Coal Combustion Simulation in a 300 MW Coal-Fired Power Plant

Abstract

Indonesia’s growing electricity demand, projected to reach 2,169 TWh by 2060, poses challenges for coal-fired power plants (CFPPs), especially with the limited long-term viability of plants designed for high-rank coal (HRC). Given that a majority of the nation’s coal reserves are low-rank coal (LRC), coal blending presents a promising solution. This study investigates the impact of LRC blending on the performance of a 300 MW CFPP using process modeling and simulation through Aspen HYSYS. The model was validated against heat balance data. Eleven blending scenarios (0–100% LRC) were analyzed to assess their effects on fuel consumption, thermal efficiency, and flue gas composition. Results show that system efficiency follows a non-linear trend, with peak efficiency at a coal mass flow of 160,000 kg/h. Increasing LRC content raises coal consumption, reduces boiler efficiency, and increases air requirements, highlighting the importance of identifying an optimal air-to-fuel ratio (9.5–10.0 kg air/kg coal). The simulation also demonstrated that flue gas composition—particularly CO₂, CO, NO₂, and SO₂—serves as a key indicator of combustion quality. These findings emphasize the importance of optimizing coal blending strategies for improved performance and reduced emissions in CFPP operations.