Académique Documents
Professionnel Documents
Culture Documents
Conservation
(PROMEEC) for Major Industry in Southeast Asia
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
Pellet:
Slab Steel Plant Hot Rolling Mill Cold Rolling Mill
Iron ore
(2,000,000 t/y) (850,000 t/y)
(2,200,000 t/y)
O2
STEAM
NATURAL H2O
GAS
REFORMER GAS
H2O HEATER
DRI
WATER FUEL
NATURAL
GAS
PT KRAKATAU STEEL
Cilegon-Indonesia www.ks.co.id
SLAB STEEL PLANT
SCRAP
SLAB
DRI LADLE
ELECTRIC ARC FURNACE
FURNACE
CONTINUOUS CASTING
MACHINE
HBI PIG IRON
RH-VACUM
DEGASSING
PT KRAKATAU STEEL
Cilegon-Indonesia www.ks.co.id
HOT STRIP MILL
LAMINAR COOLING
HOT ROLLED COIL DOWN COILER
PT KRAKATAU STEEL
Cilegon-Indonesia www.ks.co.id
COLD ROLLING MILL
CONTINUOUS ELECTROLYTiC
HOT ROLLED COIL TANDEM COLD MILL CLEANING LINE
PICKLING LINE
CONTINUOUS
ANEALING LINE
SLITTING/RECOILING LINE
SLITTED/RECOILED
SHEARING LINE
SHEET
PT KRAKATAU STEEL
Cilegon-Indonesia www.ks.co.id
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%
PT KRAKATAU STEEL
Cilegon-Indonesia www.ks.co.id
Energy Cost Structure (Crude
Steel) at PT. KS
Raw Material,
54%
PT KRAKATAU STEEL
Cilegon-Indonesia www.ks.co.id
Electricity Consumption Segment at PT. KS
6%
18%
76%
79%
PT KRAKATAU STEEL
Cilegon-Indonesia www.ks.co.id
Distribusi Daya Listrik PT. KS
K 87 %
D 400 Steel Making
L MVA
95 %
PT KS
P
L 13 %
Others
N 200
MVA
5% Subsidiary
Company
PT KRAKATAU STEEL
Cilegon-Indonesia www.ks.co.id
Energy Conservation Group Organization
President Director
Mgr Research & Development of Mgr Technology Mgr Research & Mgr Product
Process & Energy Conservation Planning. Development Services Development
Chief Engineer
Senior Eng. Energy Senior Eng. Process Senior Eng. Raw Mat’l
Conservation & Waste
Energy inefficiency
Environmental Issue
PT KRAKATAU STEEL
Cilegon-Indonesia www.ks.co.id
Energy Saving Potential at PT. KS Plants
Scrap pre-heating
EAF Oxygen lancing (9x107 Kwh/y)
PT KRAKATAU STEEL
Cilegon-Indonesia www.ks.co.id
Energy Conservation Activities at PT KS
1. Examples of Options Successfully Implemented
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
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
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%) Before: 16 Nm3/Ton
2 heat treatment periods
EAF 09 EAF 10 After : 7 Nm3/Ton of the Ladle & Tundish :
Signal Power On Time
ò òSignal Power On Time 1. Preheating
ø ø
2. Drying
Natural Gas
Result:
PLC MMI + Monitoring
Shorter heating time, reduce
fuel consumption significantly
LD 01
from 1244 NM3 / heat to 499
TDH 01
NM3/heat.
LD 02 LP 01 LP 02 TDH 02
EAF: Electrical Arc Furnace LD : Ladle Drying LP : Ladle Preheating TDH : Tundish Heating
PT KRAKATAU STEEL
Cilegon-Indonesia www.ks.co.id
Slabs Hot Charging
Basic Concept
Cold Charging
± 30 oC
RHF
Hot Charging
Potential Saving: ± 530 oC
1.5 x 1011 Kcal/year RHF
PT KRAKATAU STEEL
Cilegon-Indonesia www.ks.co.id
Recovering Waste Heat through Billet
Transportation System Modification
BILLET STRAND CASTER
350 cm
CUTTER
T = 900 °C
Billets
Mechanical 150 cm
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 Insulation
T = 130 °C AIR: T = 39 °C
CUTTER
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
COKEOVEN CDQP
DRPLANT
EAF EAF
KDL
(PowerPlant)
PLN
Design of Energy Control
Centre Network
PANT ANT
(SSP1&2) (BSP)
KDL
HEADCOMPUETER
(gasstation
PRODUCTION-LAN
ECC CONFIGURATION
SINTERING STEELPLANT
APPLICATION Optimizing Controlling Analyzing Reporting WAN–Connectionto
PLANT (fuelgasholder) Energy
remoteSystem
ENERGYCONTROLCENTER Cont rol –and
BLAST I nf ormat I on
(ECCforthenetworkof water, steam, MixGas
FURNACE
fuelgases,technicalgases, Aplication-BUS Syst em
incl.PCI Station
electricity,compressedair,
observingtheenergy–contract) HUB2
BOF Substitute
PLANT fuelgasses Monitor2 Monitor6
Server1 Monitor1 DataTrans
station CONTROL Archive Emergency
Monitoring
Gateway
Controlling
HSM
Monitoring Monitoring
Compressed Controlling Controlling
Redundant Control
Air SystemBusses
CRM HUB2
Technical
Gasses
WRM (O2,Ar,N2) HUB1
PT KRAKATAU STEEL
Cilegon-Indonesia www.ks.co.id
Neuro Furnace Controller
(Reduce Electricity Consumption at the Steel Making Plant)
PT KRAKATAU STEEL
Cilegon-Indonesia www.ks.co.id
HyL-3 Partial Oxidation Process
(Save Natural Gas)
Iron T1 = Before Inject O2
cooler
48,000 Ore
Ton/h
H2O T2 = After Inject O2
water
CO2
N.G.
absorber Cap.: 1,5x106 T/y
20,000 Nm3/h
CO
H2
Nat. Gas
OXYGEN FLOW :
fuel
O2 Injection
Rate : 800 NCMH, Press. = 14 Bars
Process Gas Temperature
Before: 360 Nm3/Ton Before Inject O2 (T1): 933 C
After : 340 Nm3/Ton After Inject O2 (T2) : 980 C
Save : 20 Nm3/Ton (5,5%) DRI
PT KRAKATAU STEEL
Cilegon-Indonesia www.ks.co.id
Total Energy Saving
PT KRAKATAU STEEL
Cilegon-Indonesia www.ks.co.id
PARTNERSHIP PROGRAM ON EE&C FOR
INDUSTRY AND COMMERCIAL BUILDING
PT KRAKATAU STEEL
Cilegon-Indonesia www.ks.co.id
ENERGY AUDIT RESULT - INDUSTRY
ENERGY SAVING POTENTIAL
INDUSTRY
(%) US$/Year
Ispatindo,
Ispatindo, East Java 6.76 2,080,441
Roda Mas Baja Inti,
Inti, South Sulawesi 10.75 11,280
Barawaja,
Barawaja, South Sulawesi
20.6 9,745
TEXTILE
FLOUR MILLS
PT KRAKATAU STEEL
Cilegon-Indonesia www.ks.co.id
ENERGY AUDIT RESULT - BUILDING
ENERGY SAVING POTENTIAL
BUILDING
(%) US$/Year
COMMERCIAL BUILDING
¾ Graha Pangeran,
Pangeran, East Java 9.83 18,386
¾ Bimantara,
Bimantara, Jakarta 11.09 49,225
¾ Plaza Permata,
Permata, Jakarta 15.08 33,386
PT KRAKATAU STEEL
Cilegon-Indonesia www.ks.co.id
Conclusion
PT KRAKATAU STEEL
Cilegon-Indonesia www.ks.co.id