KEMAMPUAN SARANA PRODUKSI DAN TEKNOLOGI INDUSTRI BESI BAJA

GUNUNG GROUPSteel Is Our Business

Disampaikan oleh:Ir. Ketut Setiawan IWE

GUNUNG GROUPSteel Is Our Business

PT. GUNUNG GARUDA

PT. GUNUNG RAJA PAKSI

PT. GUNUNG GAHAPI SAKTI

PT. BUKIT TERANG PAKSI

FACILITIES & PRODUCT

Bloom

Beam blank

Billet

Electrical Arc Furnace Melting

Continuous Caster

GUNUNG GROUPSteel Is Our Business

SARANA PRODUKSI

FACILITIES & PRODUCT

HOT SECTION MILL

GUNUNG GROUPSteel Is Our Business

IWF & H BEAM

ANGLE

C - CHANNEL

FACILITIES & PRODUCT GUNUNG GROUPSteel Is Our Business

BAR & WIRE ROD MILL

WIRE ROD MILL

BAR ROLLING MILL

WIRE ROD

ROUND BAR

DEFORM BAR

FACILITIES & PRODUCT

PLATE MILL

PLATE

HOT ROLLED COILHOT STRIP MILL

HOT ROLLING MILL

GUNUNG GROUPSteel Is Our Business

Limbah Dust Collector

Limbah Steel Slag

Limbah Mill Steel

Limbah Oli Bekas

llimbah mill scale

Llimbah olie bekas

Pada TPS olie bekas ada serbuk gergaji

TEKNOLOGI PADA INDUSTRI BAJA

FUCHS- COSS

Regenerative Burners- Why?

Save Fuels Uses Advance Modern Age Technical to Harvest Energy and Reduce Waste

Save Cost Fuels and Materials are getting more and more expansive, Saving Fuels will lead to

Saving Cost

Save Earth Burning of Fuels produce Carbon Dioxide and cause Global Warming and Flooding

Better Quality Achieve Good and Even Temperature in the Reheating Furnace

Better Quantity Less Scale Loss and Less downtime, hence leads to Increase in Production Quantity

Regenerative Burners- Which? Regenerative Burners vs. Recuperative Burners

Regenerative is a newer technology and can save 20-30% more

compared to Recuperative Burners

Regenerative Burners can achieve less than 200oC for exhaust air, with most of the

heat passed back into the burners through alumina balls

In terms of Scale Comparison, Recuperative Burners creates more

scale compared to Regenerative Burners because of

Because Regenerative Burners’ flames are longer, temperature at the center and at

the side of the furnace are more even – can be controlled within 15oC difference.

Recuperative Burners’ flames are short and strong, differences from side to center

of furnace can be 50oC. This can also lead to the sides of the materials to melt.

With controlled firing and absorb from the opposites sides of the furnace,

temperature is well distributed and furnace pressure is well maintained. This

prevents too much oxygen from entering, hence minimizing the formation of

scales.

Regenerative Burners- How?

Regenerative Burners works with a pair of burners at opposites sides of the reheating furnace. Each pair alternately fire combustion air and receive the exhaust air. For the burner that receives, the exhaust air passes through a medium that is filled with alumina balls. The alumina balls has properties to act as a medium to absorb the heat. When the medium is fully heated, the pair will change their cycle. The exhaust burner will become the firing burner and the previous firing burner will become the exhaust burner. The now firing burner will receive air that passed through its already heated medium – this medium now pass out its stored heat into the combustion air. Thus, most of the heat is being cycled in the furnace thus reducing heat loss.

Efficiency Calculation

A = Hl + Tf * Cf + Ao * µ * Ta * Ca – { Go + Ao * (µ - 1.0) } * Tg * Cg

= 8,865 kcal/Nm3 + 30oC * 0.410 kcal/Nm3·C + 10.952 * 1.05 * 300oC * 0.313 – { 12.052 + 10.952 * ( 1.05 – 1.0 ) } * 450oC * 0.3425

= 8,015

A’ = 8,865 kcal/Nm3 + 30oC * 0.410 kcal/Nm3·C + 10.952 * 1.1 * 1040oC * 0.3442 – { 12.052 + 10.952 * ( 1.1 – 1.0 ) } * 200oC * 0.332

= 12,317

Efficiency = A / A’

= 65.08 %

Fuel savings is 34.92%

Before, kcal/ton consumption is 540,000 kcal/ton, therefore future consumption of gas will be 351,406 kcal/Ton or 39.64 Nm3/Ton

Production Increase

Less heating time Usually, rolling mills has problems whereby the materials at the center are not

heated enough and thus has to wait for the temperature to be well distributed. With Regenerative Burners, temperature in furnace is better distributed, hence this problem is minimized.

Less Scale Pressure in furnace is better

Side burners does not need to fire too high

More materials from the recovery of scales to be rolled into product

Less Stoppage time to maintain Furnace

Refractories, Castables, and Skis, Water Pipe last longer – reduce maintenance cost

Scales at the bottom of the furnace does not need to be clean up as often as before

Scheduled Maintenance can be less frequent

Environment Conservation

CO2 Reduction = (Consumption Before – Consumption Now) / Kcal in Gas

Per Year * Annual Production * 0.002 ton CO2

= (540,000 kcal/ton – 351,406 kcal/ton) / 8,865 kcal/Nm3

* 300,000 Ton/Year * 0.002 ton CO2

= 12,764.4 ton CO2

STRATEGI GUNUNG STEEL GROUP DALAM MENDUKUNG PEMBANGUNAN MEGA PROYEK JEMBATAN DAN KAWASAN SELAT SUNDA

MENERAPKAN SISTIM MANAJEMEN AN TARA LAIN ; SISTIM MANAJEMEN MUTU ISO 9001-2008 ,SISTIM MANAJEMEN LINGKUNGAN ISO 14000 , QUALITY MANAGEMENT SYSTEM STANDARDS LLOYD ‘S REGISTER, ABS GRADE OF ORDINARY AND HIGHER STRENGTH HULL STRUCTURAL STEEL PLATE AND COILS

BERUSAHA MENGAPLIKASIKAN TEKNOLOGI PROSES DALAM MENJNGKATKAN MUTU PRODUK DAN PRODUKTIVITAS YANG BERWAWASAN LINGKUNGAN

MENERAPKAN STANDAR MUTU PRODUK TERUTAMA SNI DAN STANDAR2 INTERNASIONAL SERTA MENYEDIAKAN STOCK PRODUK DALAM MEMENUHI KEBUTUHAN PELANGGAN

PERMASALAHAN INDUSTRI BAJA DALAM MENDUKUNG PEMBANGUNAN NASIONAL

BAHAN BAKU

ADANYA HAMBATAN DALAM IMPORTASI FERRO SCRAP SEBAGAI BAHAN BAKU INDUSTRI PELEBURAN BAJA, KARENA MASIH DIKATAGORIKAN SEBAGAI LIMBAN NON B3

BELUM ADANYA KEBIJAKAN PEMERINTAH YANG MENGATUR TATA NIAGA FERRO SCRAP SEBAGAI BAHAN BAKU, SEPERTI NEGARA LAIN YANG MENERAPKAN STANDAR INTERNASIONAL ISRI DENGAN IMPURITIES KURANG LEBIH 2%

PASAR DALAM NEGERI

BANJIRNYA PRODUK BAJA IMPOR YANG MEREBUT PASAR

DALAM NEGERI DENGAN HARGA DUMPING

ADANYA INDIKASI PELARIAN NO.HS PADA IMPORTASI PRODUK2 BAJA DENGAN MENGGUNAKAN NO.HS ALLOY STEEL ,SEHINGGA TERBEBAS DARI INSTRUMEN ANTIDUMPING TAX DAN TECHNICAL BARRIER

KEBIJAKAN LINGKUNGAN HIDUP

BELUM KONDUSIPNYA KEBIJAKAN LINGKUNGAN HIDUP DALAM MENDUHUNG PEMBANGUNAN INDUSTRI BAJA NASIONAL

ENERGI

KWALITAS SUPLAI ENERGI LISTRIK KURANG MENDUKUNG

ENERGY GAS UNTUK ALOKASI INDUSTRI BAJA KURANG MENDUKUNG PEMBANGUNAN INDUSTRI BAJA ,TERKADANG SHORTAGE DISAMPING HARGANYA SERING NAIK

INFRA STRUKTUR

PENYEDIAAN INFRA STRUKTUR KURANG MENDUKUNG

PELUANG DAN HARAPAN TERHADAP PENGEMBANGAN INDUSTRI BAJA NASIONAL

PELUANG

TERSEDIANYA MINERAL BIJH BESI,BIJIH NICKEL DAN MANGAN DAN BATU BARA SEBAGAI BAHAN BAKU IRON MAKING

ADANYA KEBUTUHAN PRODUK BAJA YANG CUKUP BESAR

KONSUMSI PER KAPITA BAJA NASIONAL MASIH RENDAH DIBANDINGKAN NEGARA2 LAIN

HARAPAN

ADANYA DUKUNGAN DARI PEMERINTAH UNTUK PENGEMBANGAN INDUSTRI BAJA NASIONAL MELALUI KEBIJAKAN2 YANG DITERBITKAN

ADANYA PENGEMBANGAN INFRA STRUKTUR (PELABUHAN,JALAN DAN JEMBATAN, DAN JALUR KERETA API)

ADANYA KERJA SAMA DAN SINERGI DENGAN LEMBAGA R&D PEMERINTAH

ADANYA KERJA SAMA DAN SINERGI ANTARA DUNIA USAHA DAN LEMBAGA R&D PEMERINTAH SEPERTI BPPT, DALAM PENGEMBENGAN TEKNOLOGI TERAPAN

TERBENTUKNYA FORUM DISKUSI PENGEMBANGAN INDUSTRI BAJA NASIONAL SEBAGAI WADAH PEMBAHASAN DAN LANGKAH2 PENGEMBANGAN INDISTRI BAJA ,DENGAN MENGIKUT SERTAKAN SEMUA STAKE HOLDER YANG ADA

Thank you…