As a big agricultural country, Pakistan is rich in biomass resources such as rice husk, especially in the surrounding areas of Karachi, where the acquisition cost of biomass fuel is low and the supply is stable. At the same time, in recent years, the local government has continuously strengthened the supervision of industrial emissions, encouraged factories to use renewable energy, and reduced dependence on fossil fuels.
As an important local textile enterprise, the production line of this towel factory runs continuously all year round, which requires high stability, economy and environmental protection of steam supply. The energy consumption of the original heating scheme is high, and the pressure of operating cost is increasing year by year. Therefore, enterprises urgently need to introduce a set of efficient, mature biomass steam boiler system suitable for local fuel to support long-term stable production.
In the early stage of the project, the customer focuses on the following issues:
-Whether the rice husk fuel is fully burned, and whether it is easy to slag and block.
-boiler stability under high load continuous operation conditions
-Is the degree of automation sufficient to reduce the intensity of manual operation?
-Installation guidance, commissioning and after-sales service capabilities of overseas projects.
According to the customer's demand, EPCB boiler technical team combined with the characteristics of steam consumption in textile industry and local fuel conditions, customized a set of overall solution for 10-ton DZL series biomass steam boiler, covering the boiler body and complete auxiliary machine system.
1. Boiler body design
The project selects a 10-ton chain grate biomass boiler, which is a mature export product of EPCB, with stable structure and rich operation experience. The pressure parts of the boiler are all made of high-quality boiler steel, and the international manufacturing and welding standards are strictly implemented, and multi-channel nondestructive testing is carried out to ensure long-term safe operation.
In view of the light weight and high volatile content of rice husk fuel, EPCB has optimized the furnace structure and heating surface layout:-prolonging the residence time of fuel in the furnace-increasing the burnout rate and reducing unburned particles-effectively controlling slagging and ash accumulation.
2. Biomass feeding and combustion system
The system is equipped with a continuous feeding device to ensure that rice husk fuel enters the grate evenly and stably, and avoid unstable combustion caused by fuel fluctuation. The chain grate runs smoothly, and with reasonable air distribution design, the full combustion of biomass fuel is realized.
3. Intelligent control system
The boiler is equipped with PLC intelligent control system to realize:-automatic adjustment of fuel feeding-automatic control of boiler water level-stable adjustment of steam pressure-real-time monitoring of key operating parameters.
At the same time, the system supports remote monitoring and fault early warning, which provides convenience for daily management and maintenance of customers.
4. Water supply system and steam system
According to the characteristics of continuous towel production and large amount of steam consumption, EPCB matched the stable and reliable water supply system and steam pipeline system for customers to ensure the stable steam output pressure and meet the requirements of steam quality and continuity in the production line.
In the process of project promotion, EPCB maintains high-frequency and professional technical communication with customers:-Through three rounds of online technical meetings, it answers the questions of boiler selection, fuel adaptability and operating cost in detail-Inviting customers to conduct field visits in EPCB factory to intuitively understand the boiler manufacturing process, quality control system and export project experience.
With accurate demand matching ability, mature technical scheme and perfect after-sales service commitment, EPCB has won the full trust of customers. The two parties formally signed the contract in December 2023.
EPCB meets the local construction specifications in Pakistan before the equipment is shipped, assists customers to complete the equipment customs clearance, and confirms the basic conditions on site in advance. At the same time, bilingual installation and operation manuals are provided to provide clear guidance for on-site construction.
The boiler system is promoted in an orderly manner according to the standard process: 1. Installation and leveling of the boiler body; 2. Installation of the feeding system and the water supply system; 3. Connection of the steam pipeline and the valve system; 4. Wiring and joint debugging of the control system.
In the commissioning stage, the uniformity of biomass feed, combustion state and steam pressure stability are repeatedly tested to ensure the stable operation of the system under different loads.
EPCB engineers provide on-site training for customers' operators, covering:-daily operation and maintenance specifications-key points of biomass fuel management-safety interlock and emergency handling procedures.
Through systematic training, help customers quickly grasp the key points of boiler operation and realize compliance and safe operation.
Customer Operation Feedback: Excellent Quality and Reliable Service
After the boiler was put into operation, customers spoke highly of the overall performance of EPCB boiler:
Strong Fuel Adaptability
The boiler can burn rice husk fuel efficiently, with stable combustion and less slagging. The measured thermal efficiency of the system reaches 88%, which significantly reduces the fuel consumption cost.
High Level of Automation
During the operation of the boiler, the feeding, water level and steam pressure are automatically controlled, which greatly reduces manual intervention and reduces the operation and management costs.
The Service Responds Quickly
EPCB provides 24-hour remote technical support to respond to customer operation problems in time; The actual installation cycle was completed three days ahead of schedule, which was well received by customers in writing.
The successful implementation of this project has once again verified the technical strength and service ability of EPCB boilers in the field of biomass energy:
· Mature and reliable DZL biomass boiler technology
· Customization design ability for local fuel conditions
· Strict manufacturing quality and factory inspection system
· Installation guidance and after-sales support covering the global market
EPCB Boiler always adheres to the customer demand as the core, provides efficient, stable, energy-saving and environmentally-friendly steam solutions for industrial users around the world, and helps enterprises achieve sustainable development.
