Performance Evaluation and Energy-Saving Prioritization of Thermal Oil Heater in Plastic Manufacturing Plant

Arya  Bima Putra; Faiz Husnayain

doi:10.31258/ijeepse.9.2.79-93

Arya Bima Putra Universitas Indonesia, Depok, Indonesia
Faiz Husnayain Universitas Indonesia, Depok, Indonesia

DOI: https://doi.org/10.31258/ijeepse.9.2.79-93

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Keywords: Analytic hierarchy process, Direct method, Energy performance indicator (EnPI), Linear regression, Thermal oil heater.

Abstract

Heating systems are one of the main contributors to energy consumption in industry. This study was conducted on the Thermal Oil Heater (TOH) system at PT XYZ, a plastic manufacturing company in West Java, to evaluate TOH performance using the direct method, linear regression modeling, and the Energy Performance Indicator, as well as to identify and prioritize energy-saving opportunities in the TOH system using the Analytic Hierarchy Process. The results of the direct method show that the average TOH efficiency was 65.78%. The linear regression equation was η = 1246.889 - 0.2428X₁ - 4.2929X₂, where gas flow rate and thermal oil inlet temperature significantly affected TOH efficiency. The EnPI method produced a baseline value of 1.58. The identified energy-saving potential was 26%. Based on the AHP analysis, the priority order of the criteria is as follows: energy-saving potential, ease of implementation, impact on operations and production, and investment cost. The priority order of the alternatives is as follows: optimization of gas fuel consumption rate, improvement of monitoring and control of operating parameters, improvement of the TOH system maintenance program, more efficient operating temperature control, increasing the temperature difference, burner combustion optimization, periodic cleaning of heat transfer pathways, and improvement of pipe and TOH body insulation.

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