In the agricultural industry of Ba Ria-Vung Tau, a significant challenge arose for an agricultural company in Chau Duc when their thermal oil heater system, a crucial component in the corn drying process, had severely deteriorated after years of neglect and disuse. Faced with this situation, the company turned to Prebecc, hoping to restore the system to meet their current production needs.
1. The Challenge: An Old Thermal Oil Heater System
The thermal oil heater system that we assessed had been in operation for many years without proper maintenance, leading to severe degradation. Even the estimated technical specifications of the heater hinted at the scale and complexity of the restoration work:
- Combustion Chamber: Outer Diameter (OD) = 2000mm, Height (H) = 2500mm
- Connecting Flange Between Combustion Chamber and Boiler Body: OD = 2240mm, H = 50mm
- Estimated Total Height of the Heater: 7000mm (Exact height not measured)
The issues the client faced extended beyond the age of the heater and lack of maintenance. Many parts were rusted, heavily damaged, and some components even showed signs of corrosion. Additionally, the insulation of the heater was severely compromised, significantly reducing the system’s operational efficiency.
2. Survey Process: Assessing the Current Condition
Prebecc’s team of experts conducted a comprehensive survey to evaluate the actual condition of the heater system. During this process, we identified several major issues:
- Heater Body: Due to onsite conditions, we were unable to inspect the interior of the heater body, presenting a significant challenge in accurately determining the extent of internal damage.
- Oil Pump: Completely non-functional and beyond repair.
- Blower Fan: Severely rusted, with the fan motor also non-functional.
- Flue Gas Duct: Reusable, but requires thorough cleaning and maintenance to ensure safety and efficiency.
- Oil Tank: OD = 1210mm, H = 2010mm, with a support frame of DxWxH = 2010x1200x1610 (V50).
- Site Layout: Heater installation area measured at DxR = 17m x 16m.
3. Restoration Solution: Reviving Operational Efficiency
After completing the survey, Prebecc’s experts proposed a comprehensive solution to restore the thermal oil heater system, aiming to bring the heater back to optimal operational condition to meet the corn drying requirement with a desired capacity of 2 Mkcal/h.
3.1. Reconstructing the Heater System Using Specialized Software:
First, we reconstructed the entire heater structure using specialized software. This process allowed us to accurately identify areas needing restoration and technical intervention. By utilizing 3D modeling, we could clearly visualize the actual condition of the heater, enabling precise restoration planning.
3.2. Cleaning and Maintaining Reusable Components:
Components that are still reusable, such as the flue gas duct, will undergo thorough cleaning to remove accumulated dirt and rust. This step not only ensures operational efficiency but also extends the service life of the heater system.
3.3. Replacing Severely Damaged Equipment:
Severely damaged equipment, including the oil pump, blower fan, and fan motor, will be completely replaced. This measure ensures the system operates stably and achieves optimal efficiency, meeting the client’s production requirements.
3.4. Recalculating Heater Capacity:
Finally, we recalculated the heater’s capacity based on the requirement to dry corn at a capacity of 2 Mkcal/h. All factors, from temperature and pressure to oil flow rate, were meticulously considered to ensure the system achieves maximum drying efficiency.
Through surveying and evaluating this thermal oil heater system, Prebecc once again asserts its position as a leader in providing high-tech solutions for industrial systems. For every challenge posed by our clients, we always deliver an optimal solution, ensuring the system’s efficiency and long-term durability.