Boiler Selection Guide for Chemical Plants: Enhancing Production Efficiency

A coking plant is a specialized facility that heats coal to produce coke oven gas through distillation, primarily generating coke for use in steelmaking. Alongside coke production, the process yields by-products such as coal tar, toluene, xylene, naphthalene, ammonium sulfate, and large quantities of coke oven gas. However, due to the low calorific value and the presence of impurities in coke oven gas, its use has traditionally been limited, often resulting in flaring and significant energy waste. At the same time, coke production requires large amounts of steam, yet the available fuel supply is often insufficient, leading to a supply-demand imbalance.

To resolve this issue, the chemical plant’s chief engineer turned to EPCB Boiler for technical support. After conducting a thorough analysis of the plant’s production processes and energy requirements, we developed a customized solution. Through multiple rounds of technical simulations and theoretical calculations, we designed a system that efficiently harnesses coke oven gas, transforming this by-product into a valuable energy source for the plant's operations.

Comprehensive?Solution for Converting Coke Oven Gas into Clean Fuel

In the coking process, coke oven gas is a by-product with high impurity content and low calorific value, making its utilization challenging. To effectively use this energy source, EPCB Boiler offers a comprehensive coke oven gas purification and fuel conversion solution:

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Initial Treatment of Coke Oven Gas

Once coke oven gas is generated, it must undergo initial purification to remove particulate impurities like coal dust and ash. If these impurities are not eliminated, they can negatively affect combustion and cause damage to boiler equipment. In the initial treatment phase, the gas passes through filtration devices designed to remove large particles, ensuring a baseline level of cleanliness. Simultaneously, some of the gas is stored in buffer tanks to create a stable fuel source for future use. This step prevents fuel supply fluctuations, ensuring a continuous and stable system operation.

Pressure Control System

Fluctuations in the pressure of coke oven gas can directly impact boiler combustion, with excessively high or low pressure reducing both efficiency and safety. EPCB Boiler addresses this issue with an expansion bladder technology designed to stabilize gas pressure. The expansion bladder absorbs pressure variations, ensuring a consistent system pressure. This method prevents the loss of combustion efficiency or the development of safety hazards caused by pressure shifts, ensuring continuous and stable boiler performance, especially during high-load conditions.

Gas-Liquid Separation Treatment

Coke oven gas often contains liquid impurities, such as tar, oil mist, and water vapor, which can interfere with combustion. EPCB Boiler's solution incorporates a gas-liquid separator to remove these liquid contaminants from the gas. By using the gas-liquid separator, the system effectively eliminates these impurities, enhancing fuel purity and improving combustion efficiency. This step also helps extend the boiler's service life by preventing equipment corrosion or failure caused by the buildup of liquid contaminants.

Fine Filtration

After the initial filtration and gas-liquid separation, further fine filtration is essential to ensure the gas meets strict cleanliness standards for combustion. EPCB Boiler utilizes a U-shaped dual-channel filter for deep filtration, removing any remaining small particulate matter. This process ensures that the gas is free of residual impurities, preventing carbon buildup and the formation of harmful substances during combustion. The scientifically designed filter delivers high filtration efficiency without restricting airflow, providing high throughput and low maintenance costs while achieving clean, efficient, and safe combustion.

Application and Results of EPCB Boiler System

After the above treatments, coke oven gas is converted into clean and pressure-stable fuel for efficient combustion in the boiler system. The steam generated is not only used to support coke production but can also be supplied to neighboring plants, achieving circular resource utilization and maximizing energy efficiency.

The solution designed by EPCB Boiler for this project not only significantly reduced production costs but also helped the customer recover their investment within just three months. Additionally, the project created a true closed-loop economic model through efficient resource recycling, enhancing both production efficiency and environmental sustainability.

Key Takeaways for Boiler Selection in Chemical?Plants

1. Choose a Boiler Supplier that Understands Customer Needs

When selecting a boiler, it is crucial to find a supplier that deeply understands both the actual and potential needs of the customer. With years of industry experience, EPCB Boiler can provide customized boiler solutions tailored to customers' specific requirements, effectively solving production bottlenecks and ensuring the continuity and efficiency of plant operations.

2. Emphasize Extensive On-Site Project Experience

Practical experience is key to the success of any project. Through a wealth of customer projects and on-site operational experience, EPCB Boiler ensures that every solution is optimized to maximize system efficiency, reduce energy consumption, and improve the overall reliability of equipment operation.

3. Choose a Systematic Solution, Not Just Boiler Equipment

Selecting a boiler is not just about purchasing a piece of equipment; it’s about choosing a complete, integrated solution that matches the needs of the plant. From system design and equipment manufacturing to on-site installation and commissioning, EPCB Boiler provides comprehensive technical support, ensuring seamless integration with the plant's production processes and meeting long-term, stable, and efficient operational needs.

4. Prioritize Safety and System Security

In the chemical industry, safety is always a top priority. EPCB Boiler implements comprehensive safety management from the boiler itself to auxiliary equipment, strictly controlling safety at every stage. Additionally, EPCB’s engineering team provides on-demand technical support and maintenance services, ensuring the safety and stability of system operation.

Conclusion

With its strong technical capabilities, extensive project experience, and customized solutions, EPCB Boiler helped the chemical?plant overcome complex energy challenges, achieving efficient and safe boiler system operation. By optimizing the use of coke oven gas, EPCB boiler significantly improved the customer's production efficiency and promoted a sustainable, circular economy model. Whether you’re looking to increase energy efficiency, reduce production costs, or achieve higher environmental and safety standards, EPCB is dedicated to providing the best boiler system solutions. If your business is also seeking a boiler system partner that can meet your unique needs, EPCB Boiler is your most trusted choice. Feel free to contact us to discuss your customized solution needs.