Guide to Boiler Selection for Chemical Plants: How to Improve Production Efficiency

A coking plant is a specialized chemical plant that heats coal to generate coke oven gas through distillation, mainly producing coke used in steelmaking. At the same time, the coking process produces a series of by-products such as coal tar, toluene, xylene, naphthalene, ammonium sulfate, and large amounts of coke oven gas. However, due to the low calorific value of coke oven gas and the presence of various impurities, its utilization has traditionally been limited. It is often disposed of by flaring, resulting in significant energy waste. Meanwhile, coke production itself requires a large amount of steam, but fuel supply is often insufficient, leading to an imbalance between supply and demand.

To address this issue, the chief engineer of this chemical plant sought technical support from EPCB Boiler. We conducted an in-depth analysis of the plant's production processes and energy needs. After several rounds of technical simulations and theoretical calculations, we designed a tailor-made solution to fully utilize coke oven gas, turning this by-product into a highly efficient energy source.

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:

Initial Treatment of Coke Oven Gas

After being generated, coke oven gas requires initial purification. It often contains large amounts of particulate impurities, such as coal dust and ash. If not removed, these impurities can adversely affect the subsequent combustion process and even damage boiler equipment. In the initial treatment phase, coke oven gas passes through filtration devices to remove large particulate matter, ensuring a preliminary level of cleanliness. Simultaneously, some of the gas is stored in buffer tanks to serve as a stable fuel source for future combustion. This process helps prevent fuel supply instability caused by gas fluctuations, ensuring continuous system operation.

Pressure Control System

Pressure fluctuations in coke oven gas can directly affect boiler combustion. Excessively high or low pressure can compromise boiler efficiency and safety. EPCB Boiler uses an expansion bladder technology to control and stabilize gas pressure. The expansion bladder absorbs pressure fluctuations, ensuring system pressure stability. This approach effectively prevents combustion efficiency loss or safety hazards caused by pressure changes, ensuring continuous and stable boiler operation, especially under high loads.

Gas-Liquid Separation Treatment

Coke oven gas often contains liquid impurities such as tar, oil mist, and water vapor, which can negatively impact boiler combustion. EPCB boiler's solution includes a gas-liquid separator, which removes liquid impurities from the gas. Through the gas-liquid separator, these liquid components are effectively removed, reducing their interference in the combustion process and enhancing fuel purity. This meticulous step improves combustion efficiency and extends the boiler's service life, preventing equipment corrosion or failure caused by impurity buildup.

Fine Filtration

After initial filtration and gas-liquid separation, further fine filtration is necessary. EPCB Boiler uses a U-shaped dual-channel filter for deep filtration, removing remaining small particulate matter to ensure that the gas meets the strict cleanliness requirements for combustion. This fine filtration process thoroughly eliminates residual impurities in the gas, preventing carbon buildup or the production of harmful substances during combustion, ultimately achieving clean, efficient, and safe combustion. The filter is scientifically designed to maintain high filtration efficiency without affecting airflow, with high throughput and low maintenance costs.

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.