Boiler Fuel Conversion

By
Milind Chittawar Chittawar@satyam.net.in www.letsconserve.org

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Introduction PCIPL manufactures Formaldehyde & Pentaerythritol. In the production process, steam is required as source for heating at various stages. The plant has three Residual Fuel Oil fired Boilers (8 TPH x 1 and 12 TPH x 2) contributing to GHG emissions.

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Introduction This CDM project activity primarily aims at reducing GHG emissions by fuel conversion in the boilers for steam generation (i.e. firing briquettes in place of Residual Fuel Oil) Oil Fired Boilers fully comply the existing pollution norms and also operate efficiently PCIPL has opted for more environmentally sustainable solution for steam generation, i.e. through briquette firing

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Project activity In first phase, one of the RFO fired boiler (8 TPH) has been converted to briquette fired by retrofitting extended furnace to facilitate manual briquette firing In second phase, the project activity involves installing a new 14 TPH briquette fired boiler After commissioning of the new briquette fired boiler (14 TPH), the total steam requirement is met by this boiler and the other boilers are kept as stand-bye.

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Technology employed: The technology involves a retrofit operation on existing 8 TPH boiler wherein burner and RFO firing system is removed. A well-insulated extended furnace (to facilitate manual firing of briquettes that burn over grate and hot flue gas 1400 to 1600oC is supplied to the boiler through duct) is constructed near the boiler. Briquettes are fired on the grate by charging manually and the hot flue gases are allowed to pass over the boiler tubes through connecting duct of 6 m.
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Conceptual Drawing Indicating Arrangement of Furnace for Briquette Burning & ID Fan

Contribution of the project activity to sustainable development: 1. Social well being:

Generating employment for the deprived segment of the society at the rural level (which is major concern in India) for collection, processing and supply of the biomass Employment generation in urban area also as due to manual firing of briquettes more charge-men are required as compared to operators required for RFO fired boilers

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Contribution of the project activity to sustainable development: 2. Economic well being: Better use of agricultural residues, the project offers monetary benefits to the farmers by selling these residues, thus making villages more self sustainable Reduction in petroleum oil import requirement for the country, saving in foreign exchange and diversion of flow of money towards rural area Installation of briquette manufacturing plant near to villages resulting in industrial investments in rural area and also employment generation
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Contribution of the project activity to sustainable development: 3. Environmental well being: Reduction in the amount of GHG emissions Significant reduction in SOx & NOx emissions Reduction in petroleum oil requirement by use of sustainable source of energy

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Contribution of the project activity to sustainable development:

4. Technological well being: Transfer of technology for boiler conversion as well as briquette manufacturing is within India Design of extended furnace (I phase) & new briquette fired boiler (II phase) are proven & environmentally safe Briquette manufacturing plants are simple & safe in operation

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Baseline Scenario Majority of the boilers in the region are RFO fired where as some are coal fired resulting in GHG emissions (CH4, N2O & CO2 emissions) In addition to GHG emissions, SOx & NOx emissions are also occurring Field burning of biomass in the region resulting in CH4 & N2O emissions

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Project Scenario Boiler operation on Briquette GHG emissions are reduced from 21661 to 2404 tCO2-e per year Project significantly reduces SOx & NOx emissions

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Emission Reduction The boilers consume average 7062.61 KL of fuel oil/year generating 21661 tonnes of CO2 equivalent per year. Briquette consumption equivalent to RFO quantity is 15 KT generating 2404 tonnes of CO2 equivalent per year. CER generated are about 19257 tonnes of CO2 equivalent per year.

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Storage of briquettes See-Tech Solutions

Industrial Oil Fired where in Red Colored Burners can be taken out and Hot Duct can be placed and nearby furnace can be installed for burning briquettes

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Pictorial View & Details Of Briquetting Machine Briquette Manufacturing Machine, Suitable for Distributed Installations near the source of biomass (Agriculture & forestry)

Working Drawing of Briquette Manufacturing Machine: Simple & Reliable

Briquettes (Compacted biomass)

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Internal rate of return without CER Revenue Project Cost (Both phase I & phase II), Rs. Miscellaneous (including maintenance cost) , Rs. Total , Rs. RFO Consumption, KL RFO Price, Rs./lit Total RFO Price, Rs. Briquette consumption, KT Cost of Briquette, Rs./kg Fraction of RFO consumed RFO Consumption (if any), KL Total Briquette +fuel bill, Rs. Savings in fuel cost, Rs. Annual Internal rate of return without CER revenue
Annual Internal rate of return with CER revenue

15200000 375000 15575000 7063 12 84751320 13.53 3.9 0.1 706 61242132 23509188 151%
186%

Other Projects
(1) Cetane Enhancer Resulting in Improved Engine Performance (2) Supply of Briquette as a source of thermal energy (3) Electricity Generation from Municipal Solid Waste (4) Afforestation Project (5) Methane Avoidance from Poultry Waste (6) Energy Efficiency & Fuel Change in Grinding Wheels Factory (7) Co-generation from biomass in Engineering unit

CERs Ranging from 25000 to 3,00,000