Effective Thermal utilization of Biomass for Cement · PDF fileSemen Indonesia (Persero) Tbk. ... The conclusions of this study on "Effective Thermal Utilization of Biomass for Cement

Effective Thermal Utilization of Biomass for Cement Production

Arif Hidayat1 (Researcher), Nobuo Takasu2 (Host Researcher)1Semen Gresik Foundation – Indonesia, Renewable Energy Researchers

Invitation Program 2013- New Energy Foundation–Japan2JFE Engineering Corporation – 2-1, Shuehiro-cho,

Tsurumi-ku Yokohama 230-8611-Japan

New Energy Foundation - Japan 2013

• Title

• Table of Content

• Chapter 1 : Introduction

• Chapter 2 : Evaluation of business condition

• Chapter 3 : Effective thermal concept

• Chapter 4 : Technology evaluation and transfer plant

• Chapter 5 : Evaluation of Environmental impact

• Chapter 6 : Profitability evaluation

• Chapter 7 : RDF as a biomass energy

• Chapter 8 : Biomass in PT. Semen Indonesia (Persero) Tbk.

• Chapter 9 : Conclusions

• Attachment

TABLE OF CONTENT


INTRODUCTION


Biomass means all plant and animal matter on the Earth's surface. Biomass is used to

describe material of recent biological origin that can be used either as a source of energy or for its chemical components

Global warming became an issue after scientists, particularly in fields related to the atmosphere,

studied observational data on the Earth's surface temperature and noted a quite significant increase in the temperature

difference after the Industrial Revolution, and especially since 1990


Background

a) Indonesia’s total primary energy consumption in 2012 andb) target energy consumption in 2025.

Source: Ministry of Energy and Decree of President No. 5/2006. The most detailed breakdown of “Other Renewable” states that hydro power, solar power, and wind power

will contribute 5%, with the remaining 2% to be provided by liquefied coal.

INTRODUCTION

ENVIROMENTAL IMPACT EVALUATION


Environmental impact of utilizing biomass, source :

http://www.climatemanual.org/Cities/Chapter5/LongTermInitiatives/CPM_Chapter5_LocalActionPlan_LongTermInitiatives_WasteManagement.htm

http://www.climatemanual.org/Cities/Chapter5/LongTermInitiatives/CPM_Chapter5_LocalActionPlan_LongTermInitiatives_WasteManagement.htm



a.) waste management hierarchy b.) Combustion of coal in industry without co-processingc.) Co-processing (combustion of coal in industry combined with biomass combustion)

Source: Wikipedia, the free encyclopedia, energy recovery: 2010



Source : Wikipedia, the free encyclopedia, energy recovery: 2010

Biomass and carbon dioxide (CO2) cycle

BUSINESS CONDITION EVALUATION


Potential of Biomass as an alternative fuel

Global Energy consumption and projection by fuel in percentage 1990–2040

Source: EIA, International Energy Outlook 2013



Potential of Biomass as an alternative fuelMain industrial coal users in Indonesia (2012)

Source: Study team of National Coal, Policy of Coal and Mineral Group,Research Center for Mineral and Coal Technology, Indonesia, 2012 .

Global carbon emissions from fossil fuel combustion and cement manufacture,

Source: EIA, International Energy Outlook 2011



Capacity Production Cement in Indonesia

Transitions of cement production capacity of companies in Indonesia

Source: Resource Development Center Investment, Ministry of Public Works, SISDI@ 2011

Main cement makers in Indonesia 2010-2013

Source: Resource Development Center Investment, Ministry of Public Works, SISDI@2011

EFECTIVE THERMAL CONCEPT


Parameters and composition of biomass as alternative fuel

Source: Development Process, Energy, and Environment Section, PT. Semen Gresik (Persero) Tbk., 2012. Unpublished document



Site location

Location of project at Ngipik, Gresik, East Java, Indonesia;

1) Map of East Java;

2) Map of Gresik Regency; and

3) Map of Ngipik-Gresik, East Java, former mining area of PT. Semen Gresik (Persero) Tbk, 2012



Concept of separation MSW at Ngipik, Gresik, East-Java, Indonesia, 2012

Operation Process



Operation Process

Composition of waste from landfill area at Ngipik, 2012



Operation Process

Component ratio of MSW at Ngipik landfill(former mining land of PT. Semen Gresik (Persero) Tbk.)



Simple flow of alternative fuel manufacturingprocess for old MS at Ngipik, Gresik



Simulation of simple flow process

Old Waste

Balistic Separator

fine shredder

RDF

Metal, stone,soil, sand etc.

Back to land fill

RDF /Flammable Materials

Loader

10 tons/hours

20 tons/hours

Magnetic Pulley



Product

MSW and product; 1) Flammable materials from landfill owned by PT. Semen Gresik (Persero) Tbk before

processing;2) Destroyed Materials (mixture of material derived from waste is decomposed and

destroyed), low calorie, around 1500 – 2000 Kcal/Kg; 3) Material Added (soil mixed with other materials, which can serve as material added),

including metal, stone, glasses, etc.; and4) Flammable Materials, i.e., combustible material which has a high caloric value and can

be used as an alternative energy (not composted in fermentation process), high GHV of around 3800-4800 kcal/Kg.



The effective thermal concept when using biomass fuels is to maintain relatively stable combustion of the biomass fuel. Mixing RDF and rice

husks (agriculture waste) at a certain ratio makes it possible to control the

moisture content of the fuel, and lowering the moisture contents results in a higher heating value.

A low moisture content will maintain the stability of the heating value of the alternative

fuel on the level of 3800-4800 kcal/kg

PROFITABILITY EVALUATION


Investment cost of Waste to Zero ProgramSource: Engineering Department PT. Semen Gresik (Persero) Tbk, 2013



Operational cost assumptions, Waste to Zero Program

Source: Engineering Department PT. Semen Gresik (Persero) Tbk, 2013

Operational cash flow, Waste to Zero Program

Source: PT. Semen Indonesia (Persero) Tbk, 2013



Feasibility study, Waste to Zero ProgramSource: PT. Semen Indonesia (Persero) Tbk, 2013

RDF as a biomass Energy


Transport process in a trial project, Waste to Zero Program,at PT. Semen Gresik (Persero) Tbk, Tuban Plant III, 2012

Simple flow process in trial project, Waste to Zero Program,at landfill at Ngipik, Gresik, 2012



Trial result :

Operational results1. Coal consumption was reduced from 29 to 27.5 tons/hour.2. Reduction of CO and O2 increased, although this increase was not significant.

Problems1. RDF jammed in the hopper outlet 463BC7 because the size was still relatively

large.2. Homogeneity becomes very important when mixing RDF and rice husks;

there is a screen on the regulator 463BC8 gate and transfer point.3. The moisture content of the RDF is relatively high, at around 30%, and the

availability of rice husks is seasonal (very large stock at harvest time, very small stock during planting season).

4. Physically, RDF and rice husks are very light and are interrelated. As a result, the process will be hampered by hanging of the mixture in the feeding hopper.



1. Waste in Indonesia is heterogeneous. Initial separation is the most important thing of this process. It will cause damage to the engine if not done properly separation.

2. With the separation will also make the process easier, and in accordance with the specifications of the cement industry.

3. Selection of the right machine will make a sustainable commercial operation.

4. The next process is the manufacture of pelleted,

The functions of Pellet are :a. Reduce moisture to 3%,b. Calories more stable around 4200 kcal / kg,c. Easy to transport, andd. Overcome the deadlock problem in feeding hopper.

General problem


RDF as a biomass EnergySolutions in flow of RDF production process

Biomass in PT. Semen Indonesia (Persero) Tbk


Realization and target biomass consumption inPT. Semen Gresik (Persero) Tbk,

Source: Wartapedia.com/business/financial/



Roadmap and schedule for RDF utilization

Source: Department of Engineering, PT. Semen Indonesia (Persero) Tbk, 2013.



Schedule of old waste management for RDF plant project Waste to Zero Program for MSW,

Source: Department of Engineering, PT. Semen Indonesia (Persero) Tbk, 2013

CONCLUTION


The conclusions of this study on "Effective Thermal Utilization of Biomass for Cement Production" are as follows:

1. The functions of biomass utilization are energy conservation and reduction of fossil energy consumption by substitution of renewable energy for fossil fuels. Biomass can be sourced from Municipal Solid Waste (MSW), and in this case, it is called Refuse Derived Fuel (RDF). Any substance which is combustible and has a high gross heating value (GHV) can potentially serve as a solid fuel substitute.

2. The effective thermal concept for biomass fuels is to maintain relatively stable combustion of the fuel. A mixture of RDF with rice husks (agriculture waste) at a certain ratio is useful for controlling the moisture content of the fuel. Lowering the moisture content results in a higher fuel heating value.

3. To maintain the quality of calories, a mixing, drying, hardening, and controlling process will help stabilize the calorific and heat quality of alternative fuel. Prevention of foreign matter is prioritized. A drier-type moisture control system can keep the moisture content to a maximum 20%, Pelletizing can reduce moisture to 3%, realize a more stable heating value of around 4200 kcal/kg, and produce a fuel that is easy to transport and handle in the combustion transfer process in cement plants.


4. The principle of combustion implemented in the cement plant is co-processing. This concept has been proven to reduce demand for natural resources, reduce pollution, and save landfill space, thereby reducing environmental impacts.

5. Biomass and RDF are important for reducing CO2 by a) reducing CO2 emissions associated with conventional incineration of household waste and b) reducing CO2

emissions caused by burning fossil fuels, especially coal.

6. In direct economic terms, RDF is an expensive fuel due to the high cost of converting MSW to RDF, but RDF has greater environmental benefits, such as:

a. Conservation/reduction of non-renewable energy by utilization of waste as a solid fuel substitute in combustion processes.

b. Reduction of emissions by co-processing of MSW.c. Reduction of landfill space requirements.d. Compliance with national energy policy and energy saving regulations.e. Efforts within the framework of sustainable economics

CONCLUTION


Dōmo arigatō gozaimashitaTerima kasih banyak

Thank you very much

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Effective Thermal utilization of Biomass for Cement · PDF fileSemen Indonesia (Persero) Tbk. ... The conclusions of this study on "Effective Thermal Utilization of Biomass for Cement