly developed, state of the art PLC control offers
highest efficiency, availability and
low effort for operation.
pt maxxtec teknologi indonesiaCelsiThe steam process is economically & technologically a very common solution for power generation and CHP
Power generation with steam turbine
Our Technology is suitable for optimal converting of the primary energy into electrical power
SIMPLIFIED COMBINED POWER GENERATION PROCESS WITH STEAM CYCLE STEAM BENEFITS
The necessary
amount of heat is automatically uncoupled forward
of the low pressure of the turbine.
An optimal current efficiency is
achieved, when no heat is required.
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pt maxxtec teknologi indonesiaCelsiTechnical scheme of the steam process
Biomass
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2
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1311
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1
3
4
5
6
C B
B
A
D
Combustion Condensate System Water Treatment
1 Firing
2 Steam boiler
3 Steam drum
4 Superheater
5 Economizer
6 LUVO
7 High pressur
vapour
distributor
8 Pressure reduction
station
9 Low pressure
vapour distributor
10 Degassers / Feed
water tank
11 Turbine
12 Generator
13 Steam by-pass
14 Heat consumer
15 Air condenser
16 Condensate tank
17 Condensate Pump
18 Feed water pump
19 Water treatment
A Combustion air
C for
flue gas cleaning
Steam System Steam Turbine
Steam cycles are the most common process to produce electrical power
Steam process for electricity production with biomass
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pt maxxtec teknologi indonesiaCelsiElectricity power generation with organic rankine cycle (ORC)
More than 120 ORC-Modules for high temperature applications are successful in operation
DESCRIPTION ORC MODULE
Use your energy and convert them into electricity:
The ORC systems make use of medium
temperatures around 300 °C and transfers them into
electricity up to 2,5 MW.
YOUR BENEFITS
Primary energy consumption can be
reduced by 10 %
Use of free primary energy
Low operating costs
Short payback times
No additional CO2 emission
Improving the energy efficiency
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pt maxxtec teknologi indonesiaCelsiTechnical scheme of combined ORC heat and power generation process
Combustion
Thermal Oil System
Heating Water System
G
270 °C / 10 bar
230 °C / 0,2 bar
320 °C / 10 bar
240 °C
95 °C / 0,2 bar
80 °C
60 °C170 °C
370 °C
80 °C
Biomass
1
2
3
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B
B
C
D
E
A
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1 Firing2 Thermal oil heater3 Economizer TO
4 Economizer Water5 LUVO
6 ORC Vaporizer7 Primary pump8 Turbine
9 Generator10 Regenerator
11 Condenser12 ORC circulation pump13 Heating water pump
14 Heat consumer
A Combustion airC for flue gas cleaningD of
heating water returnE for heating water flow
ORC - Process
Simple process for modulating operation with low pressures and low temperatures 14
pt maxxtec teknologi indonesiaCelsiHeat recovery from any heat source
offers many different solutions HEATERS, BOILERS & ECONOMIZERS
Almost every industrial process offers potential
for waste heat recovery.
Our units are available with capacities from 0,01
to 50 MW; depending on the application
In the temperature range up to 1500°C
If required, surface cleaning during full operation
In many cases very short payback
Usable energy sources:
Flue gases from burners, ovens, dryers, printing
machines
Waste heat from the engines, gas turbines
Exhaust gas from steel production, cement
manufacturing.
Any other industrial waste heat.
Helical coil boilers are perfect in combination with organic heat carriers 15
pt maxxtec teknologi indonesiaCelsiFully automatic surface cleaning systems
OUR SUPPLY CLEANING SYSTEMS
We have different cleaning systems :
Ball cleaning systems
Soot blower systems
Shaking systems
airmaxx – Fully automatic pressure pulse
cleaning systems
Deposits work in heating surface linke an
Isulating layer - the heat transfer is hindered and
the flue gas temperature rises
The efficiency drop down and causes an increase
in fuel consumption
Excessive flue gas temperatures can lead to
overstrain and damage
CLEANING FOR CONSTANT EFFICIENCY
Constant energy efficiency and long operation periodes by the patented airmaxx technology 16
pt maxxtec teknologi indonesiaCelsiORC can use low temperature heat
The ORC process allows to exploit efficiently low temperature heat sources to produce electricity in a wide range of power outputs (from few kW to some 2.5 MW electric power per unit).
SIMPLIFIED COMBINED HEAT AND POWER GENERATION PROCESS ORC BENEFITS
Economic viability
• Higher efficiency
• Reduction of operating personnel
• Reduced installation costs/time
• Automatic start-up & shut-down
Technological advantages
• No use of chemicals
• Low temperatures for electricity
generation
• No super heater is required
• Better part load efficiency
Flexibility
• Reduced project-engineering
• Standardized systems
• Flexibility for primary
temperatures and energy
sources
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2
3
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pt maxxtec teknologi indonesiaCelsi
Environmental friendly and cost effective Energy from organic and low calorific production residue.
Integrated Biogas treatment
Integrated Biogas treatment offers
various advantages in terms of energy
efficiency.
Using of existing cooling water instead of installing an expensive chiller
Providing individual Biogas quality in relation with the Consumer (Engines have other requirements then Burners)
Combinations of fuel, for example for process heating plants, allow flexible operation in relation to fuel availability and cost. Multifuel burners and synchronous operation with different fuels are reducing operation cost.
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pt maxxtec teknologi indonesiaCelsi
Lower investment and operation costs
Biogas Dewatering
Conventionel Biogas Dryer (Cooler)Biogas Dryer
45 °C 15 °CBiogas Biogas
7 °C15 °C
79 °C
34 °C
40 °C
29 °C
Biogas
Biogas
Cooling WaterCooling Water
Cooling Water
Cooling Water
Advantages of the Biogas Dryer?
Significant energy saving
Lower opex (often existing cooling water
can be used.
Lower capex (maintenance)
Better condensate separation
Lower space required (vertical design)
40 °C
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pt maxxtec teknologi indonesiaCelsi
Extended lifetime of engines and reduced maintenance by fine - desulfurisation
Biogas Fine Desulphurization
Doted activated carbon allows to absorb large
quantities of hydrogen sulfide
Even in fluctuating conditions, the sulfur can be deduced constantly below 1ppm
Operation time of the lubrication oil in Biogas
Engines can be doubled
Reduced downtime and maintenance costs for
the engines
cartridge absorbers make
replacement of the active coal very easy.
Removable cartridges can be filled externally
Silica gel indicators indicate the condition of the
filling and avoid unnecessary change.
Fine – Desulfurization with doted
activated carbon
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pt maxxtec teknologi indonesiaCelsi
Integration of both liquid and solid biogenic residues with one system
21
SIMPLIFIED SCHEME OF A COMBINED POWER GENERATION PROCESS
WITH STEAM AND BIOGAS CYCLE
STEAM AND BIOGAS
BENEFITS
Highest efficiency
• Most complete use of
solid and liquid residue
• Integrated system allows
almost complete use of
the energy potential.
• Power generation for
internal consumption and
for feeding into the public
grid.
• Waste water treatment
included.
• Reduction of methane
emission to protect the
environment.
Heat & Power from solid residues and effluent
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pt maxxtec teknologi indonesiaCelsi
Complete utilization of the energy potential at highest efficiency.
Coal fired steam boiler Karawang
Indonesian coal contains a high content of volatile matters.
Travelling grates often cannot use the full energy content,
since there is only one single combustion zone.
Declined reciprocating grate systems offer full
combustion and therefore fast return on investment.
Long lifetime, high efficiency and low operating cost and low
emissions make the difference on the long run.
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Declined reciprocating grate. Fully automatic
fuel feeding and ash discharge. Combi-Steam
Boiler with Economiser, high efficient dust separator (Multi Cyclone)
with Big Bag collection system, Fully automatic PLC – Control
system with O2 sensor for highest efficiency and lowest emissions.
Steam capacity: 10.5 t/h at 10barg
Fuel: Low caloric coal
pt maxxtec teknologi indonesiaCelsi
Complete utilization of all available energy potentials with highest flexibility.
PKS fired TO-Heater, Bangka
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Flat reciprocating grate systems offer complete
combustion, especially for dry materials.
Standardized unity offer long lifetime, high efficiency, low investment
and low operating cost at low emissions.
Thermal Oil Process
heating Plant. Installed in
Bangka Island.
Th. capacity 3000kW
Oil Temp: 300 / 185°C
Fuel: Palm Kernel Shell
delivery:
-Fuel feeding system
-Furnace with deashing
-Multicyclone dust
separator
-Automatic deashing
-TO Heater system with
cooling shield, 3-pass
Thermal Oil Heater and
Economiser
-Thermal Oil system
-3 Oil-Air Heat exchanger
pt maxxtec teknologi indonesiaCelsiProcess heat for drying of the tapioka starch replacing coal
combustion
Utilize Biogas in the best possible way requires an integrated view of all related systems
OVERVIEW PROJECT SIMPLIFIED SCHEME
Requirement: Complete substitution of coal combustion
through the use of excess biogas and waste heat from the
gas engines.
Solution:
• Significantly reduced power consumption by highly
efficient process heating plant.
• Installation of a biogas -fired thermal oil heater to
replace the existing high-temperature heaters.
• Installation of an additional low-temperature air
preheater with associated low-temperature
thermal oil circuit. The engine waste heat can be
optimally utilized in this manner to pre-heat the
process air
Result: The amortization is taken place by the saved fuel
costs in less than 12 months
Efficient utilization of Biogas
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pt maxxtec teknologi indonesiaCelsi
Application of vertical EGHE
Energy generation for Tapioka productionEnergy plant for Tapioka Production
installed in 6 different locations in Indonesia. Thermal capacity: up to 10MW Fuel: Biogas and Engine exhaust gas.
Oil Temperature: 280 / 120°CDelivery range: Thermal Oil Heater with biogas burner, Exhaust Gas Heat exchangers, Thermal Oil System, Oil / Air Heat exchangers,
Biogas dryers
In several realized projects it is approved, that the consumption of fossil fuels could be reduced significantly and the investment is paid back in less than 2 years.
High temperature cycle with Maxxtec Biogas Heater
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pt maxxtec teknologi indonesiaCelsi
Multi fuel burners offer better flexibility and therefore reducing energy cost
Liquid, gaseous or dusty production residues can be valuable energy
sources.
• Process heaters with multi fuel burners for high and medium calorific production residues in liquid or gaseous condition.
• Synchronous operation of 2 different fuels
• Fuel treatment systems to adjust viscosity and to remove particles and other contaminations.
• Fuel control systems to ensure emission free combustion and safe operation.
• Seamless integration into existing plants and processes
• Remote control systems for centralized plant monitoring, information processing and process control.
Multifuel combustion for highest flexibility
Thermal Oil Process Heating Plant in Kisaran, Thermal capacity 9MW, fired by Biogas, Diesel Oil and Palm Crude oil,
Delivery range: Thermal Oil System with Oil / Air heat exchanger, Warm Water System with Water / Air heat exchanger,
3 Exhaust gas / Thermal Oil Heat exchangers, 3 Water / Water Heat Exchangers, Biogas Treatments System with Biogas Dryer
and Fine Desulphurisation, Biogas Flare, Process Automation.
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pt maxxtec teknologi indonesiaCelsi
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Instead of making bad experience, trust in quality and reliability
Contact us:PT Maxxtec Teknologi IndonesiaPhone +62 21 53670749maya.sefyen@maxxtec.co.id
Mobile: +62 857 437 56 221www.maxxtec.co.id
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