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Furnace Combustion

Optimization Project
(OL/0854)
For EU2 & EU3

Presentation for Site Visit


With Bidders
April 2015

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Purpose of Presentation
The purpose of this presentation is to explain the overall Scope of the Project to all
Bidders to carryout Detail Engineering.

Project : Furnace Combustion Optimization project in EU2 and EU3. (OL/0854)

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Background
Process description

Each

of the furnaces is currently equipped with the in situ type of zirconium oxide

analyzers that is installed at the furnace bridge wall.

The

fuel-air ratio is a critical parameter to ensure efficient combustion. As per

design, furnaces are operated with 2% excess O2.

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Background (cont.)
Problem description

The existing measurement point (at the bridge wall) leads to imprecise reading. This
forces operating the furnaces at higher excess oxygen to ensure complete
combustion at the expense of thermal efficiency.

Sketch of the existing scheme


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Proposed Solution
The proposed modification is to optimize the combustion via installation of Tunable
Diode Laser Spectroscopy (TDLS) analyzers in all EU2 and EU3 furnaces, as per
the following setup:

Sketch of the proposed scheme


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Trial Test
Trial Performance Test

EU2 furnaces have installed new analyzers from two available suppliers (Servomex
and Yokogawa) for testing purposes.

Servomex

analyzer was installed in one firebox while Yokogawa analyzer was

installed in the other firebox of the same furnace.

The purpose of the test was to compare both analyzers in terms of their performance
(readings accuracy), operability and maintainability.

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Trial Result
Servomex: The target CO content

measurement is steady when excess oxygen was

reduced from 2.0% to 1.45%, indicating good control over combustion.

Yokogawa: During the same exercise, CO measurement was heavily fluctuating.


Therefore, burner optimization cannot be achieved with the Yokogawa analyzer.

The test confirmed fuel gas savings and lower stack temperature (140 oC
Servomex analyzer was found to be acceptable for the application.

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to 134 oC).

Project SOW
Complete Detail Engineering (Package shall be prepared as IFC).
Relevant HSEIA Studies to be conducted.
HAZOP chairman can be from 3rd party or from same Consultant but shall not be from
same Project team.
Design using 3D Modelling and Intools through workshare procedure. For detail please
In EU2 and EU3, Each Unit : 7 Furnaces, total furnaces :14 Nos., Each furnace : two
fire box per each Furnace, (Total Fire Box: 28 Nos.)
On each Fire Box : One CO Analyzer and one O2 Analyzer to be installed.
Total 28 No. CO Analyzers and 28 Nos. O2 Analyzers to be installed.

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Project SOW (cont.)


On Each Fire box, one O2 and one CO analyzer to be installed.

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Project SOW (cont.)


Each furnace have one existing Instrument JB, currently 5 spares available in each JB,
4 spares to be used.
Each Furnace has one existing UPS. Many options to be explored and a reliastic
solution shall be finalized during DE.
Each Furnace has one existing Instrument Air Line. Instrument Air Line with a manifold
to be provided for each furnace. (New Instrument Manifold shall be located near the
Analyzers).
Analyzer to be installed on existing Furnace Peep Doors. Peep doors to be modified.
Drawings and relevant docs to prepared and existing docs shall be updated. 4 peep
doors to be modified on each Fire-box.
E&I cable schedules, E&I cable trays layout to be prepared for the cables, routing from
Instrument to the existing JBs.
For CO and O2 Analyzer Data Sheets to be developed. A F2F meeting would be held
with M/s SERVOMEX during DE phase.

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Questions and Clarifications

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Thank You

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