GYPROC SAINT-GOBAIN

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CASE STUDY

Customer: GYPROC – SAINT-GOBAIN

Location: Parow, Cape Town, SA

Year: Autust 2023

Boiler: Limpsfield LCLPGK73       

Controller: Autoflame Mini MK8 MM, Autoflame MK8 EGA, 24/7 Combustion Technology Management System Interface, Custom built control panel

Fuel: Paraffin

SCOPE OF WORK

The Scope of the project for Combustion Technology was to remove a 73 MW SAACKE rotary cup burner, and replace it with a Limpsfield Burner. The new Limpsfield burner had to incorporate pre heated air via the gympsom air dryer jacket.

KEY OBJECTIVES

The objective of this installation was to successfully remove the existing SAACKE burner and modify the dryer to enable the Limpsfield Burner to reuse the heated air from the process and air jacket. Once this was done, the aim was to successfully commission the burner to operate in coordination with the plants process demands via external load input/output using the Autoflame Combustion Management System.

INSTALLATION DETAIL

    The installation took place in August 2023, over a period of 14 days. The Combustion Technology team removed the old SAACKE burner, control panel and Air fan initially.

    Once the Site was cleared of all old equipment, the modifications to the dryer chamber began. The Limpsfield Burner would need Heated air from around the chamber, thus the ducting to the burner was directed from the bottom of the chamber, where a square opening was cut out to suit the duct.

    The burner and duct were mounted and fixed to the chamber. The fuel pump skid was placed to then right side of the burner, so that the ring main could supply paraffin to the pump which would in turn supply the burner with fuel at 25 Bar, and the fuel returned to the ring main’s low-pressure side. The fan was pushed into place and fixed to the ground and dryer chamber.

    The new Autoflame control panel was moved into place, and the fixed in place, where the cable tray and cables were layed from and to the burner, pump skid, and air fan as well as the new site feature, the Autoflame Exhaust Gas Analyser (EGA).

    Once all the wiring was terminated within the panel and in the field, the testing commenced, and the pre commissioning checks were carried out. The Client requested that the burner be driven and controlled by the plants PLC, so as to supply heat as per the processes demand.

    The burner was started up and commissioned to ensure safe and efficient combustion in conjunction with the Autoflame EGA, sampling the emissions within the chamber.

    BENEFIT AND COST SAVING ACHIEVED

    The Site initially had a very outdated control panel and burner that would give problems with little to no warning or description of what was wrong with the burner. The burner was unable to be used at full capacity without locking out.

    With the latest technology of Limpsfield and Autoflame installed now, the site can optimise production by getting the full capacity from the burner now and minimising the loss in production due to unexpected and intermittent burner lockouts. All this whilst also being able to reduce fuel used by sampling the exhaust gas emissions with the EGA and trimming the burner air input to maintain commissioned Air/Fuel ratios throughout the year.