Bagasse Boiler Heater Modification

Our client’s boiler is fired on bagasse used to generate superhead steam primarily used to supply a turbine for power generation.

Project Requirements

Uneek Energy replaced original turbine. We found the superheater steam temperature was not high enough to achieve optimal turbine efficiency.

Uneek Energy was engaged to review the boiler and superheater was not high enough to achieve optimal turbine efficiency.

Uneek Energy was engaged to review the boiler and superheater to determine what changes would be required to increase the superheater temperature.

Design Methodology
Thermal Modelling

We developed a thermal model of the superheater, based on process data supplied by the client.

This model was used to determine the effects on superheated steam temperature by increasing the total superheater heat transfer area.

The heat transfer area is increased by non major modifications of tubes within the constraints of the available space in the boiler.

The thermal model was developed and used to review the flow on effects including higher superheater pressure loss due to modified wall temperature increase due to higher superheated steam temperature, lower downstream flue gas temperatures and overall fuel usage.

3D Model

A 3D model of the superheater was created using the 2D drawings provided by the client.
This model was used for the pressure part design and generation of fabrication drawings.

Pressure Part Design

The revised superheater arrangement has a different arrangement and a higher design temperature than what is covered by the original Statutory Design Registration.

The overcome pressure part calculations were undertaken with the revised arrangement and design conditions with the completed calculations being third party verified so we have full confidence.

The verified calculations and drawings were submitted to the Statutory Authority for review and an updated Design Registration was issued.

Component Manufacture

Follow completion of engineering the additional tube sections manufactured by our sister company, Uneek Bending for installation of the boiler during the clients planned installation activity.