25 May 2016

Summary of Blended Coal Feeding- Performance Comparison

The blending of Indonesian and Australian coal was started on 08 May 2016. The feeding ratio is 55.4 % of Indonesian and
44.6 % of Australian coal. The blended coal was fed to all the units. The blended coal analysis for 10 days is

Average Blended Coal Analysis (Indonesia: 55.4 %, Australia: 44.6%)

Coal Blended Coal

Proximate
S.No UOM
analysis Indonesian Australian Unit I Unit II Unit III Unit IV

1 Inherent Moisture % 15.82 9.5 13.55 12.61 12.57 12.18

2 Total Moisture % 35.72 17.2 28.18 28.03 28.12 28.26
3 Ash % 3.36 8.51 5.7 5.77 5.89 5.46
4 Volatile Matter % 30.1 27.36 31.12 31.11 30.97 31.18
5 Fixed Carbon % 30.84 46.94 35.01 35.09 35.02 35.11
6 GCV kcal/kg 4078 5779 4753 4747 4752 4752

The Performance Test of Unit IV was conducted on 21 May 2016 with blended coal of 57.39 % Indonesian
and 42.61 % of Australian Coal.

IM : 13.14% , TM : 28.40% , Ash : 5.07% , VM : 30.86% , FC : 35.67 % , GCV : 4760 kcal/kg

Unit IV Performance Comparison with GCV of 4096 and 4760 kcal/kg

S.No Thermal Losses in Boiler Design 28-Mar-16 21-May-16

A GCV of Coal Kcal/kg 4800 4096 4760
1 Heat loss due to dry flue gas L1 % 4.54 5.74 4.79
2 Heat Loss due to formation of H2 in fuel L2 % 3.96 4.86 3.48

3 Heat Loss due to moisture in Fuel L3 % 3.99 5.96 3.82

4 Radiation loss L4 % 0.39 0.5 1.55

5 Loss due to combustible in total ash L5 % 0.65 0.05 0.4

6 Loss due to Sensible heat in Ash(Bed and Fly ash) L6 % 0.2 0.18 0.28

7 Loss due to moisture in air L7 % 0.27 0.02 0.17

8 Credits (corrections) L8 % 0.49 0.47

BOILER EFFICIENCY % = 100 - (L1+L2+L3+L4+L5+L6+L7-

9 % 86 83.03 85.98
L8)
There is a benefit of 2.95% improvement in Boiler Efficiency with blended coal GCV of 4760 kcal/kcal
when compared with Indonesian coal GCV of 4114 kcal/kg

Station Heat Rate Comparison with GCV of 4114kcal/kg and 4760 kcal/kg

28-Mar-16 21-May-16
S.No PARAMETERS UOM (Indonesian (Blended
coal) coal)
1 M/S PRESSURE kcal/kwh -5.34 -24.31
2 M/S TEMPERATURE kcal/kwh -1.83 -1.05
3 FLUE GAS TEMP. kcal/kwh 22.37 9.29
4 WET FLUE GAS LOSS kcal/kwh 4.01 1.28
5 R/H TEMPERATURE kcal/kwh 1.15 5.29
6 VACUUM kcal/kwh 2.91 15.86
7 RH SPRAY kcal/kwh 18.87 10.02
8 Feed Water Temperature kcal/kwh 0.27 7.62
9 RADIATION LOSS kcal/kwh 30.04 30.04
10 D.M MAKE UP kcal/kwh 0 0
11 BLOWDOWN LOSS kcal/kwh 0 0
12 MOISTURE IN AIR kcal/kwh 1.17 0.5
13 UNACCOUNTED kcal/kwh 10 10
14 TOTAL LOSSES kcal/kwh 83.62 64.54
15 Actual SHR (2385+total losses) kcal/kwh 2468.62 2449.54
16 Actual SHR (GCVxSp.Coal) kcal/kwh 2686 2613.4
17 Difference in SHR(16-15) kcal/kwh 217.38 163.86

a. There is an improvement of 72.6kcal/kwh with firing of blended coal when compared with Indonesian
coal.
b. Increased losses in Vacuum due to high ambient temperature effect is 12.95 kcal/kwh, otherwise the
SHR would be 2436.59kcal/kwh
c. SHR calculation with heat loss method is 2449.54 kcal/kwh but station heat rate (2613.4kcal/kwh)
by coal loss method is more by 163.86 kcal/kwh. Difference is due to coal feeder measurement
accuracy and coal losses in handling. Average difference should be normally below 50kcal/kwh.
 Auxiliary Power Consumption of BTG Data recorded during Internal Performance test

S.No Area UOM 28-Mar-16 21-May-16 Difference

1 ID Fan -4A kwh 1154 1003 -151
2 PA Fan -4A kwh 1074 1022 -52
3 SA Fan -4A kwh 578.33 646 67.67
4 CCW Pump -4A kwh 400.33 415.65 15.32
5 CEP-4B kwh 355 632.45 7.45
6 ESP kwh 138 135.79 -2.203
7 ID Fan -4B kwh 1161.67 1031.25 -130.42
8 BFP-4B kwh 3967 3798.25 -168.75
9 PA Fan -4B kwh 1078 1045.75 -32.25
10 SA Fan -4B kwh 640 667.6 27.6
11 USS-1 kwh 252 377.84 125.84
12 USS-2 kwh 128.67 146.998 18.33
13 SSS kwh 112 106.235 -5.77
14 Total kwh 11038.67 10758.82 -279.845
15 BTG % 7.38 7.17 -0.21

There is a reduction of 0.0.21 % in BTG auxiliary power consumption when blended coal of 4760 kcal/kg is fired when
compared to 4114 kcal/kg coal and optimization of process parameters.

CONCLUSION: Benefits with blended coal

a. Boiler Efficiency Gain : 2.95%

b. SHR Gain : 85.55 kcal/kwh
c. Auxiliary Power(BTG); 0.21%