Heat Exchanger Performance Calculation Based on Fouling Factor as an Indicator of Effectiveness in the Phase 1 Closed-Loop Cooling System at PLTU PT. Bintan Alumina Indonesia

Abstract

Within the closed-loop cooling system of PT. Bintan Alumina Indonesia (BAI) Steam Power Plant, the heat exchanger is a critical unit for sustaining heat-transfer efficiency and keeping plant operational stable. When the heat exchanger operation continuosly, fouling can build up and reducing performance effectiveness. This study aims to analyze effect of the fouling factor on operating parameters and heat exchanger performance, and evaluate performance before and after cleaning. A quantitative approach was employed using operational data before and after cleaning. The data were analyzed using heat transfer equations to determine the LMTD, fouling factor, efficiency and effectiveness. The result showed that fouling factor decreased from 0,0021049 m2.C/W to 0,0004772 m2.C/W after cleaning, indicating reduced thermal resistance due to fewer material deposits. Consequently, heat transfer became more effective, with efficiency increasing from 17.34% to 48.07% and effectiveness from 23% to 54%. These improvements demonstrate that cleaning restored heat exchanger performance close to optimal operating conditions. Therefore, the fouling factor directly affects heat exchanger effectiveness, higher fouling factor values reduce effectiveness, whereas lower values improve effectiveness and produce a more efficient, stable reliable, heat transfer system-supporting long-term power plant operation.