http://www.engineeringnews.co.za
  SEARCH
Login
R/€ = 14.25Change: 0.06
R/$ = 11.29Change: -0.01
Au 1207.71 $/ozChange: -0.98
Pt 1292.00 $/ozChange: -10.00
 
 
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 Contact Us
 
 
 
RSS Feed
Article   Comments   Other News   Research   Magazine  
 
 
Jan 30, 2009

Large coal-to-gas boiler conversions completed

Back
Construction|DURBAN|Engineering|Africa|Alstom John Thompson South Africa|CoAL|Fire|Industrial|PROJECT|Saacke South Africa|Safety|Spring Lights Gas|System|Water|Africa|South Africa|NCP Alcohols' Durban Distillery|NCP Alcohols’ Durban Distillery|Energy|Gas Boiler Conversions|Gas Guns|Gas Pipeline Route|Gas Practices|Integrated Software Programme|Local Gas Supply Pipeline|Low-pressure Gas-fired Boiler|Natural Gas Supplier|Pipeline Gas|Screen|Environmental|Motsamai Koapeng|Water|Ethernet
Construction|Engineering|Africa|CoAL|Fire|Industrial|PROJECT|Safety|System|Water|Africa|||Energy|Screen|Environmental|Water|
construction|durban|engineering|africa-company|alstom-john-thompson-south-africa|coal|fire|industrial|project|saacke-south-africa|safety|spring-lights-gas|system|water-company|africa|south-africa|ncp-alcohols-durban-distillery|ncp-alcohols-durban-distillery-facility|energy|gas-boiler-conversions|gas-guns|gas-pipeline-route|gas-practices|integrated-software-programme|local-gas-supply-pipeline|lowpressure-gasfired-boiler|natural-gas-supplier|pipeline-gas|screen-industry-term|environmental|motsamai-koapeng|water|ethernet
© 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 Gas News
Welding and construction-related equipment supplier Renttech South Africa’s acquisitions of East London-based gas and welding supplier East Coast Industries (ECI), in July, has offorded Renttech South Africa a far greater presence in the Eastern Cape. “With branches...
COLD BOX The cold box, which weighs almost 100 t, was designed and manufactured by Germany-based Linde Group
South African gas company Afrox’s R300-million, 150 t/d air separation unit (ASU) in the Coega industrial development zone of the Eastern Cape, is more than 75% complete, Afrox MD Brett Kimber tells Engineering News. Major equipment, including the cold box and...
More
 
 
Latest News
Information and communication technology services group Gijima on Tuesday announced that it would undertake a rights offer and restructure its existing trade receivables securitisation funding programme to ensure that it had sufficient working capital to underpin the...
Lynne Brown
Public Enterprises Minister Lynne Brown has urged that the best candidates be nominated to serve on the boards of State Owned Entities (SOEs). “Help me identify your brightest and our best,” said Minister Brown as she launched an initiative to obtain the best pool of...
The Square Kilometre Array (SKA) has brought art and science together in an exhibition celebrating ancient humanity’s appreciation of the night sky. In a first for the SKA Organisation, indigenous and local artists from South Africa and Australia have collaborated in...
More
 
 
Recent Research Reports
Road and Rail 2014: A review of South Africa's road and rail infrastructure (PDF report)
Creamer Media’s Road and Rail 2014 report examines South Africa’s road and rail transport system, with particular focus on the size and state of the country’s road and rail network, the funding and maintenance of these respective networks, and the push to move road...
Real Economy Year Book 2014 (PDF Report)
This edition drills down into the performance and outlook for a variety of sectors, including automotive, construction, electricity, transport, steel, water, coal, gold, iron-ore and platinum.
Real Economy Insight: Automotive 2014 (PDF Report)
This four-page brief covers key developments in the automotive industry over the past 12 months, including an overview of South Africa’s automotive market, trade figures, production and the policies influencing the sector.
Real Economy Insight: Construction 2014 (PDF Report)
This five-page brief covers key developments in the construction industry over the past 12 months. It provides an overview of the sector and includes details of employment in the sector, infrastructure and municipal spending, as well as insight into companies’...
Real Economy Insight: Electricity 2014 (PDF Report)
This five-page brief covers key developments in the electricity industry over the past 12 months, including details of State-owned power utility Eskom’s generation activities, funding and tariffs, independent power producers and prospects for the sector.
Real Economy Insight: Road and Rail 2014 (PDF Report)
This six-page brief covers key developments in the road and rail industries over the past 12 months, including details of South Africa’s road and rail network and prospects for both sectors.
 
 
 
 
 
This Week's Magazine
The South African new vehicle market is likely to reach around 630 000 units in 2014, down from the 650 000 units recorded in 2013, says Toyota South Africa Motors (TSAM) president and CEO Dr Johan van Zyl. Van Zyl is also president of the National Association of...
Efforts by the Kenya government to increase energy generation by 5 000 MW over the next three years received a major boost following the award of a $2-billion contract to build a coal power plant in Lamu.  Despite allegations of irregular tendering process, the...
Using crafty wordplay on a well-known Internet meme, brilliant South African-born US entrepreneur and businessperson Elon Musk announced that Tesla Motors would not initiate patent lawsuits against anyone who, in good faith, wanted to use its technology. Instead,...
August new vehicle sales declined by 1.4%, to 55 722 units, compared with the same month last year. Assisted by the car rental market, the South African new passenger car market, at 37 953 units, contracted by 1 047 units, or 2.7%, compared with August last year.
With South Africans facing the challenge of reducing electricity consumption, the biennial Eskom Energy Efficient Lighting Design Competition, to encourage the integration of energy efficient lighting in architectural, engineering and interior design, received a...
 
 
 
 
 
 
 
 
 
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