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Reference FSDPs
(EC-ASEAN COGEN Programme Phase II)
An efficient wood waste-fired boiler for a plymill (Indonesia)
BACKGROUND
 Being an integrated plywood manufacturer with around 850 cubic meters of log input per day, KMPI produces huge amounts of residues. In the past, these residues have been used as fuel for three boilers producing steam for the heat requirements of the mill. However, the boilers are currently operating inefficiently, some of them at low pressure, not to mention their poor environmental performance. Wanting to abide by the Indonesian government’s call for cleaner air emissions by industry, and to be able to generate electricity to cover its full power requirements, KMPI invested in a new, higher pressure boiler. Coupled with its existing turbo-generator, the energy plant is expected to produce enough power for the mill and meet strict environmental standards.
LOCATION
The power plant is located in Pulau Borang, Palembang, Sumatra, Indonesia.
TECHNOLOGY
The plant consists of a wood waste-fired boiler with a capacity of 35 tonnes per hour at 35 bar g and 380 deg C superheated steam, coupled to an existing 3.2 MW fully condensing steam turbine.
SOME ECONOMICS
The total cost for the complete wood waste-fired water tube boiler system is around ECU 1,333,000 (US$ 1,600,000), excluding civil works. Based on the present diesel consumption and price, the annual savings in diesel purchase will be more than ECU 1 million (US$ 1.2 million). The expected pay back time of the plant is just over 1 year after commissioning.
CONTACTS
Customer |
European Supplier |
PT Kurnia Musi Plywood Industries (Indonesia)
Tel:(62-711) 311489; Fax: (62-711) 311331 |
Aalborg Boilers/Aalborg Industries (Denmark)
c/o PT Aalborg Sunrod (Indonesia)
Tel: (62-21) 4610569; Fax: (62-21) 46110568 |
CUSTOMER'S VIEW POINT
 "PT KMPI is a member of Priosoetanto International Corporation (PIC), explains Sapta Tandi, Director. The core business of PIC is wood processing, with some other business interests in real estate, mining and plantations. Our mission, particularly at KMPI, is to maximise the utilisation of the raw material resources by improving recovery, efficiency of operation and cost control. We are able to do this because of the fact that PIC is totally vertically integrated in the wood industry. Sister companies of PT KMPI are involved in forest plantations, logging, sawmilling, wood working and furniture. These activities support PT KMPI as a plywood manufacturer for its raw material supply and end-product usage."
PT KMPI and Aalborg have had a long business relationship," pursues Herman Tan, Plant Manager. The purchase of the equipment from Aalborg instead of other suppliers was due to the confidence that Aalborg would supply a modem, efficient and reliable boiler, which would be easy to operate and maintain. We expect some benefits such as saving in fuel cost, efficiency of operation and less pollution from the stack. We also expect to achieve savings in electricity consumption, as the steam will be used to run our existing turbine at full load.
The training of our boiler operators, which is supported by the COGEN Programme will also help educate them on how to operate a modem automatic boiler."The COGEN Programme has also helped in providing technical advice on how to achieve better efficiency and cost savings in electricity generation," concludes Sapta Tandi.
SUPPLIER'S VIEW POINT
 Our company, PT Aalborg Sunrod Indonesia, a member of the Aalborg Industries Group from Denmark, started its activities in Indonesia in 1987 and was fully established in 1991, explains Knud B. Bach, Managing Director of PT Aalborg Sunrod Indonesia. Our main activities are manufacturing of waste heat recovery boilers and of conventional gas, oil or biomass-fired boilers.
Aalborg Boilers Denmark supported by PT Aalborg Sunrod Indonesia has already installed more than 50 waste heat recovery boilers in Indonesia ranging from 1 to 220 tonnes of steam per hour. We produce under license from Aalborg Boilers Denmark. This includes basic design and technical support. This guarantees a high product quality, but at a reasonable cost as most of the labour intensive parts are manufactured locally. We are not the cheapest in the market, but we are on top when it comes to the quality/price ratio. Moreover, our local presence secures a reliable and fast after sales service.
 Another key-service that we offer is repair and rehabilitation of existing boilers,pursues Niels Nissen, Technical Advisor. In the case of KMPI, during the late 80s, we even commissioned a boiler that had been supplied by a competitor. This service was very much appreciated by our customer and it built up a strong relationship of trust between us. Also, we convert boilers, for example, from using conventional fuel to using biomass.
We can upgrade the boiler capacity by adding a membrane wall furnace and an economiser."Given the integration of the wood working activities of the PIC Group, less residues than usual are generated. Thus, there is a need to use high efficiency boilers to cover all energy requirements. We are confident that the new boiler will be properly operated by the KMPI staff, especially thanks to the training support from the COGEN Programme, concludes Knud Bach.
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