Slagging & Fouling Control Project - Indonesia
Comprehensive slagging and fouling control strategy for an Indonesian power plant, achieving significant reductions in cleaning frequency and improving plant availability through advanced diagnostics and targeted interventions.
Key Results
Before & After Comparison
| Metric | Before | After |
|---|---|---|
| Cleaning Frequency | Bi-weekly | Monthly |
| Plant Availability | 89% | 94% |
The Challenge
The Indonesian coal-fired power plant experienced severe slagging and fouling issues that required frequent unplanned outages for cleaning. The high-ash Indonesian coal combined with suboptimal combustion conditions led to heavy ash deposits on heat transfer surfaces, reducing boiler efficiency and forcing costly maintenance interventions.
Our Solution
TABi conducted comprehensive ash chemistry analysis and CFD modeling to identify the root causes of deposition. The solution included optimized sootblowing schedules, fuel blending strategies to modify ash fusion temperatures, and combustion tuning to reduce furnace exit gas temperatures in high-deposition zones.
Results Achieved
Cleaning frequency was reduced by 60%, from bi-weekly to monthly interventions. Plant availability improved by 5%, and annual maintenance costs decreased significantly. The optimized combustion also delivered secondary benefits in heat rate and emissions performance.
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