HERU DEWANTO
President Director, Cirebon Power
Transformation of Technology in Cirebon Power Indonesia
International Conference on Coal-Based Power
New Delhi, 17 – 19 March 2016
1
Coal-based Power - Global
2
Coal-based Power - Indonesia
3
Transformation Technology in the pursuit of
efficiency
1
1
2
Coal-based Power - Global
E ergy Reser es for the Pla et ….
ENERGY
Technology Pursuit: Efficient Finite energy and
Economical Renewable energy
3
Po er y Sour e ….
Installed capacity by source
The Outlook for Energy: A View to 2040
ExxonMobil
Power generator by source
(OECD and Non-OECD)
Reliance of Asia and Developing Countries on Coal- ased Po er….
 Asia and developing countries require coal fired power plant for stable base load
supply in their national power development plants in order to comply with their
rising electricity demands.
 There are reasonable grounds for developing countries to depend on coal power
generation from the viewpoint of the impact on balance of payments, as coal is
widely traded commodity with a stable price.
 It is not realistic for developed countries to restrict access of developing countries
to coal for future use in power generation without considering energy
circumstances of those countries, in particular countries having abundant coal
reserves.
 It is more realistic to promote clean coal technology for coal power generation:
 High-efficiency , Low-emission (CO2) coal fired power plant (SC, USC, etc.)
 Greenhouse gas reduction (Carbon Capture and Storage - CCS)
OECD on Coal- ased Po er ….
PLNT UNIT SIZE
(Gross Installed
capacity)
Unit > 500
MW
U it ≥ 00
to 500 MW
Unit < 300
MW
Ultra-supercritical
12 Yeas
(Steam pressure > 240
ar a d te perature ≥
593 C) or Emission <
750 gCO2/kWh
12 years
12 years
Supercritical (i.e.
Illegible
Steam pressure > 221
bar and temperature >
550 C) or Emission
between 750 and 850
gCO2/kWh
10 years
10 years and
only in IDAeligible
countries
Subcritical (i.e Steam
Illegible
pressure < 221 bar) or
Emission >850
gCO2/kWh
Illegible
10 years and
only in IDAeligible
countries
1. Where eligible for official
support, an additional
two-years
repayment
term is allowed for
project
finance
transactions
2. To help address energy
poverty, ten-year export
credit support may be
provided in all countries
where the National
Electrification Rate is
reported as 90% or
below
3. Export credit support
may be provided in nonIDA-eligible countries for
geographically isolated
locations
Te h ologi al E olutio Leadi g Effi ie y ….
+ 11.3%
Plant Net Efficiency
LE2
+ 2%
+ 8.7%
RDK8
+ 6.0%
+ 6.4%
+ 4.0%
Baseline
170 bar
540 o C
540 o C
Sub-critical
260 bar
565 o C
585 o C
Supercritical
260 bar
600 o C
600 o C
275 bar
600 o C
620 o C
Ultra-supercritical
RDK8: Successful boiler pressure test at block 8 of Rheinhafen-Dampfkraftwerk
LE : Leading Efficiency
Source: GE
320 bar
605 o C
630/630o C
Double reheat
350 bar
700 o C
720/720 o C
700+oC
Coal Fired Po er Pla t ….
Facts
Proposed
Policy
-
The problem - It emits a large amount of greenhouse gas
-
Yet, an important fuel for base load power supply because it involves
the lowest geopolitical risk and has the lowest price per unit of heat
energy among fossil fuels.
-
Technology pursuit - reducing the environmental impact through the
development of highly efficient coal thermal power generation
technology.
-
Promoting the replacement of aging thermal power plants
-
Introducing available leading-edge technology through the
construction of new facilities and the expansions of front runners
-
Further promotes the development of technology (e.g. IGCC) to
drastically reduce greenhouse gas emission for unit of generated
power by greatly improving power generation efficiency
-
It is necessary to use coal while reducing the global environmental
impact by promoting the introduction of such high efficiency
technology
2
9
Coal-based Power - Indonesia
I do esia Ele tri ity at Prese t ….
TOTAL INSTALLED PLANT CAPACITY (July 2015)
53.535 MW
(PLN: 37.820 MW, IPP: 10.975 MW, PPU: 2.349 MW, IO Non BBM: 2.391 MW)
ELECTRICITY CONSUMPTION (2014)
ELECTRICITY PRODUCTION (2014)*)
199 TWh
228 TWh
RATIO ELECTRIFICATION (July 2015)
86.39%
KWH PER KAPITA (2014)
865 kWh/Capita
Older Power Plan (RUPTL 2015 – 2024) ….
2015
RUPTL 2015-2024
Power Plant
: 70,4 GW
Transmission
: 63,000 kms
Substation
: 45 GVA
2024
Requirement Capex : Rp 1586 T
To support economic growth 6,7% pa
with electricity demand 8,7% pa and
electrification ratio 99,4%
New Power Plan (RUPTL 2016 – 0 5)….
2016
2025
Source: RUPTL PLN : 2016-2025
5 GW Proje t Mappi g ….
Source: RUPTL PLN : 2016-2025
Courageous Cha ge ….
Project
Previous Plan
New Plan - without
Nuclear PP
New Plan - with
Nuclear 3 GW
Deviation
Coal Fired PP
38
36
34
-3.7
Geothermal PP
5
6
6
+1.4
CC Gas Fired PP
10
13
13
+3.4
Gas Fired PP
5
5
5
Hydro PP
10
14
14
+4.7
Renewable
0
2
2
+1.8
4
+3.6
+11.2
Nuclear PP
Total (GW)
68
76
78
Total Investment (USD bio)
130
152
175
 To meet MEMR target of renewable energy of 25% by 2025, additional capacity of renewable is
needed. Total new capacity becomes 78 GW
 To reduce coal portion to 50%, around 5 GW of old Coal PP will not be operated, while new coal PP
listed in 35 GW with high efficiency shall continue
 Investment budget increased to USD 175 billion in the period 2016-2025
 Notes: (i) government's financial support is indispensable for developing renewable energy (ii) nuclear
power requires long time through political muscling (iii) courageous yet very challenging.
Coal Po er proje ts are a elled ….
No
Project
Capacity
(MW)
New
(MW)
1
COD
New
COD
Sumsel-8 MMPP
2x660
0
2019
>2025
2
Sumsel-9 MMPP
2x660
0
2020/21
>2025
3
Sumsel-10 MMPP 1x660
0
2020
>2025
4
Jawa-11 CFSPP
1x660
0
2021
>2025
5
Jawa-12 CFSPP
2x1000
0
2022/23
>2025
6
Jawa-13 CFSPP
2x1000
0
2024
>2025
Remarks
Because coal price for non Mine
Mouth Power Plant (MMPP) is
currently cheaper than for MMPP then
MMPP postponed.
Due to reduced demand and to meet
renewable energy target of 25%, some
of coal power projects are postponed.
Uncertainty on Coal Supply ….





In previous plan, GOI targets coal as the main source by 60% or 20 GW of the 35 GW program
However, coal industry is facing economic challenges: falling profitability and production cuts
(EBITDA fell by 76%, CAPEX dropped by 79% from 2011 to 2015)
Exploration of new reserves has essentially stopped
35 GW program is expected to revive Indonesian coal industry
Indonesia Coal association and PWC preliminary projections suggest that there will not be
enough coal reserves at the current market price to supply 20 GW of new and existing coal
fired PP over 25 years. Coal reserves will run out by 2036.
Source: PWC
3
17
Transformation Technology in the pursuit of
efficiency – Cirebon Power
Su Criti al to Super riti al a d Ultra Super riti al ….
• Supercritical pressure is a state above the critical pressure of water (3208 psi and 706°F)
where vapor and liquid are indistinguishable.
• A conventional supercritical unit operates at steam pressures typically above 3500 psi (240
bar) or higher and steam temperatures of 1000 - 1050°F (538 - 566°C).
• A sub Critical unit operates below the critical pressure, typically below 2400 psi (165 bar).
1100°F (593°C)
Temperatur
e
1000 – 1050°F (538 - 566°C)
Ultra Supercritical
Supercritical
Sub-critical
Supercritical point
706°F (375°C)
221 bar (3208 psi)
Rejected Heat
Entropy
• The plant efficiency increases by about one percentage point for every 20 C (36 F)
rise in superheat and reheat temperature.
Clean Coal Te h ology Tra sfor atio i I do esia ….
SC, = up to 40%
U USC,
42%
= up to
Jawa-4 (USC 2x1000 MW)
Jawa-5 (USC 2x1000 MW)
Jawa-7 (USC 2x1000 MW)
2012
2015
2020
IGCC
= 45-48%
2025
Jawa-6 SC 2x1000 MW)
Cirebon-1 (SC 1x660 MW)
Paiton-3 (SC 1x815 MW)
Source: JICA CCT Study and PLN
Central Java (USC 2x1000 MW)
Cirebon Expansion (USC 1x1000 MW)
Indramayu #1 (USC 1000 MW)
Cire o Po er Tra sfor atio ….
ITEM
CIREBON #1 1X660 MW
Location
Capacity (NDC)
Shareholder






Kanci, Cirebon, West Java
1 x 660MW
Indika (Indonesia)
Marubeni Corp (Japan)
KOMIPO Co (South Korea)
Samtan Co (South Korea)
Total Investment
Lenders
Boiler Technology





US$ 877.5 million
JBIC, KEXIM, and commercial banks
Once Through
Tangential Firing with Tilted Burners
Supercritical, Heat Rate 2.312
Kcal/Kwh, CV Coal 4,500 kcal/kg
Main Steam Pressure : 250 bar
Main Steam Temperature : 569 0C
PLN
30 years (from COD)
Operation since 2012
Off-taker
PPA
Status





CIREBON #2 1X1000 MW
















Kanci, Cirebon, West Java
1 x 1000MW
Indika (Indonesia)
Marubeni Corp (Japan)
KOMIPO Co (South Korea)
Samtan Co (South Korea)
Chubu Electric (Japan)
App. US$ 2 billion
JBIC, KEXIM, and commercial banks
Once Through
Front-Rear Firing with Tilted Burners
Ultra Supercritical, Heat Rate 2.305
Kcal/Kwh, CV Coal 4,500 kcal/kg
Main Steam Pressure : 258 bar
Main Steam Temperature : 600 0C
PLN
25 years (from COD)
 Under development
Cire o Po er Tra sfor atio ….
ITEM
FGD
CIREBON #1 1X660 MW
 Not Installed due to the coal has very
low content of sulfur (less than 0.2%)
CIREBON #2 1X1000 MW
 Will be installed to anticipate difficulty of
getting low sulfur coals
Main Steam Flow at  2,127,018 kg/hr
TMCR
Reheat Steam Flow at  1,733,835 kg/hr
TMCR
 50 bar
Re-heater outlet
pressure at TMCR
 2,813,400 kg/hr
 569 0C
Re-heater outlet
temperature at TMCR
 610 0C
 2,289,536 kg/hr
 45 bar
Cire o Po er Tra sfor atio ….
Capacity (gross)
Main/Reheat
Temperature
Boiler Efficiency
Turbine Efficiency
Plant Efficiency (net)
Coal Caloric Value
Heat Rate
Ultra-Supercritical (USC)
Plant
1,006 MW
600 ℃ / 610 ℃
86.00%
48.87%
41.00%
Supercritical (SC)
Plant
698 MW
566 ℃ / 569 ℃
85.88%
46.80%
39.00%
4,500 kcal/kg
2305 kcal/kWh
2312 kcal/kWh
Difference
(SC – USC)
+0.2%
+2.00%
+ 7 kcal/kWh
SOX Emission (mg/Nm3)
Design
510
Operation
-
Design
750
Operation
250
-240 mg/Nm3
NOX Emission (mg/Nm3)
625
-
680
200
-55 mg/Nm3
Challe ges i the Tra sfor atio ….
 Local Content Requirement
 Indonesia Regulation minimum requirement local content : 38.21%
 optimizing the achievement of local content for USC technology : 15.20%
 Operational
 Operator’s skill needs to be improved by providing knowledge training regarding
Supercritical technology and safe operation of the boiler since some conditions
good for Sub-critical Boilers are not good enough for Supercritical Boilers.
HERU DEWANTO
President Director, Cirebon Power
Continuous Emissions Monitoring Systems – Indonesia Experience
International Conference on Coal-Based Power
New Delhi, 17 – 19 March 2016
Content …..
1
More Stringent Regulations
2
Monitoring
3
ECMS
4
Reporting
25
CEMS is a Must for Coal Fired Po er ….
In Indonesia the installation of CEMS is a must for Coal Fired Plants complied with
Environmental Minister Regulation No 21 Year 2008 :
 Clause 6.2 for businesses and or activities of thermal power plants to install CEMS,
emission quality standards can be exceeded up to a limit of 5% of the daily data for 3
months of operating time
 Responsible for the business or activity thermal power plants must:
 Clause 9.1 (c) Installing a Continuous Emission Monitoring System (CEMS) at chimney
with the highest pollution load, which is calculated at early stages of planning the
installation, and operating continuously, for fossil-fueled power plants with a capacity
above 25 MW built prior to the enactment of this Regulation.
 Clause 9.1 (e) Measuring parameters of SO2, NOx, opacity, O2, CO and the flow rate
and calculate the CO2 and total particulate emission measurements with Continuous
Emission Monitoring System (CEMS).
 Clause 9.1 (i) Reporting the results of the monitoring and measurements according to
the report format as specified in Annex VIII of this regulation every 6 months for the
measurement of CEMS to the regent / mayor with a copy to the governor and the
Minister
 Clause 9.1 (j) Has a Quality Assurance system (QA) and Quality Control (QC) for the
operation of CEMS and calculation parameter emissions of SO2, NOx, total
particulates, and CO2
CEMS is a Must for Coal Fired Po er ….
In Indonesia the installation of CEMS is a must for Coal Fired Plants due to
environmental regulations for emission is getting stricter over years :
I do esia’s Regulation – Emission Limit
Increasingly stringent
Env. Ministry. Decree
13/MENLH/3/1995
Parameter
1995
2000
Env. Ministry.
Reg. 7/2007
2007
Env. Ministry.
Reg. 21/2008
2008
2008
Emission
Thresholds for Ambient
Total Solid Particle
(TSP) (mg/Nm3)
300
230
230
100
230 micro g/Nm3 max for 24
hours average
Sulfur Dioxide (Sox)
(mg/Nm3)
1500
800
750
750
900 micro g/Nm3 max for 1
hour average
Nitrogen Dioxide
(Nox) (mg/Nm3)
1700
1000
825
750
400 micro g/Nm3 max for 1
hour average
40
35
20
20
-
Opacity (%)
Carbon Mono Oxide
30,000 micro g/Nm3 max for 1
hour average
E issio …
PARAMETER
EMISSION
AMBIENT
Regulation
Cirebon Power
Regulation
Cirebon Power
TSP (mg/Nm3)
100
15,9
230 micro g/Nm3
(24 hours)
76.6
SOx (mg/Nm3)
750
200
900 micro g/Nm3
(1 hour)
25
NOx (mg/Nm3)
750
225
400 micro g/Nm3
(1 hour)
225
Opacity (%)
20
8,6
----
----
Carbon Mono Oxide
30,000 micro
g/Nm3 (1 hour)
1,700
CEMS ….
 In order to ensure that these values are not exceeded CEMS must be installed and
maintained in a good manner.
 CEMS uses many sensitive sensors so routine maintenance such as sensor cleaning
and calibrating must be performed to ensure accurate readings.
 Automatic calibrations is one of the way to maintain their accuracy, in which
technicians will need to ensure the availability of calibration gas at all time.
 Also by regulations it needs to conduct manual sampling of the Flue Gas 4 times a
year to ensure that the readings by CEMS do not offset too much compared with the
calibrated equipment. These data will be reported to the local authorities 2 times a
year.
Simple Illustration for CEMS ….
Sample of CEMS Readings ….
Other than measuring SO2, NO2, CO
and Opacity the CEMS is also
reporti g Cal ulated CO2
production
E issio Reporti g ….
 The Environmental and Social Impact Analysis which at local called AMDAL requires
the owner of the power plant to report detailed environmental monitoring data
including the data from CEMS every 6 months to the local authorities. For ambient air
sampling we have designated 9 sampling locations near the power plant including the
Permanent Ambient Air Monitoring Station which is located 4.5 km west of the
chimney.
 The above 6 monthly regular report cover the data collected by manual sampling
from the chimney which are conducted 4 times a year.
 The reports are submitted to the Environmental Minister, Province and Region
Environmental Offices as well as Sub-District Office
Cirebon Power #1: Fly Ash
33
Managing Fly Ash ….





In Indonesia Fly Ash is categorized as Toxic Waste, therefore handlings and
treatment must strictly follow environmental regulations
Storing at site (in a pond) must follow a strict regulations to built 7 layer basement
and one of them is HDPE liner (High Density Poly Eurethene.)
Installing monitoring wells around the pond to ensure no contaminated water
leaching through the ground
Transportations (on land or sea) must use enclosed tanks to avoid spill.
Treatment can only be conducted by Certified Factories such as Cement Factories
to be used as raw material for cement
Indonesian government encourages the ash producers to re-use the
ash for other valuable products.
Cirebon Power Case ….
 In normal days the Fly Ash is temporarily stored in a Silo (350 m3 capacity) while a
truck is under the Silo loading the Fly Ash into it’s enclosed tank.
 The trucks bring the Fly Ash directly to a Cement Factory for about 5 hour
traveling time.
 Everyday 6 trucks (capacity of 35 ton each truck) are bringing Fly Ash to a cement
factory.
 In up-normal days, such as Long holidays for Idul Fitr and X-mash-new year, where
trucks are not allowed to be on the roads the Fly Ash is stored in a bigger Silo
(1000 m3 Capacity). If these 2 Silos are full the Fly Ash will be loaded to stand-by
trucks. If all stand-by trucks are also full the Fly Ash will be dumped on the Ash
Pond and will become/considered to be Bottom Ash.
Note : 2 Fly Ash Silos could store the production of ash of 11 days at 100% Power
Plant load, while long holidays are 11 – 14 days depends on government decision.
Fly Ash Silo ….
Left side is 350 m3 Fly Ash Silo and right side is 1000 m3 Fly Ash Silo, and 3 trucks with
enclosed tank
Ash Po d ….
Ash Pond, always empty due to the ash (including Bottom Ash) are all taken out by a
cement factory.
The Ash Pond was last used in mid 2012.