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Predictive Maintenance with Machine Learning: A Comparative Analysis of Wind Turbines and PV Power Plants Uhanto, Uhanto; Yandri, Erkata; Hilmi, Erik; Saiful, Rifki; Hamja, Nasrullah
Heca Journal of Applied Sciences Vol. 2 No. 2 (2024): September 2024
Publisher : Heca Sentra Analitika

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.60084/hjas.v2i2.219

The transition to renewable energy requires innovations in new renewable energy sources, such as wind turbines and photovoltaic (PV) systems. Challenges arise in ensuring efficient and reliable performance in their operation and maintenance. Predictive maintenance using machine learning (PdM-ML) is relevant for addressing these challenges by enhancing failure predictions and reducing downtime. This study examines the effectiveness of PdM-ML in wind turbine and PV systems by analyzing operational data, performing data preprocessing, and developing machine learning models for each system. The results indicate that the model for wind turbines can predict failures in critical components such as gearboxes and blades with high accuracy. In contrast, the model for PV systems is effective in predicting efficiency declines in inverters and solar panels. Regarding operational complexity, each model has advantages and disadvantages of its own, but when compared to conventional maintenance techniques, both provide lower costs with greater operational efficiency. In conclusion, machine learning-based predictive maintenance is a promising solution for enhancing the reliability and efficiency of renewable energy systems.

Potential for Electrical Energy Savings in AC Systems by Utilizing Exhaust Heat from Outdoor Unit Hamja, Nasrullah; Yandri, Erkata; Hilmi, Erik; Uhanto, Uhanto; Saiful, Rifki
Heca Journal of Applied Sciences Vol. 2 No. 2 (2024): September 2024
Publisher : Heca Sentra Analitika

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.60084/hjas.v2i2.223

This study explores the potential of utilizing waste heat from air conditioning systems, one of the largest consumers of electrical energy. Currently, most of the waste heat generated by outdoor units is typically released into the environment without being utilized, leading to missed energy-saving opportunities. This study analyzes the potential for improving electrical energy efficiency in air conditioning (AC) systems by harnessing this waste heat. Two primary approaches are evaluated: the first is the use of waste heat for domestic water heating, and the second is the conversion of heat into electrical energy using thermoelectric generators (TEG). The results of this research indicate that both methods have the potential to improve overall energy efficiency significantly. However, challenges related to conversion efficiency and integration of these technologies with AC systems require further, more specific studies. These findings are expected to contribute to more efficient and environmentally friendly cooling systems by optimizing technology and overcoming barriers to wider implementation.

Optimizing Compressed Air Operations for Electrical Energy Savings: A Case Study in Pharmaceutical Packaging Manufacturing Candra, Arief; Yandri, Erkata; Saiful, Rifki; Uhanto, Uhanto; Hilmi, Erik; Hamja, Nasrullah; Ariati, Ratna
Grimsa Journal of Science Engineering and Technology Vol. 2 No. 2 (2024): October 2024
Publisher : Graha Primera Saintifika

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.61975/gjset.v2i2.58

This study in pharmaceutical packaging manufacturing focuses on improving compressed air efficiency through targeted strategies at both the source and user levels by establishing a baseline to analyze energy consumption patterns. Key measures, including minimizing air leaks, adjusting pressure, and optimizing compressor performance, aim to achieve a 20-50% increase in efficiency, thereby supporting environmental sustainability. The User Point and Source Point approaches are expected to lower Specific Power Consumption (SPC), with data collected from December 2020 to May 2022 providing insights into potential energy savings. Establishing this baseline, based on machine runtime and productivity, offers a solid foundation for evaluation. Results show a 23% reduction in compressor electricity usage and a 7-8% decrease in compressed air consumption. A structured improvement process and strong collaboration between engineering and management are essential for enhancing productivity and achieving sustainable energy efficiency in the industrial sector.

Hybrid Energy Solutions for Sustainable Offshore Oil and Gas Operations: Leveraging Thermoelectric, Solar, and Wind Potential Hilmi, Erik; Yandri, Erkata; Uhanto, Uhanto; Saiful, Rifki; Hamja, Nasrullah
Leuser Journal of Environmental Studies Vol. 2 No. 2 (2024): October 2024
Publisher : Heca Sentra Analitika

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.60084/ljes.v2i2.218

The transition towards sustainable offshore oil and gas operations is increasingly important given the declining conventional energy reserves and growing environmental concerns. This research developed a concept design to enhance sustainability in offshore operations by integrating local solar and wind energy sources. The proposed hybrid system combines solar energy systems and wind turbines with traditional Thermoelectric Generators (TEGs), which have traditionally relied on natural gas. The study found that incorporating these renewable energy sources into the system significantly reduces carbon emissions, lowers dependency on fossil fuels, and improves overall operational efficiency. The main conclusion of this research is that integrating local renewable energy sources into offshore operations mitigates environmental impact, offers long-term cost savings, and enhances energy security. This framework provides practical solutions for the energy sector's transition towards greener, more resilient offshore operations.

Optimizing Motorcycle Manufacturing Sustainability through the Integration of Waste Heat Recovery and Metal Scrap Recycling: A Process Engineering Approach Saiful, Rifki; Yandri, Erkata; Hilmi, Erik; Hamja, Nasrullah; Uhanto, Uhanto; Fitriani, Fitriani; Ibrahim, Riki Firmandha
Leuser Journal of Environmental Studies Vol. 2 No. 2 (2024): October 2024
Publisher : Heca Sentra Analitika

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.60084/ljes.v2i2.225

The automotive industry manufacturing has experienced rapid growth 2–3 times by 2050, with motorcycles constituting around 30% of vehicles worldwide, but this increase in production has significantly heightened the demand for raw materials and energy. A major challenge arises in managing material waste and waste heat generated during the manufacturing process. This research aims to develop a framework that optimizes the synergy between material waste recycling and waste heat recovery to enhance the sustainability of the motorcycle industry, reduce waste, and lower energy consumption. The design leverages waste heat from the melting process to preheat raw materials, raising temperatures from around 50 °C to 350 °C before melting, thereby reducing additional energy needs, lowering emissions, and decreasing operational costs. Utilizing waste heat for preheating not only mitigates environmental impact and thermal load but also significantly improves energy efficiency, ultimately resulting in cost savings and optimized resource use. Utilizing waste heat directly for preheating raw materials has effectively lowered energy consumption by as much as 30%. This approach not only improves operational efficiency but also decreases production costs and minimizes environmental impact, offering a more sustainable solution for the manufacturing sector.

Design and evaluation of a TEG-PV hybrid energy system for sustainable offshore oil and gas operations using PVsyst simulation Hilmi, Erik; Yandri, Erkata; Uhanto, Uhanto; Saiful, Rifki; Lodewijk, Dewi Putriani Yogosara; Ariati, Ratna
SINERGI Vol 29, No 3 (2025)
Publisher : Universitas Mercu Buana

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.22441/sinergi.2025.3.007

The rising demand for sustainable offshore oil and gas operations has accelerated the need for efficient, low-emission energy systems. Conventional fossil fuel-based systems significantly contribute to greenhouse gas emissions, underscoring the need for innovative alternatives. This study proposes and evaluates a hybrid energy system that integrates thermoelectric generators (TEGs) and photovoltaic (PV) panels to enhance energy efficiency, reduce emissions, and improve the sustainability of offshore operations. The system design utilizes both manual calculations and simulations, employing PVsyst software, to evaluate performance metrics. Results show that the TEG + PV hybrid system improves energy efficiency and reduces carbon emissions by approximately 40% compared to traditional fossil fuel systems. TEGs utilize waste heat from natural gas combustion, while PV panels capture solar energy, creating a synergistic effect that significantly reduces environmental impact. This hybrid configuration also aligns with emission reduction regulations in the oil and gas sector. Beyond environmental benefits, the hybrid system offers economic advantages. Fuel consumption and operational costs are notably reduced, with total savings in capital and operational expenditures (CAPEX and OPEX) reaching IDR 2.53 billion. These savings demonstrate the system’s financial viability and support its adoption in real-world offshore applications. In conclusion, the integration of TEG and PV technologies into a hybrid energy system offers a practical and sustainable solution for offshore oil and gas operations. The system achieves emission reduction targets, enhances operational efficiency, and delivers cost savings, thereby supporting the industry's transition toward more environmentally responsible energy practices.

Bioenergy as a Key Driver of Energy Transition: A Case Study of Emission Reduction and Energy Security Saiful, Rifki; Nur, Syukri M
JOURNAL OF MECHANICAL ENGINEERING MANUFACTURES MATERIALS AND ENERGY Vol. 9 No. 2 (2025): December 2025 Edition
Publisher : Universitas Medan Area

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.31289/jmemme.v9i2.14158

The transition to renewable energy is an urgent step in addressing the global climate crisis and reducing dependence on fossil fuels, which have increased greenhouse gas emissions and exacerbated climate change. In this context, bioenergy emerges as an important solution because it not only helps reduce carbon emissions through cleaner and carbon-neutral combustion but also increases energy security by diversifying energy sources, especially through the utilization of organic biomass such as agricultural and forestry waste. This study aims to study more deeply about bioenergy as a key driver of energy transition through case studies related to emission reduction and energy security enhancement. Bioenergy plays an important role in the global energy transition because it is able to reduce dependence on fossil fuels and reduce carbon emissions. In addition to helping create a more resilient energy system by utilizing local biomass resources, bioenergy also supports the principle of a circular economy through the utilization of organic waste. Despite offering many benefits, bioenergy development faces challenges such as resource supply and production efficiency, but the opportunities to overcome these challenges remain large through technological innovation and supportive policies. Bioenergy plays an important role in the global energy transition towards clean energy by reducing carbon emissions and increasing energy security through the utilization of renewable biomass. Despite challenges in terms of policy, technology, and raw material supply, the great potential of bioenergy can be optimized through innovation and policy support to strengthen a more sustainable energy system. This study shows that bioenergy has great potential to reduce carbon emissions and increase energy security through the use of renewable biomass, but further development is needed to overcome efficiency and policy challenges to support the transition to a more sustainable energy system.

Design of Development Waste Heat Recovery in Metal Casting Industry: Exploring Energy Saving Potentials Saiful, Rifki; Hilmi, Erik; Nasrullah, Nasrullah; Uhanto, Uhanto; Arneta, Vanesa; Rifiana Dewi, Shanaya
Jurnal Energi Baru dan Terbarukan Vol 6, No 3 (2025): Oktober 2025
Publisher : Program Studi Magister Energi, Sekolah Pascasarjana, Universitas Diponegoro, Indonesia

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.14710/jebt.2025.29202

The metal casting industry is known for its energy-intensive consumption and the generation of large amounts of waste heat and materials during the melting, casting, and cooling processes. If this heat is not utilized properly, it not only causes environmental degradation but also contributes to significant economic inefficiencies. Therefore, the need for more sustainable practices is increasingly driving the industry to seek solutions to optimize energy consumption and reduce waste. One promising solution is the implementation of waste heat recovery (WHR) systems, which aim to model waste heat recovery, evaluate potential energy savings, and provide solutions to improve sustainability in the sector. By developing hybrid system designs that combine fossil fuels and renewable energy sources, such as solar panels (PV), batteries, and inverters, the industry can reduce its reliance on fossil fuels while improving overall energy efficiency. Furthermore, the implementation of WHR technology not only offers technical benefits but also contributes to lower operational expenses and carbon emissions, as demonstrated by the reduction in unit production costs from various simulations. These results demonstrate that this new system has positive economic and environmental impacts, creating a more environmentally friendly and sustainable solution for the metal casting industry.

Design of Development Waste Heat Recovery in Metal Casting Industry: Exploring Energy Saving Potentials Saiful, Rifki; Hilmi, Erik; Uhanto, Uhanto; Arneta, Vanesa; Dewi, Shanaya Rifiana
Eksergi Vol. 22 No. 01 (2026): JANUARY 2026
Publisher : Politeknik Negeri Semarang

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.32497/eksergi.v22i01.7138

The metal casting industry is known for its energy-intensive consumption and the generation of large amounts of waste heat and materials during the melting, casting, and cooling processes. If this heat is not utilized properly, it not only causes environmental degradation but also contributes to significant economic inefficiencies. Therefore, the need for more sustainable practices is increasingly driving the industry to seek solutions to optimize energy consumption and reduce waste. One promising solution is the implementation of waste heat recovery (WHR) systems, which aim to model waste heat recovery, evaluate potential energy savings, and provide solutions to improve sustainability in the sector. By developing hybrid system designs that combine fossil fuels and renewable energy sources, such as solar panels (PV), batteries, and inverters, the industry can reduce its reliance on fossil fuels while improving overall energy efficiency. Furthermore, the implementation of WHR technology not only offers technical benefits but also contributes to lower operational expenses and carbon emissions, as demonstrated by the reduction in unit production costs from various simulations. These results demonstrate that this new system has positive economic and environmental impacts, creating a more environmentally friendly and sustainable solution for the metal casting industry.

Process Optimization of Heating Ovens for Energy Saving and Emission Reduction in Industrial Electrodeposition Painting Saiful, Rifki; Cahya, Satiya
Jurnal Energi Baru dan Terbarukan Vol 7, No 1 (2026): Maret 2026
Publisher : Program Studi Magister Energi, Sekolah Pascasarjana, Universitas Diponegoro, Indonesia

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.14710/jebt.2026.31237

This study discusses efforts to improve the heating oven system in the painting process to increase energy efficiency, reduce operational costs, and lower CO₂ emissions without compromising product quality, including the deactivation of the Recuperative Thermal Oxidizer (RTO) to reduce energy consumption and CO₂ emissions. Prior to improvement, the heating process consisted of three separate stages—pre-heat, heat-up, and keep zone—with a total processing time of approximately 60 minutes. This configuration resulted in annual LNG consumption of 230,866 m³, significantly impacting energy costs and the carbon footprint of the production process. Through process engineering, these stages were simplified into a single rapid-heating phase up to a peak temperature of 180°C, followed by stabilization at 150°C with a total duration of around 18 minutes. This operational redesign reduced cycle time by nearly 50% while optimizing heat distribution inside the oven. The implementation produced significant results: LNG consumption decreased by more than 50%, energy costs dropped from IDR 1.49 billion to IDR 0.71 billion per year, and total CO₂ emissions were reduced from 417.87 tons to 199.56 tons within two years. Product quality evaluation confirmed that the process changes did not affect performance or compliance with specification standards. Additionally, this study recommends further development through data-driven optimization, integration of sensors and IoT for more precise automatic control, and opportunities to utilize renewable energy as part of sustainable manufacturing strategies.

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