STUDY OF COAL USAGE IN INDONESIAN STUDY OF COAL USAGE IN INDONESIAN TEXTILE INDUSTRIES AS BASIC TEXTILE INDUSTRIES AS BASIC

CONSIDERATIONS FOR EMISSION CONSIDERATIONS FOR EMISSION STANDARD DETERMINATIONSTANDARD DETERMINATION

bybyKania DewiKania Dewi

Faculty of Civil and Environmental EngineeringFaculty of Civil and Environmental EngineeringInstitut Teknologi Bandung - IndonesiaInstitut Teknologi Bandung - Indonesia

BackgroundBackground

Ambient air quality should be maintainedAmbient air quality should be maintained Point sources such as stack textile boilers Point sources such as stack textile boilers

contribute significant emissionscontribute significant emissions The increase use of coal as alternative source of The increase use of coal as alternative source of

energy due to the sharp raise of oil and gas fuel energy due to the sharp raise of oil and gas fuel price in Indonesia. price in Indonesia.

Indonesia has abundant amounts of coal storageIndonesia has abundant amounts of coal storage Government policy in energy field to use coal as Government policy in energy field to use coal as

alternative energy for replacing liquid fuelalternative energy for replacing liquid fuel No emission standard for textile coal boilers has No emission standard for textile coal boilers has

been specified by the Indonesian Governmentbeen specified by the Indonesian Government

Indonesian Coal SourcesIndonesian Coal Sources BackgroundBackground

Provinces Potential Sources (million tons)

Reserve-mineable(million tons)

Aceh 450.15 0

North Sumatra 26.97 0

Riau 2,057.22 15.15

West Sumatra 719.09 36.07

Bengkulu 198.37 21.12

Jambi 1,592.57 9.00

South Sumatra 22,240.40 2,653.98

Lampung 106.95 0

West Kalimantan 527.52 0

Middle Kalimantan 1,399.21 48.59

South Kalimantan 8,674.56 1,787.32

East Kalimantan 19,567.79 2,410.33

South Sulawesi 132.01 0.06

Middle Sulawesi 1.98 0

Papua 138.30 0

Banten 13.75 0

Middle Java 0,82 0

East Java 0,08 0

Total 57,847.74 6,981.62

Case Study:

Textile Industries in Bandung Metropolitan

City

ObjectiveObjective Identifying coal usage in textile industriesIdentifying coal usage in textile industries

Coal usage as energy source Coal usage as energy source Textile coal boiler and air pollution controlTextile coal boiler and air pollution control Emission from coal boiler including historical dataEmission from coal boiler including historical data Coal, fly ash and bottom ash characteristicsCoal, fly ash and bottom ash characteristics Fly ash and bottom ash managementFly ash and bottom ash management

Preliminary emission factor determinationPreliminary emission factor determination Identifying basic factors which influence emission standard determinationIdentifying basic factors which influence emission standard determination

MethodMethod Gathering Primary and Secondary DataGathering Primary and Secondary Data

Field visit in textile industries for spreading questionnaires and doing interviews to Field visit in textile industries for spreading questionnaires and doing interviews to gather information related to the coal usagegather information related to the coal usage

Stack sampling in two selected textile industries for approximated emission factor Stack sampling in two selected textile industries for approximated emission factor determination.determination.

Collection of coal, fly ash and bottom ash samples for coal and coal ash Collection of coal, fly ash and bottom ash samples for coal and coal ash characteristic determinationcharacteristic determination

Laboratory analysisLaboratory analysis Data analysisData analysis

Number of Samples : 300 textile industries

Type of Product

Amount %

Cotton

0,25 - 30 ton /month

1.500 - 200.000 m/day

40

Blends 25 ton/month 8

Rayon10.000 yard/day

10 ton/month24

Polyester5 - 470 ton/month450.000-800.000

yard/day56

Cotton6.000 ton/month8.800-1.000.000

m/month24

Others 8

General Condition of Textile IndustriesGeneral Condition of Textile Industries ResultResult

(Case Study: Bandung Metropolitan City)(Case Study: Bandung Metropolitan City)

Investment Type- Foreign investment 11,54%

- Domestic investment 65,38%

- Others 3,85%

Starting Production Year 1963 - 1996

Building Physical condition

Very Good-3.85%

Good-15.32%

Fair-76.92%

Total Size1 - 38,773 ha

Built: 6,000-130,410 m2

Employee number 60-2800 people

Production Type Other Information

Coal Usage in Textile IndustriesCoal Usage in Textile Industries

Source of Energy

Energy Consumption

User Percentage

Petroleum 15 - 50 liter/day 15,38

Diesel oil50 - 3.100 liter/day 42,31

Kerosene 60 - 80 liter/day 7,69

Coal 7- 200 ton/day 76,92

Others 7,69

Coal Sources (%)

Bukit Asam- South Sumatera 5,26

Lati-adaro South Kalimantan 52,63

Satui Senakin - South Kalimantan 31,58

others

Source: Questionnaire data for textile industries in Bandung Metropolitan, 2005

Energy Source

Boiler System %

Grate Firing 68.18

Fluidized Bed 50.00

Pulverized Coal none

Coal Sources

Boiler Type

Coal Ashes Production (ton/day)

Fly AshFly Ash 0.2 - 20 ton/day

Bottom AshBottom Ash 0.08 - 7 ton/day

Coal Ashes Production

Result

Source: from textile industries in Bandung Metropolitan, 2005

Industries Particulate Control

Gas Control

PT 1 Cyclone Scrubber

PT 2 Cyclone Wet Scrubber

PT 3 Scrubber

PT 4 Scrubber

PT 5 Cyclone Wet Scrubber

PT 6 Cyclone Scrubber

PT 7 Cyclone Scrubber

PT 8 Cyclone

PT 9 Water Spray Absorber

PT 10

PT 11 Wet Scrubber Wet Scrubber

PT 12 Cyclone Scrubber

Bag House Filter

PT 13 Cyclone

PT 14 Bag House Filter Scrubber

PT 15 Cyclone

PT 16 Cyclone Scrubber

Coal fired boiler

Wet Scrubber

Air Pollution ControlResult

Emission from Textile BoilerEmission from Textile Boiler ResultResult

350

0

100

200

300

400

500

1 3 5 7 9 11 13 15 17 19 21 23 25 27

Boiler Number

Con

cent

ratio

n (m

g/m

3)

Particulate Particulate limit

800

1000

0

400

800

1200

1 3 5 7 9 11 13 15 17 19 21 23 25 27

Boiler Number

Con

cent

ratio

n (m

g/m

3)

Sulfur dioxide (SO2) Nitrogen dioxide (NO2)

SO2 limit NO2 limit

30

0

10

20

30

40

1 3 5 7 9 11 13 15 17 19 21 23 25 27Boiler Number

%

Opasity Opasity limit

Source: Monitoring data from textile industries in Bandung Metropolitan, data 2004-2005

Problem

• validity data, not accredited lab

• no specific regulation for lab reporting data

• no specific emission standard for coal textile boilers

Coal and Its Ash CharacteristicsCoal and Its Ash Characteristics

ParameterAdaro-KalselLow Calorie

Arutmin KalselHigh Calorie

Sample fromTextile Industry

Total water content, % 23-25 11.2 15.64

Fixed water, % 14-16 5..2 13.79

Ash,% 1 12.1 8.38

Fly matter, % 43-44 42 37.67

Carbon content, % 37-39 39-42 40.16

Energy value , kkal/kg 5400-5800 6300-6600 5382

Sulfur, % 0.1 0.2-1 1.36

Source: Data from Center for Investigation and Development of Mineral Technology and Coal, 2005

Parameter Satuan Boiler Ash (Bottom Ash)

Economizer Ash (Fly Ash)

Filter Ash (Fly Ash)

Water content % 78.86 76.50 74.63

Ash % 16.54 18.18 20.26

Flying matter % 1.8 1.81 1.99

Fixed carbon content % 0.23 0.18 0.27

Energy value Kkal/kg 1303 1405 1575

Coal Characteristic

Ash Characteristic

Result

Parameter Sample 1 UnitStandard

  Coal Fly ash Bottom ash  

Abu 12.19 81.03 96.46 % ASTM D.3174

Karbon 55.24 15.69 4.03 % ASTM D.3178

Hidrogen 5.19 0.35 0.47 % ASTM D.3179

Nitrogen 0.81 0.23 0.1 % ASTM D.3179

Total Sulfur 0.83 0.28 0.1 % ASTM D.3177

Oksigen 25.74 2.42 0.66 % ASTM D.3176

ParameterSample 2

Unit StandardBatubara Fly ash Bottom ash

Abu 4.15 87.49 74.8 % ASTM D.3174

Karbon 53.59 10.92 21.78 % ASTM D.3178

Hidrogen 5.59 0.41 0.46 % ASTM D.3179

Nitrogen 0.74 0.2 0.29 % ASTM D.3179

Total Sulfur 0.65 0.4 0.25 % ASTM D.3177

Oksigen 35.35 0.65 2.42 % ASTM D.3176

Ultimate Analysis

Coal and Its Ash CharacteristicsCoal and Its Ash CharacteristicsResult

No Color BoilerWater Content % Wet Basis

Volatile Content % Dry Basis

1 FA-brownish yellow Grate firing 0.583 5.2122 FA-blackish brown Fluidized bed 0.29 8.1033 BA-blackish brown Grate firing 36.914 48.7374 FA-blackish brown Fluidized bed 1.199 37.265 FA-brownish black Grate firing 30.425 7.896 FA-brownish black Fluidized bed 0.589 17.6437 FA-black Grate firing 1.606 23.2878 BA-blackish brown Grate firing 29.099 14.119 FA-brownish yellow Fluidized bed 54.536 13.974

10 FA-black Fluidized bed 59.629 31.011

Source: Solid and Hazardous Waste Laboratory - Environmental Engineering ITB

Ash CharacteristicsAsh CharacteristicsResult

Coal Coal AshesAshes Handling Handling

Coal ash is used as substance to make paving block

Coal ash is stored inside the factory (no license for storage from the government)

Coal Ashes

Taken by coal supplier according to the contract

Result

Emission SamplingEmission Sampling

Parameter Industry 1 Industry 2Stack height 50 M 22MSampling hole height 30 M 8MStack diameter 2.5 M 1MStack pressure 778.4 mmHg 774.7 mmHgStack gas velocity 7.2 m/s 13.1Stack gas flowrate 9.6 l/m 17.6 l/mBoiler capacity 31 ton/day 200 ton/dayParticulate concentration 140.56 (mg/m3) 160.77(mg/m3)SO2 concentration 478.91 (mg/m3) 613.00 (mg/m3)NOx concentration 137.51 (mg/m3) 151.81 (mg/m3)

Source: Emission Sampling by Air Quality Laboratory – Environmental Engineering ITB

Air Emission Sampling in Selected Textile Industry

Concen-tration

Gas Velocity

Stack Area

Emission Flowrate Boiler Capa-city

Emission Factor

mg/m3 v (m/second)

m2 mg/s mg/day ton/day

Ton/day

Industry-1Particulate 160.77 13.16 0.79 1660.44 143,461,689.12 0.14 31 0.00463SO2

613.01 13.16 0.79 6330.97 546,995,542.99 0.55 31 0.01765NOx

151.81 13.16 0.79 1567.85 135,462,008.80 0.14 31 0.00437

Industry 2Particulate 140.56 7.17 4.91 4947.33 427,449,416.53 0.43 200 0.00214SO2

478.91 7.17 4.91 16856.22 1,456,377,524.39 1.46 200 0.00728NOx

137.51 7.17 4.91 4839.94 418,170,671.56 0.42 200 0.00209

Calculation of Air Pollution Emission Factor Based on Air Emission Sampling

Result

Emission Standard ConsiderationEmission Standard Consideration

Coal quality as input solid fuelCoal quality as input solid fuel CCompliance ability, including considering best ompliance ability, including considering best

available technologyavailable technology BBoiler capacity, fuel type, boiler oiler capacity, fuel type, boiler

technologytechnology/combustion type/combustion type, unit control , unit control availabilityavailability

Data validityData validity Accredited laboratory for emission/ambient Accredited laboratory for emission/ambient

monitoringmonitoring Historical data monitoring from textile boilersHistorical data monitoring from textile boilers

Result

ConclusionConclusion Diversification of energy source is a must, coal is a good

alternative.

Many textile industries in Metropolitan Bandung have started to use coal, a cheaper solid fuel, as the source of energy.

Various coal types are used in textile industries, no collective system exists for buying the same type of coal.

Various coal quality leads to various strength of emissions.

No certain system for handling coal ashes.

Accredited laboratory should be available for emission sampling.

Standardization of lab reporting emission data is needed to gain more information during stack sampling.

The concentration of pollutants derived from stack sampling if reported with supporting data is able to be used for emission factor determination.

Specific emission standard for coal textile boilers should be determined.