p–ISSN: 2723 - 6609 e-ISSN: 2745-5254
Vol. 5, No. 11, November 2024 http://jist.publikasiindonesia.id/
Indonesian Journal of Social Technology, Vol. 5, No. 11, November 2024 4780
Exhaust Temperature Control of Double Tail Flue Boiler
Muhammad Akbar M1*, Wang Jinsong2
PT. DSSP Power Kendari, Indonesia
Email: [email protected]1*, [email protected]2
*Correspondence
ABSTRACT
Keywords: double tail
flue exhaust temperature
control; pulverized coal
boiler; thermal efficiency.
The performance of the DG230 / 9.81-Ⅱ16 pulverized coal
boiler at a thermal power plant in Indonesia has been
compromised by consistently high exhaust gas temperatures,
which have adversely affected its thermal efficiency and
increased operational risks. The issue, first identified in late
2019, was linked to several factors, including misalignment
of the burner, coking on the superheater surfaces, blockages
in the economizer, and improper damper settings. These
issues led to inefficiencies in heat transfer, increased fuel
consumption, and operational instability. The research
involved comprehensive field inspections, operational data
collection, and collaborative analysis with technical experts
to pinpoint critical problem areas. Data collection focused on
exhaust gas temperatures and pressure differentials, with
sensors installed at strategic points throughout the boiler.
Following the diagnosis, corrective measures such as
adjusting burner angles, optimizing superheater cleaning,
clearing blockages in the economizer, and fine-tuning
damper settings were executed. Results from the corrective
actions, implemented in 2023, demonstrated a significant
reduction in exhaust gas temperatures, bringing them within
the design range. The adjustments improved the overall
efficiency of the boiler by achieving more uniform heat
distribution and enhancing combustion stability. After six
months of monitoring, the exhaust temperatures remained
stable, confirming the success of the interventions. This
study underscores the critical role of burner alignment and
damper control in managing exhaust gas temperatures and
offers practical recommendations for improving operational
efficiency and safety in similar boiler systems.
Introduction
Boiler exhaust temperature is a critical parameter in thermal power plant operations,
significantly impacting thermal efficiency and overall system economy. Elevated exhaust
temperatures can result in suboptimal heating of the working medium in downstream heat
exchange surfaces, leading to reduced thermal efficiency, increased fuel consumption,
Vol. 5, No. 11, November 2024 http://jist.publikasiindonesia.id/
Indonesian Journal of Social Technology, Vol. 5, No. 11, November 2024 4780
Exhaust Temperature Control of Double Tail Flue Boiler
Muhammad Akbar M1*, Wang Jinsong2
PT. DSSP Power Kendari, Indonesia
Email: [email protected]1*, [email protected]2
*Correspondence
ABSTRACT
Keywords: double tail
flue exhaust temperature
control; pulverized coal
boiler; thermal efficiency.
The performance of the DG230 / 9.81-Ⅱ16 pulverized coal
boiler at a thermal power plant in Indonesia has been
compromised by consistently high exhaust gas temperatures,
which have adversely affected its thermal efficiency and
increased operational risks. The issue, first identified in late
2019, was linked to several factors, including misalignment
of the burner, coking on the superheater surfaces, blockages
in the economizer, and improper damper settings. These
issues led to inefficiencies in heat transfer, increased fuel
consumption, and operational instability. The research
involved comprehensive field inspections, operational data
collection, and collaborative analysis with technical experts
to pinpoint critical problem areas. Data collection focused on
exhaust gas temperatures and pressure differentials, with
sensors installed at strategic points throughout the boiler.
Following the diagnosis, corrective measures such as
adjusting burner angles, optimizing superheater cleaning,
clearing blockages in the economizer, and fine-tuning
damper settings were executed. Results from the corrective
actions, implemented in 2023, demonstrated a significant
reduction in exhaust gas temperatures, bringing them within
the design range. The adjustments improved the overall
efficiency of the boiler by achieving more uniform heat
distribution and enhancing combustion stability. After six
months of monitoring, the exhaust temperatures remained
stable, confirming the success of the interventions. This
study underscores the critical role of burner alignment and
damper control in managing exhaust gas temperatures and
offers practical recommendations for improving operational
efficiency and safety in similar boiler systems.
Introduction
Boiler exhaust temperature is a critical parameter in thermal power plant operations,
significantly impacting thermal efficiency and overall system economy. Elevated exhaust
temperatures can result in suboptimal heating of the working medium in downstream heat
exchange surfaces, leading to reduced thermal efficiency, increased fuel consumption,
Muhammad Akbar M, Wang Jinsong
Indonesian Journal of Social Technology, Vol. 5, No. 11, November 2024 4781
and, in severe cases, safety risks due to potential unplanned shutdowns. Maintaining
exhaust temperature within an optimal range is essential for ensuring both safety and
efficiency. This requires stringent control over thermal deviations across the various heat
exchange surfaces in the boiler's rear section to keep flue gas temperature within
prescribed safety limits.
The DG230 / 9.81 - Ⅱ16 pulverized coal boiler, produced by Dongfang Boiler Co.,
Ltd., is a high-temperature, high-pressure natural circulation drum boiler. It features four-
corner tangential combustion, known for stable and efficient combustion. The design
includes a full-radiation superheater tube screen in the upper furnace, a high-temperature
superheater above the flame folding angle, and a low-temperature superheater in the
horizontal flue. While these components optimize heat exchange and minimize thermal
losses, issues such as improper burner alignment, coking, ash accumulation, and
ineffective damper control can disrupt this balance, leading to increased exhaust
temperatures.
In late 2019, two units of this boiler were commissioned at a power plant. By
October 2020, operators noted a gradual increase in exhaust gas temperature in both
boilers, coupled with a rise in flue gas differential pressure before and after the high-
temperature economizer and an increase in induced draft fan current. These deviations
risked operational stability and boiler efficiency.
A comprehensive inspection and analysis, conducted in collaboration with the
Central South Institute and technical experts, identified several contributing factors:
misalignment of the boiler flame centre due to incorrect burner tilt, coking on superheater
surfaces, and blockage in the high-temperature economizer. The flue gas regulating
dampers also contributed to the issue. A technical rectification plan was proposed in
January 2023, and implemented in February and August of the same year. Continuous
monitoring and adjustment over six months confirmed the success of the corrective
measures.
Recent studies have investigated various strategies for controlling flue gas
temperature in boilers, emphasizing burner tilt adjustments. Liu et al. ( 2024) and Tian et
al., (2015) Found that optimizing burner tilt angles could significantly reduce exhaust
temperatures while maintaining stable combustion. Chen et al., (2017) Demonstrated that
dynamic control of burner tilt and real-time flue gas monitoring enhance boiler efficiency.
Wu et al., (2024) Explored the impact of burner tilt on combustion characteristics,
highlighting environmental benefits. (Park et al., 2013) and Chen et al., (2017) Showed
that burner configuration and operation mode significantly affect boiler performance,
particularly in large-scale, ultra-supercritical boilers.
Chang, Wang, Zhou, Chen, & Niu, (2021) emphasized integrating advanced control
systems with burner tilt adjustments to optimize heat distribution and reduce exhaust
temperatures. (Xue et al., 2024) demonstrated that machine-learning algorithms can
predict optimal burner tilt angles in real time, enhancing temperature control efficiency.
(Xue et al., 2024) demonstrated that online monitoring and optimization of soot-blowing
frequency in air preheaters enhance temperature control efficiency. (Zhang et al., 2015)
Indonesian Journal of Social Technology, Vol. 5, No. 11, November 2024 4781
and, in severe cases, safety risks due to potential unplanned shutdowns. Maintaining
exhaust temperature within an optimal range is essential for ensuring both safety and
efficiency. This requires stringent control over thermal deviations across the various heat
exchange surfaces in the boiler's rear section to keep flue gas temperature within
prescribed safety limits.
The DG230 / 9.81 - Ⅱ16 pulverized coal boiler, produced by Dongfang Boiler Co.,
Ltd., is a high-temperature, high-pressure natural circulation drum boiler. It features four-
corner tangential combustion, known for stable and efficient combustion. The design
includes a full-radiation superheater tube screen in the upper furnace, a high-temperature
superheater above the flame folding angle, and a low-temperature superheater in the
horizontal flue. While these components optimize heat exchange and minimize thermal
losses, issues such as improper burner alignment, coking, ash accumulation, and
ineffective damper control can disrupt this balance, leading to increased exhaust
temperatures.
In late 2019, two units of this boiler were commissioned at a power plant. By
October 2020, operators noted a gradual increase in exhaust gas temperature in both
boilers, coupled with a rise in flue gas differential pressure before and after the high-
temperature economizer and an increase in induced draft fan current. These deviations
risked operational stability and boiler efficiency.
A comprehensive inspection and analysis, conducted in collaboration with the
Central South Institute and technical experts, identified several contributing factors:
misalignment of the boiler flame centre due to incorrect burner tilt, coking on superheater
surfaces, and blockage in the high-temperature economizer. The flue gas regulating
dampers also contributed to the issue. A technical rectification plan was proposed in
January 2023, and implemented in February and August of the same year. Continuous
monitoring and adjustment over six months confirmed the success of the corrective
measures.
Recent studies have investigated various strategies for controlling flue gas
temperature in boilers, emphasizing burner tilt adjustments. Liu et al. ( 2024) and Tian et
al., (2015) Found that optimizing burner tilt angles could significantly reduce exhaust
temperatures while maintaining stable combustion. Chen et al., (2017) Demonstrated that
dynamic control of burner tilt and real-time flue gas monitoring enhance boiler efficiency.
Wu et al., (2024) Explored the impact of burner tilt on combustion characteristics,
highlighting environmental benefits. (Park et al., 2013) and Chen et al., (2017) Showed
that burner configuration and operation mode significantly affect boiler performance,
particularly in large-scale, ultra-supercritical boilers.
Chang, Wang, Zhou, Chen, & Niu, (2021) emphasized integrating advanced control
systems with burner tilt adjustments to optimize heat distribution and reduce exhaust
temperatures. (Xue et al., 2024) demonstrated that machine-learning algorithms can
predict optimal burner tilt angles in real time, enhancing temperature control efficiency.
(Xue et al., 2024) demonstrated that online monitoring and optimization of soot-blowing
frequency in air preheaters enhance temperature control efficiency. (Zhang et al., 2015)
Exhaust Temperature Control of Double Tail Flue Boiler
Indonesian Journal of Social Technology, Vol. 5, No. 11, November 2024 4782
examined how ash fouling and soot-blowing influence heat exchanger efficiency,
contributing to both efficiency and emissions reduction. (Wu et al., 2021) and Hu et al.
(2018) examined how burner tilt can mitigate thermal NOx formation, contributing to
both efficiency and emissions reduction.
Research on boiler structure and its influence on exhaust temperatures is also
relevant. Guo et al. (2021) studied heat exchanger configurations and found that
optimized layouts reduce temperature gradients and improve efficiency. Wang et al.
(2019) investigated economizer design and its impact on thermal performance,
highlighting the need for precise engineering to avoid temperature deviations.
Advancements in sensor technology and data analytics, as reported by Zhao et al. (2020)
and Liu et al. (2021), offer new tools for monitoring and controlling exhaust temperatures,
enabling more responsive adjustments.
This paper aims to analyze the causes behind high exhaust temperatures in the
DG230 / 9.81 - Ⅱ16 pulverized coal boilers and present the results of the implemented
corrective actions. The findings contribute to a broader understanding of flue gas
temperature control in high-temperature, high-pressure boilers, with implications for
enhancing the efficiency and safety of similar units.
Method
The study began with a literature review, including an examination of the
Dongfang boiler manual, international journals, and other relevant sources. Field visits
were conducted to collect operational data on various parameters. During unit shutdowns,
conditions within the flue gas flow were inspected. New operational patterns were
trialled, followed by an analysis of their effects. Subsequent shutdowns involved
inspections to evaluate the outcomes of the implemented changes.
The following steps were taken to complete the research methodology:
1. Research Location:
This research was conducted at a Thermal Power Plant utilizing the DG230 / 9.81
- Ⅱ16 pulverized coal boiler. The research site is located at [PT DSSP Power Kendari,
IPP PLTU kendari-3], [Jl. Poros Kdi.- Moramo, Tj. Tiram, Kec. Moramo Utara,
Kabupaten Konawe Selatan, Sulawesi Tenggara 93891], [Indonesia]. This location was
selected due to the issue of high exhaust gas temperatures in the boiler units, which
became the focus of this study.
2. Research Subjects:
The research subjects were two units of the DG230 / 9.81 - Ⅱ16 pulverized coal
boiler operating at the power plant. These units experienced a significant increase in
exhaust gas temperature, making them the target for analyzing and resolving this issue.
3. Data Collection Techniques:
a. Direct Observation: Operational data were collected through direct observation and
recording of boiler performance parameters during operation. Recorded parameters
included exhaust gas temperature, pressure differentials, hot air temperature,
secondary air temperature, and data from various sensors and actuators.
Indonesian Journal of Social Technology, Vol. 5, No. 11, November 2024 4782
examined how ash fouling and soot-blowing influence heat exchanger efficiency,
contributing to both efficiency and emissions reduction. (Wu et al., 2021) and Hu et al.
(2018) examined how burner tilt can mitigate thermal NOx formation, contributing to
both efficiency and emissions reduction.
Research on boiler structure and its influence on exhaust temperatures is also
relevant. Guo et al. (2021) studied heat exchanger configurations and found that
optimized layouts reduce temperature gradients and improve efficiency. Wang et al.
(2019) investigated economizer design and its impact on thermal performance,
highlighting the need for precise engineering to avoid temperature deviations.
Advancements in sensor technology and data analytics, as reported by Zhao et al. (2020)
and Liu et al. (2021), offer new tools for monitoring and controlling exhaust temperatures,
enabling more responsive adjustments.
This paper aims to analyze the causes behind high exhaust temperatures in the
DG230 / 9.81 - Ⅱ16 pulverized coal boilers and present the results of the implemented
corrective actions. The findings contribute to a broader understanding of flue gas
temperature control in high-temperature, high-pressure boilers, with implications for
enhancing the efficiency and safety of similar units.
Method
The study began with a literature review, including an examination of the
Dongfang boiler manual, international journals, and other relevant sources. Field visits
were conducted to collect operational data on various parameters. During unit shutdowns,
conditions within the flue gas flow were inspected. New operational patterns were
trialled, followed by an analysis of their effects. Subsequent shutdowns involved
inspections to evaluate the outcomes of the implemented changes.
The following steps were taken to complete the research methodology:
1. Research Location:
This research was conducted at a Thermal Power Plant utilizing the DG230 / 9.81
- Ⅱ16 pulverized coal boiler. The research site is located at [PT DSSP Power Kendari,
IPP PLTU kendari-3], [Jl. Poros Kdi.- Moramo, Tj. Tiram, Kec. Moramo Utara,
Kabupaten Konawe Selatan, Sulawesi Tenggara 93891], [Indonesia]. This location was
selected due to the issue of high exhaust gas temperatures in the boiler units, which
became the focus of this study.
2. Research Subjects:
The research subjects were two units of the DG230 / 9.81 - Ⅱ16 pulverized coal
boiler operating at the power plant. These units experienced a significant increase in
exhaust gas temperature, making them the target for analyzing and resolving this issue.
3. Data Collection Techniques:
a. Direct Observation: Operational data were collected through direct observation and
recording of boiler performance parameters during operation. Recorded parameters
included exhaust gas temperature, pressure differentials, hot air temperature,
secondary air temperature, and data from various sensors and actuators.
Muhammad Akbar M, Wang Jinsong
Indonesian Journal of Social Technology, Vol. 5, No. 11, November 2024 4783
b. Sensor Data: Continuous data were collected from strategically placed temperature
sensors across key areas of the boiler, including the furnace outlet, high-temperature
economizer inlet and outlet, and preheater. Pressure sensors monitored differentials
across critical points in the economizer and preheater, capturing fluctuations related
to the buildup of ash or coking.
4. Data Analysis
a. Trend Analysis: Historical data on exhaust gas temperature and pressure
differentials were analyzed to identify patterns or trends associated with changes
in operational or environmental conditions. This analysis helps distinguish
between long-term issues and transient fluctuations.
b. Comparative Analysis: A comparison of key parameters before and after
corrective actions, such as exhaust gas temperature and furnace outlet
temperature, was used to measure the effectiveness of the technical interventions.
This includes evaluating the impact of burner position adjustments and damper
settings on temperature stability.
c. Root Cause Analysis: Root cause analysis was conducted to identify the primary
factors contributing to the increase in exhaust gas temperature. By evaluating field
inspection data and expert input, this analysis uncovered specific issues such as
burner misalignment and economizer blockages that affected heat balance.
5. Research Instruments:
a. Temperature Sensors: Temperature sensors were strategically placed at various
points within the boiler, including the furnace outlet, high-temperature economizer
inlet and outlet, and preheater. These sensors were used to monitor exhaust
temperatures in real-time.
b. Burner Actuators: Actuators were used to adjust the tilt angles of the burners. These
adjustments were made to optimize heat distribution within the furnace.
c. Pressure Measurement Devices: Pressure measurement devices were used to
measure the pressure differential of exhaust gas across the economizer and
preheater.
6. Field Visits and Inspections :
During unit shutdowns, conditions within the flue gas flow were thoroughly
inspected. Inspections were conducted to identify blockages, coking, and other
structural issues that might affect the exhaust gas temperature.
7. New Operational Patterns:
Trials of new operational patterns were conducted by implementing suggested
changes to burner tilt angles and damper settings. The effects of these changes were
monitored and analyzed to evaluate their impact on exhaust gas temperature.
Evaluations were performed during subsequent shutdowns to assess the outcomes of
the adjustments and improvements made.
Indonesian Journal of Social Technology, Vol. 5, No. 11, November 2024 4783
b. Sensor Data: Continuous data were collected from strategically placed temperature
sensors across key areas of the boiler, including the furnace outlet, high-temperature
economizer inlet and outlet, and preheater. Pressure sensors monitored differentials
across critical points in the economizer and preheater, capturing fluctuations related
to the buildup of ash or coking.
4. Data Analysis
a. Trend Analysis: Historical data on exhaust gas temperature and pressure
differentials were analyzed to identify patterns or trends associated with changes
in operational or environmental conditions. This analysis helps distinguish
between long-term issues and transient fluctuations.
b. Comparative Analysis: A comparison of key parameters before and after
corrective actions, such as exhaust gas temperature and furnace outlet
temperature, was used to measure the effectiveness of the technical interventions.
This includes evaluating the impact of burner position adjustments and damper
settings on temperature stability.
c. Root Cause Analysis: Root cause analysis was conducted to identify the primary
factors contributing to the increase in exhaust gas temperature. By evaluating field
inspection data and expert input, this analysis uncovered specific issues such as
burner misalignment and economizer blockages that affected heat balance.
5. Research Instruments:
a. Temperature Sensors: Temperature sensors were strategically placed at various
points within the boiler, including the furnace outlet, high-temperature economizer
inlet and outlet, and preheater. These sensors were used to monitor exhaust
temperatures in real-time.
b. Burner Actuators: Actuators were used to adjust the tilt angles of the burners. These
adjustments were made to optimize heat distribution within the furnace.
c. Pressure Measurement Devices: Pressure measurement devices were used to
measure the pressure differential of exhaust gas across the economizer and
preheater.
6. Field Visits and Inspections :
During unit shutdowns, conditions within the flue gas flow were thoroughly
inspected. Inspections were conducted to identify blockages, coking, and other
structural issues that might affect the exhaust gas temperature.
7. New Operational Patterns:
Trials of new operational patterns were conducted by implementing suggested
changes to burner tilt angles and damper settings. The effects of these changes were
monitored and analyzed to evaluate their impact on exhaust gas temperature.
Evaluations were performed during subsequent shutdowns to assess the outcomes of
the adjustments and improvements made.
Exhaust Temperature Control of Double Tail Flue Boiler
Indonesian Journal of Social Technology, Vol. 5, No. 11, November 2024 4784
The study involved a detailed analysis of a double-tail flue boiler with adjustable
burners. Temperature sensors were strategically placed throughout the boiler to monitor
exhaust temperatures, and actuators were used to adjust burner angles. Experimental
methods were employed to evaluate the effectiveness of control strategies.
Results and Discussion
The corrective measures for high exhaust temperatures in the boiler resulted in
significant improvements. Initial issues included deviations in burner positions, coking
on superheaters, ash blockage in the high-temperature economizer, and improper use of
the flue gas regulating damper.
1. Burner Position Adjustment: calibration of burner angles was performed to ensure
consistent positioning. Adjusting the bottom burner to -10° and the middle and upper
burners to -15° maintained the flue gas temperature below the design value of 916°C.
This adjustment addressed the issue of flue gas overheating at the furnace outlet.
Table 1
Boiler Main Parameters Before Adjustment (January 2023)
Parameter Unit Design
value
No. 1
Furnace
Completion
Value
No. 2
Furnace
Completion
Value
Furnace outlet flue gas
temperature ℃ 143 187 178
Flue gas pressure difference
at inlet and outlet of upper
economizer
KPa 0.75 1.47 1.54
Hot air temperature ℃ 386 423 417
Hot secondary air
temperature ℃ 362 338 325
Boiler outlet flue gas
temperature ℃ 916 1043 1121
High-temperature
economizer inlet flue gas
temperature
℃ 594 679 703
Literature Study Site Inspection
Operation
Parameter
Collection
Analysis and
Initial New
Operation Mode
Validation and
Implementation
Evaluation and
Improve the
WI/SOP
Result and
Discussion
Indonesian Journal of Social Technology, Vol. 5, No. 11, November 2024 4784
The study involved a detailed analysis of a double-tail flue boiler with adjustable
burners. Temperature sensors were strategically placed throughout the boiler to monitor
exhaust temperatures, and actuators were used to adjust burner angles. Experimental
methods were employed to evaluate the effectiveness of control strategies.
Results and Discussion
The corrective measures for high exhaust temperatures in the boiler resulted in
significant improvements. Initial issues included deviations in burner positions, coking
on superheaters, ash blockage in the high-temperature economizer, and improper use of
the flue gas regulating damper.
1. Burner Position Adjustment: calibration of burner angles was performed to ensure
consistent positioning. Adjusting the bottom burner to -10° and the middle and upper
burners to -15° maintained the flue gas temperature below the design value of 916°C.
This adjustment addressed the issue of flue gas overheating at the furnace outlet.
Table 1
Boiler Main Parameters Before Adjustment (January 2023)
Parameter Unit Design
value
No. 1
Furnace
Completion
Value
No. 2
Furnace
Completion
Value
Furnace outlet flue gas
temperature ℃ 143 187 178
Flue gas pressure difference
at inlet and outlet of upper
economizer
KPa 0.75 1.47 1.54
Hot air temperature ℃ 386 423 417
Hot secondary air
temperature ℃ 362 338 325
Boiler outlet flue gas
temperature ℃ 916 1043 1121
High-temperature
economizer inlet flue gas
temperature
℃ 594 679 703
Literature Study Site Inspection
Operation
Parameter
Collection
Analysis and
Initial New
Operation Mode
Validation and
Implementation
Evaluation and
Improve the
WI/SOP
Result and
Discussion
Muhammad Akbar M, Wang Jinsong
Indonesian Journal of Social Technology, Vol. 5, No. 11, November 2024 4785
High-temperature
economizer outlet flue gas
temperature
℃ 410 478 469
Table 2
Boiler Main Parameters After Adjustment (March 2024)
Parameter Unit Design
Value
No. 1 Furnace
Completion
Value
No. 2 Furnace
Completion
Value
Furnace outlet flue gas
temperature ℃ 143 141 139
Flue gas pressure
difference at inlet and
outlet of upper
economizer
KPa 0.75 0.34 0.51
Hot air temperature ℃ 386 383 379
Hot secondary air
temperature ℃ 362 367 353
Boiler outlet flue gas
temperature ℃ 916 932 927
High-temperature
economizer inlet flue gas
temperature
℃ 594 601 588
High-temperature
economizer outlet flue gas
temperature
℃ 410 417 422
2. Superheater Coking and Ash Accumulation: During maintenance, Coking on
superheater surfaces was removed using high-pressure water guns, which improved
heat exchange efficiency. Soot blowing frequency was optimized to prevent
excessive coking due to poor heat exchange.
3. Economizer and Preheater Blockage: Blockages in the high-temperature economizer
and air preheater pipelines were addressed using mechanical dredging and high-
pressure water jetting. These methods effectively cleared coke blocks, restoring heat
exchange and reducing flue gas temperature increases.
4. Flue Gas Damper Adjustment: The flue gas damper was adjusted based on
temperature measurements at the terminal preheater inlet. Reducing the damper
opening from 90% to approximately 10% balanced temperature across preheaters and
minimized heat loss, addressing uneven flue gas temperatures.
The improvements recorded in this study align with many findings from previous
studies that have examined the optimization of burner angles to enhance thermal
performance in boilers. For example, the adjustment of the burner angle in the DG230 /
9.81 - II16 boiler, which significantly reduced flue gas temperature and improved
operational stability, confirms similar results found by (Liu et al., 2024) Numerical
investigation of stable combustion at ultra-low load for a 350 MW wall tangentially fired
pulverized-coal boiler: Effect of burner adjustments and methane co-firingZhang et al.,
Indonesian Journal of Social Technology, Vol. 5, No. 11, November 2024 4785
High-temperature
economizer outlet flue gas
temperature
℃ 410 478 469
Table 2
Boiler Main Parameters After Adjustment (March 2024)
Parameter Unit Design
Value
No. 1 Furnace
Completion
Value
No. 2 Furnace
Completion
Value
Furnace outlet flue gas
temperature ℃ 143 141 139
Flue gas pressure
difference at inlet and
outlet of upper
economizer
KPa 0.75 0.34 0.51
Hot air temperature ℃ 386 383 379
Hot secondary air
temperature ℃ 362 367 353
Boiler outlet flue gas
temperature ℃ 916 932 927
High-temperature
economizer inlet flue gas
temperature
℃ 594 601 588
High-temperature
economizer outlet flue gas
temperature
℃ 410 417 422
2. Superheater Coking and Ash Accumulation: During maintenance, Coking on
superheater surfaces was removed using high-pressure water guns, which improved
heat exchange efficiency. Soot blowing frequency was optimized to prevent
excessive coking due to poor heat exchange.
3. Economizer and Preheater Blockage: Blockages in the high-temperature economizer
and air preheater pipelines were addressed using mechanical dredging and high-
pressure water jetting. These methods effectively cleared coke blocks, restoring heat
exchange and reducing flue gas temperature increases.
4. Flue Gas Damper Adjustment: The flue gas damper was adjusted based on
temperature measurements at the terminal preheater inlet. Reducing the damper
opening from 90% to approximately 10% balanced temperature across preheaters and
minimized heat loss, addressing uneven flue gas temperatures.
The improvements recorded in this study align with many findings from previous
studies that have examined the optimization of burner angles to enhance thermal
performance in boilers. For example, the adjustment of the burner angle in the DG230 /
9.81 - II16 boiler, which significantly reduced flue gas temperature and improved
operational stability, confirms similar results found by (Liu et al., 2024) Numerical
investigation of stable combustion at ultra-low load for a 350 MW wall tangentially fired
pulverized-coal boiler: Effect of burner adjustments and methane co-firingZhang et al.,
Exhaust Temperature Control of Double Tail Flue Boiler
Indonesian Journal of Social Technology, Vol. 5, No. 11, November 2024 4786
who reported that burner tilt affects temperature distribution within the boiler and reduces
heat wastage (Zhang et al., 2020. Similarly, Liu et al. (2019) and Tan et al. (2017) also
noted that adjusting the burner angle can improve combustion and optimize flue gas
temperature by balancing the heat distribution throughout the boiler. Therefore, these
findings not only support the existing theoretical framework but also demonstrate the
relevance of this solution in the broader context of industrial boilers.
The theoretical principle behind the burner angle adjustment relates to optimizing
airflow and combustion to maintain flame stability and ensure proper distribution of flue
gas temperature. Burner imbalance can lead to overheating in certain areas of the furnace,
which in turn may cause flue gas temperatures that deviate from the design specifications,
thus reducing boiler efficiency. Based on this principle, the burner angle adjustments
applied in this study—-10° for the lower burner and -15° for the upper and middle burner
successfully returned the flue gas temperature closer to the original design values, as also
evidenced by previous studies highlighting the importance of burner alignment in
pulverized coal boilers.
Additional improvements, such as the removal of superheater coking and proper
damper settings, corroborate findings by (Pattanayak et al., 2015), who demonstrated that
optimal soot-blowing frequency can enhance boiler performance and prevent excess
coking and dynamically adjusting operational parameters can maximize thermal
efficiency. Moreover, Shi et al. (2015) highlighted the importance of online monitoring
and soot-blowing optimization for convective heat exchangers, which further validates
the method used in this study to manage ash accumulation and blockage in the
economizer. In their study, adjusting burner parameters not only improved energy
efficiency but also reduced the accumulation of unburned carbon in fly ash, which could
affect the overall system efficiency. Similar findings were presented by Wu et al., (2024),
who stated that proper burner settings could reduce NOx emissions, although this study
focused more on emission control than on flue gas temperature.
Overall, the results obtained in this study are consistent with the existing literature,
supporting the idea that burner adjustments and management of other operational
parameters, such as dampers and soot cleaning, are key steps in controlling high flue gas
temperatures. However, this study also highlights the importance of managing other
often-overlooked factors in the literature, such as blockage in the economizer and coking
issues in the superheater, which also contribute to overall boiler performance degradation.
Therefore, a more comprehensive approach to managing flue gas temperature and boiler
efficiency could be adopted to mitigate broader issues in industrial combustion systems.
(Niu et al., 2015).
In summary, this study’s adjustments and improvements align with the literature
and strengthen our understanding of operational mechanisms that influence thermal
performance in pulverized coal boilers. Further research could explore integrating control
systems with advanced optimization technologies in various industrial boiler settings to
enhance efficiency and stability.
Indonesian Journal of Social Technology, Vol. 5, No. 11, November 2024 4786
who reported that burner tilt affects temperature distribution within the boiler and reduces
heat wastage (Zhang et al., 2020. Similarly, Liu et al. (2019) and Tan et al. (2017) also
noted that adjusting the burner angle can improve combustion and optimize flue gas
temperature by balancing the heat distribution throughout the boiler. Therefore, these
findings not only support the existing theoretical framework but also demonstrate the
relevance of this solution in the broader context of industrial boilers.
The theoretical principle behind the burner angle adjustment relates to optimizing
airflow and combustion to maintain flame stability and ensure proper distribution of flue
gas temperature. Burner imbalance can lead to overheating in certain areas of the furnace,
which in turn may cause flue gas temperatures that deviate from the design specifications,
thus reducing boiler efficiency. Based on this principle, the burner angle adjustments
applied in this study—-10° for the lower burner and -15° for the upper and middle burner
successfully returned the flue gas temperature closer to the original design values, as also
evidenced by previous studies highlighting the importance of burner alignment in
pulverized coal boilers.
Additional improvements, such as the removal of superheater coking and proper
damper settings, corroborate findings by (Pattanayak et al., 2015), who demonstrated that
optimal soot-blowing frequency can enhance boiler performance and prevent excess
coking and dynamically adjusting operational parameters can maximize thermal
efficiency. Moreover, Shi et al. (2015) highlighted the importance of online monitoring
and soot-blowing optimization for convective heat exchangers, which further validates
the method used in this study to manage ash accumulation and blockage in the
economizer. In their study, adjusting burner parameters not only improved energy
efficiency but also reduced the accumulation of unburned carbon in fly ash, which could
affect the overall system efficiency. Similar findings were presented by Wu et al., (2024),
who stated that proper burner settings could reduce NOx emissions, although this study
focused more on emission control than on flue gas temperature.
Overall, the results obtained in this study are consistent with the existing literature,
supporting the idea that burner adjustments and management of other operational
parameters, such as dampers and soot cleaning, are key steps in controlling high flue gas
temperatures. However, this study also highlights the importance of managing other
often-overlooked factors in the literature, such as blockage in the economizer and coking
issues in the superheater, which also contribute to overall boiler performance degradation.
Therefore, a more comprehensive approach to managing flue gas temperature and boiler
efficiency could be adopted to mitigate broader issues in industrial combustion systems.
(Niu et al., 2015).
In summary, this study’s adjustments and improvements align with the literature
and strengthen our understanding of operational mechanisms that influence thermal
performance in pulverized coal boilers. Further research could explore integrating control
systems with advanced optimization technologies in various industrial boiler settings to
enhance efficiency and stability.
Muhammad Akbar M, Wang Jinsong
Indonesian Journal of Social Technology, Vol. 5, No. 11, November 2024 4787
Conclusion
The high exhaust temperature issue in the plant's boiler was primarily caused by
deviations in burner position, resulting in an inefficient flame centre. Additionally, coking
on superheaters and ash blockage in the high-temperature economizer exacerbated the
problem. The lack of an intuitive basis for using the flue gas regulating damper also
contributed to high exhaust temperatures. By adjusting burner positions and the flue
damper, the deterioration in furnace operating conditions was addressed, leading to a
reduction in exhaust temperature and maintenance within design limits. Corrective
actions, including addressing coking and blockages, successfully controlled exhaust
temperatures and restored normal boiler operation. This study demonstrates that burner
tilting adjustments can significantly improve exhaust temperature control and heat
distribution in double-tail flue boilers. Future research should explore the integration of
these control systems with other boiler optimization technologies and their application in
different industrial settings.
Indonesian Journal of Social Technology, Vol. 5, No. 11, November 2024 4787
Conclusion
The high exhaust temperature issue in the plant's boiler was primarily caused by
deviations in burner position, resulting in an inefficient flame centre. Additionally, coking
on superheaters and ash blockage in the high-temperature economizer exacerbated the
problem. The lack of an intuitive basis for using the flue gas regulating damper also
contributed to high exhaust temperatures. By adjusting burner positions and the flue
damper, the deterioration in furnace operating conditions was addressed, leading to a
reduction in exhaust temperature and maintenance within design limits. Corrective
actions, including addressing coking and blockages, successfully controlled exhaust
temperatures and restored normal boiler operation. This study demonstrates that burner
tilting adjustments can significantly improve exhaust temperature control and heat
distribution in double-tail flue boilers. Future research should explore the integration of
these control systems with other boiler optimization technologies and their application in
different industrial settings.
Exhaust Temperature Control of Double Tail Flue Boiler
Indonesian Journal of Social Technology, Vol. 5, No. 11, November 2024 4788
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hydrodynamics, combustion and NOx emission in a tangentially fired pulverized-
coal boiler at low load operating conditions. Advanced Powder Technology, 32(2),
290–303.
Chen, S., He, B., He, D., Cao, Y., Ding, G., Liu, X., Duan, Z., Zhang, X., Song, J., & Li,
X. (2017). Numerical investigations on different tangential arrangements of burners
for a 600 MW utility boiler. Energy, 122, 287–300.
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tangentially fired pulverized-coal boiler: Effect of burner adjustments and methane
co-firing. Applied Thermal Engineering, 246, 122980.
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four-wall tangential firing pulverized coal furnace. Applied Thermal Engineering,
90, 471–477.
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Numerical and experimental investigations on the gas temperature deviation in a
large scale, advanced low NOx, tangentially fired pulverized coal boiler. Fuel, 104,
641–646.
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frequency to improve boiler performance and reduce combustion pollution. Clean
Technologies and Environmental Policy, 17(7), 1897–1906.
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Influence of vertical burner tilt angle on the gas temperature deviation in a 700 MW
low NOx tangentially fired pulverised-coal boiler. Fuel Processing Technology,
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pulverized coal co-firing with ammonia. International Journal of Hydrogen
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power plants and industrial boilers. Science of The Total Environment, 756, 144063.
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Reconstructing near-water-wall temperature in coal-fired boilers using improved
transfer learning and hidden layer configuration optimization. Energy, 294, 130860.
Muhammad Akbar M, Wang Jinsong
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