http://www.engineeringnews.co.za
  SEARCH
Login
R/€ = 13.70Change: -0.06
R/$ = 12.40Change: -0.09
Au 1168.23 $/ozChange: -0.57
Pt 1061.00 $/ozChange: -21.00
 
 
Note: Search is limited to the most recent 250 articles. Set date range to access earlier articles.
Where? With... When?








Start
 
End
 
 
And must exclude these words...
Close Main Search
Close Main Login
My Profile News Alerts Newsletters Logout Close Main Profile
 
Agriculture   Automotive   Chemicals   Competition Policy   Construction   Defence   Economy   Electricity   Energy   Environment   ICT   Metals   Mining   Science and Technology   Services   Trade   Transport & Logistics   Water  
What's On Press Office Tenders Suppliers Directory Research Jobs Announcements Letters Contact Us
 
 
 
RSS Feed
Article   Comments   Other News   Research   Magazine  
 
 
Jan 30, 2009

Large coal-to-gas boiler conversions completed

Back
Construction|Engineering|Africa|CoAL|Environment|Fire|Gas|Industrial|PROJECT|Safety|Screen|Storage|System|Water|Africa|Energy|Solutions|Environmental|Water|Operations
Construction|Engineering|Africa|CoAL|Environment|Fire|Gas|Industrial|PROJECT|Safety|Screen|Storage|System|Water|Africa|Energy|Solutions|Environmental|Water|Operations
construction|engineering|africa-company|coal|environment|fire|gas|industrial|project|safety|screen|storage|system|water-company|africa|energy|solutions|environmental|water|operations
© Reuse this



One of South Africa’s largest coal-to- gas boiler conversions has been successfully completed at ethanol distiller NCP Alcohols’ Durban distillery. The inconsistent quality of coal supply meant that management of the process performance was becoming increasingly more difficult to achieve and steam demands for distillation were being compromised.

Natural gas supplier Spring Lights Gas was contracted to convert a water tube boiler, used for generating steam in its distillery, from coal to gas. The conversion represents a landmark in the history of both companies.

The planning phase was carried out over a period of two years, with strict adherence to environmental compliance requirements, supported by the necessary approvals and licensing applications. The construction phase was completed over a two-month period and conformed strictly to safety standards and international gas practices.

The first phase of construction involved the connection of the distillery to a 6,3-km local gas supply pipeline. As NCP Alcohols is situated near a residential area, the community and all interested parties along the gas pipeline route were consulted and integrated into the environmental study, before the pipeline was constructed.

Once the pipeline was completed, a 32-t low-pressure gas-fired boiler was installed to replace the 30-t coal-fired low-pressure coal boiler, followed by the complete re- engineering of the coal-fired boiler to burn pipeline gas. Both these processes were controlled by a fully integrated software programme, which ensured the safety and efficiency of the boiler operation.

The coal-fired boiler, which generated 20-bar process steam within the distillery, was retired and replaced with two natural gas-fired dried distiller’s grain (DDG) 12 burners supplied by industrial combustion company Saacke South Africa. The conversion to gas was undertaken by Saacke, in close cooperation with boiler and environmental solutions company Alstom John Thompson South Africa.

Each boiler has an output of 16 MW and is designed to guide the gas to the combustion zone by means of several gas guns that are located in the core air tube. The gas guns are connected to one another by an outer gas ring body, which may be adjusted from the outside by turning the gas guns to optimally adjust the gas flame and achieve the lowest emission values. Alstom John Thompson carried out the assembly under the supervision of Saacke, and commissioning of the burners was completed after two weeks.

To effectively manage the burner control system, NCP Alcohols introduced a computerised process monitoring and management system, which allows for the integration of the safe Ethernet and visuali- sation (Se@vis) burner control system with the current process management interface programmes. The Se@vis system creates a secure Ethernet connection between the control system and the combustion process. All its sensors and actuators are connected to a fail-safe single-touch screen that can be operated and its performance optimised from one location.

The interface provides information on all current process dimensions, such as operating conditions, parameters and alarms. The Se@vis system is able to manage other operations, such as firing range control, pressure control, temperature control and level control, as well as automatic firing sequence control and fuel-to-air ratio control. This newly developed system has extended the operational capability of NCP Alcohols to manage the respective processes by accessing process data through a single- point touch screen.

Spring Light Gas CEO Motsamai Koapeng says that cooperation between all parties involved in the project resulted in the conversion being carried out without delays. “NCP Alcohols has clearly demonstrated its unwavering commitment to making a success of this project by not only looking beyond the immediate obstacles and challenges, but by also focusing on the strategic advantages and the long-term benefits for the company and surrounding communities,” he adds.

The gas boiler system has been in opera- tion since August 2008 and has resulted in several benefits for NCP Alcohols. The storing of coal, and the associated risks, such as fire and groundwater contamination, have been eliminated, and the fuel storage area has been reduced, creating a safer operating environment and higher savings through the elimination of fuel storage costs and ash removal costs.

The boiler’s efficiency since conversion has been consistently at 92% and higher. The main advantage of this has been the enhanced efficiency and elasticity of the 32-t/h boiler, which allows for quicker process start-up times, energy that is clean burning and on tap, improved process efficiency and capacity, increased operational efficiency and improved operational response to meet process demands.

There has been a significant reduction in greenhouse gases, as well as harmful stack emissions, volatile organic compounds and ash, with emissions well below the limited values prescribed by law. There is also potential benefit to be had from the sale of carbon credits.

Edited by: Laura Tyrer
© Reuse this Comment Guidelines (150 word limit)
 
 
 
 
 
 
 
 
Other Energy News
Updated 5 hours ago South Africa-focused mineral explorer and developer White Rivers Exploration (WRE) has signed a memorandum of understanding (MoU) with Windfall Energy to facilitate the joint exploration and development of WRE’s Heilbron and Kroonstad gas assets in the Witwatersrand...
Tanzania's parliament on Sunday approved a legal and regulatory framework for developing its nascent hydrocarbons industry, after days of contentious debate. East Africa has become a new oil and gas frontier after a string of discoveries that producers hope to...
Most commodity prices suffered falls on Monday, compounding worries about oversupply, after Greece rejected terms for a bailout and top consumer China unleashed emergency measures over the weekend to prevent a full-blown stock market crash. Brent crude fell below $60...
More
 
 
Latest News
Updated 4 hours ago State-owned entity Transnet National Ports Authority (TNPA) has started the registration process for its integrated port management system (IPMS), which is scheduled to go live in the Port of Durban at the end of July. TNPA started issuing registration instructions...
Updated 5 hours ago The development of rural road infrastructure and public transport services remains critical to the delivery of South Africa’s – and other African States’ – developmenta agenda, requiring meticulous planning that ties in with the socioeconomic needs of the host...
Updated 5 hours ago South Africa-focused mineral explorer and developer White Rivers Exploration (WRE) has signed a memorandum of understanding (MoU) with Windfall Energy to facilitate the joint exploration and development of WRE’s Heilbron and Kroonstad gas assets in the Witwatersrand...
More
 
 
Recent Research Reports
Real Economy Year Book 2015 (PDF Report)
There are very few beacons of hope on South Africa’s economic horizon. Economic growth is weak, unemployment is rising, electricity supply is insufficient to meet demand and/or spur growth, with poor prospects for many of the commodities mined and exported. However,...
Real Economy Insight: Automotive 2015 (PDF Report)
Creamer Media’s Real Economy Year Book comprises separate reports under the banner Real Economy Insight and investigates key developments in the automotive, construction, electricity, road and rail, steel, water, gold, iron-ore and platinum sectors.
Real Economy Insight: Water 2015 (PDF Report)
Creamer Media’s Real Economy Year Book has been divided into individual reports under the banner Real Economy Insight and investigates key developments in the automotive, construction, electricity, road and rail, steel, water, coal, gold, iron-ore and platinum sectors.
Real Economy Insight: Construction 2015 (PDF Report)
Creamer Media’s Real Economy Year Book has been divided into individual reports under the banner Real Economy Insight and investigates key developments in the automotive, construction, electricity, road and rail, steel, water, coal, gold, iron-ore and platinum sectors.
Real Economy Insight: Electricity 2015 (PDF Report)
Creamer Media’s Real Economy Year Book has been divided into individual reports under the banner Real Economy Insight and investigates key developments in the automotive, construction, electricity, road and rail, steel, water, coal, gold, iron-ore and platinum sectors.
Real Economy Insight: Road and Rail 2015 (PDF Report)
Creamer Media’s Real Economy Year Book has been divided into individual reports under the banner Real Economy Insight and investigates key developments in the automotive, construction, electricity, road and rail, steel, water, coal, gold, iron-ore and platinum sectors.
 
 
 
 
 
This Week's Magazine
NHLANHLA NENE The main constraints to economic growth are domestic
Finance Minister Nhlanhla Nene earlier this month stated that, while South Africa’s 2015 economic growth target of 2% was achievable, it was not enough to deliver the tax revenue needed to combat the country’s challenges.
The World Steel Association has published the 2015 edition of the World Steel in Figures report, which shows an increase in steel production as well as provides an overview of steel industry activities from crude steel production to apparent steel use.
The 25-year master plan for Gauteng’s Aerotropolis project will go through a process of approval and adoption during June and July, says Aerotroplis project manager Jack van der Merwe. “We are also in the process of putting together a special purpose vehicle (SPV) to...
SOLAR PANELS The existing buildings in the Coega Industrial Development Zone lent themselves well to rooftop solar panel installations
The Coega Development Corporation (CDC) plans to fit 15 of its buildings, totalling 127 000 m2 of roof space, in the Coega Industrial Development Zone (IDZ), in the Eastern Cape, with solar panels.
The Supreme Court of Appeal’s (SCA’s) November 2014 judgment, ordering steel producer ArcelorMittal South Africa (AMSA) to hand over the 2003 Environmental Master Plan for its Vanderbijlpark steel plant to environmental pressure groups, confirmed the right of civil...
 
 
 
 
 
 
 
 
 
Alert Close
Embed Code Close
content
Research Reports Close
Research Reports are a product of the
Research Channel Africa. Reports can be bought individually or you can gain full access to all reports as part of a Research Channel Africa subscription.
Find Out More Buy Report
 
 
Close
Engineering News
Completely Re-Engineered
Experience it now. Click here
*website to launch in a few weeks
Subscribe Now for $96 Close
Subscribe Now for $96