Soluciones Integrales de Combustión has undertaken the optimization process of the boiler room in a paper production plant in Levante. The solutions proposed by thermal engineering company contemplate the tasks of replacing the existing boiler with equipment that works with gas, as well as the insulation of the installations and the implementation of a Low Nox burner, as well as a preheater and a recirculation system of combustion gases, among other measures.

The objective for tackling the boiler room optimization works is to equip the plant with high energy efficiency solutions, which allow optimum performance to reduce fuel consumption, with the consequent energy savings, and adaptation to the European environmental regulations to reduce emissions. The expected result will allow achieving the proposed efficiency, as well as safety, reliability and sustainability. Specifically, the performance of the installation is estimated at around 93-94%.

The Soluciones Integrales de Combustion boiler room optimization tasks previously analyze all the possibilities to provide a personalized response in solving the specific challenges of each company.

Boiler room optimization process phases

In the modernization of this specific facility, the company has proceeded to remove the obsolete boiler, which worked with fuel oil, to replace it with a single boiler that will operate with natural gas. Likewise, the water tubes have been changed and their convenient insulation has been carried out to avoid energy losses. Subsequently, the 1-pass gas tubes have been replaced.

The operation has continued with the implementation of a Low Nox JBD 6000 burner designed to overcome high overpressures in the combustion chamber, and prepared for hot air at 100º C. Likewise, Soluciones Integrales de Combustion has incorporated a SICAPH combustion air preheater, which It will allow heat transfer from the outgoing combustion gases to enter the burner. In this way, not only are polluting emissions reduced and the chimney outlet temperature reduced, but they also imply significant fuel savings.

The company’s combustion air preheaters are designed to operate with all types of fuels and lead to greater energy efficiency.

One of the main additions to this air preheating installation is the installation of a Flue Gas Recirculation (FGR) system aimed at reducing emissions. In this way, the sum of the combustion gas recirculation systems together with the JBD Low NOx burner makes it possible to achieve NOx emissions with natural gas below 60 mg/Nm3, exceeding the most demanding regulations established in the EU at this time. The advantage of this combined system is the use of a single duct from the preheater installation and the hot air ducts to implement the FGR itself. This achieves a truly ecological system, as well as being efficient and profitable.