Maintaining Performance and Lifetime of Boiler Assets During Implementation of Cofiring and Coal Switching by Using Integrated Digital Boiler Combustion Tuning

Abstract

Implementing coal switching and co-firing at the JPR coal-fired power plant significantly impacts life assets and plant performance, especially in the boiler. This phenomenon happens because low-calorie coal and biomass in Indonesia have a very high water content of up to 56%. According to the problem, an improvement based on a digital system was carried out to adjust the combustion pattern to achieve the operation parameter target for the main boiler equipment. This study was completed in three steps: first, the mixing characteristics of biomass and coal were validated; second, the combustion process was optimized through boiler tuning, which involves figuring out the best value for every fuel modification; and third, a digital platform was developed to make the process of controlling, monitoring, and optimizing combustion more straightforward. The work process begins with inputting daily operation planning data, and then the digital boiler system identifies fuel needs based on availability at the coal yard. Moreover, it also shows the recommendation for the baseline operating parameters executed by the plant operator. The system automatically warns if there is a difference between the actual operating pattern and the baseline. As a result, this study creates a symmetrical fireball concerning the combustion chamber and reduces SO2 and NOx emissions. Boiler performance indicators such as O2 outlet at 3-4 % and other indicators can operate within the baseline parameter. Boiler efficiency increased by 0,8 %, or equivalent to savings of $ 1.272.992,83, and decreased electricity generation cost to $ 0,000081/kWh. The pipe thickness rate is also reduced, preventing leakage in the boiler and, as an indication, increasing the boiler’s lifetime.