Case Study of Biomass and Energy Efficiency in Cocoa ...foodreview.co.id/seminarsept18/Sindra Wijaya...
Transcript of Case Study of Biomass and Energy Efficiency in Cocoa ...foodreview.co.id/seminarsept18/Sindra Wijaya...
Case Study of Biomass and Energy Efficiency in Cocoa Processing Industry
Sindra Wijaya, SE
Director
PT. Bumitangerang Mesindotama ( BT Cocoa )
Pendahuluan
• Efisiensi pada dasarnya sangat diperlukan di semua
perusahaan untuk menghadapi persaingan global,
terlebih pada industri kakao yang profit marginnya tipis.
• Kebutuhan gas di BT Cocoa sekitar 500,000 m3 per
bulan.
• BT menggunakan Vyncke Steam Boiler kapasitas 10
ton/jam.
• Bahan bakarnya menggunakan cocoa shell (kulit biji
kakao)
Indonesia
$ 7.50
Mexico (N/A)
Argentina (N/A)
(16.5 Milion TPA)
(115.8 Million TPA)
(7.6 Million TPA)
(8.4 Million TPA)
(26.2 Million TPA)
(2.3 Million TPA)
Brazil (0.2 Million TPA)
USA(68.5 Million TPA)
Canada(9.5 Million TPA)
Spain (N/A)
(0.6 Million TPA)
Legend(....) = Kapasitas produksi berbagai
produk PetrokimiaTPA= Ton Per Annual
HARGA GAS BUMI DUNIA (Mei 2016)
3HARGA GAS DI INDONESIA TERTINGGI DI DUNIA !
Penetapan Tarif Gas
di Tangerang - Banten
PemasokTarif
(USD/MMBTU)%
Rata-rata(USD/MMBTU)
PGN 7.56 75% 5.67
Pertagas 16.70 25% 4.18
Rata-rata 100% 9.85
Untuk industri yang pemakaian gasnya besar PGN mewajibkan
menggunakan Pertagas sekitar 25% dari total pemakaian. Dengan
alasan PGN kekurangan pasokan gas. ( Hingga tahun 2016 )
Perbandingan Harga Gas
di Industri Kakao
Negara Tarif GasPer mmbtu
Indonesia Usd 9.85
Malaysia Usd 6.2
Singapura Usd 5.3
Note : Tingginya harga gas menyebabkan daya saing
industri kita kalah dibanding negara lain.
Jokowi Instruksikan Harga Gas
Turun Jadi US$5-US$6 per MMBTUChristie Stefanie, CNN Indonesia | Selasa, 04/10/2016 16:30 WIB
Presiden Joko Widodo menginstruksikan penurunan harga gas untuk industri
nasional antara US$5-US$6 per Million Metric British Thermal Unit (MMBTU).
(REUTERS/Mark Schiefelbein).
Jakarta, CNN Indonesia -- Presiden Joko Widodo menginstruksikan penurunan
harga gas untuk industri nasional antara US$5-US$6 per Million Metric British
Thermal Unit (MMBTU). Instruksi itu diberikan karena harga gas untuk industri
di Indonesia tergolong tinggi, bahkan tertinggi di Asia Tenggara.
"Saya kemarin hitung-hitungan, kira-kira US$5-6 per MMBTU. Syukur di bawah
itu," kata Jokowi di Kantor Presiden, Selasa (4/10).
https://www.cnnindonesia.com/ekonomi/20161004161920-85-163252/jokowi-instruksikan-harga-gas-turun-jadi-us-5-us-
6-per-mmbtu
Sektor industri yang diusulkan mendapat penurunan
harga gas :
1. Pupuk
2. Petrokimia
3. Baja
4. Keramik
5. Kaca
6. Sarung tangan karet
7. Tekstil
8. Alas Kaki
9. Pulp & Kertas
10.Makanan/Minuman
Sektor industri yang mendapat penurunan harga gas :
1. Pupuk
2. Petrokimia
3. BajaBUMN
• Gagalnya mendapat penurunan harga gas dari
pemerintah, membuat kami terus berupaya untuk
meningkatkan efisiensi.
• Tahun 2017 kami menggunakan jasa dari Forbes
Marshall Indonesia untuk membenahi jalur steam dan
boiler di pabrik agar lebih efisien.
Energy requirements biomass unit Natural Gas unit
Average energy output boiler 12.00 Gcal/h 12.00 Gcal/h
13.92 MW 13.92 MW
50.23 GJ/h 50.23 GJ/h
Efficiency boiler 87% % 85% %
Average energy input boiler 13.79 Gcal/h 14.12 Gcal/h
16.00 MW 16.00 MW
57.74 GJ/h 59.10 GJ/h
Hours per day of boileroperation 24 h 24 h
Days per year of boileroperation 330 d 330 d
Hours per year of boileroperation 8,000 h/y 8,000 h/y
Caloric value of fuel 4,200 kcal/kg 9,000 kcal/l
17,581 kJ/kg-m³-l 37,674 kJ/l
YEARLY ENERGY OUTPUT 110.2 GWh 110.2 GWh
Investment Cocoa Shell Natural Gas unit
Off-shore (Vyncke) portion 1,600,000 EUR 0 EUR
0 RM
On-shore (local) portion 100,000 EUR 0 RM
Other (civil works, transport, etc) 100,000 EUR 0 RM
TOTAL INVESTMENT COST 1,800,000 EUR 0 RM
Investment parameters Cocoa Shell Natural Gas unit
Down-payment period cashloan 5 y 3 y
Interest rate cash loan 5.0% % 0.0% %
Operational costs Cocoa Shell Natural Gas unit
Average yearly interest cost (loan) 63,539 EUR/Y 0 EUR/Y
Yearly intrest costs 63,539 EUR/Y 0 EUR/Y
Average consumption per hour of fuel 1.900 ton/h 720 m3/hr
Average consumption per year of fuel 15,200 ton/year 5,760,000 m3/year
Purchase price fuel 1,200 Rp/kg 6,000 Rp/ton
Purchase price fuel 101.74 EUR/ton 0.51 EUR/m3
annual fuel cost 1,546,405 EUR/year 2,930,030 EUR/y
Installed electrical capacity installation 150 kW 30 kW
Average electrical load 100% % 100% %
Yearly electricity consumption 1,188,000 kWh 237,600 kWh
Electricity price (average) 0.058 EUR/kWh 0.058 EUR/kWh
Total yearly electricity costs 68,489 EUR/y 13,698 EUR/y
Yearly spare part costs boiler 48,000 EUR/y 9,000 EUR/y
Yearly spare part costs fluegascleaning 0 EUR/y 0 EUR/y
Total yearly spare part costs 48,000 EUR/y 9,000 EUR/y
Manhours per day for boileroperation and cleaning 24 manhour/d 0.0 manhour/d
Manhours per year for boileroperation and cleaning 7,920 manhours/y 0 manhours/y
Labor costs per manhour 0.22 EUR/h 0.22 EUR/h
Yearly manhours costs 1,742 EUR/Y 0 EUR/Y
Yearly costs of boilerapproval 0 EUR/Y 0 EUR/Y
Yearly costs of measuring CO, NOX, … 0 0 EUR/Y
Yearly costs of measuring dioxines 0 0 EUR/Y
Yearly measurem. costs 0 0 EUR/Y
YEARLY OPERATIONAL COSTS 1,728,176 2,952,728 EUR/Y
Investment analysis biomass vs NG unit
Yearly savings operational costs 1,224,552 EUR/Y
Additional investment cost 1,800,000 EUR
PAY BACK PERIOD 1.47 y
INVESTMENT ANALYSIS BIOMASS FIRED STEAM GENERATOR
FOR BT COCOA
Energy requirements Cocoa Shell unit Solar unit
Average energy output boiler 12.00 Gcal/h 12.00 Gcal/h
13.92 MW 13.92 MW
50.23 GJ/h 50.23 GJ/h
Efficiency boiler 87% % 85% %
Average energy input boiler 13.79 Gcal/h 14.12 Gcal/h
16.00 MW 16.00 MW
57.74 GJ/h 59.10 GJ/h
Hours per day of boileroperation 24 h 24 h
Days per year of boileroperation 330 d 330 d
Hours per year of boileroperation 8,000 h/y 8,000 h/y
Caloric value of fuel 4,200 kcal/kg 9,000 kcal/l
17,581 kJ/kg-m³-l 37,674 kJ/l
YEARLY ENERGY OUTPUT 110.2 GWh 110.2 GWh
Investment Cocoa Shell Solar unit
Off-shore (Vyncke) portion 1,600,000 EUR 0 EUR
0 RM
On-shore (local) portion 100,000 EUR 0 RM
Other (civil works, transport, etc) 100,000 EUR 0 RM
TOTAL INVESTMENT COST 1,800,000 EUR 0 RM
Investment parameters Cocoa Shell Solar unit
Down-payment period cashloan 5 y 3 y
Interest rate cash loan 5.0% % 0.0% %
Operational costs Cocoa Shell Solar unit
Average yearly interest cost (loan) 63,539 EUR/Y 0 EUR/Y
Yearly intrest costs 63,539 EUR/Y 0 EUR/Y
Average consumption per hour of fuel 1.900 ton/h 720 m3/hr
Average consumption per year of fuel 15,200 ton/year 5,760,000 m3/year
Purchase price fuel 1,200 Rp/kg 9,000 Rp/ton
Purchase price fuel 101.74 EUR/ton 0.76 EUR/m3
annual fuel cost 1,546,405 EUR/year 4,395,045 EUR/y
Installed electrical capacity installation 150 kW 30 kW
Average electrical load 100% % 100% %
Yearly electricity consumption 1,188,000 kWh 237,600 kWh
Electricity price (average) 0.058 EUR/kWh 0.058 EUR/kWh
Total yearly electricity costs 68,489 EUR/y 13,698 EUR/y
Yearly spare part costs boiler 48,000 EUR/y 9,000 EUR/y
Yearly spare part costs fluegascleaning 0 EUR/y 0 EUR/y
Total yearly spare part costs 48,000 EUR/y 9,000 EUR/y
Manhours per day for boileroperation and cleaning 24 manhour/d 0.0 manhour/d
Manhours per year for boileroperation and cleaning 7,920 manhours/y 0 manhours/y
Labor costs per manhour 0.22 EUR/h 0.22 EUR/h
Yearly manhours costs 1,742 EUR/Y 0 EUR/Y
Yearly costs of boilerapproval 0 EUR/Y 0 EUR/Y
Yearly costs of measuring CO, NOX, … 0 0 EUR/Y
Yearly costs of measuring dioxines 0 0 EUR/Y
Yearly measurem. costs 0 0 EUR/Y
YEARLY OPERATIONAL COSTS 1,728,176 4,417,743 EUR/Y
Investment analysis biomass vs NG unit
Yearly savings operational costs 2,689,567 EUR/Y
Additional investment cost 1,800,000 EUR
PAY BACK PERIOD 0.67 y
INVESTMENT ANALYSIS BIOMASS FIRED STEAM GENERATOR
FOR PT.X
BIOMASSVS
NATURAL GAS & SOLAR
Investment analysis Biomass vs NG unit
Yearly savings operational costs 1,224,552.09 EUR/Y
Investment cost 1,800,000.00 EUR
PAY BACK PERIOD 1.47 year
Investment analysis Biomass vs SOLAR unit
Yearly savings operational costs 2,689,567.23 EUR/Y
Investment cost 1,800,000.00 EUR
PAY BACK PERIOD 0.67 year
BENEFITS
• Lebih efisien.
• Meningkatkan profit.
• Mengurangi peredaran Cocoa Shell
Powder yang dilarang pemerintah.
• Turut menciptakan Green Energy.
VYNCKE AT BT COCOA
SEKILAS TENTANG BT COCOA
Pendiri – Piter Jasman
Memiliki 100% BT Cocoa
Banyak pengalaman di bidang kakao & cokelat
Mempunyai bisnis lain: Istana Nelayan (Hotel &
Restaurant), PT Wihadil (Pemanis buatan), PT
Amco (Herbisida)
Ketua Asosiasi Industri Kakao Indonesia (AIKI).
Salah satu pendiri dari Dewan Kakao Indonesia
(Dekaindo)
Pengurus Kadin Indonesia bidang Agro industri.
Visi & Misi
VISI
Diakui sebagai penyedia kakao global yang fokus pada pertumbuhan berkelanjutan.
MISI
Memenuhi kebutuhan kakao pelanggan dengan semangat dan integritas yang tinggi, memastikan pertumbuhan yang berkelanjutan baik secara ekonomi dan lingkungan.
Sejarah
Quality Assurance & Control
BAHAN BAKU
(LABORATORIUM BIJI KAKAO):
Memastikan biji kakao memenuhi
persyaratan FCC (import) dan SNI
(lokal).
Analisa kimia (kadar air, pH, lemak),
tes fisik, cut test, bean count & kadar
shell.
Quality Assurance & Control
BARANG JADI & DALAM PROSES (LABORATORIUM KIMIA & FISIKA):
Memastikan produk sesuai dengan
spesifikasi
Memastikan konsistensi produk
Analisa warna Intrinsik color, rasa,
kadar lemak, kadar shell, kadar abu,
pH, kadar air, kehalusan, dan
parameter kimia lainnya untuk cocoa
butter (FFA, POV, titik didih, dll)
Quality Assurance & Control
Barang Jadi & Dalam Proses –
Laboratorium Mikrobiologi:
Memastikan produk bebas dari
kontaminasi mikrobiologi
Analisa TPC, Yeast & Mould,
Coliform, Pathogen Salmonella
& E. Coli
Research & Development
Pengembangan produk
Optimalisasi proses produk
Pengembangan aplikasi
Pelatihan untuk umum di Chocolate
Academy
Pelanggan Lebih Dari 50 Negara Didunia
Produk kami – Cocoa Liquor
Asal:
Indonesia
Blend Asian / African
Ivory Coast
Ghana
Profil Roasting:
Rendah
Medium
Tinggi
Produk kami– Cocoa Powder
ASAL:
Blend Asian/ African
Indonesia
Variasi Warna:
Cokelat Muda
Cokelat Sedang
Cokelat Kemerahan
Cokelat Gelap
Merah Tua
Hitam
Produk kami– Cocoa Butter
Natural PPP Cocoa Butter
Deodorized Cocoa Butter
Bleached Cocoa Butter
Primaniyarta Awards
Primaniyarta Award 2008 Primaniyarta Award 2009
Primaniyarta Award 2013Primaniyarta Award 2011
Primaniyarta Award 2010
Primaniyarta Award 2014
Program Quality Assurance
FSSC 22000 : 2011
ISO 22000:2005
ISO 17025 : 2005
HACCP
SNI
HALAL
KOSHER
CUSTOMER KUNCI
THANK YOU