Kemampuan Sarana Produksi dan Teknologi Industri Besi dan Baja

1. KEMAMPUAN SARANA
PRODUKSI DAN
TEKNOLOGI INDUSTRI
BESI BAJA
GUNUNG GROUP
Steel Is Our Business
Disampaikan oleh:
Ir. Ketut Setiawan IWE

2. GUNUNG GROUP
Steel Is Our Business
PT. GUNUNG GARUDA
PT. GUNUNG RAJA PAKSI
PT. GUNUNG GAHAPI SAKTI
PT. BUKITTERANG PAKSI

3. FACILITIES & PRODUCT
Bloom
Beam blank
Billet
ElectricalArc Furnace
Melting
Continuous Caster
GUNUNG GROUP
Steel Is Our Business
SARANA PRODUKSI

4. FACILITIES & PRODUCT
HOT SECTION MILL
GUNUNG GROUP
Steel Is Our Business
IWF & H BEAM
ANGLE
C - CHANNEL

5. FACILITIES & PRODUCT GUNUNG GROUP
Steel Is Our Business
BAR &WIRE ROD MILL
WIRE ROD MILL
BAR ROLLING MILL
WIRE ROD
ROUND BAR
DEFORM BAR

6. FACILITIES & PRODUCT
PLATE MILL
PLATE
HOT ROLLED COIL
HOT STRIP MILL
HOT ROLLING MILL
GUNUNG GROUP
Steel Is Our Business

8. Limbah Dust Collector
Limbah Steel Slag
Limbah Mill Steel
Limbah Oli Bekas

10. llimbah mill scale
Llimbah olie bekas
PadaTPS olie bekas ada serbuk gergaji

32. TEKNOLOGI PADA INDUSTRI BAJA

33. FUCHS- COSS

37. 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

38. 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.

39. 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.

40. 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

41. 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

42. 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

43. STRATEGI GUNUNG STEEL GROUP DALAM MENDUKUNG
PEMBANGUNAN MEGA PROYEK JEMBATAN DAN
KAWASAN SELAT SUNDA
 MENERAPKAN SISTIM MANAJEMEN ANTARA 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 PLATEAND
COILS
 BERUSAHA MENGAPLIKASIKANTEKNOLOGI PROSES DALAM
MENJNGKATKAN MUTU PRODUK DAN PRODUKTIVITASYANG
BERWAWASAN LINGKUNGAN
 MENERAPKAN STANDAR MUTU PRODUKTERUTAMA SNI DAN
STANDAR2 INTERNASIONAL SERTA MENYEDIAKAN STOCK
PRODUK DALAM MEMENUHI KEBUTUHAN PELANGGAN

44. 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
 BELUMADANYA KEBIJAKAN PEMERINTAHYANG MENGATUR
TATA NIAGA FERRO SCRAP SEBAGAI BAHAN BAKU, SEPERTI
NEGARA LAINYANG MENERAPKAN STANDAR INTERNASIONAL
ISRI DENGAN IMPURITIES KURANG LEBIH 2%
PASAR DALAM NEGERI
 BANJIRNYA PRODUK BAJA IMPORYANG MEREBUT PASAR
DALAM NEGERI DENGAN HARGA DUMPING

45.  ADANYA INDIKASI PELARIAN NO.HS PADA IMPORTASI PRODUK2
BAJA DENGAN MENGGUNAKAN NO.HSALLOY STEEL ,SEHINGGA
TERBEBAS DARI INSTRUMENANTIDUMPINGTAX DAN
TECHNICAL BARRIER
KEBIJAKAN LINGKUNGAN HIDUP
 BELUM KONDUSIPNYA KEBIJAKAN LINGKUNGAN HIDUP DALAM
MENDUHUNG PEMBANGUNAN INDUSTRI BAJA NASIONAL
ENERGI
 KWALITAS SUPLAI ENERGI LISTRIK KURANG MENDUKUNG
 ENERGYGAS UNTUKALOKASI INDUSTRI BAJA KURANG
MENDUKUNG PEMBANGUNAN INDUSTRI BAJA ,TERKADANG
SHORTAGE DISAMPING HARGANYA SERING NAIK
INFRA STRUKTUR
 PENYEDIAAN INFRA STRUKTUR KURANG MENDUKUNG

46. PELUANG DAN HARAPANTERHADAP PENGEMBANGAN
INDUSTRI BAJA NASIONAL
PELUANG
 TERSEDIANYA MINERAL BIJH BESI,BIJIH NICKEL DAN MANGAN DAN
BATU BARA SEBAGAI BAHAN BAKU IRON MAKING
 ADANYA KEBUTUHAN PRODUK BAJAYANG CUKUP BESAR
 KONSUMSI PER KAPITA BAJA NASIONAL MASIH RENDAH DIBANDINGKAN
NEGARA2 LAIN
HARAPAN
 ADANYA DUKUNGAN DARI PEMERINTAH UNTUK PENGEMBANGAN
INDUSTRI BAJA NASIONAL MELALUI KEBIJAKAN2YANG DITERBITKAN
 ADANYA PENGEMBANGAN INFRA STRUKTUR (PELABUHAN,JALAN DAN
JEMBATAN, DAN JALUR KERETAAPI)
 ADANYA KERJA SAMA DAN SINERGI DENGAN LEMBAGA R&D
PEMERINTAH

47.  ADANYA KERJA SAMA DAN SINERGIANTARA DUNIA USAHA DAN
LEMBAGA R&D PEMERINTAH SEPERTI BPPT, DALAM PENGEMBENGAN
TEKNOLOGITERAPAN
 TERBENTUKNYA FORUM DISKUSI PENGEMBANGAN INDUSTRI BAJA
NASIONAL SEBAGAI WADAH PEMBAHASAN DAN LANGKAH2
PENGEMBANGAN INDISTRI BAJA ,DENGAN MENGIKUT SERTAKAN SEMUA
STAKE HOLDERYANG ADA

48. Thank you…