1. STUDY OF COAL USAGE IN INDONESIAN TEXTILE INDUSTRIES AS BASIC CONSIDERATIONS FOR EMISSION STANDARD DETERMINATION by Kania Dewi Faculty of Civil and Environmental Engineering Institut Teknologi Bandung - Indonesia

2. Background  Ambient air quality should be maintained  Point sources such as stack textile boilers contribute significant emissions  The increase use of coal as alternative source of energy due to the sharp raise of oil and gas fuel price in Indonesia.  Indonesia has abundant amounts of coal storage  Government policy in energy field to use coal as alternative energy for replacing liquid fuel  No emission standard for textile coal boilers has been specified by the Indonesian Government

3. Indonesian Coal Sources Background Provinces Potential Sources (million tons) Reserve-mineable (million tons) Aceh450.150 North Sumatra26.970 Riau2,057.2215.15 West Sumatra719.0936.07 Bengkulu198.3721.12 Jambi1,592.579.00 South Sumatra22,240.402,653.98 Lampung106.950 West Kalimantan527.520 Middle Kalimantan1,399.2148.59 South Kalimantan8,674.561,787.32 East Kalimantan19,567.792,410.33 South Sulawesi132.010.06 Middle Sulawesi1.980 Papua138.300 Banten13.750 Middle Java0,820 East Java0,080 Total57,847.746,981.62 Case Study: Textile Industries in Bandung Metropolitan City

4. Objective  Identifying coal usage in textile industries  Coal usage as energy source  Textile coal boiler and air pollution control  Emission from coal boiler including historical data  Coal, fly ash and bottom ash characteristics  Fly ash and bottom ash management  Preliminary emission factor determination  Identifying basic factors which influence emission standard determination Method  Gathering Primary and Secondary Data  Field visit in textile industries for spreading questionnaires and doing interviews to gather information related to the coal usage  Stack sampling in two selected textile industries for approximated emission factor determination.  Collection of coal, fly ash and bottom ash samples for coal and coal ash characteristic determination  Laboratory analysis  Data analysis

5. 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 Rayon 10.000 yard/day 10 ton/month 24 Polyester 5 - 470 ton/month 450.000-800.000 yard/day 56 Cotton 6.000 ton/month 8.800-1.000.000 m/month 24 Others8 General Condition of Textile Industries Result (Case Study: Bandung Metropolitan City) Investment Type - Foreign investment11,54% - Domestic investment65,38% - Others3,85% Starting Production Year1963 - 1996 Building Physical condition Very Good-3.85% Good-15.32% Fair-76.92% Total Size 1 - 38,773 ha Built: 6,000-130,410 m 2 Employee number 60-2800 people Production Type Other Information

6. Coal Usage in Textile Industries Source of Energy Energy Consumption User Percentage Petroleum15 - 50 liter/day15,38 Diesel oil 50 - 3.100 liter/day42,31 Kerosene60 - 80 liter/day7,69 Coal7- 200 ton/day76,92 Others7,69 Coal Sources(%) Bukit Asam- South Sumatera5,26 Lati-adaro South Kalimantan52,63 Satui Senakin - South Kalimantan31,58 others Source: Questionnaire data for textile industries in Bandung Metropolitan, 2005 Energy Source Boiler System% Grate Firing68.18 Fluidized Bed50.00 Pulverized Coalnone Coal Sources Boiler Type Coal Ashes Production (ton/day) Fly Ash 0.2 - 20 ton/day Bottom Ash 0.08 - 7 ton/day Coal Ashes Production Result

7. Source: from textile industries in Bandung Metropolitan, 2005 IndustriesParticulate Control Gas Control PT 1CycloneScrubber PT 2CycloneWet Scrubber PT 3Scrubber PT 4Scrubber PT 5CycloneWet Scrubber PT 6CycloneScrubber PT 7CycloneScrubber PT 8Cyclone PT 9Water SprayAbsorber PT 10 PT 11Wet Scrubber PT 12CycloneScrubber Bag House Filter PT 13Cyclone PT 14Bag House FilterScrubber PT 15Cyclone PT 16CycloneScrubber Coal fired boiler Wet Scrubber Air Pollution Control Result

8. Emission from Textile Boiler Result 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

9. Coal and Its Ash Characteristics Parameter Adaro-Kalsel Low Calorie Arutmin Kalsel High Calorie Sample fromTextile Industry Total water content, %23-2511.215.64 Fixed water, %14-165..213.79 Ash,%112.18.38 Fly matter, %43-444237.67 Carbon content, %37-3939-4240.16 Energy value, kkal/kg5400-58006300-66005382 Sulfur, %0.10.2-11.36 Source: Data from Center for Investigation and Development of Mineral Technology and Coal, 2005 ParameterSatuanBoiler Ash (Bottom Ash) Economizer Ash (Fly Ash) Filter Ash (Fly Ash) Water content%78.8676.5074.63 Ash%16.5418.1820.26 Flying matter%1.81.811.99 Fixed carbon content%0.230.180.27 Energy valueKkal/kg130314051575 Coal Characteristic Ash Characteristic Result

10. ParameterSample 1Unit Standard CoalFly ashBottom ash Abu12.1981.0396.46%ASTM D.3174 Karbon55.2415.694.03%ASTM D.3178 Hidrogen5.190.350.47%ASTM D.3179 Nitrogen0.810.230.1%ASTM D.3179 Total Sulfur0.830.280.1%ASTM D.3177 Oksigen25.742.420.66%ASTM D.3176 Parameter Sample 2 UnitStandard BatubaraFly ashBottom ash Abu4.1587.4974.8%ASTM D.3174 Karbon53.5910.9221.78%ASTM D.3178 Hidrogen5.590.410.46%ASTM D.3179 Nitrogen0.740.20.29%ASTM D.3179 Total Sulfur0.650.40.25%ASTM D.3177 Oksigen35.350.652.42%ASTM D.3176 Ultimate Analysis Coal and Its Ash Characteristics Result

11. NoColorBoiler Water Content % Wet Basis Volatile Content % Dry Basis 1 FA-brownish yellowGrate firing 0.5835.212 2 FA-blackish brownFluidized bed 0.298.103 3 BA-blackish brownGrate firing 36.91448.737 4 FA-blackish brownFluidized bed 1.19937.26 5 FA-brownish blackGrate firing 30.4257.89 6 FA-brownish blackFluidized bed 0.58917.643 7 FA-blackGrate firing 1.60623.287 8 BA-blackish brownGrate firing 29.09914.11 9 FA-brownish yellowFluidized bed 54.53613.974 10 FA-blackFluidized bed 59.62931.011 Source: Solid and Hazardous Waste Laboratory - Environmental Engineering ITB Ash Characteristics Result

12. Coal Ashes 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

13. Emission Sampling Parameter Industry 1 Industry 2 Stack height50 M22M Sampling hole height30 M8M Stack diameter2.5 M1M Stack pressure778.4 mmHg774.7 mmHg Stack gas velocity7.2 m/s13.1 Stack gas flowrate9.6 l/m17.6 l/m Boiler capacity31 ton/day200 ton/day Particulate concentration140.56 (mg/m 3 )160.77(mg/m 3 ) SO 2 concentration478.91 (mg/m 3 )613.00 (mg/m 3 ) NO x concentration137.51 (mg/m 3 )151.81 (mg/m 3 ) 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/m 3 v (m/ second) m2m2 mg/smg/day ton/ day Ton /day Industry-1 Particulate160.7713.160.791660.44143,461,689.120.14310.00463 SO 2 613.0113.160.796330.97546,995,542.990.55310.01765 NO x 151.8113.160.791567.85135,462,008.800.14310.00437 Industry 2 Particulate140.567.174.914947.33427,449,416.530.432000.00214 SO 2 478.917.174.9116856.221,456,377,524.391.462000.00728 NO x 137.517.174.914839.94418,170,671.560.422000.00209 Calculation of Air Pollution Emission Factor Based on Air Emission Sampling Result

14. Emission Standard Consideration  Coal quality as input solid fuel  Compliance ability, including considering best available technology  Boiler capacity, fuel type, boiler technology/combustion type, unit control availability  Data validity  Accredited laboratory for emission/ambient monitoring  Historical data monitoring from textile boilers Result

15. Conclusion   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.