Optimization of Fuel Additive Utilisation at Boiler of Paiton Coal Fired Steam

Power Plant Unit 1& 2

By : Sugiyanto
email: sugiyanto@ptpjb.com

I. Introduction
1.1. The Paiton Steam Power Plant Operation Description

The Paiton steam power plant Unit 1&2 consist of 2 x 400 MW pulverized coal
firing boiler. The plant has been in operation since 1993/1994 with variety of coal supply
from Kalimantan island of Indonesia. The boiler vendor is ABB-Combustion
Engineering, USA ( now Alstom Power Boiler ). The basic design of the boiler is
tangential firing with reheater, 5 elevation of burner, main steam condition : 540 oC , 167
kg/cm2, MCR ( maximum continues rating) steam flow 1330 ton/hr reheater design was
540 oC , 42 kg/cm2 . The design of coal fuel for boiler is bituminous coal of HHV 6040
kcal/kg ( ar) and sub-bituminous coal. Each boiler has 5 coal mills of HP 963 , 4 mill in
service and one(1) as spare .
The slagging on the furnace of boiler was detected since 2007 after changing
supply of of coal, the deposition of slag mostly concentrated at the division panel of
superheater ( S-28) and the final reheater. The sootblower was not installed for these area
as per design of boiler. The effect of the slag deposit was the increasing of flue gas
temperature on the range of ( 5 - 15) oC , that is equivalent with the decreasing the boiler
efficiency of (0.25 -0.75)%. The magnesium based coal additive was tested to see the
effectiveness on slag removal.

1.2. The consideration of Fuel Additive Utilization

There were several technology available dealing with the slagging and fouling issue on
the coal fired boiler. The EPRI ( electric power research institute ) had research
technologies for slagging and fouling mitigation; namely :
a. Intellegent sootblowing system
b. Sonic horn cleaning
c. Accoustic cleaning
 d. Fuel additive ( combustion optimizer)
The fuel additive was adopted at Paiton boiler rather than other technologies due
to the reasons below ;
a. The coal supply has no long term contract, so the coal type and quality will
variably from time to time
b. There is not need big capital investment
c. Can be optimized the dosage depend on the degree severity of slagging
d. Widely used at pulverized coal boiler
e. The cost likely feasible
f. No modification required on the existing plant
g. No negative effect to the boiler tube life

II. Slagging and Its Effect

2.1. Ash chemistry
The salgging tendency usually can be predicted by the ash chemistry composition
1. Acids (A) : Silicon dioxide (SiO2), Aluminum oxide (Al2O3), Titanium dioxide
(TiO2)
2. Bases (B) : Iron oxide (Fe 2O3), Calcium oxide (CaO), Magnesium oxide (MgO),
Potasium oxide (K2O), Sodium oxide (Na2O)

R= B/A
R= (Fe2O3+CaO + MgO + Na2O + K2O(/ (SiO2 + Al2O3 + TiO2)

If R 0.4 to d 0.7 →High Slagging Potential.

2.2. The Effect of slagging

The effect of slag deposite on tube surface :
1. Reduce the heat transfer, reduce boiler efficiency
2. High temperature corrosion
3. Tube metal overheating.
4. Shorthen the tube life
2.3.How the Coal Additive Working
The chemical reaction of magnesium based coal additive :

MgO + SO2 ↔ MgSO3

The formation of magnesium sulfit (MgSO3 ) has friable characteristic which

make slag deposit easy to breakdown .

2.4. The available Coal Additives at the market

a. Magnesium base
b. Silica base
c. Organic base
d. Others
2.5. Technical specification of magnesium base fuel additive :
Physical Properties (Typical):
Product : Magnesium based
Based : Magnesia Combustion Improver
Loss on Drying : 0,40 %
Specific Gravity : 2,36
Application dosage : variable

III. The Method of Test

3.1. The Description of slagging and fouling in Paiton SPP boiler
The Fig 3.1. showing the upper half of the furnace of boiler Paiton steam power
plant. The slag deposit mostly located at the superheater devisison panel S-28 and S-31.
The slag also covered several of the wall tube,and final reheater R-12 . The absence of
sootblower at area of S-28 and S-31 make the slag deposit uncontrollable. The most
risk of the slag is when the big piece of slag falling down into the bottom furnace tube , it
will lead tube leak. The thickness of slag deposited up to 30 cm.
 Fig 3.1. The upper half of furnace

3.2. The method of injection of Fuel additive

There were several methods of fuel additive injection on coal fired power plant.
The most commonly used was injection of fuel additive at the coal feeder and at coal belt
conveyor. These two methods will be effective only if the slag deposited almost in all
surface of the furnace, in case the slag deposited only at several area of the furnace these
methods are not efficient. The table 3.1. as the guidance to determine where the point of
injection of fuel additive to get effective and efficient procedure.

Table.3.1 The method of fuel additive injection

No Point of Injection Fuel Additive Effectiven Tool for Injection
Consumption ess
1 Coal Conveyor ∆∆∆∆ ∆ Permanent /high
coast
2 Coal Feeder ∆∆∆∆ ∆∆ Permanent/high cost
3 Furnace – Random Point ∆∆ ∆∆∆ Portable/low cost
4 Furnace- CFD Assisted ∆ ∆∆∆∆ Portable/low cost

3.3. The flow chart of the CFD aided fuel additive injection
a. The CFD(computational fluid dynamic) of combustion in boiler
The computational fluid dynamic ( CFD) based on FLUENT has been used to
model the combustion process in the furnace of the boiler. The model was developed at
2006 when there was problem on the un even gas distribution at final reheater tube banks.
The HRL ‘ ( Australian Engineering Company) was assigned for this modeling. The
model has been verified and tested for the accuracy, so it is can be used to study the
other behavior of the combustion on the furnace. The coal particle trajectory (route )
from burner tip to the upper furnace can be visualized by using of the model. Further, the
injection point of coal additive can predict precisely to shoot the S 28 and S-31
superheater panel where the slag was deposited.
The tangential firing of Alstom design is based on the formation of fireball inside
the furnace. The mixture of combustion air and pulverized coal flowing in tangential
angle to form the circular pattern of flame inside the furnace. The combustion process of
coal particle occur at the front of the burner tip till the complete at the front of the OFA (
over fire air ) . According to the Fig. 3.2. the particle and gas flowing in the circular
pattern, the highest level of burner it turn about 2.5 times before reach to the area of S-28
and S-31. The gas flow mostly flowing through middle edge of furnace rather than in the
center of furnace.

b.The particle trajectory in furnace

The Fig. 3.2. was the FLUENT model of Paiton boiler which showing the particle
trajectory inside the furnace. In this experiment this model will be used to determine the
injection point of fuel additive.
 Fig.3.2. The particle trajectory of CFD model

c. The determination of injection point of fuel additive for S-28 and S-31
The injection point of coal additives for S-28 and S-31 superheater panel was
determined by two factors , the CFD model and availability of peephole at boiler wall .
The availability of peephole at the furnace wall is key success of the effective injection to
shoot the slag target at the S-28 and S-31. Unfortunately, at several area of furnace wall
the peephole was not available. The table 3.2. showing the point of injection , and dosing
rate of CA(coal additive) for each location.
Table 3.2. Point of injection and dosage of fuel additive
No Location of Injection Distance to Dosage rate Depth of injection (from
(peephole) S-28 ( m) (kg/day) wall tube) ( m )
A Seventh floor of boiler
Peep hole no 1 to 12 1.5 m 3 kg/hole 0.5 to 4 m
b Fourth floor of boiler
Peep hole no 1 to 8 15 m 2 kg/hole 1 to 4 m
c Second floor of boiler
Peephole no 1,3,5,7 30 2 kg/hole 1 to 4 m
Total injection 60 kg/day
3.4. The tool of injector
The tool of the experiment consist of the portable pneumatic ejector as shown at
Fig. 3.3. The tool has specification as below ;
Name of tool : Pneumatic Powder Ejector
Capacity of bin : 30 kg
Feed tube : SS 316 , 1 inch OD, 4 meters length
Press air supply : 6 bar
Mode of operation : Portable , manual operated
Capacity of injection : 20-40 kg/hr

portable coal
additive tank

Inlet Valve

Preesurised Air

Stainless stell feed tube Pneumatic ejector

( 4 meters)

Fig. 3.3. The Fuel Additive Injector

3.5. The Procedure of trial operation

The test was done by following procedure :
a. The boiler was operate at normal load ( under LDC)
b. The coal type may varying during test
c. The period of test and observation is for 20 days, consist of 10 days consecutive
with fuel additive injection and rest 10 days for observation only.
d. The injection to be performed on daily basis, from 08.00 to 12.00 am
 e. The observation of S-28 and recording of flue gas temperature was taken on daily
basis at full load condition
f. The daily dosage of fuel additive was 60 kg, the total was 600 kg for 10 days test
g. The tool as per fig.3.3
h. The location of injection as per table 3.2

Safety precaution :
Due to working on the risky area such as boiler area, the safety precaution during test was
established. The safety apparatus during test are : gloves heat resistant, peephole heat
exposure protection, the ear plug, and the masker to prevent inhalation of coal additive
powder .

3.6. The KPI(key performance indicator) test of fuel additive

The key performance indicator of the test consist of the two parameters, first is
the visual appearance at the S-28 and the second is the flue gas temperature . The visual
inspection at S-28 was done as periodical basis during test while the recording
temperature at flue gas was picked up from DCS . The indicator such as boiler
efficiency , turbine heat rate and thermal efficiency was not used due to variability of
coal calorific value during test. The table 3.3 showing the degree of cleanliness of tube
S-28 during the test. The dedicated Operator to observe and record the appearance of
tube panel on daily basis at the pre determined operation condition.

Tabel 3.3. The KPI test of fuel additive

No Legend The Condition of Slag Remark
Deposit
1 ∆ Clean Slag thickness < 1 cm
2 ∆∆ Slightly Clean Slag thickness more than 1 cm but
less than 10 cm and spread over
surface of several area of tube
panel
3 ∆∆∆ Dirty Slag thickness more than 10 cm
but less than 30 cm and spread
over surface of the tube panel
4 ∆∆∆∆ Very Dirty Slag thickness > 30 cm and spread
over surface of tube panel
 The flue gas temperature was used to measure the effectiveness of the CA . If the
CA is successfully make the slag deposit fall down from the S-28 tube panel it will make
the heat absorption increase, so the flue gas temperature will decrease. The decreasing of
flue gas temperature of 10 o C will improve boiler efficiency as much as 0.5% ( Ref, 1).
This reference will be used as cost and benefit analysis for the utilization of coal
additive.

IV. The Evaluation

4.1.The result
The table 4.1 is the result of the test which record the KPI parameters during 20
days test. The first of 10 days the furnace was injected with fuel additive. The breakdown
of the slag deposit at S-20 was observed since day fourth and became stagnant at day
seventh. At day tenth the injection was ended , while it was observed that after 4 days the
slag build up grown as the day second. The slag was not able to be cleaned properly
especially at panel 2,3,and 5, this is mostly due to peephole of the injection was not
closed to the panel, there was angle to shoot the panels. The Fig 4.1 showing the panel S-
28 before and after injection.

The flue gas temperatute

Fig 4.1. The S-28 before and after test

Table 4.1. test record and observation
 Panel 1 Panel 2 Panel 3 Panel 4 Panel 5 Panel 6 Temp. Flue
No. Date Injection (kg) SUPERHEATER S-28 PANEL gas (°C) Load (MW)
1 May, 12 2008 60 ∆∆∆∆ ∆∆∆∆ ∆∆∆∆ ∆∆∆ ∆∆∆∆ ∆∆∆ 154 400
2 May, 13 2008 60 ∆∆∆ ∆∆∆ ∆∆∆∆ ∆∆∆ ∆∆∆∆ ∆∆∆ 153 400
3 May, 15 2008 60 ∆∆∆ ∆∆∆ ∆∆∆ ∆∆∆ ∆∆∆ ∆∆∆ 152 400
4 May, 16 2008 60 ∆∆ ∆∆∆ ∆∆∆ ∆∆∆ ∆∆∆ ∆∆ 148 400
5 May, 17 2008 60 ∆ ∆∆ ∆∆∆ ∆∆∆ ∆∆ ∆∆ 144 400
6 May, 18 2008 60 ∆ ∆∆ ∆∆ ∆∆ ∆∆ ∆ 143 400
7 May, 19 2008 60 ∆ ∆∆ ∆∆ ∆∆ ∆∆ ∆ 142 400
8 May, 20 2008 60 ∆ ∆∆ ∆∆ ∆∆ ∆∆ ∆ 141 400
9 May, 21 2008 60 ∆ ∆∆ ∆∆ ∆∆ ∆∆ ∆ 142 400
10 May, 22 2008 60 ∆ ∆∆ ∆∆ ∆∆ ∆∆ ∆ 141 400
11 May, 23 2008 0 ∆ ∆∆ ∆∆ ∆∆ ∆∆ ∆ 142 400
12 May, 24 2008 0 ∆∆ ∆∆ ∆∆ ∆∆ ∆∆ ∆∆ 143 400
13 May, 25 2008 0 ∆∆ ∆∆∆ ∆∆∆ ∆∆∆ ∆∆ ∆∆ 147 400
14 May, 26 2008 0 ∆∆∆ ∆∆∆ ∆∆∆ ∆∆∆ ∆∆∆ ∆∆∆ 151 400
15 May, 27 2008 0 ∆∆∆ ∆∆∆ ∆∆∆ ∆∆∆ ∆∆∆ ∆∆∆ 153 400
16 May, 28 2008 0 ∆∆∆ ∆∆∆ ∆∆∆ ∆∆∆ ∆∆∆ ∆∆∆ 153 400
17 May, 29 2008 0 ∆∆∆ ∆∆∆ ∆∆∆ ∆∆∆ ∆∆∆ ∆∆∆ 152 400
18 May, 30 2008 0 ∆∆∆ ∆∆∆ ∆∆∆ ∆∆∆ ∆∆∆ ∆∆∆ 152 400
19 May, 31 2008 0 ∆∆∆ ∆∆∆ ∆∆∆ ∆∆∆ ∆∆∆ ∆∆∆ 152 400
20 June,1 2008 0 ∆∆∆ ∆∆∆ ∆∆∆ ∆∆∆ ∆∆∆ ∆∆∆ 152 400

The utilization of fuel additive should consider the cost and benefit to evaluate
the whether it is has benefit or not. The table 4.2. showing the balance between cost and
benefit. The assumption of analysis is :
-Price of coal : $ 50/ton
-Price of fuel additive : $5/kg ( not include the cost for injection)
-The 10oC of flue gas temperature decreasing will equal 0.5% of boiler efficiency
improvement
-The other parameter of boiler kept at similar condition during test
The result in the point of view of cost, the test it seem feasible, the ratio of benefit to the
cost is > 4. On the other hand, other benefit such as prevention high temperature
corrosion and the risk of tube leak due to overheating are not calculated.
The above achievement of the test proven that method has been developed able to
reduce the consumption of fuel additive than conventional method. If the conventional
method was applied ( as per fuel additive vendor experience at other power plant), it will
consume about 3-4 times than consumed during this test. In this method of test, the
additive directly shoot the target of slag deposit, which the conventional method would
not.
Table 4.2. The cost and benefit analysis

Temp. Flue Flue gas temp Boiler eff. Coal saving $ saving due Cost of fuel
Day no gas (°C) decrease Improvement % (ton) to coal additive $ Load (MW)
1 154 13 0 0.00 0 300 400
2 153 12 0.05 2.25 112.5 300 400
3 152 11 0.1 4.50 225 300 400
4 148 7 0.3 13.50 675 300 400
5 144 3 0.5 22.50 1125 300 400
6 143 2 0.55 24.75 1237.5 300 400
7 142 1 0.6 27.00 1350 300 400
8 141 0 0.65 29.25 1462.5 300 400
9 142 1 0.6 27.00 1350 300 400
10 141 0 0.65 29.25 1462.5 300 400
11 142 1 0.6 27.00 1350 0 400
12 143 2 0.55 24.75 1237.5 0 400
13 147 6 0.35 15.75 787.5 0 400
12375 3000

V.Conclusison
a. The CFD assisted additive injection able to reduce the consumption of additive
b. The intermittent injection ( 10 days injection) and followed 4 days without injection ,
is the lowest cycle cost for fuel additive utilization

VI. Reference
1. The heat rate hand book, The Southern Company,USA
2. The Paiton boiler design manual volume 1-3, ABB –CE , 1993
3. The Aderco fuel additive web : www.aderco.com
4. Mulyawan, The result of test of magnesium base fuel additive, BPPT ,2006