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 GROUNDS
Indonesia’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.
The Asia Power & Electricity Convention 2016, Jakarta - Indonesia

BACK GROUNDS
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
The Asia Power & Electricity Convention 2016, Jakarta - Indonesia

BACK GROUNDS

To whom is importance to addresses of this topic ?

1. Power plant developer
2. Investors , Bankers
3. Plant equipment manufacture
The Asia Power & Electricity Convention 2016, Jakarta - Indonesia

BACK GROUNDS – WHATS THE EXISTING FIGURES ?

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%
The Asia Power & Electricity Convention 2016, Jakarta - Indonesia

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%
The Asia Power & Electricity Convention 2016, Jakarta - Indonesia

What's the methods for improving Power Plant performance

 To Improve thermal cycle

1. Need more regenerative heaters

2. Need Reheater
3. Should be higher steam pressure & temperature.
a. Highest pressure and Temp .Subcritical
b. Super critical
c. Ultra supercritical
d. Advanced Ultra supercritical
The Asia Power & Electricity Convention 2016, Jakarta - Indonesia

Methods for improving Power Plant performance

 How to Improve thermal cycle and Reliability
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
The Asia Power & Electricity Convention 2016, Jakarta - Indonesia

 How to Improve thermal cycle and Reliability

By proper steam condition proper selection and goal

Categorizations Conditional Net Plant Net Plant

Efficiency Heat Rate (HHV)
SPP capacity < 2400 psig (16.5 MPa) 35% 9751 Btu/kwh
500Mw 1050°f/1050° 2457 kcal/kelvin
Subcritical (565°c/565°C)
SPP capacity > 500Mw >3600 psig(24.8 MPa) 38% 8981 Btu/kwh
Supercritical 1050°f/1075° (565/585°c) 2263 kcal/kelvin
(SC)
SPP capacity > 500Mw >3600 psig(24.8 MPa) >42% 8126 Btu/kwh
Ultra supercritical 1100°f/1150° 2047 kcal/kelvin
(USC) (593°C/621°C
SPP capacity 1000 5000 psig(34.5 MPa) >45% 7757 Btu/kwh
Mw class or bigger 1250°F (677° C) 1454 kcal/kelvin
“Advance” and above
Ultra supercritical
(A-USC)
Power Plant high performance –Typical goal
The Asia Power & Electricity Convention 2016, Jakarta - Indonesia

What's the methods for improving Power Plant performance

 How to Improve Reliability and cost competitive
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
Coal fired Steam power plant 600 class-typical in Indonesia
The Asia Power & Electricity Convention 2016, Jakarta - Indonesia
The Asia Power & Electricity Convention 2016, Jakarta - Indonesia

Regenerative feed water heaters installation typical

The Asia Power & Electricity Convention 2016, Jakarta - Indonesia
Case study :
Keban agung SPP 2 X 135 MW Sumatra
project Location
World Clean Coal Conference
The 2016
Asia Power & Electricity Convention 2016, Jakarta - Indonesia The Significant improvement for increasing
Indonesia
performance Of on going Power Plants Project

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

Indopower International
The Asia Power & Electricity Convention 2016, Jakarta - Indonesia

Regenerative heaters & Reheater installation typical

 The Significant improvement for increasing
The Asia Power & Electricity Convention 2016, Jakarta - Indonesia performance Of on going Power Plants Project

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

Indopower International
The Asia Power & Electricity Convention 2016, Jakarta - Indonesia
The Significant improvement for increasing
performance Of on going Power Plants Project

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.

Indopower International
 The Significant improvement for increasing
The Asia Power & Electricity Convention 2016, Jakarta - Indonesia performance Of on going Power Plants Project

Coal Characteristic

Designed Worst Coal

Description
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 7.98

Carbon 49.2 69.06 37.31 51.39

Hydrogen 3.81 5.35 3.98 5.48

Nitrogen 0.59 0.83 0.36 0.5

Sulfur 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

Indopower International
The Asia Power & Electricity Convention 2016, Jakarta - Indonesia The Significant improvement for increasing
performance Of Power Plants Project

N0 Description Unit Original 6 Htr Add 8 Htr

Net Power Output (MW)/Gross
1 (MW) 112.5/135 120/135
Power Output
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 NA
13 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

Indopower International
 The Significant improvement for increasing
performance Of on going Power Plants Project
Dr Harun Al Rosyid – Indopower International

The Asia Power & Electricity Convention 2016, Jakarta - Indonesia

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.

Indopower International
 The Significant improvement for increasing
performance Of on going Power Plants Project
The Asia Power & Electricity Convention 2016, Jakarta - Indonesia

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.
Indopower International
The Asia Power & Electricity Convention 2016, Jakarta - Indonesia
The Asia Power & Electricity Convention 2016, Jakarta - Indonesia

Thank You
The Asia Power & Electricity Convention 2016, Jakarta - Indonesia

Power plant development In Java & Sumatra

Kapasit Kapasitas
N Pemi
as Nama Pembangkit Terpasang COD
N Pemili o. lik
Nama Pembangkit Terpas COD (MW)
o. k
ang 1 PLTU Pangkalan Susu #3 (FTP2) PLN 400 2018/19
(MW) 2 PLTU Sumut 1 IPP 300 2018
1 PLTU Banten Banten prov IPP 625 2017 3 PLTU Nias (FTP2) sumut IPP 21 2021
2 PLTU Lontar Exp PLN 315 2018 1 PLTU Jambi IPP 1200 2019
3 PLTU Jawa-7 IPP 1000 2019 1 PLTU Keban Agung sum selatan IPP 225 2016
4 PLTU Jawa-5 (FTP2) IPP 1000 2019 2 PLTU Sumsel-5 (Bayung Lencir) IPP 300 2016
5 PLTU Jawa-7 IPP 1000 2019 3 PLTU Sumbagsel-1 IPP 300 2018/19
6 PLTU Jawa-5 (FTP2) IPP 1000 2019 4 PLTU Sumsel-7 IPP 300 2018
7 PLTU Jawa-9 IPP 600 2020 5 PLTU Sumsel-1 IPP 600 2019
1 PLTU Indramayu-4 (FTP2) Jabar PLN 1000 2019 6 PLTU SUmsel-6 IPP 600 2019/20
2 PLTU Jawa-1 (FTP2) IPP 1000 2019 7 PLTU Banyuasin IPP 240 2020
3 PLTU Jawa-3 (FTP2) IPP 660 2019 1 PLTU Meulaboh (Nagan Raya) IPP 400 2019/20
4 PLTU Jawa-3 (FTP2) IPP 660 2019 #3 Aceh
5 PLTU Jawa-6 (FTP2) PLN 1000 2025 1 PLTU Riau Amandemen FTP1 PLN 220 2016
6 PLTU Jawa-6 (FTP2) PLN 1000 2025 (Tenayan)
1 PLTU Adipala Jateng Prov PLN 660 2016 2 PLTU Riau-1 IPP 600 2019
2 PLTU Cilacap Exp IPP 614 2016 1 PLTU TB. Karimun #2 (FTP1) IPP 7 2016
3 PLTU Jawa-8 IPP 1000 2018 Kepri
4 PLTU Jawa Tengah (PPP) IPP 950 2019 2 PLTU Tanjung Balai Karimun -1 - 40 2020
5 PLTU Jawa-4 (FTP2) IPP 1000 2019 kepri
6 PLTU Jawa Tengah (PPP) IPP 950 2019 1 PLTU Bengkulu IPP 200 2019
7 PLTU Jawa-4 (FTP2) IPP 1000 2019 1 PLTU Tarahan 34 FTP1 PLN 100 2016
8 PLTU Jawa-10 - 660 2021 (Sebalang) Lampung
1 PLTU Tj. Awar2 Jatim Prov PLN 350 2016
2 PLTU/GU Madura - 400 2022
 Power plant development In Kalimantan & Papua

Kapasitas Kapasitas
No No. Nama Pembangkit Pemilik Terpasang COD
Nama Pembangkit Pemilik Terpasan COD
. (MW)
g (MW) 1 PLTU Jayapura (FTP1) PLN 2x10 2016
1 PLTU Sintang kalbar PLN 3x7 2016/17 2 PLTU Timika PLN 4x7 2018/19
3 PLTU Jayapura 2 PLN 2x50 2020/21
2 PLTU Ketapang PLN 10 2016
4 PLTU Nabire-Kalibobo IPP 2x7 2019
3 PLTU Parit Baru (FTP1) PLN 2x50 2017/18 1 PLTU Sorong Papua Barat PLN 2x50 2019
4 PLTU Pantai Kura-kura (FTP1) PLN 2x27.5 2018 2 PLTU Andai IPP 2x7 2019
5 PLTU Parit Baru (FTP2) PLN 2x50 2018
6 PLTU Ketapang (IPP) IPP 2x6 2016/17
7 PLTU Kalbar 1 IPP 2x100 2019
8 PLTU Kalbar 2 IPP 1x200 2021
9 PLTU Kalbar 3 IPP 1x200 2022
10 PLTU Kalbar 4 - 1x200 2025
1 PLTU Kotabaru Kalsel PLN 2x7 2017
2 PLTU Kalselteng 2 PLN 2x100 2019/20
3 PLTU Kalsel (FTP2) IPP 2x100 2018/19
1 PLTU Pulang Pisau (FTP2) PLN 2x60 2016
Kalteng
2 PLTU Kuala Pembuang PLN 2x3 2017
3 PLTU Sampit PLN 2x25 2018/19
4 PLTU Kalselteng 1 IPP 2x100 2019/20
5 PLTU Kalselteng 3 IPP 2x100 2021/22
1 PLTU Teluk Balikpapan (FTP1) PLN 2x110 2016
Kaltim
2 PLTU Tanjung Redep PLN 2x7 2017
3 PLTU Tanah Grogot IPP 2x7 2017
4 PLTU Kaltim (MT) IPP 2x27.5 2017/18
5 PLTU Kaltim (FTP2) IPP 2x100 2018/19
1 PLTU Malinau Kal Utara PLN 2x3 2017
2 PLTU Tanjung Selor PLN 2x7 2017
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