Wilmar Indonesia

Sustainability Initiative: ID-BTG-UTI00-STM11-STM-001

1 General Information (Info below is used to create the Close Out Report No.)
Sustainability Initiative Condensate Return Recovery
Country Name / Code (L1) Indonesia ID Energy / Resource Type
Site Name / Code (L2) Bitung BTG BTG Steam STM
Area Name / Code (L3) Utility UTI00 Other 1
Sub Area Name / Code (L4) Boiler STM11 Other 2

2 Initiative Details (Describe the original design / operation vs. changes made)
Original Design / Operation Changes Made
Only condensate from steam chiller return to boiler All Plant condensate recovered
3 Cost Vs. Savings Benefits - Potential
Cost Estimate to Complete

US$ 54,531
Savings Potential Identified

Inputs
Potential condensate return 338 M3/Day
Calculations
Water cost saving US$ 0,8 X 338 M3/Day = US$ 270.4/Day = US$ 8,112/Month = US$ 97,344/Year

Simple Payback Calculation

= US$ 54,531 / US$ 97,344 = 0.6 years

4 Cost Vs. Savings Benefits - Verification

Operational Trial Details (AFTER IMPROVEMENT)

Field Data
Condensate Return Flow - 6.25 TPH, Condensate Temp - 90 deg.C, Dea Steam Parameters – 5 bar.g, Sat., Boiler Steam
Parameters – 31 bar.g Sat.

Calculations
Heat Recovered from Condensate = Mc x (HL Condensate) = 6250 x 376.72 / 3600 = 654 kW = Eth
Reduction in Dea Steam = 3600 x Eth / Dea Steam Enthalpy = 3600 x 654 / 2756 = 854 kg/hr
Reduction in eq. steam at boiler end = (854 x 2756) / 2802 = 840 kg/hr

Realized Savings (AFTER IMPROVEMENT)

Inputs
Steam Cost – 17.66 USD/MT, DM Water Cost – 0.63 USD/MT, Project cost – USD 54,531, Variable Cost – 70%

Calculations
Steam Cost Savings (Energy) = 840 x 8000 x 17.66 x 70% / 1000 = USD 83,072 / Year
Water Cost Savings = 6250 x 8000 x 0.63 x 70% / 1000 = USD 22,050 / Year
Total Savings = 83,072 + 22,050 = USD 105,122 / Year

Simple Payback Calculation

= 54,531 / 105,122 = 0.52 Years

Raw water saving calculation

=6.25 TPH x 8000 hr per year x 1.4 (RO water to raw water conversion) =70,000 m3 per year lesser water withdrawn from
deepwell.

Document Title Condensate Return Recovery Sign Off Name Signature Date
Document No. ID-BTG-UTI00-STM11-STM-001 Prepared Stephen Julianto
Document Rev. No. 00 Reviewed Manish Bhola
Page No. 1 of 2 Approved Manish Bhola
Wilmar Indonesia
Sustainability Initiative: ID-BTG-UTI00-STM11-STM-001

5 Photos

Before

After

Install line, tank , pump recovery Install line, tank , pump recovery Install turbidity meter
condensate condensate

For further enquiries / details;

Pls. contact Stephen Julianto / Manish Bhola

Document Title Condensate Return Recovery Sign Off Name Signature Date
Document No. ID-BTG-UTI00-STM11-STM-001 Prepared Stephen Julianto
Document Rev. No. 00 Reviewed Manish Bhola
Page No. 2 of 2 Approved Manish Bhola