Modifikasi Proses Pengolahan Boiler Feed Water (BFW) dari All Volatile Treatment (AVT) menjadi Oxygenated Treatment (OT) untuk Produksi Listrik Ramah Lingkungan

In power plant industries, boiler feed water (BFW) quality becomes the main parameter for steam generation, which is used for electricity production. To generate standard BFW for power plants, each impurity within water resources should be removed to prevent corrosion and scale deposition by several processes such as sedimentation, coagulation, polishing, and deaeration. Operation conditions that involved high temperature would trigger corrosion as a crucial factor in the maintenance and practical lifetime of the equipment. In the beginning of the operation, PT. Cirebon Electric Power (CEP) used All Volatile Treatment–Reduction (AVT-R) by injection of both ammonia and hydrazine. In order to optimize the operation, the BFW treatment was changed to All Volatile Treatment–Oxidation (AVT-O) that only uses of ammonia and deaerator for removing the dissolved gas. Based on the actual evaluation, AVT technology showed less performance related to corrosion prevention and high chemical consumption. Therefore, PT. CEP tried to implement modification in the BFW treatment, which is AVT technology to Oxygenated Treatment (OT). This paper is to evaluate the effect of those modifications on corrosion prevention and resource-energy saving. The modification into OT showed valuable results that decrease concentration of dissolved Fe from 1 ppb to 0.1 ppb in the deaerator outlet stream. This data reveals that good corrosion prevention can be achieved through the creation of passive layers, hematite Fe2O3. Oxygen injection into the water circulation system yielded an oxidation atmosphere so that the passive layer, Fe2O3, was formed. In addition to corrosion prevention, this modification also cut the amount of ammonia injection into the system from 2 ppm to 0.12 ppm. Reduction of that ammonia injection provides other benefits such as decreasing the volume of resin regeneration, which becomes only twice a month. This situation also created other benefits such as reducing the regeneration water, chemicals, and wastewater. Thus, the modification could establish the electricity production by PT. CEP more environmentally friendly and sustainable.A B S T R A KPada operasi PLTU, kualitas boiler feed water (BFW) menjadi parameter yang krusial untuk menghasilkan steam yang akan digunakan untuk memproduksi listrik. Untuk mendapatkan BFW sesuai dengan standar yang ada, maka pengotor di dalam air baku industri harus dihilangkan karena dapat menyebabkan korosi dan pembentukan kerak, baik pada pipa maupun peralatan. Kondisi operasi yang melibatkan steam pada suhu tinggi menyebabkan korosi menjadi masalah yang krusial terutama terkait dengan maintenance dan umur efektif pabrik. Pada awal berdirinya, PT. Cirebon Electric Power (CEP) menggunakan teknologi All Volatile Treatment–Reduction (AVT-R) dengan injeksi amonia dan hidrazin. Selanjutnya, dilakukan optimasi melalui perubahan proses menjadi All Volatile Treatment–Oxidation (AVT-O) dengan hanya menginjeksikan amonia dan mengoptimalkan fungsi deaerator untuk menghilangkan pengotor dissolved gas. Berdasarkan data lapangan, teknologi AVT yang digunakan kurang memberikan pencegahan korosi yang baik dan juga jumlah bahan kimia yang digunakan masih relatif banyak. Agar lebih ramah lingkungan dan handal, PT. CEP berusaha untuk melakukan modifikasi terhadap pengolahan boiler feed water (BFW) dari yang semula menggunakan teknologi AVT-O menjadi Oxygenated Treatment (OT). Penelitian ini bertujuan untuk mengevaluasi dampak modifikasi sistem AVT menjadi OT pada pencegahan korosi dan juga penghematan sumber daya. Modifikasi sistem AVT-O menjadi OT berhasil menurunkan konsentrasi dissolved Fe dari 1 ppb menjadi 0,1 ppb pada BFW. Hal ini menunjukkan terjadinya peningkatan pencegahan korosi melalui pembentukan double protective layer yang merupakan kombinasi magnetite (Fe3O4) dan hematite (Fe2O3). Injeksi oksigen ke dalam sistem mengubah kondisi air menjadi suasana oksidasi sehingga mampu mengubah dan membentuk lapisan baru sebagai pencegahan korosi. Selain pencegahan korosi, modifikasi ini juga berhasil menurunkan jumlah injeksi amonia dari 2 ppm menjadi 0,12 ppm dalam siklus air yang ada. Penurunan jumlah injeksi amonia ini akan memberikan keuntungan beruntun berupa berkurangnya frekuensi regenerasi resin dari semula 8 menjadi 2 kali perbulan. Kondisi ini akan menghasilkan penghematan sumber daya berupa kebutuhan air untuk regenerasi, bahan kimia amonia, dan beban pencemaran. Oleh karena itu, modifikasi ini telah membuat proses produksi listrik di PT. CEP lebih ramah lingkungan dan berkelanjutan.Kata kunci: All Volatile Treatment (AVT); efisiensi energi; korosi boiler; Oxygenated Treatment (OT)

Evaluasi Manfaat Penggantian Chemical Amine N1800 menjadi N1805 dalam rangka Pengurangan Jejak Karbon

Inovasi berkelanjutan pada alat dan atau proses di dalam industri kimia untuk mencapai efisiensi dan industri yang ramah lingkungan wajib dilakukan. Dalam mendukung hal ini PT. KMI melakukan modifikasi proses dengan mengganti bahan neutralizing amine yang digunakan pada sistem boiler feed water. Penggantian amine dilakukan pada pertengahan tahun 2017, dari amine N1800 menjadi N1805. Data konsumsi amine dan air pelarut tahun 2015-2020 digunakan sebagai dasar evaluasi. Estimasi jumlah emisi juga dilakukan dengan menghitung kebutuhan air pelarut, drum kontainer bahan amine dan juga transportasi bahan dari produsen ke PT. KMI. Dari hasil perhitungan, dapat disimpulkan bahwa penggantian bahan amine dari N1800 ke N1805 memberikan benefit yang baik, yaitu: (1) menurunkan biaya tahunan untuk konsumsi amine, (2) menurunkan kebutuhan air pelarut dan beban pencemar air dan (3) menurunkan emisi secara signifikan. Penurunan emisi sebagian besar berasal dari penghematan penggunaan drum kontainer dan transportasi, sedangkan dari penurunan penggunaan air kurang signifikan.

Performance Comparison of CPC based solar installations at different locations in India and analysis of variation pattern

Currently the industrial heat demand is met by using expensive fossil fuels. Exclusive use of solar energy is not feasible due to the fluctuating pattern of solar radiation intensity. Solar hybridization with the existing heating system can be an appropriate solution to meet the process heat requirement of many industries. Concentrator Solar Thermal (CST) technologies can generate the medium temperature heat required for industrial processes. The present study was undertaken with an objective of comparing and analyzing the designed performance of the solar fields using the Compound Parabolic Concentrator (CPC) technology against the actual measured performance values for boiler feed water preheating application at two different locations in India. The optical efficiency of the CPC collector, 64.8%, obtained when tested as per part 5 of IS 16648:2017 was used for designing the solar fields as per the daily heat requirement. The performance of the installations at both the locations was monitored for a period of five months. The observed variation in the performance of each installation than the designed performance was compared and analyzed for the causes. The average variation in designed and measured performance was in the range of 9.0% to 9.8% for location 1 and 2 respectively, attributing to heat rejection from the collector attachments and fluid transfer lines, dust effect on the absorber and reflector of CPC, instrument’s uncertainty, other losses due to shadow effect, vacuum loss from the tubes, dislocation of tubes, heat removal and usage pattern etc. The reasons of the losses from both the fields were of the similar nature, which should be taken into account to design a solar thermal system to achieve predicted performance near to the designed performance. Preheating of boiler feed water is one of the potential applications of solar CPC technology.

Perancangan Alat Total Dissolved Solid (TDS) Monitoring pada Air Boiler berbasis Mikrokontroler di Pabrik Kelapa Sawit Naga Sakti

Steam is a utility that have an essential function in palm oil production. Steam is mainly used in steam turbine to move the generator to produce electricity. Steam also has a lot of other functions such as heating cold oil in storage tank, heating coil in kernel drying, etc. Steam is produced in a machine called boiler. Boiler require a treated feed water as an input. To maintain boiler performance and lifetime, one need to control the TDS (Total Dissolved Solid) in boiler feed water in a range of 2100 2500 ppm. TDS is a parameter that shows the solid concentration which dissolved in the water. TDS has to be checked every hour to maintain its concentration controlled. In a practical use, TDS monitoring is a simple process but take a lot of time to proceed. Water from the sampling pipe collected in a bottle then cooled until room temperature. TDS from cooled boiler water then measured with a device called TDS meter. To control TDS value in the standard condition, the measurement time need to be reduced. Therefore, a faster method to measure TDS in boiler water is needed. An easier and faster measurement using a system which consisted of sensor, microcontroller, LCD display is one of the idea to reduce unneccessary measuring time. The development and experiment of this TDS monitoring device is situated in Nagasakti Palm Oil Mill, Riau Province, Indonesia.

Pencegahan Kerak Dan Korosi Umpan Ketel Uap Di PG Mojo Sragen

Air umpan ketel uap adalah air yang disuplai ke dalam ketel untuk di rubah menjadi uap. Air Umpan Ketel (Boiler Feed Water) Secara umum yang akan digunakan adalah air yang tidak mengandung unsur kalsium (Ca) yang dapat menyebabkan terjadinya endapan yang dapat membentuk kerak pada ketel uap, air yang tidak mengandung unsur yang dapat menyebabkan korosi terhadap ketel dan sistem penunjangnya dan juga tidak mengandung unsur yang dapat menyebabkan terjadinya pembusaan terhadap air ketel uap. Tujuan dari penelitian ini adalah untuk mengetahui pencegahan kerak dan korosi air umpan ketel uap dalam mendukung proses produksi gula agar proses produksi dapat berjalan dengan efektif di pabrik gula mojo sragen menggunakan cara pencegahan kerak dan korosi dengan internal water treatment dan external water treatment. Hasil yang diperoleh dari penelitian ini menunjukkan bahwa penyebab dari masalah pada ketel uap yoshimine dengan tekanan kerja 17kg/jam yaitu karena terbentuknya kerak di dalam ketel yang di sebabkan terutama oleh kalsium (Ca) dan magnesium (Mg) pada dinding pipa yang dapat menghambat proses penghantaran panas serta terjadinya korosi terhadap logam ketel, sepanjang aliran air umpan dan aliran kondensat yang disebabkan oleh gas oksigen yang terlarut dalam air dan solusinya dengan external water treatmen merupakan perawatan yang dilakukan terhadap air sebelum masuk kedalam ketel uap untuk menghilangkan kandungan mineral dan gas tertentu pada air dan internal water treatmen untuk menyempurnakan apa yang telah dilakukan oleh perawatan eksternal, sehingga masalah yang mungkin terjadi didalam ketel uap dan jalur kondensat dapat diminimalkan

Ethylene Yield from a Large Scale Naphtha Pyrolysis Cracking Utilizing Response Surface Methodology

Statistical software is a robust application that has proven reliable worldwide. However, it is not normally used in the actual large scale olefin plant as it relies on the simulation software by Olefin Licensor should any issue rises. The study was conducted in a newly commissioned large scale olefin plant to see the impact of various operating variables on the ethylene yield from Short Residence Time (SRT) VII Furnace. The analysis was conducted utilizing statistical analysis, Response Surface Methodology (RSM) in Minitab Software Version 18 to develop a reliable statistical model with a 95% confidence level. The historical data was taken from the Process Information Management System (PIMS) Software, PI Process Book Version 2015, and underwent both residuals and outliers removal prior to RSM analysis. 10 variables were shortlisted from the initial 15 identified variables in the studied SRT VII via Regression analysis due to RSM limitation to conduct the larger analysis in Minitab Software Version 18. The Response Optimizer tool showed that the ethylene yield from naphtha pyrolysis cracking in the studied plant could be maximized at 34.1% with control setting at 600.39 kg/ hr of Integral Burner Flow, 6.81% of Arch O2, 113.42 Barg of Steam Drum Pressure, 496.96°C of Super High Pressure (SHP) Temperature, 109.11 t/hr of SHP Boiler Feed Water (BFW) Flow, 92.78 t/hr of SHP Flow, 63.50 t/hr of Naphtha Feed Flow, and -13.38 mmHg of Draft Pressure.

EVALUASI PERFORMANCE REGENERASI MIXED BED POLISHER PADA UNIT DEMINERALISASI

One of the important elements produced from the factory support units is air products. Regional water balance (integration) is important to support factory operations. Raw water is treated in the unit section to produce demin water and further process into Boiler Feed Water (BWF) to produce 80 kg/cm2 pressurized steam in the boiler unit, to meet the specifications as demin water it is necessary to carry out several treatments to remove mineral ions (cations and anions) dissolved in the air. In the mixed bed polisher, there is a resin regeneration process to eliminate saturation of the resin which can no longer bind mineral ions. Regeneration or regent is carried out after the resin pile is saturated which is characterized by an increase in product productivity conductivity with the desired product conductivity target of <0.2 μS/cm at a temperature of 25℃. The purpose of this study was to work or perform a mixed bed polisher, especially during regeneration in the demineralization unit. This research was conducted by making a framework of thought and writing work. The writing stage contains data collection, data processing and data analysis-synthesis, as well as drawing conclusions. Based on this research, the results showed that there was a decrease in the performance of the mixed bed with a bed expansion gain of 80.7% and a resin height of 2.42 m. The number of chemicals used for regeneration is 1170.7 kg consisting of HCL and NaOH so that the flow rate of demin water required to dilute the regenerant is 7,126 m3/h. Keywords: Mixed bad Polisher, Demin water, Resin regeneration.