Trial burning sludge to Boiler 9 PPL 2

PT South Pacific Viscose

QARD-2019
 Background + Objective

• Background
– SPV has any waste from their process, WWT plant and power plant. Such
as, WWT Sludge, DFA, bottom ash, mie tow
– WWT sludge has high content of SO3, sodium and zinc
– WWT sludge can be burnt on power plant that can produce high SO3 DFA

• Objective
– Knowing correlation about flow WWT sludge with DFA
– Even SPV burn the WWT sludge, it has to comply to Indonesia regulation
about SO2 emmision

Slide 2 of
 Methodology

• Plant trial with WWT sludge 25% (day 1: Oct 14), 50%(day 2: Oct 15),
75%(day 3: Oct 16) and 100%(day 4: Oct 17) flow rate to boiler 9 (PPL
2)
• Sampling point has identified on input until output. Sample take every
hour
Sample Name :
1. DFA PPL1
2. Bottom ash
3. DFA Economizer
4. DFA Bag filter
5. DFA Silo PPL2
6. WWT Sludge
7. Coal
8. Lime Powder

• Each daily sample will be composite and classified by flow rate WWT
sludge
Slide 3 of
 Operation Data

Coal Lime Slurry Flow Sludge Flow Estimation CEMs

Belt Press Belt Press Belt Press Belt Press

Time Boiler 9 Boiler 9 Boiler 9
No.2 No.3 No.2 No.3
Smoke O2 SO2 CO NO
TPH TPH m3/h m3/h TPH TPH
Mg/Nm 3

Day 1 (25 % flow) 18.68 1.44 14.98 1.05 10.28 4.5 281.01 7.79 112.01

Day 2 (50 % flow) 18.04 1.63 26.4 1.84 14.42 4.74 287.23 8.29 109.13

Day 3 (75 % flow) 18.8 1.82 29.7 15.47 2.07 1.08 20.63 4.38 365.71 10.17 109.69

Day 4 (100 % flow) 17.05 2.01 26.5 17.03 1.85 1.19 16.19 5.55 321.05 10.58 105.05

Day 5 (100 % flow) 17.98 2.01 34.32 20.23 2.4 1.41 18.96 5.1 295.06 11.05 107.04

1. CEMs data for SO2 maintained below the government limit

2. Increasing sludge flow from 25% - 100% flow to check increasing SO 3
on DFA
3. Lime feeding is increasing for capturing SO 3 from WWT sludge
4. There was problem on Day 4 with belt press around 4 hours, so the trial
did at Day 5
Slide 4 of
 DoS
% DoS

Time Average
WWT Lime Bottom DFA DFA Bag DFA Silo
DFA PPL 1 Economizer
Sludge Powder Ash Economizer Filter PPL 2
+ Bag Filter

Day 1 148.97 237.73 67.07 14.90 262.62 354.67 308.65 453.12

Day 2 286.74 242.39 44.00 49.39 437.31 445.21 441.26 302.25

Day 3 576.48 243.88 36.53 95.82 444.44 366.25 405.34 468.46

Day 4 453.80 237.99 38.13 80.58 604.00 505.68 554.84 409.28

Day 5 309.80 241.92 37.25 135.59 554.11 462.40 508.25 455.05

1. DoS (Degree of Sulfatisation) show us amount of SO3 that can bind

with total alkalis and release as clinker product. Standard of DoS in
cement is 80 – 120.
2. WWT sludge has same number of DoS, it also has DoS value lower
than both DFA (average mix DFA and silo PPL2)

Slide 5 of
 Correlation Amount of Sludge with SO3

• DFA Economizer • DFA Bag Filter:

TPH Sludge VS SO3 TPH Sludge VS SO3

8.00 8.00

6.00 f(x) = 1.32360179506368 x + 1.77543736560512 6.00f(x) = 0.853137017322857 x + 3.48156914509711

R² = 0.926521795496944
% SO3

R² = 0.950040130301089

% SO3
4.00 4.00

2.00 2.00

0.00 0.00
0.50 1.00 1.50 2.00 2.50 3.00 3.50 4.00 0.50 1.00 1.50 2.00 2.50 3.00 3.50 4.00
TPH Sludge TPH Sludge

As per data, we can see there is correlation between TPH sludge with
increasing SO3 on the product. High sludge that burn in boiler 9 will
produce high SO3 DFA.

Slide 6 of
 Conclusion

• As per data, we can see there is correlation between TPH sludge with
increasing SO3 on the product. High sludge that burn in boiler 9 will
produce high SO3 DFA
• DoS / Degree of Sulfatisation show amount of SO3 that can binding as
clinker product. Higher DoS means high of SO3 that can be coating in
cyclone hopper
• DoS WWT sludge is less than DFA, so better we are using WWT
sludge as alternative material than DFA from SPV

Slide 7 of
 Attachment
• Day 1 Data
3. FA FROM 4. (AB) FA FROM
2. BOTTOM ASH 5. FA FROM SILO 6. WWT SLUDGE 8. LIMESTONE
Parameter   1. FA PPL1 ECONOMIZER BAG FILTER PPL
PPL 2 PPL 2 PPL 2 PPL 2
PPL 2 2
WET CHEMISTRY ANALYSES              
Moisture Content % wt 0.19 0.04 0.02 0.08 0.12 39.56 0.03
kcal/
Heat Content kg 1028 n/d n/d n/d n/d 539 n/d
Total inorganic carbon % wt 0.59 0.38 0.66 0.89 0.68 2.31 11.57
Total organic carbon % wt 15.32 0.12 2.21 2.60 2.37 8.03 0.27
Total Carbon % wt 15.91 0.50 2.87 3.49 3.05 10.34 11.84
                 
MAIN OXIDES              
Loss on Ignition % wt 17.23 0.15 2.76 3.25 2.96 17.42 42.25
SiO2 ** % wt 32.22 50.28 33.13 25.67 27.47 0.31 1.22
Al2O3 ** % wt 14.30 17.32 12.56 11.03 11.48 0.83 0.83
Fe2O3 ** % wt 8.05 7.39 7.57 7.06 8.17 1.91 0.16
CaO ** % wt 18.87 18.94 30.39 35.96 34.59 35.43 54.79
MgO ** % wt 2.19 2.25 2.23 2.45 2.66 1.70 0.55
SO3 ** % wt 3.63 0.36 7.49 10.50 9.17 29.39 0.03
Na2O ** % wt 1.40 1.41 1.77 1.92 1.14 9.30 0.01
K2O ** % wt 0.74 0.73 0.67 0.56 0.65 0.41 0.04
P2O5 ** % wt 0.00 0.00 0.01 0.01 0.01 0.01 0.01
TiO2 ** % wt 0.80 0.75 0.69 0.63 0.74 0.18 0.04
Mn2O3 % wt 0.12 0.09 0.11 0.11 0.12 0.13 0.02
SrO % wt 0.07 0.06 0.06 0.07 0.08 0.01 0.04
Cl ** % wt 0.34 0.07 0.30 0.36 0.30 0.00 0.00
                 
Total of CaO, SiO2, Al2O3, Fe2O3* % wt 73.44 93.93 83.66 79.73 81.71 38.48 57.00
DoS   148.97 14.90 262.62 354.67 453.12 237.73 67.07
                 
TRACE ELEMENTS ANALYSES              
Arsenic (As)* ppm 2 6 <1 6 6 <1 <1
Cadmium (Cd)* ppm 1 2 2 1 2 2 2
Chromium Total (Cr)* ppm <3 12 4 <3 <3 <3 <3
Lead (Pb)* ppm 28 9 23 23 33 3 <1
Mercury (Hg)* ppm <0.2 <0.2 <0.2 <0.2 <0.2 <0.2 <0.2
Thallium (Tl)* ppm <0.5 <0.5 <0.5 <0.5 <0.5 <0.5 <0.5
Antimony (Sb)* ppm 1 0 0 1 1 2 1
Cobalt (Co)* ppm 7 24 8 6 9 <2 <2
Nickel (Ni)* ppm 43 84 45 45 56 <1 <1
Copper (Cu)* ppm 24 24 27 31 33 <3 17
Vanadium (V)* ppm 1 2 1 1 1 <0.7 <0.7
Zinc (Zn)* ppm 83 1466 2120 3802 2902 29632 34
Selenium (Se)* ppm <0.5 <0.5 <0.5 <0.5 <0.5 1 <0.5
Stannum (Sn) ppm 3 2 2 3 3 <1 2

Slide 8 of
 Attachment
• Day 2 Data
3. FA FROM 4. (AB) FA FROM
2. BOTTOM ASH 5. FA FROM SILO 6. WWT SLUDGE 8. LIMESTONE
Parameter   1. FA PPL1 ECONOMIZER BAG FILTER PPL
PPL 2 PPL 2 PPL 2 PPL 2
PPL 2 2
WET CHEMISTRY ANALYSES              
Moisture Content % wt 0.15 0.01 0.01 0.03 0.04 42.50 0.05
kcal/
Heat Content kg 733 n/d n/d n/d n/d 489 n/d
Total inorganic carbon % wt 0.99 0.08 0.88 0.87 0.72 2.53 11.60
Total organic carbon % wt 10.92 0.23 2.59 2.74 2.48 7.29 0.29
Total Carbon % wt 11.92 0.31 3.47 3.61 3.20 9.82 11.89
                 
MAIN OXIDES              
Loss on Ignition % wt 15.27 0.29 3.24 3.42 3.10 15.21 42.51
SiO2 ** % wt 27.76 48.45 29.43 23.34 26.47 1.06 1.07
Al2O3 ** % wt 12.13 16.01 10.04 9.71 11.09 0.97 0.75
Fe2O3 ** % wt 7.69 7.81 5.94 5.76 7.82 2.33 0.13
CaO ** % wt 27.83 20.04 33.96 38.04 35.58 35.02 54.85
MgO ** % wt 2.25 2.41 1.65 2.08 2.60 1.80 0.51
SO3 ** % wt 4.36 1.25 11.78 13.23 9.30 29.74 0.02
Na2O ** % wt 0.73 1.53 1.73 1.99 1.98 9.23 0.01
K2O ** % wt 0.68 0.66 0.54 0.47 0.61 0.41 0.04
P2O5 ** % wt 0.00 0.00 0.01 0.01 0.01 0.01 0.02
TiO2 ** % wt 0.72 0.70 0.53 0.54 0.70 0.21 0.01
Mn2O3 % wt 0.11 0.11 0.09 0.11 0.12 0.17 0.02
SrO % wt 0.06 0.06 0.05 0.07 0.08 0.02 0.04
Cl ** % wt 0.35 0.18 0.32 0.37 0.31 0.00 0.00
                 
Total of CaO, SiO2, Al2O3, Fe2O3* % wt 75.42 92.31 79.36 76.36 80.96 39.38 56.80
DoS   286.74 49.39 437.31 445.21 302.25 242.39 44.00
                 
TRACE ELEMENTS ANALYSES              
Arsenic (As)* ppm 6 8 3 2 8 3 <1
Cadmium (Cd)* ppm 2 2 2 2 2 2 2
Chromium Total (Cr)* ppm <3 14 4 <3 <3 <3 <3
Lead (Pb)* ppm 27 13 15 25 27 5 <1
Mercury (Hg)* ppm <0.2 <0.2 <0.2 <0.2 <0.2 <0.2 <0.2
Thallium (Tl)* ppm <0.5 <0.5 <0.5 <0.5 <0.5 <0.5 <0.5
Antimony (Sb)* ppm 1 <0.2 1 0 1 1 0
Cobalt (Co)* ppm 7 15 3 2 6 <2 <2
Nickel (Ni)* ppm 47 91 16 12 38 <1 <1
Copper (Cu)* ppm 29 15 23 29 37 <3 20
Vanadium (V)* ppm 1 1 1 1 1 <0.7 <0.7
Zinc (Zn)* ppm 86 4496 6627 8349 3138 38347 28
Selenium (Se)* ppm <0.5 <0.5 1 1 2 1 <0.5
Stannum (Sn) ppm 2 2 2 2 2 2 <1

Slide 9 of
 Attachment
• Day 3 Data
3. FA FROM 4. (AB) FA FROM
2. BOTTOM ASH 5. FA FROM SILO 6. WWT SLUDGE 8. LIMESTONE
Parameter   1. FA PPL1 ECONOMIZER BAG FILTER PPL
PPL 2 PPL 2 PPL 2 PPL 2
PPL 2 2
WET CHEMISTRY ANALYSES              
Moisture Content % wt 0.11 0.08 0.06 0.07 0.07 39.02 0.05
kcal/
Heat Content kg 824 n/d n/d n/d n/d 461 n/d
Total inorganic carbon % wt 1.07 0.13 1.08 0.96 0.73 2.20 11.61
Total organic carbon % wt 12.28 0.25 3.62 3.06 2.69 6.87 0.30
Total Carbon % wt 13.35 0.38 4.70 4.01 3.41 9.07 11.91
                 
MAIN OXIDES              
Loss on Ignition % wt 16.06 0.31 4.53 3.82 3.36 14.06 42.79
SiO2 ** % wt 20.85 48.52 24.15 16.53 21.23 1.16 0.91
Al2O3 ** % wt 8.84 15.48 8.86 7.62 9.14 1.02 0.61
Fe2O3 ** % wt 7.79 7.94 5.16 5.56 6.65 2.17 0.12
CaO ** % wt 37.92 17.87 36.57 41.53 39.71 34.88 54.88
MgO ** % wt 2.03 2.36 1.56 1.89 2.46 2.01 0.52
SO3 ** % wt 4.50 3.03 14.12 16.03 12.85 30.73 0.02
Na2O ** % wt 0.23 2.09 2.17 3.10 1.77 9.48 0.01
K2O ** % wt 0.58 0.55 0.43 0.43 0.53 0.41 0.04
P2O5 ** % wt 0.00 0.00 0.01 0.01 0.01 0.01 0.02
TiO2 ** % wt 0.69 0.65 0.51 0.59 0.62 0.19 0.01
Mn2O3 % wt 0.10 0.11 0.10 0.14 0.12 0.17 0.02
SrO % wt 0.06 0.04 0.05 0.07 0.07 0.02 0.04
Cl ** % wt 0.32 0.11 0.29 0.32 0.36 0.03 0.00
                 
Total of CaO, SiO2, Al2O3, Fe2O3* % wt 75.41 88.59 74.75 71.24 76.73 39.23 56.53
DoS   576.48 95.82 444.44 366.25 468.46 243.88 36.53
                 
TRACE ELEMENTS ANALYSES              
Arsenic (As)* ppm <1 7 4 <1 <1 4 <1
Cadmium (Cd)* ppm 2 2 1 1 1 2 2
Chromium Total (Cr)* ppm <3 9 <3 <3 <3 <3 <3
Lead (Pb)* ppm 19 14 15 17 27 <1 <1
Mercury (Hg)* ppm <0.2 <0.2 <0.2 <0.2 <0.2 <0.2 <0.2
Thallium (Tl)* ppm <0.5 <0.5 <0.5 <0.5 <0.5 <0.5 <0.5
Antimony (Sb)* ppm 2 2 1 1 0 1 <0.2
Cobalt (Co)* ppm 5 14 4 3 2 <2 <2
Nickel (Ni)* ppm 30 90 38 36 9 <1 <1
Copper (Cu)* ppm 17 13 25 27 30 <3 17
Vanadium (V)* ppm 1 1 <0.7 1 1 <0.7 <0.7
Zinc (Zn)* ppm 68 8965 14397 23269 10784 36713 15
Selenium (Se)* ppm <0.5 <0.5 2 2 <0.5 2 <0.5
Stannum (Sn) ppm 3 3 1 3 2 1 <1

Slide 10 of
 Attachment
• Day 4 Data
3. FA FROM 4. (AB) FA FROM
2. BOTTOM ASH 5. FA FROM SILO 6. WWT SLUDGE 8. LIMESTONE
Parameter   1. FA PPL1 ECONOMIZER BAG FILTER PPL
PPL 2 PPL 2 PPL 2 PPL 2
PPL 2 2
WET CHEMISTRY ANALYSES              
Moisture Content % wt 0.08 0.01 0.01 0.09 0.10 39.56 0.06
kcal/
Heat Content kg 703 n/d n/d n/d n/d 530 n/d
Total inorganic carbon % wt 2.13 0.10 1.07 0.83 0.71 2.63 11.67
Total organic carbon % wt 10.48 0.19 2.90 3.24 2.81 7.90 0.32
Total Carbon % wt 12.61 0.29 3.98 4.07 3.52 10.52 11.99
                 
MAIN OXIDES              
Loss on Ignition % wt 13.97 0.24 3.63 4.05 3.51 16.09 42.90
SiO2 ** % wt 23.43 49.28 22.92 21.23 21.43 1.01 0.88
Al2O3 ** % wt 11.09 15.38 8.36 8.74 9.05 0.93 0.68
Fe2O3 ** % wt 6.42 6.99 6.02 5.75 6.62 2.31 0.09
CaO ** % wt 36.42 18.44 39.55 38.63 40.26 33.29 54.94
MgO ** % wt 1.73 2.17 1.78 1.97 1.93 1.93 0.37
SO3 ** % wt 4.79 2.58 13.47 14.74 12.40 29.79 0.02
Na2O ** % wt 0.49 2.07 1.39 1.94 2.03 9.42 0.01
K2O ** % wt 0.50 0.63 0.52 0.48 0.48 0.42 0.03
P2O5 ** % wt 0.00 0.00 0.01 0.01 0.01 0.01 0.01
TiO2 ** % wt 0.66 0.85 0.57 0.54 0.54 0.21 0.01
Mn2O3 % wt 0.10 0.12 0.10 0.12 0.11 0.18 0.02
SrO % wt 0.06 0.04 0.05 0.06 0.06 0.02 0.04
Cl ** % wt 0.31 0.16 0.31 0.38 0.34 0.00 0.00
                 
Total of CaO, SiO2, Al2O3, Fe2O3* % wt 77.36 90.83 76.85 75.11 77.36 37.55 56.59
DoS   453.80 80.58 604.00 505.68 409.28 237.99 38.13
                 
TRACE ELEMENTS ANALYSES              
Arsenic (As)* ppm 6 11 4 <1 2 14 <1
Cadmium (Cd)* ppm 2 2 1 2 2 2 2
Chromium Total (Cr)* ppm <3 11 4 <3 <3 <3 <3
Lead (Pb)* ppm 21 12 13 20 18 <1 <1
Mercury (Hg)* ppm <0.2 <0.2 <0.2 <0.2 <0.2 <0.2 <0.2
Thallium (Tl)* ppm <0.5 <0.5 <0.5 <0.5 <0.5 <0.5 <0.5
Antimony (Sb)* ppm 1 0 0 <0.2 0 <0.2 0
Cobalt (Co)* ppm 5 13 <2 <2 4 <2 <2
Nickel (Ni)* ppm 26 103 6 3 39 <1 <1
Copper (Cu)* ppm 21 20 23 23 28 <3 18
Vanadium (V)* ppm 1 1 1 1 1 <0.7 <0.7
Zinc (Zn)* ppm 87 10031 12956 13237 12003 43932 19
Selenium (Se)* ppm <0.5 <0.5 2 1 1 1 <0.5
Stannum (Sn) ppm 2 2 1 2 2 1 1

Slide 11 of
 Attachment
• Day 5 Data
3. FA FROM 4. (AB) FA FROM
2. BOTTOM ASH 5. FA FROM SILO 6. WWT SLUDGE 8. LIMESTONE
Parameter   1. FA PPL1 ECONOMIZER BAG FILTER PPL
PPL 2 PPL 2 PPL 2 PPL 2
PPL 2 2
WET CHEMISTRY ANALYSES              
Moisture Content % wt 0.12 0.06 0.03 0.09 0.10 40.36 0.05
kcal/kg 698 n/d n/d n/d n/d 493 n/d
Heat Content
Total inorganic carbon % wt 1.25 0.21 0.84 0.90 0.79 2.45 11.67
Total organic carbon % wt 10.40 0.18 2.62 3.33 2.68 7.35 0.30
Total Carbon % wt 11.66 0.39 3.47 4.23 3.47 9.81 11.97
                 
MAIN OXIDES              
Loss on Ignition % wt 12.82 0.22 3.28 4.16 3.35 15.12 42.85
SiO2 ** % wt 21.01 45.94 22.77 17.15 20.16 1.07 0.90
Al2O3 ** % wt 10.36 14.74 8.40 7.97 8.31 0.97 0.65
Fe2O3 ** % wt 5.87 7.74 4.86 5.80 6.12 2.27 0.11
CaO ** % wt 40.73 19.78 36.20 40.34 40.06 34.20 54.91
MgO ** % wt 1.91 2.28 1.45 2.13 2.01 1.92 0.44
SO3 ** % wt 4.67 4.42 18.02 16.53 14.87 30.25 0.02
Na2O ** % wt 0.88 2.14 2.24 2.46 2.20 9.41 0.01
K2O ** % wt 0.43 0.58 0.42 0.46 0.51 0.41 0.04
P2O5 ** % wt 0.00 0.00 0.01 0.01 0.01 0.01 0.01
TiO2 ** % wt 0.69 0.83 0.49 0.59 0.58 0.20 0.01
Mn2O3 % wt 0.10 0.12 0.10 0.14 0.12 0.17 0.02
SrO % wt 0.08 0.04 0.05 0.07 0.07 0.02 0.04
Cl ** % wt 0.22 0.13 0.25 0.32 0.34 0.01 0.00
                 
Total of CaO, SiO2, Al2O3, Fe2O3* % wt 77.98 88.25 72.23 71.26 74.66 38.52 56.56
DoS   309.80 135.59 554.11 462.40 455.05 241.92 37.25
                 
TRACE ELEMENTS ANALYSES              
Arsenic (As)* ppm 4 11 4 3 3 7 <1
Cadmium (Cd)* ppm 2 2 2 2 2 2 2
Chromium Total (Cr)* ppm <3 11 4 <3 <3 <3 <3
Lead (Pb)* ppm 23 20 9 21 18 <1 <1
Mercury (Hg)* ppm <0.2 <0.2 <0.2 <0.2 <0.2 <0.2 <0.2
Thallium (Tl)* ppm <0.5 <0.5 <0.5 <0.5 <0.5 <0.5 <0.5
Antimony (Sb)* ppm 0 1 2 1 1 <0.2 0
Cobalt (Co)* ppm <2 13 3 3 4 <2 <2
Nickel (Ni)* ppm 3 98 28 34 31 <1 <1
Copper (Cu)* ppm 23 17 20 25 30 <3 18
Vanadium (V)* ppm 1 1 1 1 1 <0.7 <0.7
Zinc (Zn)* ppm 1833 9817 14419 18372 12681 39664 18
Selenium (Se)* ppm <0.5 <0.5 2 3 2 1 <0.5
Stannum (Sn) ppm 3 2 2 1 2 2 1

Slide 12 of
 Attachment
• Coal Data

Parameter Satuan Test Result

    D1 D2 D3 D4 D5

Total Moisture (ar) % 19.68 24.24 22.83 20.76 21.56

Proximate Analysis (adb)            

- Residual Moisture % 16.09 16.29 16.67 16.11 16.17
- Ash Content % 7.92 8.08 7.30 8.02 8.01
- Volatile Matter % 41.17 40.47 41.55 41.87 40.84
- Fixed Carbon % 34.81 35.16 34.48 34.00 34.98
Gross Calorific Value (adb) kcal/kg 5425 5409 5387 5387 5407.37
Total Sulfur (adb) % 0.55 0.57 0.55 0.54 0.55
Ash Composition            
- LoI % 1.89 2.57 5.46 2.36 2.27
- SiO2 % 46.70 47.30 45.57 44.79 46.26
- Al2O3 % 22.96 18.98 18.73 19.63 20.52
- Fe2O3 % 9.83 12.48 12.98 11.30 11.21
- CaO % 6.92 6.00 5.38 8.64 7.19
- MgO % 3.13 3.39 4.06 3.31 3.27
- SO3 % 5.55 6.40 4.85 7.12 6.36
- K2O % 0.82 0.81 0.81 0.77 0.80
- Na2O % 0.72 0.80 0.78 0.76 0.76

Slide 13 of
 Thank you
Slide 14 of