REPORT

COAL COMBUSTION MONITORING

UNWASHED SEMIRARA COAL

August 2021 Delivery

Prepared by:

PEDC Operations and Performance

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I. Introduction

Four barges of unwashed (4000 GAR) Semirara coal were delivered in PEDC with a total
quantity of 42,761.95MT. The first delivery arrived last August 03, 2021, and the unloading of
the last delivery was completed on August 17, 2021.

PEDC Operations and Performance groups performed coal combustion monitoring with the
use of unwashed Semirara (4000 GAR) coal in order to determine its resulting unit’s net fuel
rate considering that the plant operating parameters were maintained at design conditions. The
coal combustion monitoring was performed in the three units of PEDC wherein it was fired
using the subject coal at different blends during the stated period with varying load (refer to
Table 1). Regular monitoring and recording of plant parameters were carried out on a daily
basis and conducted disport coal analysis of samples collected during unloading of the said coal
delivery. Gathered data/results were then evaluated and used as basis to determine the
corresponding effects to the net fuel rate.

Table 1. Fuel Blend using Unwashed Semirara (4000 GAR) with Other Coal Type

Coal Blend
Date Used
PEDC Units 1 and 2 PEDC Unit 3
Indo (4500) Semi (4500) Semi (4000) Indo (4500) Semi (4500) Semi (4000)
August 05 17% 83% 67.00% 33.00%
August 06 100% 67.00% 33.00%
August 07 100.00% 100.00%
August 08 100.00% 100.00%
August 09 50.00% 100.00%
August 10 100.00% 100.00%
August 11 50.00% 100.00%
August 12 67.00% 33.00% 100.00%
August 13 100.00% 50.00% 50.00%
August 14 67.00% 33.00% 67.00% 33.00%
August 15 67.00% 33.00% 67.00% 33.00%
August 16 33.00% 67.00% 50.00% 50.00%
August 17 50.00% 33.00% 17.00% 50.00% 17.00% 33.00%

II. Coal Analysis

As shown in Table 2 is the comparison of various parameters between washed and

unwashed Semirara coal.

Table 2. Comparison of Washed and Unwashed Semirara Coal

Washed Deliveries of Unwashed Semirara (4000 GAR) Coal2

Basis / Semirara
Parameter
Unit (4500 GAR)
Coal1 August 03 August 05 August 08 August 13

Proximate Analysis
Total Moisture ARB / % 28.92 28.92 30.07 28.51 27.53
Inherent Moisture ADB / % 13.71 13.32 13.71 13.29 13.71
Ash Content ADB / % 7.72 19.63 20.30 20.36 18.64
Volatile Matter ADB / % 39.05 34.06 33.41 33.72 34.28
Fixed Carbon ADB / % 39.52 32.99 32.58 32.63 33.37
Total Sulphur ADB / % 0.53 0.79 0.70 0.82 0.86

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 Specific Energy
ADB /
GCV 5465 4559 4533 4525 4657
kcal/kg
ARB /
GCV 4501 3738 3673 3730 3911
kcal/kg
Note:
1 based on COSA of latest Washed Semirara Coal
2 based on COSA of Unwashed Semirara Coal (See Annex A)

In comparison with the washed Semirara (4500 GAR) coal, the unwashed Semirara (4000
GAR) coal has relatively high ash and sulphur content while having low amount of volatile
matter and fixed carbon that contributes to its low energy content ranging 3,600-3,900 kcal/kg.
Additionally, the moisture content of both coals is relatively the same. Furthermore, ultimate
and ash analyses are not reflected in the COSA, thus some indices were not calculated. Thus,
given such coal quality, it is likely that the boiler operations will encounter operational issues
and adjustments upon utilization. (See Annex B for the Coal Shipment Quality Report)

III. Data and Observations

Coal and Ash Handling

Issues encountered during the unloading of unwashed Semi coal and handling of ash with
the utilization of such coal as follows:

1. Low discharging or unloading rate due frequent clogging of belt conveyor chutes
attributable to extremely wet coal considering these coal deliveries were
loaded/shipped using barges that were directly exposed to prolong rainy condition
while in transit to the plant. Also, experienced frequent clogging of belt conveyor
chutes during coal stocking and reclaiming operation. Thus, helpers rendered overtime
to hasten de-clogging and to fast tract the completion of the activities.
2. Increase in ash production that resulted to hiring of Service Provider to
supplement PEDC dump trucks for fly ash evacuation and disposal.

Operational Data

The following daily average operational data (actual) composed of load, load factor and
net fuel rate were gathered and summarized based on the utilization of Unwashed Semirara
(4000 GAR) coal.

Page 3 of 17
Figure 1. Operational Data in PEDC Units 1 and 2

PEDC 1&2
1.200 120%

1.150
100%
1.100

1.050
Load Factor/ Coal Blend, %

80%

Net Fuel Rate, kg/kWh

1.000

0.950 60%

0.900
40%
0.850

0.800
20%
0.750

0.700 0%

Indo (4500 GAR) Washed Semi (4500 GAR)

August 3 (Unwashed)
August 8 (Unwashed)
AGM
Net Fuel Rate
Note: See Annex C for the Summary of Operational Data
August 5 (Unwashed)
August 13 (Unwashed)
Load Factor
ERC Cap

Throughout the period when unwashed Semirara coal was utilized, PEDC Units 1 and 2
experienced unstable operation starting August 08 to 12 resulting in unit deration with Pmax
ranging from 58MW to 82MW and 46MW to 82MW, respectively. In addition to these deration
events was the emergency shutdown of PEDC Unit 2 from August 11 to 12 that were all
attributable to the poor coal quality.

Some of the significant observations and abnormal deviations on the operating

parameters were clogging at coal crusher, coal bridging at silos, frequent tripping of coal
feeders, high furnace DP, low furnace temperature, low steam pressure and temperature,
continuous draining of bottom ash and clogging of bottom ash drain pipes, that eventually
resulted in compromising the units’ reliability and availability.

Furthermore, there was a significant increase in NFR observed when using unwashed
Semirara (4000 GAR) coal. As can be seen in Figure 1, the NFR was way above the ERC cap in
the period that the said coal was utilized at 100% blend. Additionally, when blended with other
coal (specifically 4500 GAR), NFR improved and on some dates the registered NFR was slightly
below the cap.

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Figure 2. Operational Data in PEDC Unit 3

PEDC 3
0.900 2500%

0.880

0.860 2000%
Load Factor/ Coal Blend, %

0.840

Net Fuel Rate, kg/kWh

0.820 1500%

0.800

0.780 1000%

0.760

0.740 500%

0.720

0.700 0%

Washed Semi (4500 GAR)

August 3 (Unwashed) August 5 (Unwashed)
August 8 (Unwashed) AGM
Load Factor Net Fuel Rate
ERC Cap
Note: See Annex C for the Summary of Operational Data

PEDC Unit 3 experienced the same conditions and observations with that of PEDC Units 1
and 2 wherein the unit was also derated starting August 08 to 14 with Pmax ranging from
100MW to 105MW mainly due to the poor coal quality. Also, utilizing unwashed Semirara (4000
GAR) coal in PEDC Unit 3 at 33-100% blend would result in very high NFRs way above its ERC
cap.

Shown in Tables 3 and 4, the comparison of using unwashed Semirara coal (4000 GAR)
and Indo coal (4200 GAR) to further see its impact to the units’ NFRs.

Table 3. Comparison of Unwashed Semirara (4000 GAR) Coal and Indo (4200 GAR) Coal in
PEDC Units 1 and 2
100% Galaxy August 07-11
Parameters
(4200 GAR) Coal1 100% Unwashed Semirara (4000 GAR) Coal
Average Load, MW 60.00 61.22
Load Factor, % 71.68 73.14
Net Fuel Rate, kg/kWh 0.7991 0.8921
Note:
1 based on the past 4200 GAR coal which registered the highest NFR in PEDC Units 1 and 2

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Table 4. Comparison of Unwashed Semirara (4000 GAR) Coal and Indo (4200 GAR) Coal in
PEDC Unit 3
100% Samsung August 07-12
Parameters
(4200 GAR) Coal 1
100% Unwashed Semirara (4000 GAR) Coal
Average Load, MW 110.00 108.89
Load Factor, % 73.33 72.59
Net Fuel Rate, kg/kWh 0.7400 0.8078
Note:
1 based on the past 4200 GAR coal which registered the highest NFR in PEDC Unit 3

It can be noted that using 100% Indo (4200 GAR) coal was way better than unwashed
Semirara (4000 GAR) coal given that the three units have operated at relatively the same load
for the two scenarios wherein the differences in the NFRs were about 0.1 kg/kWh and
0.07kg/kWh in PEDC Units 1 and 2 and PEDC Unit 3, respectively.

To see the effect of using unwashed Semirara (4000 GAR) coal relative to the direct
consumables considering its coal quality where the optimum limestone and sand consumption
rates were computed are shown below:

Table 5. Coal Data

Coal Supply Unwashed Coal (Semirara 4000 GAR)
Delivery Date August 3-8, 2021
Sulphur Content, % (ADB from COSA) 0.78
Optimum Limestone Rate, MT/1000MT Coal 17.88-53.43
Ash Content, % (ADB from COSA) 22.41
Optimum Sand Rate, MT/1000MT Coal 0.00

Figure 3. Limestone Consumption

100.00
90.00
80.00
70.00
Limestone Consumption, MT

60.00
50.00
40.00
30.00
20.00
10.00
0.00
1

1
/2

/2

/2

/2

/2

/2

/2

/2

/2

/2

/2

/2

/2
5

7
/0

/0

/0

/0

/0

/1

/1

/1

/1

/1

/1

/1

/1
08

08

08

08

08

08

08

08

08

08

08

08

08

PEDC Unit 1 PEDC Unit 2

PEDC Unit 3 Optimum Limestone Consumption

Figure 4. Sand Consumption

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 14

12

10
Sand Consumption, MT

0
1

1
/2

/2

/2

/2

/2

/2

/2

/2

/2

/2

/2

/2

/2
5

7
/0

/0

/0

/0

/0

/1

/1

/1

/1

/1

/1

/1

/1
08

08

08

08

08

08

08

08

08

08

08

08

08
PEDC Unit 1 PEDC Unit 2
PEDC Unit 3 Optimum Sand Consumption

Comparing the actual operational data upon utilizing 100% unwashed Semirara (4000
GAR) coal last August 07-11 versus the computed optimum limestone and sand consumption
rate with the given coal quality, it can be noted that three units where within the optimum level
except PEDC Units 1 and 2 wherein it has exceeded the range for its optimum limestone
consumption rate last August 7,8, and 11.

Furthermore, the boiler operations of PEDC Units 1 and 2 were considered unstable
since the said units consumed/co-fired diesel with coal just to maintain the furnace temperature
at its design conditions. As shown in Table 6 that PEDC Units 1 and 2 were able to consume a
total of 15,774L for the said purpose.

Table 6. Diesel Consumption

Diesel Consumption, L
Date
PEDC Unit 1 PEDC Unit 2 PEDC Unit 3
August 4, 2021 1,076.00 0.00 0.00
August 8, 2021 1,434.00 0.00 0.00
August 9, 2021 372.00 1,779.00 0.00
August 10, 2021 5,736.00 0.00 0.00
August 11, 2021 1,434.00 0.00 0.00
August 18, 2021 1,434.00 2,509.00 0.00
TOTAL 11,486.00 4,288.00 0.00

IV. Evaluation/Recommendation

In view of the findings above, this coal combustion performance of unwashed Semirara
(4000 GAR) had resulted in many operational challenges, additional expenses, and opportunity
losses plus the relatively high NFRs above the ERC cap in PEDC Units 1 and 2 (0.8124 kg/kWh)
and in PEDC Unit 3 (0.7217 kg/kWh) that can be all attributable mainly to its poor quality (low
CV, high moisture, and high ash). Even if blended with high CV coal, it will be not still enough
to attain the operational requirements. In result, the unwashed Semirara (4000 GAR) coal can
be considered not suitable as one of the supplies to PEDC operations.

Annex A

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 Certificate of Sampling and Analysis

First Shipment

Second Shipment

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Third Shipment

Page 9 of 17
Fourth Shipment

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 Annex B

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 Coal Shipment Quality Report

First Shipment

Second Shipment

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Third Shipment

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Fourth Shipment

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 Annex C

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 Summary of Operational Data

PEDC Units 1 and 2

Net Fuel Rate, Load Factor,
Date Load, MW
kg/kWh %
08/05/21 0.771 63.60 75.99%
08/06/21 0.794 63.28 75.60%
08/07/21 0.853 60.74 72.57%
08/08/21 0.853 67.13 80.20%
08/09/21 0.872 66.90 79.93%
08/10/21 0.943 57.80 69.05%
08/11/21 0.998 50.49 60.32%
08/12/21 0.809 53.61 64.05%
08/13/21 0.799 57.39 68.56%
08/14/21 0.823 54.48 65.09%
08/15/21 0.895 50.13 59.89%
08/16/21 1.040 44.78 53.50%
08/17/21 0.887 50.98 60.90%

PEDC Unit 3
Net Fuel Rate, Load Factor,
Date Load, MW
kg/kWh %
08/05/21 0.752 131.64 87.76%
08/06/21 0.725 131.18 87.45%
08/07/21 0.739 123.39 82.26%
08/08/21 0.808 111.85 74.57%
08/09/21 0.807 104.95 69.97%
08/10/21 0.810 104.80 69.87%
08/11/21 0.880 103.98 69.32%
08/12/21 0.815 104.35 69.57%
08/13/21 0.824 103.16 68.78%
08/14/21 0.775 112.48 74.99%
08/15/21 0.753 107.13 71.42%
08/16/21 0.740 113.67 75.78%
08/17/21 0.766 112.26 74.84%

Date Limestone Consumption, MT/1000MT Coal

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 PEDC Unit 1 PEDC Unit 2 PEDC Unit 3
August 5, 2021 20.02 82.54 47.75
August 6, 2021 93.00 69.90 64.40
August 7, 2021 68.01 63.65 51.06
August 8, 2021 67.11 69.86 11.81
August 9, 2021 53.46 48.49 15.89
August 10, 2021 46.78 43.45 10.56
August 11, 2021 57.79 82.44 0.00
August 12, 2021 83.47 66.37 0.00
August 13, 2021 92.05 75.71 0.00
August 14, 2021 91.58 52.42 0.00
August 15, 2021 61.44 83.00 0.00
August 16, 2021 51.42 51.19 10.41
August 17, 2021 30.04 34.00 10.55

Sand Consumption, MT / 1000 MT Coal

Date
PEDC Unit 1 PEDC Unit 2 PEDC Unit 3
August 5, 2021 0.00 0.00 0.57
August 6, 2021 0.00 0.00 0.00
August 7, 2021 0.00 0.00 0.00
August 8, 2021 0.00 0.00 0.00
August 9, 2021 0.00 0.00 1.14
August 10, 2021 0.00 0.00 0.00
August 11, 2021 0.00 0.00 0.00
August 12, 2021 0.00 0.00 0.00
August 13, 2021 0.00 0.00 0.00
August 14, 2021 0.00 0.00 0.60
August 15, 2021 0.00 0.00 0.00
August 16, 2021 0.00 0.00 0.00
August 17, 2021 12.84 5.55 0.00

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