asia power & electricity convention 2016 dr harun 241116

Significant plant improvement to be consider for new development of power generation in Indonesia

Presented by Dr. Harun Al Rosyid M Eng.PT.Indopower International -STTPLN

The Asia Power & Electricity Convention 2016, Jakarta - Indonesia

BACK GROUNDSIndonesia’s current installed power capacity is at 52GW and the government has an ambitious plan to increase another 35,000MW in another five years. Demand is expected to grow at an average of 8.4% p.a. due to rapid urbanization and industrialization. To avoid high pollution and get a power supply that is better than ever, the government requires prospective developers to build power plants with significant performance better than the previous.To support the GOI targets for cut emissions to 29% in 2030 and to develop new power stations with high efficiency and lower emissions.

Since most of the development of 35000Mw power plants are steam power plants, then the discussion of this topic is mainly specialized for the steam power plant projects.

Why Significant plant improvement to be consider for new plant development ? Because you are mostly go for Bidding it is mean you shall full

competition Un perfect feasibility study Mostly the proposed plant is using typical standard from plant

manufacturer more strict environmental requirements and more critical of community


BACK GROUNDS

To whom is importance to addresses of this topic ?1. Power plant developer2. Investors , Bankers3. Plant equipment manufacture


BACK GROUNDS


THREE SPP CATEGORIZATIONS EXISTING IN INDONESIA 1. Small capacity Capacity 10 MW at out Kalimantan, Papua - Coal fired PP with regenerative heater - Low pressure & Temp 36 bar 450 C - low efficient< 25% capacity 100 up to 150 MW Kalimantan, Papua - Coal fired PP with regenerative heater - Higher pressure & temp 89 bar,513 -less efficient < 30%2. Medium capacity 150MW up to 400MW - SPP with regenerative heater and Reheated - Higher pressure & temp 102 bar,515C, -more efficient< 35%

BACK GROUNDS – WHATS THE EXISTING FIGURES ?


THREE SPP CATEGORIZATIONS EXISTING IN INDONESIA 3. For large capacity Capacity 300MW up to 650 MW - SPP with reg. heater & Supercritical - Higher pressure & temp 174 bar,536C ,186 bar,546C - High efficient < 40 % Capacity 1000MW - SPP with reg. heater & ultra Supercritical - Once thru Boiler steam cycle system - Highest efficient < 45%

BACK GROUNDS – WHATS THE EXISTING FIGURES ?

1. Need more regenerative heaters 2. Need Reheater3. Should be higher steam pressure & temperature.

a. Highest pressure and Temp .Subcritical

b. Super critical

c. Ultra supercritical

d. Advanced Ultra supercritical


What's the methods for improving Power Plant performance To Improve thermal cycle

4 Better condenser vacuum Once thru cooling is best

Ball cleaning system

5.Consistence of coal quality Coal dryer

Coal blending

6. Suitable specification and materials Brackish water using al brass condenser tubes

Sea water by using Ti or Al cu condenser tubes

7. Environmental compliance

Follow national environmental regulation


Methods for improving Power Plant performance How to Improve thermal cycle and Reliability

Categorizations Conditional Net PlantEfficiency

Net PlantHeat Rate (HHV)

SPP capacity < 500Mw

Subcritical

2400 psig (16.5 MPa)1050°f/1050° (565°c/565°C)

35% 9751 Btu/kwh2457 kcal/kelvin

SPP capacity > 500MwSupercritical

(SC)

>3600 psig(24.8 MPa)1050°f/1075° (565/585°c)

38% 8981 Btu/kwh2263 kcal/kelvin

SPP capacity > 500MwUltra supercritical

(USC)

>3600 psig(24.8 MPa)1100°f/1150° (593°C/621°C

>42% 8126 Btu/kwh2047 kcal/kelvin

SPP capacity 1000 Mw class or bigger

“Advance”Ultra supercritical

(A-USC)

5000 psig(34.5 MPa)1250°F (677° C)and above

>45% 7757 Btu/kwh1454 kcal/kelvin

Power Plant high performance –Typical goal


How to Improve thermal cycle and Reliability By proper steam condition proper selection and goal


1. Least cost For 2 unit plant with 1 common facilities Simplest design Best site selection Well engineering design 1. Best approach to community Proper site land ,community and environmental

approach

What's the methods for improving Power Plant performance How to Improve Reliability and cost competitive

Coal fired Steam power plant 600 class-typical in Indonesia

Regenerative feed water heaters installation typical


Case study :Keban agung SPP 2 X 135 MW Sumatra project Location


Present conditionsPlant Layout Keban Agung CFSPP 2x135 MW is arranged based on the overall general layout as shown in

World Clean Coal ConferenceIndonesia 2016

The Significant improvement for increasingperformance Of on going Power Plants Project


Regenerative heaters & Reheater installation typical


The method of improvement

1. To Improve the reliability by stabilizing the coal qualities 2. To Improve thermal cycles by: Adding feed water heaters Increasing steam pressure and temperature( optional) Increasing condenser vacuum. Installing Flue gas desulfurization

The Significant improvement for increasingperformance Of on going Power Plants ProjectThe Asia Power & Electricity Convention 2016, Jakarta - Indonesia

The Objective of the Study

Owner of IPP seeks to improve the efficiency, output and environmental impact To justify an improvement of the power plant’s performance for an increase of the power plant net output and lowering the net plant heat rate (i.e. increase of efficiency), and to identify the required equipment and the related costs for the improved design accordingly.



Coal Characteristic


Description Designed Worst Coal

ar adb ar adb (1) (2) (3) (4) (5)

Moisture 28.76 13.4 47.4 18.1

Ash 4.13 5.8 5.79 7.98Carbon 49.2 69.06 37.31 51.39

Hydrogen 3.81 5.35 3.98 5.48

Nitrogen 0.59 0.83 0.36 0.5Sulfur 0.28 0.39 0.65 0.9

Oxygen 13.26 18.61 24.51 33.76

HHV [kCal/kg] 4,721 6,780 3,610 4,973

LHV [kCal/kg] 4,463 6,287 3,244 4,468


N0 Description Unit Original 6 Htr Add 8 Htr

1 Net Power Output (MW)/GrossPower Output (MW) 112.5/135 120/135

2 Net Plant Heat Rate (LHV) (Kcal/kWh) 2,646 2,436

3 Net Plant Efficiency (%) 32.52 35.3

4 Steam Pressure Turbine Inlet (kg / cm2) 132.4/23.2 132/23.2

5 Gross Turbine Heat Rate (Kcal/kWh) 2,005.40 1,994

6 Gross Turbine Heat Rate (kJ/kWh) 8396.2 kj/kWh 8342.89

7 Boiler efficiency (LHV) % 92 92

8 Auxiliary Power % 16.67 11.03

9 Steam Pressure Turbine Outlet (kg / cm2) 0.0086 0.08

10 Steam Flow Turbine Inlet per 1 unit (ton/h) 413 418.00

11 Steam Temperature Turbine Inlet (C) 535/254 535.00

12 Steam Flow Turbine Outlet (ton/h) 282.79 NA13 Cooling Water Flow Condenser Inlet (ton/h) 17,802 24936.169

14 Ambient Condition :

- Temperature DB (0C) 26.7 30.00

- Humidity Relative (%) 84 80.00

15 Coal Calorie Value (HHV) (kcal/kg) 4,721 4,721

16 Coal Consumption (ton/day)/unit 1,512 1,512

The Significant improvement for increasingperformance Of Power Plants Project


Steam Inlet Turbine Pressure

The original design is based on inlet pressure 132.4/23.2 kg/cm2, net power availability 112.5 MW and net plant heat rate of 2,700 kcal/kWh (LHV) by using six (6) steam heaters. The heat balance and water balance diagrams are originally 6 heaters and no 7 & 8 heaters are not install yet as shown in Drawing HBD-01.

The Significant improvement for increasingperformance Of on going Power Plants ProjectDr Harun Al Rosyid – Indopower International


The Results

Based on Thermo-dynamical analysis result , which that was performed by power plant thermo - dynamic simulation software, shows that plant performance of cycle will improve by installing coal pre drying ,HPFW heaters ,increasing steam condition and condenser size optimization, both will increase plant output by more than 6 % and plant heat rate will improve by more than 10% . By installing FGD, the sulfur SO2 emission impacts can be controlled to a degree much lower than limits in line with the environmental law requirement.

The Significant improvement for increasingperformance Of on going Power Plants ProjectThe Asia Power & Electricity Convention 2016, Jakarta - Indonesia

Thank You


No. Nama Pembangkit Pemili

k

Kapasitas

Terpasang

(MW)

COD

1 PLTU Banten Banten prov IPP 625 20172 PLTU Lontar Exp PLN 315 20183 PLTU Jawa-7 IPP 1000 20194 PLTU Jawa-5 (FTP2) IPP 1000 20195 PLTU Jawa-7 IPP 1000 20196 PLTU Jawa-5 (FTP2) IPP 1000 20197 PLTU Jawa-9 IPP 600 20201 PLTU Indramayu-4 (FTP2) Jabar PLN 1000 20192 PLTU Jawa-1 (FTP2) IPP 1000 20193 PLTU Jawa-3 (FTP2) IPP 660 20194 PLTU Jawa-3 (FTP2) IPP 660 20195 PLTU Jawa-6 (FTP2) PLN 1000 20256 PLTU Jawa-6 (FTP2) PLN 1000 20251 PLTU Adipala Jateng Prov PLN 660 20162 PLTU Cilacap Exp IPP 614 20163 PLTU Jawa-8 IPP 1000 20184 PLTU Jawa Tengah (PPP) IPP 950 20195 PLTU Jawa-4 (FTP2) IPP 1000 20196 PLTU Jawa Tengah (PPP) IPP 950 20197 PLTU Jawa-4 (FTP2) IPP 1000 20198 PLTU Jawa-10 - 660 20211 PLTU Tj. Awar2 Jatim Prov PLN 350 20162 PLTU/GU Madura - 400 2022

No. Nama Pembangkit Pemi

lik

Kapasitas Terpasang

(MW)COD

1 PLTU Pangkalan Susu #3 (FTP2) PLN 400 2018/192 PLTU Sumut 1 IPP 300 20183 PLTU Nias (FTP2) sumut IPP 21 20211 PLTU Jambi IPP 1200 20191 PLTU Keban Agung sum selatan IPP 225 20162 PLTU Sumsel-5 (Bayung Lencir) IPP 300 20163 PLTU Sumbagsel-1 IPP 300 2018/194 PLTU Sumsel-7 IPP 300 20185 PLTU Sumsel-1 IPP 600 20196 PLTU SUmsel-6 IPP 600 2019/207 PLTU Banyuasin IPP 240 20201 PLTU Meulaboh (Nagan Raya)

#3 AcehIPP 400 2019/20

1 PLTU Riau Amandemen FTP1 (Tenayan)

PLN 220 2016

2 PLTU Riau-1 IPP 600 20191 PLTU TB. Karimun #2 (FTP1)

KepriIPP 7 2016

2 PLTU Tanjung Balai Karimun -1 kepri

- 40 2020

1 PLTU Bengkulu IPP 200 20191 PLTU Tarahan 34 FTP1

(Sebalang) LampungPLN 100 2016


Power plant development In Java & Sumatra

No. Nama Pembangkit Pemilik

Kapasitas Terpasang (MW)

COD

1 PLTU Sintang kalbar PLN 3x7 2016/172 PLTU Ketapang PLN 10 20163 PLTU Parit Baru (FTP1) PLN 2x50 2017/184 PLTU Pantai Kura-kura (FTP1) PLN 2x27.5 20185 PLTU Parit Baru (FTP2) PLN 2x50 20186 PLTU Ketapang (IPP) IPP 2x6 2016/177 PLTU Kalbar 1 IPP 2x100 20198 PLTU Kalbar 2 IPP 1x200 20219 PLTU Kalbar 3 IPP 1x200 202210 PLTU Kalbar 4 - 1x200 20251 PLTU Kotabaru Kalsel PLN 2x7 20172 PLTU Kalselteng 2 PLN 2x100 2019/203 PLTU Kalsel (FTP2) IPP 2x100 2018/191 PLTU Pulang Pisau (FTP2)

KaltengPLN 2x60 2016

2 PLTU Kuala Pembuang PLN 2x3 20173 PLTU Sampit PLN 2x25 2018/194 PLTU Kalselteng 1 IPP 2x100 2019/205 PLTU Kalselteng 3 IPP 2x100 2021/221 PLTU Teluk Balikpapan (FTP1)

KaltimPLN 2x110 2016

2 PLTU Tanjung Redep PLN 2x7 20173 PLTU Tanah Grogot IPP 2x7 20174 PLTU Kaltim (MT) IPP 2x27.5 2017/185 PLTU Kaltim (FTP2) IPP 2x100 2018/191 PLTU Malinau Kal Utara PLN 2x3 20172 PLTU Tanjung Selor PLN 2x7 2017

No. Nama Pembangkit PemilikKapasitas Terpasang

(MW)COD

1 PLTU Jayapura (FTP1) PLN 2x10 20162 PLTU Timika PLN 4x7 2018/193 PLTU Jayapura 2 PLN 2x50 2020/214 PLTU Nabire-Kalibobo IPP 2x7 20191 PLTU Sorong Papua Barat PLN 2x50 20192 PLTU Andai IPP 2x7 2019

Power plant development In Kalimantan & Papua

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asia power & electricity convention 2016 dr harun 241116

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