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Patents from the Director General of Intellectual Property Rights (HAKI) at the Ministry of Justice and Human Rights of the Republic of Indonesia
Badak LNG has consistently put a culture of innovation into action in handling its operations. Prior to 2016, Badak LNG has received 14 patents from the Director General of Intellectual Property Rights (HAKI) at the Ministry of Justice and Human Rights of the Republic of Indonesia, namely:
1. T-Plug Installer
The previous heat exchanger repair was done by turning off the train first, then carry out the installation and welding plug. With the T-Plug Installer innovation, repairs shall be done without welding and doing online (when the plant / train is running) so it does not require a plant shut down that can lead to large amounts of feed gas being wasted. This innovation can shorten leak repair time so as to save total energy 73,313 MWh. Potential greenhouse gases can be minimized to 67,036 tons of CO2 when leaks can be prevented by using the T-Plug Installer.
2. Drying Oven
This tool has been operated as a stator dryer and high-voltage rotor using air heater blower. This tool replaces the heating using 16 pieces of 1000 Watt 220 V mercury lamp which consumes 494 hours. With the Drying Oven, stator and rotor drying shall be accomplished within a shorter period of time, so it is able to save energy use up to 14.71 MWh. In addition, this innovation also decreases the amount of waste mercury lamp waste which is B3 waste of 32 kg / year.
3. Crab Shell Biscuit
This innovation manufactures crab shells as a starch of raw materials for making biscuits with high calcium content. This innovation has been included in the program that aims to fulfill the calcium needs of people in Bontang including children, pregnant women, elderly, patients with bone and joint disorders and patients post thyroid surgery gland. As a result, the program supports the resilience and diversification of food proclaimed by the government.
4. Cooldown Startup Method
This innovation shortens the MHE (Main Heat Exchanger) cool down process by dragging cold gas into the system at the start-up of natural gas liquefaction units. The cooling gas is initially discharged immediately, recycled in the cooling system. This makes the start-up process more secure and environmentally friendly, and provides energy savings of 7,176 MWh per start-up and decrease air emission load by 1200 tons CO2e per start up. This program is a result of innovation that has not been implemented in other LNG plant worldwide so it is the first in the world (pioneer) and proven to reduce the amount of energy loss significantly.
5. Shutdown Method to Prevent Thermal shock
This innovation aims to prevent the occurrence of thermal shock phenomenon that is very likely to occur in the LNG plant shutdown process. Therefore, temperature modification should be done at the time of shutdown, so thermal shock can be prevented and more gas will be used as LNG product. This innovation can save energy of 17,072,300 MWh per shutdown and result in decrease CO2 emission load of 5,887 ton per shutdown.
6. Expansion Joint Tugboat
By modifying the Expansion Joint Tugboat Exhaust Channel, it can lower the leakage of the exhaust channels. The total energy consumption savings of 402.84 MWh / year resulted in a 10% reduction in the heat loss of Tugboat's total engine power equivalent to 402.8 MWh per year and an emission reduction of 949.73 ton CO2 / year. This innovation also reduces leakage of exhaust channels and decreases the frequency of expansion joint damage by 7 ea per year per tugboat thereby reducing the amount of waste wasted by 0.08 tons / year of non b3 solid metal waste.
7. Intelligent Pontoon
In the making a raft for carrying buoys of navigating the depth of the waters, the lighted buoys above the waters must be mandatory as a safe boundary mark for large ships to dock. By making a raft to carry a float as a sign of navigation depth of water depth, it can prevent the existence of non-B3 solid waste in the form of metal waste from lighted buoys that sink into the waters. This innovation shall reduce non B3 solid waste by 5000 kg.
8. Ground Fault Locator
Operation the LNG plant demands a DC power supply to drive instrumentation equipment derived from 80 units of rectifiers. If it is not resolved soon it will cause disruption to equipment instrumentation resulting in the plant trip. By creating a tool for determining Ground Fault Online Locator points, the program avoids plant trips and prevents energy loss of 60,000 MWh / year and prevents the release of emissions to the air by 20 tons CO2e / year.
9. Water Purifier
Freshwater fish has been treated as a commodity of public consumption so that many people are interested in cultivating them. Types of freshwater fish that are much-loved by the community such as tilapia, goldfish, carp fish, catfish and others. But in the cultivation of freshwater fish, water consumed for the cultivation shall not be directly used for all stages of cultivation. Because fresh water from rivers and lakes may have been chalked up with household waste such as detergent, soap, oil and others. The amount of this household waste affects the growth of freshwater fish. Obstacles will be experienced that if the water used from the well pump, then the cost will be high enough because the volume of clean water required is very much.
The installation of river water purification according to this present invention consumes at least three columns which function to precipitate, dry and filter. This installation tool will also contain a positive impact on the environment because it can save groundwater usage so that the ground water reserve is well-maintained. At last, with this installation, it can reduce the volume of river water contaminated with household waste.
10. Water Purifier Lengthwise Metal Protection for Water Steam Trap
Metal protector for water trap consist of: metal net made from stainless steel and has a size of 1 mesh, and alumunium plate to strengthen its metal net where the net is formed into tube shape and on the top and bottom are installed with at least one alumunium plate to support its metal net and metal net the tubular shape is connected to the surface of the water vapor trap body with the minimum distance between the metal net and the water vapor trap body is 2 inches.
11. Corrosion Early Detection Tools
Corrosion early detection device under insulation consists of zinc plate and copper plate arranged on synthetic fabric. The two plates are connected with a conductor cable using isolation as an access measurement for potential difference. This detector is placed at the bottom of the insulation equipment.
This tool can eliminate the cost of loading/installing insulation, unloading/installing scaffolding, and not producing waste insulation. In addition, the cost of maintaining insulated equipment can be reduced because of the potential for corrosion under insulation downgraded.
12. The Shutdown Main Cryogenic Heat Exchanger (MCHE) Method
Badak LNG is the largest Liquified Natural Gas processing company in Indonesia, located in Bontang,
East Kalimantan, and has 8 process train (A-H). The last unit of the process of liquefying natural gas into LNG occurs at Main Cryogenic Heat Exchanger (MCHE). MCHE is a heat exchanger with shell & tube design types. In the process this unit can be stopped either normally or in emergency conditions. Based on SOP No.OP/SD/BP-15/05-915H MCHE can be stopped at the temperature of -80°C in Cold Bundle (5TI-29 / 5TI-1A). Furthermore, if the MCHE Unit is to be repaired, it must be done Defrost (Heating system) MCHE units are carried out up to 25°C (ambient temperature). Defrost MCHE is done with drain clean and heated clean gas from the MCHE bottom within ± 11 hours and result in 286,000 Nm3 gas is discharged and burned in flares. These problems can be overcome by modifying the stop of the MCHE unit (5E-1) for maintenance at Shell Side and Tube Bundle MCHE temperatures at 5TI- 21/22/24/25/26/27/28/29/30/31/32 the average reaches -40°C, which makes the defrost process shorter because it uses clean gas with the flow of 26 kNm3 / hour.
13. The Filling of Propana Evaporator using Liquid Propana
In the process of procesing natural gas into LNG there are several stages, including Unit 1 (Purification Unit, Plant 1), Unit 2 (Dehydration Unit, Plant 2), Unit 3 (Fractionation Unit, Plant 3), Unit 4 (Refrigeration Unit, Plant 4) and Unit 5 (Liquefaction Unit, Plant 5). The main task of the Process Trains Section of the Operations Department where the cluster is to operate the EFGH Refinery starting from gas feed into unit 1 until it is liquefied into LNG in unit 5.
Unit 4 is a very important unit in the LNG liquefaction industry, in this unit the feed gas will experience cooling gradually in the evaporator (5) to -30°C before further processing until it melts into LNG at a temperature of -150°C. Besides cooling the feed gas, this propane refrigeration unit also functions to cool the MCR to a temperature of -30°C before use to cool and melt the feed gas in Unit 5.
14. Tellerette Packing Thrower Tools in Tower Type Aerator Unit
Pressurized wind-powered tellerette packing launcher from inside an aerator unit vessel, consists of: a flange which serves as a connecting part with the release hose (unloader); a concentric reducer pipe which functions as part to speed up the suction air, and the blower nozzle for the place of entry of the pressurized wind from the compressor and for channel the tellerette packing, where flanges and concentric reducer pipes are coated with a glass fiber, whereas between the concentric reducer pipe and the blower nozzle are connected to the bolt in a circular and sealed manner with rubber gaskets, and at the end of the nozzle the blower is provided with a pressurized air inlet hole.