Peningkatan daya saing industri tekstil melalui konservasi energi bppt (full)

CENTER FOR ENERGY CONVERSION AND CONSERVATION
TECHNOLOGY
DR EDI HILMAWAN
PUSAT TEKNOLOGI KONVERSI DAN KONSERVASI ENERGI, BPPT
PENINGKATAN DAYA SAING INDUSTRI TEKSTIL MELALUI
KONSERVASI ENERGI
DISAMPAIKAN PADA SEMINAR NASIONAL TEKSTIL DAN BUSINESS
GATHERING 2014
BALAI BESAR TEKSTIL BANDUNG, 24 MARET 2014

PUSAT TEKNOLOGI KONVERSI DAN KONSERVASI ENERGI
OUTLINE
• Kondisi Keenergian Nasional
• Industri Tekstil dan Penggunaan Energinya
• Konservasi Energi di Industri Tekstil
• Manajemen Energi di Industri Tekstil
• Teknologi Konservasi Energi di Industri Tekstil
• Penutup

KONDISI KEENERGIAN NASIONAL
ENERGY SUPPLY - DEMAND
• Laju Pertumbuhan Kebutuhan Energi Primer 6,2%/yr
• Ketergantungan terhadap Bahan Bakar Fosil (95%)
(Diolah dari data Pusdatin - KESDM, 2011)
• Peningkatan Energi Final 5,6%/yr
• Sektor Industri dan Transportasi adalah
Pengguna Energi Terbesar
-
200
400
600
800
1.000
1.200
1.400
2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010
Millions
Geothermal Hydro Gas Oil Coal
-
100
200
300
400
500
600
700
800
900
Millions
Other Transportation Commercial
Households Non-Energy Industry
24%
47%
24%
4%
1%
Primary Energy Composition
Coal
Oil
Gas
Hydro
Geothermal
39%
11%10%
4%
32%
4% Final Energy User
Industry
Non-Energy
Households
Commercial
Transportation
Other

KONSUMSI ENERGI FINAL DI SEKTOR INDUSTRI
2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010
Listrik 20850 21819 22578 22373 24719 26021 26736 28077 29405 28323 31254
LPG 1073 972 1093 808 1101 1131 1453 1242 1124 955 1045
BBM 74979 78033 75690 68493 74718 64239 57203 52418 48856 49952 57602
Gas Bumi 59868 59050 54662 65127 60416 61537 58982 54837 62925 89101 85729
Briket 85 78 83 77 80 94 94 89 155 219 285
Batubara 36060 37021 38698 68264 55344 65744 89043 121904 74939 80466 136540
Biomasa 58981 55186 52305 50167 46917 43920 46676 42108 44235 44496 43302
0
50.000
100.000
150.000
200.000
250.000
300.000
350.000
400.000
Sumber: Pusdatin, KESDM
(RibuSBM)
pertumbuhan
2000-2010
50%
-3%
-23%
43%
235%
279%
-27%

CENTER FOR ENERGY CONVERSION AND
CONSERVATION TECHNOLOGY
5

PROYEKSI KEBUTUHAN ENERGI KE DEPAN
Konsumsi energi final tahun 2011
mencapai 1.044 juta SBM. Dengan
laju pertumbuhan GDP rata-rata
7,1% per tahun, kebutuhan energi
meningkat sekitar 4,7% per tahun
Perkiraan kebutuhan energi final
nasional tahun 2025 sekitar 1960 juta
SBM (2 kali lipat dalam kurun waktu
15 tahun) dan 2518 juta SBM di tahun
2030 (2,5 kali lipat dalam kurun
waktu 20 tahun).
Ketergantungan terhadap
Bahan Bakar Fosil masih tinggi
Sumber: BPPT Outlook Energi Indonesia 2013
Konsumsi energi terbesar ada di sektor
industri.
Meningkat dari 37% pada tahun 2011,
menjadi 41% di tahun 2015 dan 42% di
tahun 2025.
Proyeksi kebutuhan energi final per sektor pengguna
Proyeksi kebutuhan energi final per sektor pengguna
Sumber: BPPT Outlook Energi Indonesia 2013

INTENSITAS ENERGI INDUSTRI
Besi dan Baja
–Indonesia: 650 kWh/Ton
–India: 600 kWh/Ton
–Japan: 350 kWh/Ton
Semen
–Indonesia: 800 Kcal/kg clinker
–Jepang: 773 Kcal/kg clinker
Keramik
–Indonesia: 16,6 GJ/Ton
–Vietnam: 12,9 GJ/Ton
Gelas
Indonesia: 12 MJ/ton
Korea: 10 MJ/ton
Tekstil
Spinning
Indonesia: 9,59 GJ/Ton
India: 3,2 GJ/Ton
Weaving
Indonesia: 33 GJ/Ton
India: 31 GJ/Ton
Sumber: BPPT, Kemenperin

POHON INDUSTRI TPT

KONDISI INDUSTRI TPT NASIONAL
Tahun 2010
Tahun 2010

JUMLAH MESIN INDUSTRI USIA 20 TAHUN
Pemintalan Pertenunan Perajutan Finishing Pakaian
Jadi
64,40%
82,10% 84,10%
93,20%
78,00%
Jumlah Mesin Industri Usia 20 tahun

CENTER FOR ENERGY CONVERSION AND
CONSERVATION TECHNOLOGY
11

ENERGY FOOTPRINT INDUSTRI (EXP. INDUSTRI TEKSTIL)
Sumber: DOE – USA
Machine
Drives
Process
Cooling
Process
Heating

DISTRIBUSI PENGGUNAAN ENERGI DI INDUSTRI
Subsektor
Process
Heating
(%)
Process
Cooling
(%)
Machine
Drives
(%)
Makanan dan Minuman 75,0 8,5 16,5
Tekstil dan Pakaian 59,0 6,8 34,2
Kayu dan Mebel 80,4 0,5 19,1
Pulp dan Kertas 80,4 0,5 19,1
Pupuk dan Kimia 76,7 7,2 16,1
Karet dan Plastik 49,6 7,5 42,9
Keramik dan Gelas 90,5 0,9 8,6
Semen 87,8 0,3 11,9
Besi dan Baja 91,8 0,6 7,6
Peralatan dan Permesinan 51,9 4,8 43,3
Industri Lainnya 61,3 3,9 34,8
Sumber: DOE

POLA PEMAKAIAN ENERGI
Facilities
18%
Steam
28%
Motor
driven
systems
28%
Process
cooling
4%
Fired
heater
20%
Other
2%
Final Energy End-Use in the U.S.
Textile Industry
Pump; 19%
Fan; 14%
Compressed;
15%
Refrigeration;
7%
Materials
Handling;
11%
Materials
Processing;
31%
Other
Systems; 3%
Motor Systems Energy Use in the U.S.
Textile Industry

TYPICAL FINAL ENERGY USE IN SPINNING PLANT
78%
3%
3%
16%
Machines Compressors Lighting Humidification plant
7%
1%
5%
12% 11%
7%
20%
37%
0%
5%
10%
15%
20%
25%
30%
35%
40%

THERMAL ENERGY USE IN DYEING PLANT, AND WET PROCESS
Product
heating
16%
Product
drying
17%
Waste
water loss
25%
Heat
released
from
equipment
12%
Exhaust gas
loss
9%
Idling
4%
Evaporation
from liquid
surface
5%
Un-
recovered
condensate
4%
Loss during
condensate
recovery
1%
Others
7%
Breakdown of Thermal Energy Use in Dyeing
Plant
Product form /
Machine type
Process
Energy requirement
(GJ/ton output)
Desize unit Desizing 1.0–3.5
Kier Scouring/bleaching 6.0–7.5
J-box Scouring 6.5–10.0
Open width range Scouring/bleaching 3.0–7.0
Low energy steam
purge Scouring/bleaching 1.5–5.0
Jig/winch Scouring 5.0–7.0
Jig/winch Bleaching 3.0–6.5
Jig Dyeing 1.5–7.0
Winch Dyeing 6.0–17.0
Jet Dyeing 3.5–16.0
Beam Dyeing 7.5–12.5
Pad/batch Dyeing 1.5–4.5
Continuous/thermosol Dyeing 7.0–20.0
Rotary Screen Printing 2.5–8.5
Steam cylinders Drying 2.5–4.5
Stenter Drying 2.5–7.5
Stenter Heat setting 4.0–9.0
Package/yarn
Preparation/dyeing
(cotton) 5.0–18.0
Package/yarn
Preparation/dyeing
(polyester) 9.0–12.5
Continuous hank Scouring 3.0–5.0
Hank Dyeing 10.0–16.0
Hank Drying 4.5–6.5

TYPICAL ELECTRICITY AND THERMAL ENERGY USED IN A
COMPOSITE TEXTILE PLANT
Spinning (ring
spinning);
41%
Weaving
preparation;
5%
Weaving
preparation;
13%
Humidificatio
n; 19%
Wet-
processing;
10%
Lighting; 4%
Others; 8%
Typical Electricity Use in a Composite Textile Plant
Bleaching
and
finishing;
35%
Dyeing and
printing;
15%
Humidificat
ion, sizing
and others;
15%
Boiler plant
losses; 25%
Steam
distribution
losses; 10%
Typical Thermal Use in a Composite
Textile Plant

PENDEKATAN KONSERVASI ENERGI TERINTEGRASI
Energy
Conservati
on
Energy
Managem
ent
Energy
Efficiency
Improvem
ent
Energy
Efficient
Design
EXISTING SYSTEMNEW SYSTEM
Monitoring and
Control System
Operation and
Maintenance
Energy Efficiency
Standard
Low Energy
System Design
Energy Efficient
Technology
System
Optimization

PENDEKATAN KONSERVASI ENERGI TERINTEGRASI
Energy
Conservati
on
Energy
Managem
ent
Energy
Efficiency
Improvem
ent
Energy
Efficient
Design
NEW SYSTEM
Monitoring and
Control System
Operation and
Maintenance
Energy Efficiency
Standard
Low Energy
System Design
Energy Efficient
Technology
System
Optimization
Energy Management
Information System
Implementation of
ISO 50001 EnMS
Advanced Control
System
Low Energy Process
High Eff Furnace
Cogeneration
Regenerative Burners
Material Preheater
VSD for motors
etc ....
Pump System
Steam System
Waste heat Recovery
Compressed Air
Water Suppy System
Process Integration
COGENERATION
High eff Boiler
High eff Cooling System
High Eff Burner
High Eff Compressor
Green Industry

ISO 50001 ENERGY MANAGEMENT
• Management Participation
– Management Representative
– Energy Policy
– Management Review
• Energy Planning
Energy review, Significant Energy
User, EnPI, Baseline and Target,
Action Plan
20
• Control and Monitoring
–Nonconformities,
–correction, corrective and
preventive action
• Implementation and Operation
–Operational Control
–Maintenance Control
–Training and Socialization
–Energy Efficient Design
–Procurement

0 5Years
-25%
-20%
-15%
-10%
-5%
0
+5%
Costs
Biaya Tinggi
 Audit Energi
Tindakan Penghematan
Terkendali
Biaya naik lagi:
Kapan audit terakhir ?
Mulai
sekali lagi!
Manajemen Energi :
Pendekatan Konvensional vs Pendekatan Sistemik

PENDEKATAN SISTEMATIS
Komitmen Senior Manajemen
0 3Years
-20%
-25%
-15%
-10%
-5%
0
+5%
Costs
Investment
Penghematan Awal
Terjaga
Mulai dari housekeeping
 Investasi tinggi
Menjadi Budaya
Perusahaan

MANAJEMEN ENERGI : AUDIT ENERGI
• Audit energi adalah aktifitas yang dilakukan untuk
mengevaluasi pola penggunaan energi sebuah
sistem, baik itu berupa industri maupun bangunan,
guna mengidentifikasi peluang-peluang
penghematan yang dapat dilakukan.
• Audit Energi adalah bagian dari Manajemen Energi
• Sasaran
– Memperoleh Gambaran Pola Penggunaan Energi
• Fluktuasi Penggunaan Energi (faktor berpengaruh
• Neraca/Distribusi energi (input = output ?)
• Efisiensi Penggunaan Energi
– Mengidentifikasi sumber-sumber pemborosan
energi dan menyusun langkah-langkah
pencegahannya
• Waste Energy (reduce, reuse, recycle)
• Rasionalisasi dan optimalisasi penggunaan energi
– Dasar untuk melakukan peningkatan efisiensi
penggunaan energi
• Perbaikan manajemen operasi dan perawatan
peralatan konversi energi
• Reparasi alat dan retrofit
• Instalasi peralatan baru/teknologi hemat energi
PRELIMINARY
AUDIT
EFISIEN ?
MONITORING
DETIL AUDIT
REKOMENDASI
NO/LOW
COST
MEDIUM COST
HIGH COST
Implementasi
Feasibility
Study
REKOMENDASI
AWAL
Tidak
Ya

MANAJEMEN ENERGI: OPERATION AND MAINTENANCE
24
Fan masih menyala pada saat
mesin tidak beroperasi
Contoh Kasus: Stenter Machine
Motor beroperasi hanya
setengah dari daya terpasangnya
 Pemasangan inverter
Sumber: JICA – BPPT Study (2008)
Pabrik A
Pabrik B

25
Contoh Kasus: Cylinder Dryer
Temp Silinder rendah, distribusi
uap tidak merata, kondensat tidak
terbuang dengan baik
Temp kain turun,
Pemanasan kurang efektif,
Pemborosan Uap

26
Contoh Kasus: Washing Machine
TDS di bak 2 rendah, Indikasi
kebanyakan air,
Temp rendah, PH terjaga tinggi
Sistem individu, air limbah dibuang
Sistem Counterflow
Kontrol temperatur

MANAJEMEN ENERGI: PERFORMANCE MONITORING
• Regresi Linier : Konsumsi energi vs faktor yang mempengaruhi
(ex. Produksi vs Electricity)
y = 3,3272x + 4784,8
R² = 0,71
0
20.000
40.000
60.000
80.000
100.000
120.000
140.000
160.000
0 10.000 20.000 30.000 40.000
Electricity[kWh]
Production
Electricity vs Production
Y = 3,3272 X + 4784,8
Slope
Intercept = Baseload
Baseload menunjukkan konsumsi energi
ketika tidak ada produksi
Seharusnya nol !
 Hindari penggunaan energi saat tidak
berproduksi
Persamaan regresi dapat juga digunakan sebagai :
• baseline untuk menentukan target (persamaan baru)
• Tool untuk monitor kinerja energi,
baseline
target
Regresi lainnya : Multivariable regression (Y = b + a1 X1 + a2 X2 + ...)
Polynomial regression, Non Linier Regression
Gunakan metoda paling sederhana dan mudah diterapkan

(SPINNING PLANT)
Annual Electricity Consumption
- 2011 : 25.061.873
- 2012 : 26.169.520
Cummulative Saving
- Baseline 2011 :
- Per Des 2012 : 1.551.140 (5,6%)
- Per Agustus 2013 : 3.056.024 (6,4%)
- Baseline 2012 :
- Per Agustus 2013 : 441.099
(2,4%)

(FINISHING PLANT)
Annual Steam Consumption (ton)
- 2011 : 111.311
- 2012 : 114.552
Cummulative Saving
- Baseline 2011 :
- Per Des 2012 : 38.140 (25,0%)
- Per Agustus 2013 : 105.796 (37,8%)
- Baseline 2012 :
- Per Agustus 2013 : 9.089
(13,2%)
Sumber: UNIDO Pilot Project (2013)

ENERGY EFFICIENCY IMPROVEMENT
A. Application of Energy Efficient Technology
• High Efficiency Energy Conversion Technology
– Boiler, Power Generation, Air Compressor,
Cogeneration System, etc
• Low Energy Consumption Process Equipment
– (Process Specific for each industries)
• Waste Heat Recovery Equipment
– WHRB, Economizer, Preheater, etc
• Energy and Process Management
– Process Automation
– Energy Monitoring and Control System
• Renewable Energy
– Biomass
– Geothermal
B. System Optimization
• Electrical System, HVAC System, Steam System,
Pump System, Compressed Air system, etc
• Process Integration
30

EE TECHNOLOGY IN SPINNING AND WEAVING PROCESS
no Technologies Electricity Saving Installation Cost
Preparasi
1 High Speed Carding Machine
Ring Frame
2 The use of lighter spindle 23 MWh/year/ring frame 13,500 /ring frame
3 Installation of energy-efficient motor 6.3 -18.83 MWh/year/motor 1950 - 2200 /motor
4 The use of light weight bobbins 10.8 MWh/year/ring frame 660 /ring frame
Windings, Doubling, and finishing process
5 Installation of Variable Frequency Drive on Autoconer
machine
331.2 MWh/year/plant 19500/plant
6 Replacing the Electrical heating system with steam
heating system for the yarn polishing machine
19.5 MWh/year/machine 980/ humidification
plant
Air conditioning and Humidification system
7 Installation of Variable Frequency Drive (VFD) for
washer pump motor, Humidification System Fan Motor,
Humidification system Pumps
20 MWh/year/humidification
plant
1100/ humidification
plant

EE TECHNOLOGY IN SPINNING AND WEAVING PROCESS
no Technologies Electricity Saving Installation Cost
8 Replacement of the existing Aluminium alloy fan
impellers with high efficiency F.R.P (Fiberglass
Reinforced Plastic) impellers in humidification fans and
cooling tower fans
55.5 MWh/year/fan 650/ fan
General
9 Replacement of Ordinary ‘V – Belts’ by Cogged ‘V –
Belts’
1.5 MWh/year/belt 12.2/belt
Weaving Process
10 Energy efficiency of compressed air system in the Air-
jet weaving plant
US$440,000 /year (for 500 air
jet looms)

EE TECHNOLOGY IN WET PROCESS
no Technologies Energy Saving Installation Cost
Preparasi
Cold-Pad-Batch pretreatment 38% of fuel use
50% of electricity use
Bleach bath recovery system ** US$38,500 -US$118,400 saving 80000 -246,000
Use of Counter-flow Current for washing 41% - 62% of washing energy
use
Dyeing and Printing Process
Installation of Variable Frequency Drive on pump
motor of Top dyeing machines
26.9 MWh/year/machine 3100 /machine
Cold-Pad-Batch dyeing system 1215000/ system
Single-rope flow dyeing machines 2.5 kg steam /kg fabric
0.16 - 0.20 kWh/kg fabric
Microwave dyeing equipment 96% fuel saving
90% electricity saving
450000/ machine
Use of steam coil instead of direct steam heating in
batch dyeing machines (Winch and Jigger)
4580 GJ/year/plant 165500/plant
Heat recovery of hot waste water in Autoclave 554 MJ/batch product

EE TECHNOLOGY IN DRYING AND FINISHING
no Technologies Energy Saving Installation Cost
Drying
Introduce Mechanical Pre-drying
Avoid Overdrying, intermediate drying
Recover Condensate and Flash Steam
The use of Low Pressure Microwave drying machine
for bobbin drying instead of dry-steam heater
107 kWh/tonne yarn 500000/plant
High-frequency reduced-pressure dryer for bobbin
drying after dyeing process
200 kWh/tonne product 500000/machine
Finishing
Conversion of Thermic Fluid heating system to Direct
Gas Firing system in Stenters and dryers
11000 GJ/year/plant
120 MWh/year/plant
50000/plant
Introduce Mechanical De-watering or Contact Drying
Before Stenter
13% - 50% of stenter energy use
Optimize exhaust humidity in stenter 670 GJ/year US$600
Install heat recovery equipment in stenter 30% energy saving US$77,000 to
US$460,000
General
The recovery of condensate in wet-processing plants
Heat recovery from the air compressors for use in
drying woven nylon nets

CROSS CUTTING TECHNOLOGY
• Electrical demand control
• Energy-efficiency improvement opportunities in electric
motors
• Energy-efficiency improvement opportunities in
compressed air systems
• Energy-efficiency improvement opportunities in pumping
systems
• Energy-efficiency improvement opportunities in fan
systems
• Energy-efficiency improvement opportunities in lighting
system
• Energy-efficiency improvement opportunities in steam
systems

CONTOH KASUS :
PENERAPAN HIGH EFFICIENT COMPRESSOR DI INDUSTRI TEKSTIL
36
Investment Cost (Rp) 180.000.000,-
Equipment & Installation 180.000.000,-
Benefit (Rp/Year) 580.500.000,-
Net Electricity Saving 580.500.000,-
Simple Pay Back (year) 0,31
Electricty Consumption
Old : 32 kWh/bale
New : 19 kWh/bale

CONTOH KASUS :
PENERAPAN TEKNOLOGI MICROTURBIN COGENERATION DI PABRIK LAMPU
* Operasi 8 jam/hr
before
after
Equipment
Installation
498.750.000,-
142.500.000,-
Net Electricity Saving* 116.000.000,-

OPTIMASI SISTEM : PUMP SYSTEM OPTIMIZATION
38
Sumber (UNIDO)

ENERGY EFFICIENT DESIGN : ENERGY EFFICIENCY STANDARD
• Energy Performance Standard for Equipments
(High Energy Perfomance Standard, Minimum
Energy Performance Standard)
– Boiler
– Motor
– Air Conditioner
– Compressor
– Pumps
– Lamps
• Energy Performance Standard for System
– Green Industry
– Green Building
39
EU
Thailand
Cina
Hong kong
India
Malaysia
Using Energy Efficiency Standard as
reference to purchase new equipments
and/or design new system

ENERGY EFFICIENT DESIGN : COGENERATION
• Cogeneration is a thermal energy
conversion system that simultaneously
produce electricity and heat at the
same time
• Another term: Combined Heat and
Power, CHP
C65
C65
C65
C65
C65
C65
C65
C65
C65
C65
C65
C65
C65
C65
C65
C65
Ads Chiller
180 TR
Ads Chiller
180 TR
Ads Chiller
180 TR
ELECTRICAL LOAD
COOLING LOAD
HOT WATER
C65
C65
Microturbine
MT + CHP module
Electrical Line
Flue Gas Line
Hot Water Line
Chilled Water Line
Multi Pack
Eff 35%
Eff 80%
Trigeneration Application of Microturbine
Cogenerations in a Commercial Building

ENERGY EFFICIENT DESIGN : PROCESS INTEGRATION IN INDUSTRY
Process Integration
Optimizing waste heat
utilization to
minimize needs of
hot and/or cold
utilities

PENDEKATAN LIFE CYCLE COST UNTUK PENILAIAN INVESTASI
Proyek Efisiensi Energi harus mampu menghitung semua
keuntungan/penghematan yang diperoleh terhadap biaya-biaya yang
timbul akibat proyek tersebut.
Keuntungan (benefit) dalam proyek efisiensi energi mencakup
•Keuntungan secara finansial
•Keuntungan dalam penghematan penggunaan energi
•Keuntungan secara lingkungan (biaya eksternal)
•Peningkatan produktifitas akibat meningkatnya efisiensi dan
manajemen operasi dan perawatan peralatan yang optimal
Biaya-biaya dalam proyek efisiensi energi mencakup
•Biaya Langsung Proyek (Direct project cost)
•Biaya tambahan Operasi dan Perawatan (Additional operations and
maintenance cost)
•Capacity Building Cost (Training of personnel on new technology etc.)
Penilaian Investasi mencakup :
•Simple Payback Period (PBP)
•Return on Investmen (RoI)
•Net Present Value (NPV)
•Internal Rate of Return (IRR)
Investasi
Ops
Ops
Ops
Ops
Disposal
Investasi
Ops
Disposal
Ops
Ops
Ops
Live Cycle Cost Analysis
benefit
TotalCost
Existing New

PENUTUP
• Pendekatan Konservasi Energi di Industri tekstil harus
dilakukan secara sistematik dan terintegrasi, mulai dari
manajemen energi, penerapan teknologi efisien dan optimasi
sistem, disain dan pengadaan sistem baru yang hemat energi
• Penerapan Manajemen Energi berbasis SNI ISO 50001 terbukti
mampu mengendalikan dan menurunkan konsumsi energi
secara berkelanjutan, dimulai dari pembenahan manajemen
operasional dan perawatan peralatan
• Penerapan standard minimum efisiensi dan pendekatan Life
Cycle Cost Analysis perlu dilakukan untuk pengadaan
peralatan-peralatan baru untuk pabrik
43

TERIMA KASIH
Contact
Dr Edi Hilmawan
Ka Bidang Konservasi Energi,
Pusat Teknologi Konversi dan
Konservasi Energi, BPPT
HP : 081380731007
Email : hilmi0374@yahoo.com

REFERENSI

Name : Dr Edi Hilmawan .
Place/Date of Birth : Malang, 10 Maret 1974
Contact : 081380731007 (HP)
hilmi0374@yahoo.com
Current Job :
Head of Energy Conservation Division,
Center for Energy Conversion and Conservation Technology,
Agency for Assessment and Application of Technology (PTKKE-BPPT)
Expertise/Specialization :
Process and Chemical Engineer, Heat Transfer and Energy Analyst, Thermodynamics,
System Analysis and Optimization
Last Academic Achievement :
Doctor of Engineering from Graduate School of Natural Science and Technology, Kanazawa
University, Japan (2001)
Work Experiences (2002-now)
• Project Director/Chief Engineer/Engineer in several energy related projects
• Instructur of Energy Management Trainings
• Lead Consultant on Energy Efficiency Consultation Projects
• Lead Energy Auditors on Industries and Commercial Buildings

CONTOH KASUS :
PENERAPAN HIGH EFFICIENT COMPRESSOR DI INDUSTRI TEKSTIL
48
Equipment & Installation 180.000.000,-
Net Electricity Saving 580.500.000,-
Electricty Consumption
Old : 32 kWh/bale
New : 19 kWh/bale

POTENSI PENGHEMATAN ENERGI DI INDUSTRI
52

PENGHEMATAN ENERGI SEKTOR INDUSTRI
(SKENARIO RENDAH DAN TINGGI)
Skenario
Penghematan (juta SBM)
2010 2015 2020 2025
Konservasi Rendah 2.05 17.48 46.45 99.74
Konservasi Sedang 4.09 34.95 92.90 199.48
Konservasi Tinggi 6.14 52.43 139.34 299.22
(BPPT, 2011)

POTENSI PENGHEMATAN ENERGI INDUSTRI TEKSTIL
• Penghematan energi industri tekstil sebesar 40 juta SBM pada tahun 2030
atau sebesar38%.
• Total Listrik yang bisa dihemat 2010 – 2030 adalah 19,6 TWh atau setara
dengan daya pembangkit 2,8 GW pada tahun 2030.
• Kumulatif penghematan energi final non listrik 2010 – 2030 adalah
sebesar 170 juta SBM atau setara dengan 6,5 bulan lifting minyak sebesar
0,9 juta SBM per hari

ISO 50001 ENERGY MANAGEMENT STANDARD
• Based on the PDCA concept Source ISO50001:2011

MANAGEMENT RESPONSIBILITY
• Is the top management really
comitted?
• Will you support the system?
• This is a decision point!
• If not, we can all go for more coffee
now!
• Will you make the necessary
resources available (technical,
financial and human)
• We assume you will if you believe
there is an adaquate return on your
effort or investment

POLICY
• Management commitment
• Not just a signature!
• Define scope of EnMS
• Appropriate to scale
• Commitment to continual
improvement
• Make resources available
• Framework for target
setting and review
organizations

PLANNING
• How much energy are you using?
• Where are you using it?
– Which are the biggest users?
• What is driving this use?
• What is your baseload?
• Who is influencing its use?
• Is an energy audit required – focus it?
• System Optimization
• Renewable energy options
• Develop baseline & indicators
• Set objectives and targets
• Action Plan

IMPLEMENTATION & OPERATION
• Competence, training and awareness
• Documentation
• Operational control
• KEY AREA
• Operation & Maintenance
• Service contractors
• Training
• Implement your action plan
• Communication
• Design
– Energy Efficient Design (EED)
• Purchasing energy, services, goods

CHECKING
 Technical checking
• Monitoring and targeting
(software may be justifiable?)
• Equipment checking
 System checking
• Is everyone doing what is
required?
• Corrective and preventive action
• Non-conformities
 Performance checking
• Check Energy Performance
Indicators (EnPIs)

MANAGEMENT REVIEW
• Regular presentation
• Frequency based on
requirements
• How are we getting on?
• Is performance improving as
targeted?
• Problems and barriers to
overcome?
• Achievements
• What is the plan for next
year?
• What do we need to achieve
this plan?

YOU’RE NOT FINISHED – THIS IS NOT A PROJECT!
• Then
• you
• start
• all
• over
• again!!

ENERGY MANAGEMENT SYSTEM ISO 5001
STEP 1. TOP MANAGEMENT COMMITMENT
Komitmen manajemen
• Menunjuk MR
• Membentuk tim
• Membuat policy

STEP 2. PLANNING
Planning:
•Analisis Data Energi
•Identifikasi Pengguna Energi
Signifikan (SEUs)
•Tetapkan Faktor Pendorong
•Tetapkan Indikator Kinerja Energi,
Baseload, Baseline
•Identifikasi Peluang Perbaikan
•Tetapkan Tujuan dan Target
•Susun Rencana Aksi

STEP 3. IMPLEMENTATION OPERATION & CHECKING
Implementation:
•Competence, training and awareness
•Documentation
•Operational Control
•Communication
•Design
•Purchasement
Checking:
•Check Operations
• Operator record, maintenance
record, equipment checking
•Check the System
•Check Performance
• EnPIs, Trends, cost
•Check Progress
• Against plans

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