Boiler Performance Optimization With Expert Combustion Tuning (X-Toni) Method To Support Implementation Of Coal Switching & Co-Firing Program

Abstract

Implementing coal switching and co-firing at Pelabuhan Ratu Coal-Fired Power Plant is a policy derivative from Indonesia's Electricity Company (PT. PLN) to lower the electricity generation cost and increase the share of renewable energy. This implementation, however, has a detrimental effect on boiler performance and increases the likelihood of the boiler not producing electricity until it reaches the maximum load. According to the April 2021 Energy Audit report, performance indicators such as Orsat O2, unburnt carbon, and others were unable to reach baseline, resulting in decreased boiler efficiency. Therefore, optimizing boiler performance with expert combustion tuning (X-Toni) is necessary. The main method of X-Toni is to validate fuel characteristics, numerical simulations, and experimental tests on various loads and types of fuel, and determine the baseline for boiler operating performance when using low-calorie and biomass fuels. Additionally, there is online monitoring of the combustion effectiveness via PI Vision. The benefits of this innovation include the ability to create a symmetrical fireball concerning the combustion chamber and reduce SO2 and NOx emissions. Boiler performance indicators such as O2 outlet at 3–4 %, and other boiler performance indicators can operate within the parameters specified in the baseline. Boiler efficiency increased by 0.8 %, or e equivalent to savings of $ 1,272,992.83, and decreased electricity generation cost to $ 0.000081/kWh.