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…