"Excellence is the steady result of continually striving to do better...... The finest pursuit is the hunt for excellence," according to an old adage (-\) An integrated method to accomplish continuous improvement and strive for excellence in the operation of utility boilers.
This paper presents a case study of the successful trial run of the Flue Gas Recirculation of the Utility Boiler of the Numaligarh Refinery Limited's Cogeneration Plant in Golaghat, Assam. The researchers investigated why the Flue Gas Recirculation (FGR) fans trip, how it affects the burner, and how it affects the boiler. It elucidates the various aspects that contribute to the challenges and roadblocks encountered during the trial run of the Flue Gas Recirculation (FGR) fans. This fan has been unable to operate since the boiler was installed. After a thorough study, the problems could be identified and remedied, and the fans could be successfully run without tripping the boiler. After the utility boiler is successfully placed into service, several positive results are recorded and resulted in process and energy optimization in the operation of the boiler.
Utility Boiler (UB) is utilised in Numaligarh Refinery Limited's (NRL) Co-generation plant (CGP) to produce high pressure super-heated steam. Due to technical difficulties, one of the accessories, the Flue Gas Recirculation (FGR), was unable to be installed. FGR stands for "combustion modification." The combustion process is characterised by quick oxidation, light phenomena, and the release of enormous amounts of energy, allowing it to operate at high temperatures. A percentage of the combustion products that exit the boiler are recirculated and introduced into the primary combustion zone, as the name implies. There are two groups of FGR enthusiasts in UB. They could not, however, be placed into duty for a long time after being commissioned. The problems or factors, such as selecting the correct UB load at which the fan should be started, dampers adjustment, burner flame stability, and so on, were determined after a series of studies and trials. The FGR fans could be successfully run and put into continuous operation when these difficulties were identified and resolved.
The following benefits were realised in UB as a result of the FGR fans' service:
Increases the UB's steaming rate, which saves energy (Fuel optimization)
Emissions of the hazardous NOx gas have been reduced.
Temperature of flue gas at the back end has risen.
As the amount of fossil fuel used is lowered, CO2 emissions are reduced.
As a result of the aforesaid case study, one of the most essential UB accessories was successfully installed, resulting in a variety of benefits, flexibility, and process optimization in the UB's operation.
Author(s) Details:
Dinesh Brahma,
Numaligarh Refinery limited, Captive Power Plant (CPP) Control Room, Power
& Utility Department (P&U), Golaghat, Assam, India.
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