pt krakatau steel - Energy Conservation Center

pt krakatau steel - Energy Conservation Center

Seminar on Promotion of Energy Efficiency and
Conservation
(PROMEEC) for Major Industry in Southeast Asia
Energy Efficiency and Conservation Best
Practices at PT. Krakatau Steel-Indonesia
PT KRAKATAU STEEL
Cilegon-Indonesia www.ks.co.id
Contents
• Company Background
• Energy Profile
•Energy Issues
•Energy Management & Conservation
•R & D and Future Planning
•Government Programs on EE&C
•Conclusions
PT KRAKATAU STEEL
Cilegon-Indonesia www.ks.co.id
PT. Krakatau Steel
‰ State Owned Company (Established: August 31,1970 )
‰ The first integrated steel plant in Southeast Asia
‰ Responsible for fulfill the steel demand domestic and
abroad
‰ As a backbone of industrial development in the country
‰ Meet the national and international quality standard
such as JIS, ASTM, DIN, ISO9001:2000, ISO 14001,
ISO 17025
‰ Production capacity : 2.000.000 MT per year
‰ Supported by more than 6000 employees
‰ Located in Banten Province, on the westernmost of the
Java Island
PT KRAKATAU STEEL
Cilegon-Indonesia www.ks.co.id
Production Process at PT Krakatau
Steel
Pellet:
Iron ore
Slab Steel Plant
Hot Rolling Mill
(2,000,000 t/y)
(2,200,000 t/y)
Direct Reduction Plant
Billet Steel Plant
PT KRAKATAU STEEL
Cilegon-Indonesia www.ks.co.id
Wire Rod Mill
(600,000 t/y)
Cold Rolling Mill
(850,000 t/y)
DIRECT REDUCTION PLANT
IRON ORE
CO2
FUEL
H2O
REACTOR
O2
STEAM
NATURAL
GAS
H2O
REFORMER
WATER
GAS
HEATER
H2O
FUEL
PT KRAKATAU STEEL
Cilegon-Indonesia www.ks.co.id
DRI
NATURAL
GAS
SLAB STEEL PLANT
SCRAP
DRI
ELECTRIC ARC
FURNACE
SLAB
LADLE
FURNACE
CONTINUOUS CASTING
MACHINE
HBI PIG IRON
RH-VACUM
DEGASSING
PT KRAKATAU STEEL
Cilegon-Indonesia www.ks.co.id
HOT STRIP MILL
SLAB
REHEATING FURNACE
SIZING PRESS
HOT ROLLED COIL
SHEARING LINE
SLITTING/RECOILING LINE
SHEET AND PLATE
SLITTED AND
RECOILED
PT KRAKATAU STEEL
Cilegon-Indonesia www.ks.co.id
ROUGHING MILL
DOWN COILER
FINISHING MILL
LAMINAR COOLING
SKIN PASS MILL
RECOILED
HOT ROLLED COIL
COLD ROLLING MILL
BATCH ANEALING FURNACE
HOT ROLLED COIL
CONTINUOUS
PICKLING LINE
TANDEM COLD MILL
ELECTROLYTiC
CLEANING LINE
CONTINUOUS
ANEALING LINE
TEMPER MILL
COLD ROLLED COIL
COLD ROLLED COIL
SLITTING/RECOILING LINE
SHEARING LINE
PT KRAKATAU STEEL
Cilegon-Indonesia www.ks.co.id
SLITTED/RECOILED
SHEET
PT. K S - Products
PT KRAKATAU STEEL
Cilegon-Indonesia www.ks.co.id
Product Applications
PT KRAKATAU STEEL
Cilegon-Indonesia www.ks.co.id
Energy Cost Segmentation at PT.
KS
10%
30%
60%
Electricity
PT KRAKATAU STEEL
Cilegon-Indonesia www.ks.co.id
Natural Gas
Oil Fuel
Energy Cost Structure (Crude
Steel) at PT. KS
Fix Cost, 12%
Others, 12%
Energy, 22%
Raw Material,
54%
PT KRAKATAU STEEL
Cilegon-Indonesia www.ks.co.id
Electricity Consumption Segment at PT. KS
18%
6%
76%
Iron making
Steel Making
Rolling Mill
Natural Gas Consumption Segment at PT. KS
15%
6%
79%
Iron Making
PT KRAKATAU STEEL
Cilegon-Indonesia www.ks.co.id
Steel Making
Rolling Mill
Distribusi Daya Listrik PT. KS
K
D
L
P
L
N
87 %
400
MVA
Steel Making
95 %
PT KS
13 %
Others
200
MVA
5%
PT KRAKATAU STEEL
Cilegon-Indonesia www.ks.co.id
Subsidiary
Company
Energy Conservation Group Organization
President Director
Director
Director of Planning & Technology
Director
Director
G M Research & Technology
Mgr Research & Development of
Process & Energy Conservation
Mgr Technology
Planning.
Mgr Research &
Development Services
Chief Engineer
Senior Eng. Energy
Conservation
Senior Eng. Process
Senior Eng. Raw Mat’l
& Waste
Engineer Energy
Conservation
Engineer Process
Engineer Raw Mat’l &
Waste
Technicians
PT KRAKATAU STEEL
Cilegon-Indonesia www.ks.co.id
Technicians
Technicians
Mgr Product
Development
Energy Issues:
„
„
High Energy Price (especially oil
fuel)
Energy Supply Limitation (Natural
Gas)
„
Energy inefficiency
„
Environmental Issue
PT KRAKATAU STEEL
Cilegon-Indonesia www.ks.co.id
Energy Saving Potential at PT. KS Plants
Unit
Potential Projects
Fuel oil substitution
Rolling
„ Slab hot charging (1,5x1011 Kcal/y)
Mills
„ Waste Heat Recovery
„
DR
„
Boiler fuel substitution
Scrap pre-heating
„ Oxygen lancing (9x107 Kwh/y)
„ Dedusting Optimation EAF 5&6 (1,5x107 Kwh/y)
„
EAF
Power
Plant
Fuel oil substitution
„ Waste heat Recovery
„
PT KRAKATAU STEEL
Cilegon-Indonesia www.ks.co.id
Countermeasures
Energy efficiency and conservation
programs
„ Energy diversification / substitution
„ Sufficient NG supply security
„ Plant improvement and
modification
„ Cleaner production program
„
PT KRAKATAU STEEL
Cilegon-Indonesia www.ks.co.id
Energy Conservation Activities at PT KS
1. Examples of Options Successfully Implemented
ƒ
ƒ
ƒ
ƒ
Burner Control System in Ladle Drying and Preheating
Steam Traps & Leaks Survey, Repair and Replacement
Neuro Furnace Controller implementation
Partial Oxidation
2. Examples of Options Potentially Implemented
ƒ
ƒ
ƒ
Electricity Saving by Power Reduction of Recirculating
Pumps
Generate Power from Excess High Pressure Natural Gas
through Turbine Expansion & Electrical Generator.
Recovering Waste Heat through Billet & Slab
Transportation System Modification (Hot Charging)
3. Examples of Options Others Succesfully & Potentially
Implemented
ƒ
ƒ
Implementation Network ECC
Fuel Oil Substitution
PT KRAKATAU STEEL
Cilegon-Indonesia www.ks.co.id
Burners Control System for Ladle Drying and
Preheating Process in Slab Steel Plant
Otomation in LADLE & TUNDISH HEATING SYSTEM
Save Natural Gas : 9 Nm3/Ton (56%)
EAF 09
ò
ø
EAF 10
Signal Power On Time
Before: 16 Nm3/Ton
After : 7 Nm3/Ton
òSignal Power On Time
ø
2 heat treatment periods
of the Ladle & Tundish :
1. Preheating
2. Drying
Result:
Natural Gas
MMI + Monitoring
PLC
LD 01
LD 02
EAF: Electrical Arc Furnace
TDH 01
LP 01
LD : Ladle Drying
LP 02
TDH 02
LP : Ladle Preheating TDH : Tundish Heating
PT KRAKATAU STEEL
Cilegon-Indonesia www.ks.co.id
Shorter heating time, reduce
fuel consumption significantly
from 1244 NM3 / heat to 499
NM3/heat.
Slabs Hot Charging
Basic Concept
„
Cold Charging
± 30 oC
RHF
„
Hot Charging
Potential Saving:
1.5 x 1011 Kcal/year
PT KRAKATAU STEEL
Cilegon-Indonesia www.ks.co.id
± 530 oC
RHF
Recovering Waste Heat through Billet
Transportation System Modification
BILLET STRAND CASTER
350 cm
CUTTER
T = 900 °C
Billets
150 cm
Mechanical
Transport
System
1 st COOLINGBED
T = 450 °C
CUTTER
t = 1 Hour
COOLING BED PIPE
25 cm
8 cm
V = 6 m/s, RH = 65%
2nd COOLINGBED
CUTTER
T = 130 °C AIR: T = 39 °C
Insulation
Refractory
Goal : to minimize heat loss during transferring time from BSP to WRM
by performing modification / optimation on Billet Transportation
System
PT KRAKATAU STEEL
Cilegon-Indonesia www.ks.co.id
DRPLANT
COKEOVEN
PANT
CDQP
ANT
EAF
(SSP1&2)
KDL
EAF
(BSP)
PLN
(PowerPlant)
KDL
HEADCOMPUETER
(gasstation
Design of Energy Control
Centre Network
PRODUCTION-LAN
ECC CONFIGURATION
STEELPLANT
SINTERING
PLANT
(fuelgasholder)
ENERGYCONTROLCENTER
BLAST
FURNACE
incl.PCI
(ECCforthenetworkof water, steam,
fuelgases,technicalgases,
electricity,compressedair,
observingtheenergy–contract)
MixGas
Station
Optimizing
APPLICATION
Controlling
Analyzing
Reporting
Aplication-BUS
Energy
Cont rol –and
I nf ormat I on
Syst em
WAN–Connectionto
remoteSystem
HUB2
BOF
PLANT
Substitute
fuelgasses
station
Server1
Archive
CONTROL
HSM
Monitor6
Monitoring
Controlling
Monitoring
Controlling
Compressed
Air
CRM
Monitor2
Monitor1
Monitoring
Controlling
DataTrans
Emergency
Gateway
Redundant Control
SystemBusses
HUB2
Technical
Gasses
(O2,Ar,N2)
WRM
WATER
TREATMENT
STEAM
BLOCKS
MeteringGas
Station
Pgi&
PERTAMINA
AirLiquid
HUB1
Gateway1
DATA
ACQUISITION
Gateway2
DataTransmission
DataTransmission
PLC-BUS
ECC COMUNICATION SYSTEM
PT KRAKATAU STEEL
Cilegon-Indonesia www.ks.co.id
concentrator
concentrator
concentrator
concentrator
concentrator
PLC
1
PLC
2
PLC
3
PLC
4
ToPLcin
productionplant
ToPLcin
productionplant
ToPLcin
productionplant
ToPLcin
productionplant
PLC
5
Neuro Furnace Controller
(Reduce Electricity Consumption at the Steel Making Plant)
Before : 669 Kwh/TLS
After : 634 Kwh/TLS
Save : 35 Kwh/TLS ( 5 %)
PT KRAKATAU STEEL
Cilegon-Indonesia www.ks.co.id
HyL-3 Partial Oxidation Process
(Save Natural Gas)
48,000
Ton/h
water
N.G.
Iron
Ore
cooler
CO2
T1 = Before Inject O2
T2 = After Inject O2
H2O
absorber
Cap.: 1,5x106 T/y
20,000 Nm3/h
CO
H2
OXYGEN FLOW :
fuel
Rate : 800 NCMH, Press. = 14 Bars
Before: 360 Nm3/Ton
After : 340 Nm3/Ton
Save : 20 Nm3/Ton (5,5%)
PT KRAKATAU STEEL
Cilegon-Indonesia www.ks.co.id
O2
Nat. Gas
Injection
Process Gas Temperature
Before Inject O2 (T1): 933 C
DRI
After Inject O2 (T2) : 980 C
Total Energy Saving
‰
‰
‰
Natural Gas (saving from: Partial Oxidation,
Steam leaks reparation and Ladle & Tundish
Heating Automation):
= 60 x 106 Nm3 /y = US$ 5,610,326 / y
Electricity (saving from: Neuro Furnace
Controller and others):
= 80 x 106 Kwh /y = US$ 3,804,347 / y
Total Saving
PT KRAKATAU STEEL
Cilegon-Indonesia www.ks.co.id
= US$ 9,414,674 / y
PARTNERSHIP PROGRAM ON EE&C FOR INDUSTRY
AND COMMERCIAL BUILDING
ƒ
ƒ
ƒ
Partnership program is the government program on energy
conservation focused on energy efficiency improvement for
energy intensive industries and commercial buildings
Government support e.g. Energy Audit (Free of Charge);
Training; Technical Assistance and Seminar/ Workshop
Parties involved in the program which started in 2003 are
Government, State-owned Electricity Company, Financial
Agency, Industry and Commercial Building
PT KRAKATAU STEEL
Cilegon-Indonesia www.ks.co.id
PARTNERSHIP PROGRAM ON EE&C FOR
INDUSTRY AND COMMERCIAL BUILDING
ƒ
ƒ
ƒ
In 3 years committed industries and buildings report to
government every 6 (six) month about the progress
implementation of the energy audit recommendation.
In this year, there are 32 industries and building
participate in partnership program
Energy Audit in industries and buildings will be expanded
to almost 250 objects (industries and buildings) next year
under government budget.
PT KRAKATAU STEEL
Cilegon-Indonesia www.ks.co.id
ENERGY AUDIT RESULT - INDUSTRY
INDUSTRY
ENERGY SAVING POTENTIAL
(%)
US$/Year
Ispatindo,
Ispatindo, East Java
6.76
2,080,441
Roda Mas Baja Inti,
Inti, South Sulawesi
10.75
11,280
20.6
9,745
2.6
272,554
IRON AND STEEL
Barawaja,
Barawaja, South Sulawesi
TEXTILE
Roda Vivatex – West Java
Bhineka Karya Manunggal 1 - West Java
15.74
64,385
Bhineka Karya Manunggal 2 - West Java
3.99
493,250
Vastex Prima - West Java
7.58
69,200
Indah Jaya Textile – Banten
13.74
77,921
FLOUR MILLS
Berdikari Sari Utama,
Utama, West Java
PT KRAKATAU STEEL
Cilegon-Indonesia www.ks.co.id
22.2
195,179
ENERGY AUDIT RESULT - BUILDING
BUILDING
ENERGY SAVING POTENTIAL
(%)
US$/Year
COMMERCIAL BUILDING
¾
Graha Pangeran,
Pangeran, East Java
9.83
18,386
¾
Sarana Jaya, Jakarta
10.10
43,400
¾
Dharma Niaga,
Niaga, Jakarta
10.86
14,109
¾
Bimantara,
Bimantara, Jakarta
11.09
49,225
¾
Plaza Permata,
Permata, Jakarta
15.08
33,386
¾
Ina Bali Beach Hotel, Bali
10.74
113,692
¾
Fantasi Mall, East Kalimantan
19
30,967
GOVERNMENT OFFICE
¾
Bank of Indonesia, South Sumatera
1.92
34,875
¾
R&D Oil and Gas, Jakarta
0.7
848
¾
Training Center MEMR, Jakarta
9.71
5,041
¾
DGEEU, Jakarta
PT KRAKATAU STEEL
Cilegon-Indonesia www.ks.co.id
24
13,120
OVERSEAS COOPERATION ON EE&C
I.
GREENHOUSE GAS EMISSION REDUCTION from INDUSTRIES in ASIA and
PACIFIC (GERIAP) – UNEP
ƒ
Enhancing energy efficiency improvement for mitigating GHG emission
ƒ
Energy Audit for intensive energy industry :
- Cement
- Fertilizer
II.
- Pulp & Paper
- Iron & Steel
PROMOTION on ENERGY EFFICIENCY and CONSERVATION (PROMEEC), ASEAN
– ECCJ/METI JAPAN
ƒ
Promoting energy saving implementation for industry and building in ASEAN
region
ƒ
Energy Audit/Energy Management, Database, Benchmarking for industry and
building :
- Industry (2005)
- Commercial building (2004)
PT KRAKATAU STEEL
Cilegon-Indonesia www.ks.co.id
: Pulp & Paper Mills, Spinning
: Hotel - 2 (two) five star class
Conclusion
• The energy conservation efforts have reduced
energy consumption rate and production cost
and at the same time contribute to create
better environmental condition.
• Supported by the management and all
employee, these efforts have been
implemented succesfully and continuously.
PT KRAKATAU STEEL
Cilegon-Indonesia www.ks.co.id