Sugar Mill Boiler Retrofit: More Steam Within the Existing Footprint
3D modeling and detailed engineering supported a bagasse-fired boiler rebuild that increased reported steam output to 130,000 lb/hr within the existing plant.
Existing boiler before modifications.
Project Details
Client
Sugar processor
Location
Southeastern United States
Project Type
Detailed engineering and retrofit
Fuel Type
Bagasse
Key Upgrade
Water-cooled walls and grate conversion
Services Provided
- Collected site information and modeled the existing boiler and proposed modifications in 3D.
- Completed ASME BPVC Section I calculations for new and modified pressure parts.
- Prepared demolition plans, P&IDs, and detailed drawings for pressure parts, piping, ductwork, and refractory.
- Engineered structural and foundation modifications for the revised boiler arrangement.
The Challenge
A sugar mill needed to increase steam generation from its bagasse-fired boiler within the existing boiler house footprint and height constraints. The upgrade needed to provide sufficient bagasse firing capacity to meet the increased steam demand, which, as a secondary benefit, would help the mill keep pace with bagasse generated during crushing. This had to be achieved while maintaining complete combustion, efficient fuel utilization, and acceptable emissions performance.
Engineering the retrofit around the existing plant
The retrofit added water-cooled furnace walls and a fixed, inclined, pinhole water-cooled grate. CPE used site measurements and existing drawings to model the boiler and proposed modifications in 3D. The model defined how the new arrangement would connect with the boiler drums, piping, supports, and foundations, and informed the demolition and construction drawings. The design also accommodated foundation conditions identified in the field.
More steam within the existing plant
Reported steam output increased from approximately 90,000 to 130,000 lb/hr after the rebuild. The modifications fit the existing plant's footprint and height constraints, and the rebuilt boiler started up at the beginning of the production campaign.
130,000 lb/hr
Steam output
Steam output following the rebuild, up from approximately 90,000 lb/hr.
Existing footprint
Capacity upgrade
The capacity upgrade accommodated the mill's existing footprint and building-height constraints.
Campaign startup
Production schedule
The rebuilt boiler started up at the beginning of the production campaign.
Need more steam from an existing boiler?
Talk with CPE about the capacity, layout, and engineering requirements for your boiler retrofit.