Cogeneration System and Energy Saving in Sugar MillPrepared byPT Chazaro Gerbang Internasional (CGI)Jl. Sapta Taruna Raya No.16, Lebak Bulus, Jakarta Selatan 12310, Indonesia

IntroductionIndonesia sugar demand in 2005 was over 5 mio tonnesGovernment of Indonesia targeted sugar self sufficiency in 2014Total number of sugar-mill in Indonesia are 61 sugar-mill, with crushing capacity ranging 1000-12000 TCD, total crushing capacity is 225.000 TCDTotal sugar-mill plantation in Indonesia is 441.440 ha which is concentrated in east java (45%) and Lampung (25%)Most of sugar-mill in Indonesia are old factories and operate in-efficiently

Material Balance Typical Sugarcane Industries

Status of Sugar Cogen in IndonesiaAll Sugar Mill Constructed With CHP Plant to Meet The Steam and Power NeedsExcess Bagasse Saved is sold as FuelTypical Electricity Consumption: 11-34 kWh/ton CaneTypical Steam Consumption: 0.48-0.60 Ton Steam/Ton CaneTypical Utility Configuration of Indonesia Sugar Mill:Steam Generator of about 50% of cane crushing capacity at 17-20 Kg/cm2, back pressure turbine to meet plant power needs, mechanical drive for mill Typical Power Generation 100 kW/ton Bagasse

Catalytic measures required for rapid penetrationWide dissemination on operations of successful integrated sugar complexesFuel linkages during sugar off-seasonImproving energy efficiency of sugar mill. Measures: changeover from mechanical drives to electrical drives utilisation of exhaust steam only on first body, Appropriate sizing of pumps & fans, VFDs on large continuously operating pumps, fans, conveyors, design & control for low bagasse moisture, efficient evaporator set up &control, combustion control, better housekeeping

Case study: Sugarmill Cogen in India

Case Study: Sugarmill Cogen in IndonesiaSugarmill existing Capacity: 6300 TCDTurbine Alternator : 4.2 Mwe2 Unit Boiler: 130 TphMechanical Turbine:Cane cutter I Cane cutter II UNIGRATOR Gilingan I Gilingan II Gilingan III Gilingan IV Gilingan V

Case Study: Sugarmill Cogen in IndonesiaSugarmill existing Capacity: 6300 TCD

Case Study: Proposed Sugar-mill Cogen in IndonesiaBase on Empirical Data of Mauritius Sugarmill 6000 TCD100 GWh/Year

Case Study: Proposed Sugarmill Cogen in IndonesiaInstalled new Boiler 80 tph, 46 kg/cm2, 1 unit Extraction- Condensing Turbine Alternator

Case Study: Proposed Sugarmill Cogen in IndonesiaInstalled new Boiler 80 tph, 46 kg/cm2, 1 unit Full Condensing Turbine Alternator

Case Study: Proposed Sugarmill Cogen in IndonesiaInstalled new Boiler 80 tph, 46 kg/cm2, Mill Capacity : 6300 TCDInstalled 1 Unit Turbine Alternator (extraction-Condensing)Potential Power Generation 8,105.0 KW (on-season)Potential Power Generation : 6,537.0 KW (off-season)Potential Electricity Production : 63 GWh/year

Installed 1 Unit Turbine Alternator (Full Condensing)Potential Power Generation 5,982.0 KW (on-season)Potential Power Generation : 6,434.0 KW (off-season)Potential Electricity Production : 53 GWh/year

Case Study: Proposed Sugarmill Cogen in IndonesiaInstalled new Boiler 80 tph, 46 kg/cm2, 1 unit Extraction- Condensing Turbine Alternator, Capacity upgraded to 7200 TCD

Case Study: Proposed Sugarmill Cogen in IndonesiaInstalled new Boiler 80 tph, 46 kg/cm2, 1 unit Full Condensing Turbine Alternator, Capacity upgraded to 7200 TCD

Case Study: Proposed Sugarmill Cogen in IndonesiaInstalled new Boiler 80 tph, 46 kg/cm2, Mill Capacity : 7200 TCDInstalled 1 Unit Turbine Alternator (extraction-Condensing)Potential Power Generation 5,339.0 KW (on-season)Potential Power Generation 11,640.0 KW (off-season)Potential Electricity Production : 73 GWh/year

Installed 1 Unit Turbine Alternator (Full Condensing)Potential Power Generation 2,553.0 KW (on-season)Potential Power Generation 11,478.0 KW (off-season)Potential Electricity Production : 60 Gwh/year

Case Study: Energy Saving by conversion of mechanical Turbine to Electric Motor Drive

ItemMech. TurbineElectric MotorPower440 HP= 320 kW335 kWOperational CostRp.1.186.831.800/yRp. 532.826.910 /yMaintenance CostRp.52.000.000/yRp. 5.000.000/yInvestment Rp.1.000.000.000Simple Pay Back Periode2 Months

ConclusionThere were some potentials for optimizing energy consumption in sugar-mill in IndonesiaWith Sugar-Mill Operates Efficiently, then there is potential surplus of bagasseBagasse Surplus can be utilize to produce electricity through cogeneration system in sugarmill (send to grid) (7200 TCD 73 GWhr/year)