Comparative analysis of innovative coal pipe and sealpot designs on flow efficiency toward the furnace at PLN Nusantara Power Tenayan

Abstract

Coal transportation to the combustion chamber is a critical process that directly affects combustion efficiency, equipment reliability, and furnace lifespan. In practice, the conventional sealpot system often creates operational challenges such as high turbulence, particle abrasion, and uneven heat distribution due to its geometric configuration. These issues reduce thermal efficiency and accelerate furnace wear, leading to higher maintenance demands. This study aims to address these challenges by comparing the conventional sealpot design with an innovative coal pipe design implemented at PLN Nusantara Power Tenayan. Computational Fluid Dynamics (CFD) simulations were conducted to analyze air velocity distribution, particle velocity, pressure, and temperature, while Finite Element Analysis (FEA) was used to evaluate stress, deformation, and safety factors in the furnace structure. The results show that the coal pipe design yields lower particle impact stress 49.09 MPa lower than 50.20 MPa in the sealpot, smaller deformation of 1.24 mm, while the sealpot reaches 1.85 mm, and a higher safety factor with a value of 5.09, compared to 4.98 in the sealpot, indicating superior mechanical integrity and abrasion resistance. Overall, the innovative coal pipe design proves to be more efficient and durable, providing a scientific basis for improving coal distribution systems in steam power plants.