An Automotive Tyre Unit in North India
Type of Boiler – Bubbling Fluidised Bed Boiler
Capacity of the Boiler – 25 TPH
Type of Fuel Used – Imported Coal
Operation Problems faced before Oxy Booster Treatment
- High Unburnt carbon in Ash – 18 -19 %
- Fines percentage is high (above 35 % ) hence it does not get adequate residence time in furnace – Less Efficiency.
- Uneven temperature within the furnace – posing constraints in quick response time during load variation.
- Operators were constraint to maintain higher RPM of fuel feeder to match load demand by process.
Total steam output per day , in MT = 345
Total Coal used per day , in MT = 53
Landed cost of Coal , in Rs. / MT = 8000
Results achieved with Oxybooster O2 Sync
Coal consumption per day , in MT = 48
Gold grade Oxybooster O2 Sync used per day , in Kgs = 200
Saving in Coal per day , in MT = 5
Cost Economics
Cost of Coal saved per day , in Rs. = 40,000.00
Cost of Gold grade oxybooster O2 Sync in Rs. = 15,600.00
Nett Savings per day = Rs.24,400.00
Other benefits experienced
Reduction in unburnt carbon in ash from 19% to under 9 %
Reduction in Quantity of Fly Ash per day – Reduced from 9 buckets to 3 buckets
Fuel Feeder RPM reduced by approx . 40% for similar loads
Operator found it easy to response to fluctuating loads from process.
Synchronised Furnace during Oxybooster O2 sync Usage
A Coffee Unit in Kushal Nagar, Karnataka
Type of Boiler – Bubbling Fluidised Bed Boiler
Capacity of the Boiler – 20 TPH
Type of Fuel Used – Coal & less than 10% Coffee Spent with 67 % Moisture and
CV of 2200 Kcal/kg
Operation Problems faced before Oxy Booster Treatment
-
Huge stock of Spent Coffee residue ( Approx 2000 tons) which posed a disposal problem due to its nature .
-
Not able to fire consistently Coffee spent as a fuel due to high defluidisation response because of excess moisture.
-
Frequent stoppage of the boiler bed getting overloaded due to deposition of fuel.
-
ØBoiler rated output had gone down due to deposition of ash in pressure parts .
-
Frequent changing of Air Nozzles and Fuel Nozzles due to erosion and heating up.
Total steam output per day , in MT = 340-360
Total Coal used per day , in MT = 72
Landed cost of Coal , in Rs. / MT = 5500
Coffee Spent was treated with Oxybooster for 48 Hours to reduce the moisture from 67 % to below 30%
Results achieved with Oxybooster
Coal consumption per day , in MT = 48-50
Coffee Spent fired in boiler , in MT = 19.5
Silver grade Oxybooster used, in MT = 2.46
Cost Economics
Cost of Coal saved per day , in MT. = 22
Cost of Coal saved per day , in Rs. = 1,21,000.00
Cost of Silver grade oxybooster in Rs. = 73,800.00
Nett Savings per day = Rs.47,200.00
The Coffee Unit was able to use about 2000 tons of waste (Coffee Spent) as a Potential fuel in boiler , which otherwise would have posed them disposal problem.