Performance and boiler efficiency using low-grade coal on 400 MWe coal-fired power plant: Case study of Suralaya Power Plant Unit 2

Abstract

In a coal steam power plant, changes in coal quality significantly affect plant performance, especially in its boiler. A coal-fired power plant with a capacity of 400 MWe had been commissioned using coal with a calorific value of 5,242 kCal/kg. This study aims to determine the effect on unit performance and boiler efficiency due to changes in fuel use with the typical calorific value of 3,520 kCal/kg, 34,17% lower than the initial design. The performance tests were conducted using the heat loss method at loads: 50%, 65%, 75%, and 100%. The test result showed that using low-grade coal reduces boiler efficiency by 6.26%. There were four dominant boiler losses: heat loss due to moisture in dry flue gas, heat loss due to combustible in refuse, heat loss due to moisture in fuel, and heat loss due to hydrogen burning. Furthermore, the gross plant heat rate using low-grade coal was increased from 2,120 kCal/kWh to 2,718 kCal/kWh; however, the electric price becomes cheaper from 1.99 cent-USD/kWh becomes 1.31 cent-USD/kWh.