WCT 2020

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Please complete the following document

Presentation title Factors that should be considerate while evaluating Basic

Design, CAPEX and Operation Efficiency of WHRG in
Cement Plant. Case of Semen Indonesia's Tuban WHRG
Plant
Short description On 2018 Waste Heat Recovery Generator (WHRG) are
(Maximum 200 words) installed in Tuban Plants, Tuban plant consist of 4 Clinker
lines which equipped with 8 boilers (SP & AQC Boiler) and
the superheated steam are transferred to 1 unit of Steam
Turbin Generator. Generated power are synchronized to The
grid in order to stabilize the fluctuation. Annual average
targeted power in Feasibility Study are 19.6 MW considering
operation days of 4 Clinker lines and wet/dry season
condition in Tuban, East Java.This article discuss about what
should we consider when developing a basic design of
WHRG and what are the risk to Economic Feasibility. This
paper will also stretch on evaluating the available waste gas
from more than 1 clinker line to be used by WHRG
Main description Some of key factors that significantly needs to be considerate
(Maximum 1000 words) during development of WHRG Basic Design in Tuban Plant
are discussed in this paper as follow :
1. Determine available waste gas on each clinker line
with the parameter such us Gas Flow, Inlet
Temperature, Outlet Temperature, Pressure Drop on
each Equipments, Dust Content on gas flow, Material
Abrasiveness, etc. Please also consider seasonal
kiln operation requirements and supply gas for
vertical cement mill on each line
2. Decide the best system for Turbine Generator
whether it use Steam Turbin or organic rankine cycle
or kalina cycle. Each system have advantage and
disadvantage we need to evaluate what is the best
option to be installed in our plant. In Tuban steam
turbine is selected.
3. Decide the optimum position of input/output Gas flow
of Boilers in Process Flow Diagram (PFD) which not
reduce The Kiln Capacity and must be able to be
controlled when there are any changing of kiln
operation condition.
4. Review and evaluated condition of existing Clinker
line equipments and utility condition in case of
Boilers on/off such as ID Fans, ESP, Main Filter, etc.
Including consider how we can control WHRG if
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there are any changes on raw material moisture, raw

Coal moisture.
5. Evaluate and determine Boiler Heat Exchanger type
(Vertical or Horizontal type) and Boiler Dust
Treatment type. It will be depend on Δ temperature,
pinch point temperature, dust load, abrasiveness of
dust.
6. Evaluate and determine effectiveness of Boiler’s
Tubing type such as bare or fin type. Need to
consider the available and required area for Boilers
and it will drive the Capex cost
7. Evaluate and determine quantity of Steam turbine
and review turbine generator efficiency
8. Evaluate and determine plot plan and location of
each Boilers, Pump House, Turbine Generator
building, Condensers, Utility equipments Piping
layouts in each line. Also need to consider
accessibility & maintenance access for WHRG
equipments and existing equipments.
9. Evaluate and determine the use of Boiler Collected
Dust and type of Dust transport system will be used
10. Evaluate and determine configuration of Boilers,
Boiler feed Pumps, Steam Turbine, Economizer and
type of steam turbine condensate condenser (air
cooled or water cooled) and plotted in the available
area. Define the Instrumentation and control
schematic Diagram. This decision will significantly
drive Capex and Opex of WHRG Facilities.
11. Review heat loss in Boilers, Superheated Steam
Piping system and system overall heat loss. This
information can be useful to prepare sensitivity
analysis during feasibility study
12. Evaluate and determine power generation scheme
whether synchronized or not synchronized with
National Grid. Electricity utilization and cost of
synchronization with national grid need to be
considerate
13. Finally Estimated total Capex Cost and run the
Feasibility analysis to get Go/ Not Go decision from
Board of Management
Company logo Minimum size: 200px X 100px
Please attached to email titled “CompanyLogo”
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Speakers

First name Irfan

Last name Zuchrufudin

Job title Sr. Process Design & Engineer
Image name
Email address (internal use only) Irfan.zuchrufudin@sig.id
Short Bio

Please provide an image of each speaker (minimum size 250px x 250px)

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Recommended length 25 – 30 minutes

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NARRATION

Slide
No
Slide Title Narration

- Hi everyone I am Irfan Zuchrufudin

from Semen Indonesia, It have been a
honor to be here with you today, you
are the executives, experts in Global
cement industry, every member of
reputable and big players of cement
and building materials industry. And
1 Presentation Title
before I start I would like to thank you
World Cement (Mr. David Bizley) for
giving me the opportunity to share with
you in this great occasion our
experience while developing Basic
Design of whrg plant in Tuban, East
Java Indonesia.

- Ok let me start with Semen Indonesia

at glance, Semen Indonesia is a public
listed company in Indonesian stock
exchange. 51.01% of its share are
belongs to government of Indonesia
and the rest of its share are public.
- Semen Indonesia is operate
integrated cement plant in 7 location in
Indonesia and we have a lot of
packing plants and some grinding
2 Semen Indonesia at Glance
plants. And to support the export
import activities we also have ports
- We also operate 1 integrated cement
plant in Vietnam and 1 grinding plant
in Ho Chi Minh city in south of vietnam
- In 2019 we achieve over 50% of
cement market share in Indonesia as
you can see in presentation slide.
- It make Semen Indonesia as market
leader in national cement industry.

- Semen Indonesia have 2 plant of

whrg, 1st plant is in Indarung and 2nd
Brief Introduction of Waste Heat plant is in Tuban
3 - As you can see in slide, typical
Recovery Generator (WHRG)
WHRG that use steam Turbine will
get the waste heat from preheater
gas and exhaust gas of the cooler.
Pg. 06 WCT 2020

Those waste gas will convert

circulated water to superheated
steam and turn on turbine generator
to produce electricity. And then
cooled again to water to be pumped
to boilers as circulated water.

- First in order to determine how many

power you can produce from your
waste gas you need to define :
Available waste gas, utility availability
Key factors to be considerate on including power distribution load
4
basic design of whrg …1 scheme and also site condition of the
plant.
- And as design criteria you need to
define codes and standart which be
applied in whrg the plant

- Second step is evaluate & decide the

best system for turbine generator, in
practical there are two different
system in whrg plant : Steam rankine
cycle (SRC) and organic rankine
cycle (ORC).
- Different between two system is SRC
is directly using superheated steam
Key factors to be considerate on
5 as fluid to turn on the generator but in
basic design of whrg …2
ORC system, waste gas will heat up
the thermal oil first and the thermal oil
will heat up the organic fluid to turn
on generator.
- In Tuban case the SRC system is
chosen due to we consider the
efficiency, running cost and
investment cost index.

- After you decide the system you

need to start with developing the PFD
of the whrg plant, you can
communicate with the supplier to
discuss what is the best configuration
Key factors to be considerate on based on their knowledge and
6
basic design of whrg …3 capability and of course you need to
consider how you anticipating
changing on kiln operation.
- The changes such as Flow gas
condition and power load need to be
considerate and controlled
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- In tuban case we control Bypass

Damper at inlet SP & AQC Boiler, CV
inlet steam Drum, bypass
superheated steam CV, Turbine
governor and speed of ACC fans

- In order to evaluate required area

and to get the optimum efficiency of
heat transfer in boilers we need to
contact Boilers manufacturers and
provide them with the PFD then
Boilers manufacturer will propose the
basic design of Boilers.
- In Tuban case for SP Boilers we use
Key factors to be considerate on
7 vertical type tube arrangement but for
basic design of whrg …4
AQC Boilers we use horizontal Tube
Arrangement due to efficiency and
availability of area.
- In this stage we need to discuss what
kind of dust removal system in
Boilers, Many of boilers manufacturer
develop hammering system
technology as shown in the slide

- On this slide I would like to address

one of the important aspect that need
to be decide in boilers specification.
- There are 2 type of boiler tube : Fin &
Bare tube as shown in the picture.
Key factors to be considerate on Bare tube is more cheaper than
8
basic design of whrg …5 Finned tube but the its heat transfer
efficiency also lower therefore we
need to evaluate what is the best
option for each Boiler.
- This specification will drive the Capex
cost.

- In 6th step we need to evaluate and

optimize our PFD in order to achieve
maximum generated power and
determine the control philosophy of
Key factors to be considerate on system.
9
basic design of whrg …6 - If required we can perform dynamic
analysis to get better understanding
when there are any changing in
design condition eg : Gas Flow,
Power load;
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- Using process simulation software

we can perform power generation
sensitivity analysis with accurately

- After PFD and Main Equipment

specification have been defined, we
can plot all main equipment in the
layout based on arrangements from
Key factors to be considerate on equipment manufacturers.
10
basic design of whrg …7 - In this stage Heat loss analysis,
accessibility of WHRG plant and
confirmation of maintenance access
of existing equipment need to be
confirmed.

- As we all know in cement plant,

waste gas from Kiln and cooler will
contain kiln dust and clinker dust, of
course this dust will need to be
removed from the boilers and
transport to specific location.
- In Tuban case dust from SP Boiler
are injected again to system after kiln
ID Fan due to budget consideration
Key factors to be considerate on
11 but for dust from Dust Settling
basic design of whrg …8
Chamber & AQC Boilers are
transported directly as product
Clinker.
- Decision for WHRG dust transport
system are depend on existing layout
and quantity of dust, sometimes we
found that location of cement mill is
far enough from kiln as in Tuban
case.

- Step 9th we come to most complex

activities in developing basic design
of WHRG plant, we have to
determine the configuration of
Boilers, Boilers feed pumps, Steam
Turbine, economizer and type of
Key factors to be considerate on
12 steam turbine condensate condenser
basic design of whrg …9
to be plotted in available area based
on knowledge and best practice of
reputable WHRG suppliers
- In this stage operation control
schematic and utility line schematic
diagram are also determined.
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- Last but not least we need to make

decision how we distribute the power
generated by WHRG, either it is
synchronize with national grid or we
can do it with standalone. We need to
compare operating scheme and risks
Key factors to be considerate on
13 of each option.
basic design of whrg …10
- For Tuban case synchronized with
national grid is chosen considering
optimum utilization of WHRG plant
and applicability to do the
performance guarantee test as seen
in the slide.

- Finally all the calculation, Basic

Design Data, Capex cost, Revenue /
cost saving estimation and risks need
to be evaluated in Economical
feasibility analysis to get Final
14 Go or not Go Decision
Investment Decision by the Board
(Management). In my opinion this is
Engineering state of art to pursue
cement plant competitive advantage
at once contribute to green industry.

- Herewith I enclosed pictures of

WHRG plant in Tuban to give you
perspective of Tuban WHRG. You
can see the SP Boiler beside the
preheater, you can see the AQC
15 Project Documentation Boiler near clinker cooler, and our
Steam Turbine Generator located
inside Turbine House. And beside the
turbine house we install air cooled
condenser as another option for
cooling tower.

- Okay thank you very much for having

attention to my presentation,
apologized if there any inconvenient
during this presentation, hopefully
16 Closing this could be useful for all of us and if
there are any discussion please don’t
hesitate to contact me via email or
linkedin.
- Terima Kasih …