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Biomass Burner Retrofit for a 2T Vertical Thermal Oil Boiler
2025-04-15 09:23:38
Project Background
A food processing plant originally used a 2-ton vertical coal-fired thermal oil boiler. Due to tightening environmental regulations, rising coal costs, and non-compliant emissions, the company decided to transition to clean energy. After technical evaluation, they opted to replace the coal-fired system with a biomass burner to achieve an efficient, low-carbon, and cost-effective heating solution.
Pre-Retrofit Issues
Non-Compliant Emissions – The coal-fired boiler emitted excessive SO₂, NOx, and particulate matter, failing environmental standards.
High Operating Costs – Volatile coal prices and low thermal efficiency (only ~65%).
Labor-Intensive Operation – Required frequent manual coal feeding and ash removal.
Unstable Heating Performance – Incomplete coal combustion caused temperature fluctuations, affecting production quality.
Retrofit Solution
1. Biomass Burner Replacement
Installed a fully automatic biomass pellet burner, using wood pellets (calorific value ≥4000 kcal/kg).
Low-NOx combustion technology, reducing emissions (NOx <150 mg/m³, PM <30 mg/m³).
2. Optimized Combustion Control System
PLC + variable frequency control for automatic fuel feeding and air supply adjustment.
PID temperature control for precise thermal oil outlet temperature (±1°C accuracy).
3. Supporting Modifications
Added a screw-type automatic feeding system to minimize manual intervention.
Installed cyclone + baghouse dust removal to meet ultra-low emission standards.
Retained the original thermal oil circulation system, only modifying the combustion unit to reduce costs.
Post-Retrofit Results
✅ Emission Compliance – Particulate matter and SO₂ emissions well below national standards, eliminating environmental penalties.
✅ Energy & Cost Savings – Biomass pellets cost 10% less than coal, with thermal efficiency exceeding 85%.
✅ Automated Operation – Automatic ignition, feeding, and temperature control reduced labor costs.
✅ Stable Heating Performance – Improved temperature consistency enhanced product quality.
| Metric | Pre-Retrofit (Coal) | Post-Retrofit (Biomass) |
|---|---|---|
| Thermal Efficiency | 65% | ≥85% |
| Fuel Cost | ~¥800/ton (coal) | ~¥700/ton (pellets) |
| NOx Emissions | 300 mg/m³ | <150 mg/m³ |
| Labor Demand | 2 shifts of manual operation | Only periodic inspections required |
Customer Benefits
Annual fuel cost savings: ~¥120,000 (based on 300 operating days/year).
Carbon reduction: ~200 tons/year, aligning with "dual-carbon" policy goals.
Avoided environmental penalties, ensuring long-term operational stability.
Conclusion
This 2T vertical thermal oil boiler biomass burner retrofit successfully achieved environmental compliance, energy savings, and automation, providing a sustainable heating solution for the plant. The case serves as a viable model for small-to-medium thermal oil boiler clean energy retrofits in industries such as food processing, chemicals, and textiles.
For a detailed technical proposal or cost-benefit analysis, feel free to contact us!
