Boiler Combustion Technologies (BCT) was founded in 2006 by its two directors, René and Jean le Roux, both of whom are graduated mechanical engineers. The founding mission of the company was to involve itself with the optimization of combustion efficiency of coal fired steam boilers by means of a newly developed and patented electronic boiler control system. With closer control of air-fuel ratio t
his technology succeeds in saving users of steam boilers from 8% to 15% of coal usage compared to conventional electro-mechanical control systems. It also presents opportunities for substantial reduction in electricity consumption of boiler fans, typically by 40% to 60% compared to damper controlled systems. The company offers various combustion and boiler automation technologies to choose from, depending on the specific needs and preferences of users, coal usage and cost and available budget. To date this is still the core business of the company. During the past number of years the directors realised that automation is a specific intervention and that its effect is limited and still dependent on a number of other factors within the greater steam system. The company consequently broadened the scope of its business to include a greater number of efficiency related products and services which it is now able to offer to users of steam boilers as a package of integrated steam system efficiency solutions. The focus has now shifted more towards a steam system approach so that greater impact on total efficiency can be achieved through optimizing the Steam System in terms of its four main elements, viz. Steam Generation, Steam Distribution, Steam Application (Use) and Heat Recovery. BCT is well equipped to render the following steam system efficiency enhancing products and services to existing Clients and other users of steam boilers:
a) Conducting combustion and steam system surveys, using various tools, instruments and software to establish current combustion and steam system efficiency and identifying areas of energy loss, as well as areas of potential system and operational improvement. We analyze the efficiency impacts of improvements on the steam system, implement feasible improvements and monitor overall system performance. This includes steam trap surveys and supply of maintenance free venturi or***ce steam traps. b) Supply and installation of boiler automation and combustion optimization systems. Our product range includes basic metering control systems up to more sophisticated oxygen trim systems. Control platforms include Siemens and Delta Electronics plc’s and HMI’s. c) Maintenance of the BCT automation technology. This involves regular service visits to our Clients and includes the following service elements:
• Installation of control programme updates
• Combustion gas analysis and control system calibration for best combustion efficiency.
• Identification and evaluation of factors influencing boiler and steam system efficiency.
• Coal and ash evaluation (visual inspection). Alternatively comprehensive coal analysis with evaluation and report.
• Report to Client: findings and recommendations. d) Dashboards:
Once automated, boilers will be able to run more efficiently than before. However, changes in operating parameters may negate much of this gain, unless combustion settings are re-configured for changing conditions. Our newly developed boiler Dashboard remotely monitors client boilers so as to provide regular reports on boiler efficiency, fouling of heat transfer surfaces, significant events and interventions required to ensure optimal performance. e) Coal assessment and analysis. The characteristics of coal play a significant role in overall steam system efficiency. This service Includes coal analysis, visual combustion assessment, as well as coal combustion performance evaluation. It also addresses coal handling and segregation. Our coal assessment service covers the full spectrum of empirical and fundamental analysis, aimed at predicting coal performance when fired in a steam boiler, and is an essential supplement in achieving optimum steam system efficiency. f) Other Services: BCT also renders the following general services to users of steam boilers:
• Steam Outsourcing:
With BCT’s extensive knowledge and experience in the field of coal fired steam boilers we can bring great benefit to users of steam boilers by taking over one of their mission critical support, but non-core functions, viz. effective, reliable and safe steam production. Outsourcing means that a user relinquishes the operation, management and control of a non-core activity to a supplier and buys back the product of the non-core activity at an agreed price.
• Boiler Maintenance. Services in this field include general boiler repairs, steam piping installations, boiler relocations, boiler sales and boiler preparation for statutory inspections. Our Associates:
BCT has formed associations and partnerships with a number of companies of good repute over the past number of years, reinforcing its ability to provide a package of steam system and energy efficiency solutions to clients. In a recent development BCT merged with Energy Partners, an energy management and optimization company, of which the PSG Group is a major shareholder. Our Clients:
BCT is proud to be associated with companies such as Clover Dairies, SA Breweries, National Brands, Afgri Animal Feeds, Nedan Oil, Premier Foods, Mondi, Tongaat Hulett Starch and many more. We have executed efficiency improvement projects in South Africa, Lesotho, Botswana, Zambia, Mozambique and Zimbabwe.
