About this Classroom Training
In today’s rapidly changing energy landscape, power plant operators face the challenge of balancing efficiency, reliability, and sustainability amid the global energy transition. With clean power now exceeding 40% of global electricity generation and continued closures of coal-fired capacity, existing thermal plants must optimise performance to remain viable. At the same time, global coal demand and the need for smarter, more efficient power generation are driving growth in advanced control systems.
Co-firing technology offers a strategic solution, allowing operators to maintain baseload reliability while reducing emissions and optimising fuel costs. By integrating coal and gas fuels, co-firing plants can achieve up to 15% reductions in CO₂ emissions and 2 - 4% efficiency gains through advanced heat rate optimisation and performance monitoring translating to significant annual fuel savings.
This comprehensive 5-day training program equips participants with the technical expertise required to realise these benefits. Covering ASME-standard performance calculations, fuel property analysis, and diagnostic troubleshooting, participants will be empowered to enhance plant efficiency, minimise emissions, and strengthen competitiveness. Participants will gain practical analytical skills to optimise co-firing operations and support grid stability, aligning their capabilities with the evolving demands of the modern energy sector.
1. What is co-firing in power plants?
Co-firing refers to the simultaneous combustion of two different fuels—typically coal and natural gas or biomass—in the same boiler or turbine system. It enables existing thermal plants to reduce carbon emissions while maintaining grid reliability. By blending fuels, operators can diversify energy sources, optimise fuel costs, and support a smoother transition toward low-carbon energy generation.
2. Why is performance optimisation important in co-firing power plants?
Performance optimisation ensures that co-firing systems achieve maximum thermal efficiency, stable combustion, and minimal emissions. Because dual-fuel operations involve complex interactions between fuels, air supply, and temperature control, ongoing optimisation helps maintain a low heat rate, enhance fuel flexibility, and reduce operating costs while ensuring compliance with ASME and ISO performance standards.
3. How is heat rate used to measure plant performance?
Heat rate measures the efficiency of converting fuel energy into electricity, expressed as energy input per unit of electrical output (e.g., kJ/kWh). A lower heat rate indicates higher efficiency. Engineers use it as a key performance indicator to identify losses in boilers, turbines, and auxiliary systems. Optimising heat rate directly translates into fuel savings and lower greenhouse gas emissions.
4. What methods are commonly used to calculate plant efficiency?
Two primary methods are applied: the Input-Output (Direct) Method, which compares total fuel energy input with net electrical output, and the Heat Loss (Indirect) Method, which calculates efficiency by quantifying all measurable energy losses. The latter provides greater diagnostic detail and is guided by ASME PTC 4 standards, making it ideal for troubleshooting and optimisation.
5. What are the main challenges in co-firing operations?
Challenges include maintaining flame stability, preventing slagging and fouling in boilers, controlling excess air, and ensuring accurate fuel flow measurement. Differences in fuel moisture, calorific value, and ash composition can affect combustion quality. Effective performance monitoring and frequent calibration of instrumentation are critical to sustaining efficiency and reliability.
6. How does fuel blending affect power plant efficiency?
Fuel blending alters combustion characteristics and heat release patterns. Properly balanced blending ratios of coal and gas can improve boiler performance and reduce unburnt carbon losses. However, improper mixing or inadequate air distribution may cause efficiency drops or increased maintenance. Advanced fuel analysis and monitoring tools help achieve the optimal balance.
7. What standards guide performance testing in power plants?
Key standards include ASME PTC 4 (Boilers), ASME PTC 6 (Steam Turbines), ASME PTC 22 (Gas Turbines), and ISO 2314 (Gas Turbine Performance). These codes ensure accurate, repeatable measurements of efficiency, heat rate, and output under defined conditions, providing a common framework for benchmarking and improvement across the industry.
8. What role does data analysis play in performance optimisation?
Data analysis enables engineers to detect inefficiencies, quantify performance penalties, and predict maintenance needs. By using regression analysis, correction curves, and real-time monitoring software, operators can normalise performance data to reference conditions and identify trends. This analytical approach supports proactive decision-making and long-term operational planning.
9. How does co-firing contribute to decarbonisation?
Co-firing offers a transitional pathway toward decarbonisation by enabling existing thermal plants to reduce CO₂ emissions by up to 15%. It allows operators to incorporate cleaner fuels without major infrastructure changes. Combined with heat rate improvements and performance monitoring, co-firing supports national energy transition goals while maintaining grid stability.
10. What are the future trends in co-firing and plant optimisation?
Future trends include increased integration of digital twins, AI-based performance monitoring, and the use of alternative fuels like hydrogen and ammonia. Advances in sensor technology and combustion modelling will further improve accuracy and reliability. As carbon-intensity targets tighten, co-firing plants are expected to play a vital role in flexible, low-emission power generation.