Soluciones Integrales de Combustión is manufacturing and commissioning a complete boiler room for the paper industry in an operation aimed at achieving greater energy efficiency in the installation.

With this objective, the manufacture and commisioning of the boiler room solution for the paper industry proposed by the thermal engineering company proceeds to install a pressurized system together with a hot air system, two energy efficiency techniques that, combined, will allow fuel savings to be achieved greater than 12% in the plant.

In this way, the boiler room will be equipped with a pressurized tank to which the condensate from the machine arrives under pressure, which subsequently feeds the boiler, as well as a combustion air preheater (APH), a supply tank for water, a hot air propane burner, and the main factory steam collectors.

The burner used in this plant will be a JBD burner with hot air at 100º C and low NOX emissions, which operates with propane, a liquefied petroleum gas (LPG). The equipment uses a double air register and is prepared to operate with high combustion chamber overpressures.

Pressurized return to the boiler

The condensate recovery process in this recovery tank that works under pressure in the boiler room is carried out at much higher temperatures, so the return of the hot and pressurized condensate to the boiler allows the system to take advantage of this greater heat of condensate to reduce fuel consumption.

In addition to the energy savings that this process entails, the recovery tanks of the pressurized system do not emit steam into the atmosphere, which prevents evaporation and thus allows a greater amount of water to be recovered and reused.

Heat recovery 

In turn, the installation of a heat recovery system, through the incorporation of a combustion air preheater (APH) is intended to improve the technical and economic performance of the boiler room, by allowing the transfer of heat from the outgoing combustion gases that re-enter the burner or combustion furnace.

In addition to saving on fuel, among the qualities of the combustion air preheaters, its ability to reduce polluting emissions and the reduction of the outlet temperature in the chimneys stands out.

The operation of the preheaters causes fresh air to circulate inside the tubes, while the exhaust gases circulate through the smoke chamber. The first ones are made up of serrated fins on the outside, with the aim of increasing the turbulence of the exhaust gases and of the heat exchange surface of the equipment. These fresh air pipes are arranged in line and in compact blocks to achieve a high transmission coefficient and drastically reduce the temperature of the exhaust gases. For its part, the gas casing is made of reinforced premium carbon steel sheet to avoid sealing failures.

The project allows us to conclude that the boiler room will be able to achieve savings of over 12% with the incorporation of the pressurized system and the combustion air preheater.

Energy efficiency in boilers room

Energy efficiency refers to the capacity of the facilities to obtain the best yields in the activity of the plants, using the smallest possible volume of energy resources. Consequently, the objective of installing these energy efficiency systems in boiler rooms is aimed at reducing the consumption of the energy used and the consequent environmental impacts it causes.

Integral Combustion Solutions is a company that provides engineering and thermal services, specializing in “turnkey” projects. The company, with facilities in Vizcaya and Madrid, offers comprehensive solutions for any type of industrial process and adds value in the areas of energy savings, sustainability, reliability and the reduction of unnecessary stops at the facilities.

La eficiencia energética hace referencia a la capacidad de las instalaciones para obtener los mejores rendimientos en la actividad de las plantas, con la utilización del menor volumen posible de los recursos energéticos. El objetivo de la instalación de estos sistemas de eficiencia energética en las salas de calderas está dirigido a reducir el consumo de la energía utilizada y los consiguientes impactos ambientales que provoca.