In today’s world, the efficiency of industrial boilers is more crucial than ever before. An excellent boiler is not only known for its energy efficiency but also for its ability to run production processes smoothly. While various types of industrial boilers, power industries typically consume a lot of fuel, require high maintenance, and generate significant carbon emissions. These boilers are usually coal, oil, or gas-fired. With the rising prices of fossil fuels, industries are now looking for cost-effective alternatives like biomass. In this blog, we’ll explore how switching to biomass can benefit industries and how Steamax’s OBR can make the transition seamless.
Why Switching to Biomass is Beneficial?
The damage by fossil fuels can mitigate by switching to renewable energy sources. Biomass is near carbon-neutral, making it an eco-friendly alternative to fossil fuels. Moreover, with the surge in fuel prices, switching to biomass makes more economic sense. Replacing oil or gas-fired systems can reduce fuel costs by up to 60%. Thus, choosing biomass over fossil fuels helps save costs while significantly reducing greenhouse gas emissions. Also, it is readily available within the country, unlike fossil fuels, which are mostly imported.
Ways to Shift from Fossil Fuels to Biomass
If an industry wishes to transition from a fossil fuel-fired system to a biomass-based system, there are two main approaches:
- Buying a New System
- Converting the Existing Boiler to Biomass with an OBR Kit
Buying a New System
One way to shift to biomass is to replace the existing boiler with a new biomass-fired system. However, this requires significant capital expenditure and is a time-consuming process. In addition to the cost of the machinery, production losses could also be high during the transition period.
Oil to Biomass Retrofit Kit (OBR)
Another method includes retrofitting the existing diesel or gas-fired system with the OBR Kit. It involves removing the diesel or gas burner and installing the OBR Kit. Retrofitting is a quick process that takes just a few hours and costs only a fraction of the price of a new system.
| Parameter | New Boiler | Retrofitting the Existing Boiler |
| Payback period | 2-5 years | 2 months |
| Fuel Flexibility | No. Can only use biomass | Yes. User can shift between biomass & gas or oil within few hours |
| CAPEX | High | Low (<50% of the new boiler) |
| Efficiency | 75-80% | 75-80% |
| Turnaround Time/ Project completion time |
2-12 months | <30 days |
| Shutdown required | >1 month | <1 day |
Advantages of the OBR Kit
- The OBR Kit is compatible with multiple biomass fuels. Even if there is a change in government norms banning biomass usage, customers can roll back to gas or diesel within a couple of hours.
- The OBR Kit includes an automatic fuel feeding system and an ash removal system, ensuring clean and efficient combustion comparable to diesel or gas.
- The kit is design to meet government emission standards and doesn’t require any changes to the pressure parts of the boiler. Therefore, there’s no need for IBR approvals or Pollution Control Board clearances.
How is the OBR Kit Install?
The installation process of the OBR Kit depends on the type of industrial boiler:
- Horizontal Boiler :In a horizontal boiler, water flows through tubes, and with the help of a diesel burner, it converts to steam. The diesel or gas burner is remove and replaced with the OBR Kit.
- vertical boiler: It consists of a cylindrical shell oriented vertically, with water entering one end and steam being removed from the other. In this case, the diesel burner is remove, the boiler is lifted to a specific elevation, and the biomass burning system is fitted below the boiler.
How Does the OBR Kit Work?
- Fuel Feeding: The OBR Kit features an automatic fuel-feeding system. The combustion occurs in an external furnace with primary air, while secondary air ‘pushes’ the flame into the boiler.
- Efficient Performance: The fuel feeding and air supply system are automatically regulated to ensure efficient performance.
- Ash and Pollution Control: Since biomass combustion generates more ash than liquid or gaseous fuels, the OBR Kit has a tube cleaning system and a pollution control device to keep emissions within permissible limits.
There is an urgent need for solutions that effectively control pollution without imposing high fuel costs on industries. Steamax has partnered with numerous industries to develop suitable technologies . Our OBR Kit offers a seamless and cost-effective transition from fossil fuels to biomass, ensuring compliance with government regulations and significant cost savings. Are you ready to make the switch? Contact us today at +91-9315124803.
