Coal Yard Research Articles

Improve Coal Blending Optimization in CFPP by Cromosom and Fitness Function Redefinition of the Genetic Algorithm

Blending coal before it enters the power plant boiler unit is necessary to adjust the coal categories according to the boiler unit specifications. The power plant must also comply with the regulations regarding coal-biomass co-firing through blending. Applying a Genetic Algorithm that only considers the composition and fitness based on the blend's quality leads to accumulation issues, decreasing coal quality. This research proposes redefining chromosomes, fitness functions, mutation rules, population determination, and output as the best chromosome used in the Genetic Algorithm. Testing uses various compositions of coal inputs from the barge, coal yard, and biomass to simulate different conditions. The test results demonstrate that the developed algorithm can provide all possible alternative blends between the coal in the barge and at the coal yard. Under specific conditions, operators can choose a blend composition that involves coal stored in the coal yard for an extended period.

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

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.

Energy Management Assessment through Case Study in Coal Handling System of Coal-Fired Power Plant

Coal Handling System (CHS) is the main system of Coal Fired Power Plant (CFPP), managing coal transportation from Vessel by Ship Unloader to coal yard through belt conveyor (BC) and Stacker/Reclaimer (S/R), then transported to Silo, known as forwarding process. CHS involves various large electric motors. The unwisdom of operating these motors would result in wasteful electrical energy consumption. To assess the energy management, United Nations Industrial Development Organization (UNIDO) provides Energy Management System (EnMS) tools based on ISO 50001 industrial sectors. This tool identifies that operational patterns and maintenance activities have a significant impact on the energy consumption. Technically using Integrated SKF Calculation, applying the scenario of direct replacement conveyor rollers aged more than 2 years by only 30%, saves 103,144.20 kWH per cycle, equal to IDR 102,807,951, rather than replacing rollers when broken only. Meanwhile, Lean Six Sigma concept in increasing cycle performance, could save a monthly 594,984 kWH, equal to IDR 593,044,189.

Development of Sustainable Dust Compression System for Coal Yard Safety

A sustainable water mist spray system for a closed coal yard. The project aims to address the need for dust suppression in the coal yard to mitigate environmental and health risks. The design specifications will be determined by considering the coal yard's size, layout, and specific requirements. The system will utilize a pneumatic air vane motor powered by residual dry steam from the plant's operation and, coupled with a fan for effective mist dispersion. Ro Reject water, a byproduct of reverse osmosis water treatment, will be used as the water source. The project will involve collaboration with mechanical engineering, fluid dynamics, and environmental studies to develop an optimized system design. Field tests will be conducted to validate the system's functionality, mist spray effectiveness, and coverage area. Safety features will be installed to ensure operator protection, and training programs will be developed to educate operators on safe system operation. The effectiveness of the mist spray system will be evaluated and monitored through regular assessments and data collection. Maintenance activities will be conducted to ensure system functionality, and safety features will be updated as necessary. The successful implementation of this sustainable water mist spray system will contribute to dust suppression, environmental sustainability, and safety in the coal yard.

Study on the development path of cultural tourism integration in Yubai Village in the context of rural revitalization

As a historical node on the coal transportation route along the Old Road of Western Beijing, Yubai Village served as an important business travel station. However, as time passed by, the Old Road of Western Beijing transport line gradually declined, the Mentougou District coal yard shut down, the service function of Yubai Village disappeared, and the local industry development became slow, necessitating revitalization of the village economy. At present, rural revitalization has become an important strategy to promote rural modernization, and Yubai village has ushered in new opportunities for development. The village can rely on its regional advantages, adjust its own development direction, and become a distribution center on the tourism route. Based on the previous field investigation and literature review of Yubai Village, this paper integrates the current resources of the village, analyzes its realistic development predicament, and, from the perspective of culture and tourism integration, proposes new strategies suitable for the development of Yubai Village, such as improving the overall reception services, improving the village landscape node, improving the village road system, carrying out research and education activities, and developing derivative cultural and creative brands. The purposes are to extend the stay time of tourists and give full play to the function of a service station, realize the revitalization of industry, promote the economic development of the village, and provide a reference for the development of similar villages in the future.

Environmental impact assessment of the coal yard and ambient pollution.

This study investigates the vertical distribution of pollutants emitted from coal yards using unmanned aerial vehicles (UAVs). Vertical concentration measurements of black carbon (BC) and particulate matter (PM) inarange of 1m to 100m above ground level (AGL) in the central coal yard showed clear spatial patterns and gradients of these pollutants. In addition, measurements were taken at specific heights (1 m, 30 m AGL, and60mAGL) at seven locations approximately 3 km from the yard. Thirteen measurements were carried out during the non-heating period under similar weather conditions. The measured BC concentrations decreased significantly with increasing altitude, with ground-level concentrations reaching 1.88 ± 0.61µg/m3 and decreasing by over 46% at 80 m AGL. Similarly, PM10 concentrations at 60 m AGL decreased by 21.7%, with values of25.99 ± 9.24µg/m3 measured near the ground level and 16.52 ± 8.31µg/m3 at 60 m AGL. The maximum coal particle pollution from the coal depot ranges from 500 to 1,000 m. The study showed a significant decrease in BC concentrations with height above the coal yard surface. Concentrations of PM10 and PM10-TSP showed a complex distribution influenced by local emissions and long-range particle transport. Meteorological factors, especially wind speed and direction, significantly influenced the pollutant dispersion. In addition, higher pollutant concentrations were measured during dry periods than after rainfall. The findings of this study contribute to abetter understanding of the dispersion patterns and potential impacts of coal dust, enabling the implementation of targeted mitigation strategies and improved pollution control measures.

Overall distribution of tire-wear particles, nano‑carbon black, and heavy metals in size-fractionated road dust collected from steel industrial complexes

Tire-wear particles (TWP) from vehicles serves as a non-exhaust emission source. The mass content of metallic species in road dust may increase owing to the traffic of heavy vehicles and industrial activity; consequently, metallic particles are also present in road dust. Herein, road dust collected from steel industrial complexes with high traffic of high-weight vehicles and the composition distribution of five size-fractioned particle sizes were analyzed. Road dust samples were collected from three areas near steelmaking complexes. The mass distribution of TWP, carbon black (CB), bituminous coal, and heavy metals (Fe, Zn, Mn, Pb, Ni, As, Cu, Cd, and Hg) in different size fractions of road dust was quantified by combining four different analytical techniques. In the magnetic separation for <45 μm fraction, 34.4 wt% and 50.9 wt% was removed for steelmaking and steel-related industrial complexes, respectively. As the particle size decreased, the mass content of Fe, Mn, and TWP increased. The enrichment factors of Mn, Zn, and Ni were higher than two, indicating that they were related to industrial activities in steel complexes. The maximum concentrations of TWP and CB originating from the vehicle varied depending on the region and particle size range: TWP 2.066 wt% at 45–75 μm (industrial complex) and CB 5.559 wt% at 75–160 μm (steel complex). Coal was only found in the steel complex. Finally, to reduce the exposure of the finest particles to road dust, three methods were suggested. Magnetic fraction must be removed from road dust using magnetic separation; the fly dust of coal during transportation must be suppressed, and covers must be used in coal yards; the mass contents of TWP and CB in road dust should be removed by vacuum cleaning instead of water flushing.

Study on synthesis of environmentally-friendly polymer dust suppressant based on graft modification

In order to solve the dust problem caused by coal accumulation in the coal yard, a novel environmentally-friendly polymer dust suppressant was synthesized by graft copolymerization using sodium alginate (SA) and sodium carboxymethyl cellulose (CMC) as raw materials. Single factor experiments were carried out to determine the optimal synthesis conditions of SA-CMC, taking the viscosity and surface tension as the performance indicators. Under the optimal formulation, the viscosity was 80 mPa·s and the surface tension was 36.541 mN/m. Aiming to optimize the wetting property and resistance to evaporation of SA-CMC, the SA-CMC was combined with the water retention agent CMCS and the surfactant SDBS to obtain the composite dust suppressant (SA-CMC/CMCS). Fourier transform infrared spectroscopy (FTIR) and X-ray diffraction (XRD) were used to analyze the reaction process. Scanning electron microscope (SEM) was used to characterize the micro-structures of the cured layer on the coal dust surface after the dust suppressant spraying. The product performance test results showed that the dust suppressant had the characteristics of water absorption and water retention. The dust suppressant was sprayed on the surface of the coal dust to form a cured layer with high compressive strength, the bearing pressure of the cured layer was 43 N, and the dust suppression rate was as high as 99% under the strong wind (12 m/s) erosion conditions. Compared with water, the dust suppressant prepared in this paper has a better protection effect on coal dust and other forms of dust.

Stockpile Volume Estimation Calculation Based on Terrestrial Laser Scanner (TLS) Data Acquisition and 3D Surface Visualization

Stock taking is a series of activities to calculate the stock of goods that are still stored in the warehouse to be marketed. There are many activities covered in it, ranging from calculating the number of goods, conducting direct inspections, and structuring that will facilitate business operations when a certain product is needed. One of these activities is also carried out in the mining sector. Coal stock-taking is a survey activity carried out in the coal yard area to calculate the volume of the stockpile and coal tonnage after being multiplied by the density value. Large-dimensional coal stocking must be carried out quickly, accurately and in detail. The need for this can be obtained using laser scanner technology. Laser scanner is a tool designed to scan the surface of an object and represent it in 3D in the form of a height density point cloud. Based on this, in carrying out stock-taking calculation activities, measurements are needed which mainly aim to find out the stockpile volume and density in the fourth quarter of the Adipala PLTU Coal Yard. Stockpile measurement method using volumetric method. Measurement using a Laser Scanner tool to obtain the shape of the stockpile area is by seizing the entire surface of the Stockpile by setting the resolution of the density of coordinate points (x, y, z) as needed. Tool displacement when measurements are made on every detail of the Stockpile curve. Based on the calculation results, it is known that the volume value of the coal stockpile on the west side coal yard is 121,420,574 m3 and the east side coal yard is 88,230,355 m3 on. The total volume of coal amounted to 209,650,929 m3 then multiplied by the density of the bulk density survey results and obtained the tonnage of 180,384,417 MT.

A review of automatic coal volume measuring technologies

In coal-fired power plants, how to timely inventory coal storage, in order to optimize the coal stock, and improve coal blending operation, and then carry out economic dispatch scientifically and reasonably, has always been an important topic. The traditional way of artificial method has big error, high cost and serious waste of resources. Ultrasonic measurement technology is greatly affected by time difference and dust. Measurement technology based on computer vision requires interpolation to fit the correction model. The above methods all have large measurement errors and have been eliminated by the market. This paper mainly introduces coal measuring technologies based on laser and uav tilt photography which have been researched and applied more recently. Their respective installation methods, characteristics and applicable working occasions are analyzed. They have the common characteristic that the 3d coordinate point cloud data of coal yard surface needs to be solved before the 3d model of coal yard can be generated and the coal storage amount can be calculated. In the case that the 3d coordinate point cloud data of coal yard of power plant cannot be obtained directly, 3d reconstruction can be carried out by using 2d images of coal yard in coal report, or by using neural network model, and then the coal volume can be checked. This research idea is of great significance to realize effective and accurate supervision of coal storage in power plants..

석탄 저장시설의 석탄비산먼지와 총 휘발성유기화합물의 분포 특성

Coal dust scattering by the wind in the areas around outdoor coal storage facilities of steel mills and coal-fired power plants has been reported. We tried to address this issue by the indoorization of the outdoor coal yard, which will reduce the coal dust scattering. Thus, this study investigated the distribution characteristics of scattering coal dust and total volatile organic compounds, and recommended measures to improve the internal environment. The average concentration of coal dust above the ground by upper dust scattering was measured to be roughly twice as high as that closer to the ground. The highest concentration of dust particles was between 33 and 50 m above ground near the central deck. In addition, the dust concentration was always low in the north entrance area because of external ventilation provided by open door. However, the dust concentration was high in the southwest area, which lacked an entrance door and was further obstructed by mountain terrain. The concentration of total volatile organic compounds was estimated to be higher in the lower part of the coal storage than in the other areas, although there was no significant difference because it was typically extreme low concentration. Therefore, to improve the internal environment, the installation of an air purifier is recommended at the height of central deck in the southwest area of the indoor coal storage.

Experimental and simulation analysis of the initial shape of a large-span air-supported membrane structure

In recent years, air-supported membrane structures have been widely used in China’s environmental protection of closed coal yards and in sports stadiums. There have been breakthroughs year by year in the numbers constructed, unit area, and span. At present, the largest span of an air-supported membrane structure coal shed has reached 198 m. As the span increases, the force-bearing performance of the structure is more closely related to its shape. In this paper, based on a 225m×198m×66m(Length × width × height) long-span air-supported membrane structure test model, the form-finding and state-finding analysis of the air-supported membrane structure with longitudinal and transverse cable nets were carried out, and the results were compared with the forming test results. The results show that the prestressed state of the structure obtained by the state-finding analysis is closer to the test results. However, there is a specific difference with the target height. At the same time, the form-finding analysis can accurately find the target height, but the structure’s cable force and section shape are quite different from the test results.

Preparation and characterization of modified dual network dust suppression gel based on sodium alginate and soluble starch.

Aiming at the problems of complex environment and serious dust pollution in large open-pit coal yards, a dust suppression gel with a dual network structure was prepared by modifying the soluble starch and sodium alginate with iron ions. The changes of functional groups, thermal stability, and morphology structure before and after the reaction were analyzed by FTIR, TG-DSC, and SEM, and the formation mechanism of the dual network was revealed by XPS. Furthermore, the water absorption and water retention experiments proved that the dual network structure is more conducive to water retention than the single-layer network. According to molecular dynamics simulations and contact angle experiments, gel and adsorbed water molecules can approach coal dust molecules on their own to contact, wet, and combine with coal dust. The adhesion test proved that the dust suppression gel with iron ions had better adhesion to dust. The anti-freezing test shows that the dust suppression gel has good anti-freezing performance. The antifreeze test shows that the dust suppression gel still has excellent freeze-thaw resistance at the test temperature of -20℃. The mechanical property test shows that the dust suppressant gel can prevent the product from being damaged by external force. The acid and alkali resistance experiments showed that the acid and alkali resistance of the gel was improved under the condition of iron ion modification, and the flying of coal powder was effectively prevented. This research provides a new theoretical idea for coal dust control in complex environment.

An automated water dispensing system for controlling fires in coal yards

In spite of recent moves to wean the world of fossil fuels, coal remains the main source of power in many countries. Coal yards are prone to spontaneous ignition, a problem faced in every country that stores or transports coal. Depending on the environment-temperature, ventilation, and the rank of the coal-heating and self-ignition can be a longer or shorter process, but the possibility can never be entirely dismissed. A plethora of studies have modelled this oxidation behavior and proposed countermeasures. Most often, human intervention is necessary, which is both slow and dangerous for the firefighters involved. In this study, we propose to build a complete firefighting solution which is mounted on a number of towers sufficient to cover the area of an open coal yard, complete with redundancy. Each tower includes an inexpensive infrared detector, a water dispenser and a controller programmed to identify areas of elevated temperature, and actuate the dispenser. The heat direction algorithm calculates the parameters to position the water dispenser so that it covers the area. A prototype has been built from inexpensive components to demonstrate the effectiveness at detecting and extinguishing arising fires, and a solution has been costed for the coal yard in the case study. This work has been conducted in collaboration with the managers of the coal yard of a power plant.

A composite image recognition based approach for spontaneous combustion point detection and positioning in coal piles

The phenomenon of spontaneous combustion of coal piles often occurs in closed coal yards of power plants, automatic fire-fighting equipments are generally used to detect and locate the spontaneous combustion point. However, their performance (false alarm rate) are largely limited due to the complicated environment of the coal yard. To deal with this problem, this paper proposes a composite image recognition based method for detecting and positioning the spontaneous combustion point (SCP) in coal yard. Yolov5s is trained to efficiently detect SCPs and infrared information is fused to distinguish the realiability of SCP detection result via composite image registration method. In addition, an angle compensation algorithm is proposed to adjust the spray angle of the equipment for positioning the cooling area. The experimental results show that after integrating the above related technologies, the false alarm rate of the spontaneous combustion point in the scene is greatly reduced, and the work efficiency is effectively improved.

Analysis of Root Causes of Fire in Coal Fired Power Plant Using FMEA Study Case Method at PT. PJB UBJOM PACITAN

Fire is one of the highest risks in using coal as fuel for electricity generation. Coal fires often occur in the area of coal handling facilities and are caused by damage to equipment, accumulation of coal dust that has not been cleaned and burning coal itself. This study aims to find out how the application of the FMEA method for the analysis of the root causes of fires in the Coal Power Plant with a case study of the Pacitan steam power plant uses a quantitative approach to find the root cause for prevention by respondents from PT. PJB UBJOM PACITAN at manager and supervisor level. In applying FMEA, the severity, events, and detection is needed to produce risk level figures which will be used as a step in determining the priorities of the company's mitigation management. Based on this study, 15 types of equipment failures were found in the operational coal handling facility at PT PJB UBJOM PACITAN. By using the FMEA method, 6 types of critical failures can be found that require more attention, namely dust on coal which has the potential to cause self-ignition, self-ignition of coal in the area, hot surface, self- combustion in coal yards and perforated crushing bodies.

Numerical simulation and experimental study of vortex blowing suction dust control in a coal yard with multiple dust production points

The dust removal efficiency of the existing dust control technologies for coal yards involving multiple dust production spots is low and cannot satisfy the requirements stipulated by the existing standards. This paper proposes a new type of vortex blowing suction dust control technology. The principle of dust control was examined through numerical simulations. The dust control efficiency of the single suction and vortex blowing suction methods was compared experimentally. The results indicated that most of the dust particles were collected by the vortex, and they moved in a spiral from the bottom to the top. The highest vortex airflow performance corresponded to an optimal blowing ratio of 4.814. The experimental comparison indicated that the dust removal performance of the vortex blowing suction technique was better. Specifically, for the formal and latter techniques, dust removal efficiency was 93.25% and 41.19%, and dust escape rate was 6.31% and 46.60%, respectively.

Indramayu 3 x 330 MW CFPP Coal Yard Management Optimization with K-Means Clustering

Coal yard management is part of the generation management to ensure that coal supply to the unit can continue to be met. The coal entering the boiler is regulated considering various coal characteristics that differ between suppliers with coal mixing strategies, to ensure the generating unit works following the performance target. One of the generating units operated by PT Pembangkit Jawa Bali (PJB) is the Indramayu 3 x 330 MW coal-fired power plant (CFPP). Using 1507 data shipments of PLTU Indramayu from January 2017 to June 2020, a more straightforward coal yard management method can be analyzed. Data were analyzed using k-means clustering by using important parameters from coal property data. Important parameters used are Gross Caloric Value (GCV), Hardgrove Grindability Index (HGI), theoretical air for combustion, and slagging index. From the modeling with k-means clustering, the six optimal clusters are obtained. These six clusters are much simpler than before, managed in 16 clusters in the coal yard. Simplified coal yard management will have a significant impact on operational efficiency.

Root Cause Analysis of Fires in Coal Power Plants Using RFMEA Methods

Fire is one of the highest risks in using coal as fuel for electricity generation. Coal fires often occur in the area of coal handling facilities and are caused by equipment damage, accumulation of coal dust that has not been cleaned and burning coal itself. This study aims to find out how the application of the RFMEA (Risk Failure Mode Effect Analysis) method for the analysis of the root causes of fires in the Pacitan Coal Fired Power Plant case study uses a quantitative approach to find the root causes of prevention by respondents. from PT. PJB UBJOM Pacitan at manager and supervisor level. In implementing RFMEA, the severity, events, and detection are needed to produce risk level figures which will be used as a step in determining the priorities of the company’s mitigation management. Based on this study, 15 types of equipment failures were found at the operational coal handling facility at PT PJB UBJOM PACITAN. By using the RFMEA method, 1 type of critical failure can be found that requires more attention from management to mitigate the risk immediately, namely dust on coal both from barges and coal yards with risk value 32.05.

Wind Environment and Loading Mitigation Effects on Coastal Enclosed Coal Yards with Porous Gables

In order to prevent dust emission, coastal coal yards are enclosed by coal sheds. The dust suppression rate increases as the closure of the coal shed by sacrificing the ventilation rate. Adopting porous gables may provide a balance between natural ventilation and dust suppression as well as mitigate the aerodynamic loading effect. Through wind tunnel tests and numerical simulation, the present research take an practical coastal power plant coal yard as an example to illustrate the natural ventilation, dust suppression and aerodynamic loading mitigation effect quantitatively. The results have shown that, with a favourable gable prositiy of 30%, the natural ventialtion rate can be ehanced from 0.7 to over 2.0 times/hour compared with solid gables. The dust supression could be increased from 56% up to 80% compared with open gables. The unfavorable extremum aerodynamic suction coefficients on the central area and edges of roof are reduced by 20% and 70% respectively. The results provide a supportive evident that adopting prorous windbreak gables is a environemntal friendly and economic construction scheme for coastal enclosed coal yards.