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Cogeneration System and Energy

Saving in Sugar Mill


Prepared by
PT Chazaro Gerbang Internasional (CGI)
Jl. Sapta Taruna Raya No.16, Lebak Bulus,
Jakarta Selatan 12310, Indonesia

Introduction
Indonesia sugar demand in 2005 was over 5 mio tonnes
Government of Indonesia targeted sugar self sufficiency in 2014
Total number of sugar-mill in Indonesia are 61 sugar-mill, with
crushing capacity ranging 1000-12000 TCD, total crushing capacity is
225.000 TCD
Total 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 inefficiently

Material Balance Typical


Sugarcane Industries

Status of Sugar Cogen in


Indonesia
All Sugar Mill Constructed With CHP Plant to Meet The Steam and
Power Needs
Excess Bagasse Saved is sold as Fuel
Typical Electricity Consumption: 11-34 kWh/ton Cane
Typical Steam Consumption: 0.48-0.60 Ton Steam/Ton Cane
Typical 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 penetration
Wide dissemination on operations of successful integrated sugar
complexes
Fuel linkages during sugar off-season
Improving 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 Indonesia
1.
2.
3.
4.

Sugarmill existing Capacity


Turbine Alternator
2 Unit Boiler
Mechanical Turbine:
a)
b)
c)
d)
e)
f)
g)
h)

Cane cutter I
Cane cutter II
UNIGRATOR
Gilingan I
Gilingan II
Gilingan III
Gilingan IV
Gilingan V

: 6300 TCD
: 4.2 Mwe
: 130 Tph

Case Study: Sugarmill Cogen


in
Indonesia
1. Sugarmill existing Capacity
: 6300 TCD

Case Study: Proposed Sugarmill Cogen in Indonesia

100
GWh/Yea
r

Base on Empirical Data


of Mauritius Sugarmill
6000 TCD

Case Study: Proposed


Sugarmill Cogen in Indonesia
Installed new Boiler 80 tph, 46 kg/cm2, 1 unit ExtractionCondensing Turbine Alternator

Case Study: Proposed


Sugarmill Cogen in Indonesia
Installed new Boiler 80 tph, 46 kg/cm2, 1 unit Full Condensing
Turbine Alternator

Case Study: Proposed


Sugarmill Cogen in Indonesia
Installed new Boiler 80 tph, 46 kg/cm2, Mill Capacity : 6300 TCD
Installed 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 Indonesia
Installed new Boiler 80 tph, 46 kg/cm2, 1 unit ExtractionCondensing Turbine Alternator, Capacity upgraded to 7200 TCD

Case Study: Proposed


Sugarmill Cogen in Indonesia
Installed new Boiler 80 tph, 46 kg/cm2, 1 unit Full Condensing
Turbine Alternator, Capacity upgraded to 7200 TCD

Case Study: Proposed


Sugarmill Cogen in Indonesia
Installed new Boiler 80 tph, 46 kg/cm2, Mill Capacity : 7200 TCD
Installed 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

Item

Mech. Turbine

Electric Motor

Power

440 HP= 320 kW

335 kW

Operational Cost

Rp.1.186.831.800/y

Rp.
532.826.910 /y

Maintenance Cost

Rp.52.000.000/y

Rp. 5.000.000/y

Investment

Rp.1.000.000.000

Simple Pay Back


Periode

2 Months

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