A Leap Forward with VIZEN Solutions’ DCS-Based Control Systems
In the quest for sustainable energy solutions, industries worldwide are facing the dual challenge of boosting production efficiency while curbing environmental impacts. The stakes are high, with escalating energy costs and stringent regulations on greenhouse gas emissions. Amidst this scenario, VIZEN Solutions emerges as a beacon of innovation, offering a glimpse into the future of power generation through its cutting-edge Distributed Control Systems (DCS) for RDF (Refuse Derived Fuel) boilers.
The Challenge at Hand
Paper mills in India especially situated in Northern India were determined to amplify their power generation while adhering to environmental and cost-efficiency standards. The mission was clear: to integrate a new RDF boiler without disrupting the existing setup. VIZEN Solutions stepped in with a promise to deliver a comprehensive electrical and automation solution that would blend the old with the new seamlessly.
Engineering a Solution
The approach was multifaceted. VIZEN Solutions harnessed the synergy of MCC (Motor Control Center), DCS, Grate Control System, and a suite of field instruments to fine-tune the RDF boiler’s performance. The goal was to ensure that both the existing and new boilers operated in harmony, without incurring exorbitant electrical and automation expenses.
Reaping the Benefits of Automation
The results were nothing short of transformative
Power Generation Optimized: The additional power availability soared between 2.5 to 4 MW, marking a significant leap in energy production efficiency.
Emission Control Achieved: Greenhouse gas emissions plummeted by 30% annually, a testament to the commitment to environmental stewardship.
Predictive Maintenance Implemented: Boiler : downtime was slashed by 500 to 600 hours each year, thanks to the foresight of optimized automation.
Boiler Efficiency Improved: A meticulous steam control led to a 4 to 5% boost in boiler efficiency, maximizing output while trimming operational costs.
Cost of Power Generation Cut Down: The ingenious optimization of the grate control sliced the power generation cost by an impressive 50%.
Advanced DCS Control
At the core of this revolution lies the Grate Control System, powered by advanced DCS control logic. The step grate combustion chamber is a marvel of engineering, enabling the efficient burning of solid waste and adapting effortlessly to fuels of diverse characteristics. VIZEN’s DCS stands out with its model-based predictive control technology, loop-control optimization, and Honeywell’s Fault Tolerant Ethernet (FTE) capability, ensuring unwavering reliability.
The Implementation Journey
VIZEN Solutions’ commitment to excellence extends beyond mere installation. From the initial design and engineering phases to commissioning, training, and ongoing support, the company ensures a holistic approach to RDF boiler implementation, guaranteeing equipment integration that performs at its peak.
Flagship Projects: A Legacy of Success
The prowess of VIZEN Solutions is evident in its portfolio of flagship projects. Leading industrial players like Silvertoan Paper, KK Duplex, Genus Paper, Maruti Paper, and Gulshan Poly have all witnessed the transformative impact of VIZEN’s RDF boiler solutions, complete with HT Panels, Bus Duct, PCC, MCC, VFD, and DCS Panels.
In conclusion, VIZEN Solutions stands as a paragon of industrial innovation, with its expertise in maximizing RDF boiler efficiency through DCS-based control systems. This narrative is not just about technological advancement; it’s a story of sustainability, efficiency, and the relentless pursuit of progress in industrial power generation.
