RESEARCH STUDY OF CONVERSION FROM OIL-FIRED BOILER TO BIOMASS BOILER

(INTERNAL/EXTERNAL) CONVERSION

Oil and diesel are kinds of fuel that is always being used by different manufacturers and industries in
order to produce heat and steam, but oil and diesel cost today is rapidly rising than the cost of solid
fuels. The only chance left for oil and diesel users is to use an alternative source of fuel.

Based on the study conducted by Siriwardhana and Arachchilage in India, entitled, Conversion of
Furnace Oil-Fired Boiler to Biomass Fired Boiler, 1 liter of oil can be substituted with 3 kilos biomass
fuel when calorific value is being considered. In terms of calorific value, wood pellets calorific value is
4300 kcal/kg while oil and diesel have a calorific value of 10000 kcal/kg , thus in order to completely
convert to biomass, a manufacturer must use exactly 3 kilos of biomass. In terms of diesel and oil price
compared to biomass, diesel and oil costs P 30.39 per liter and per kilo while biomass wood pellets only
cost P 8 per kilo, in converting to biomass wood pellets in terms of price, 3 kilos of biomass wood pellets
cost P 24 and 1 kilo/liter of diesel and oil costs P 30.39; when we calculate the difference the answer will
be P 6.39 and that is exactly 19% of total savings.

The aim of the research study is to show the advantages of converting to biomass boiler through
internal or external conversion.

In converting to biomass, the existing fuel burner and burner arrangement of the original boiler must be
removed.
 Pre-requisites of Conversion

1. Before converting completely to biomass boiler, the space requirement must be first established.
There must be enough space for external or internal conversion and there must be also enough
space for the storage of the biomass fuel (wood pellets).
2. The consent and approval of the management.
3. Financing of conversion to biomass boiler and the money to buy biomass fuel (wood pellets).
4. Specifications of the biomass fuel (wood pellets).

Retro-fitting of the existing Boiler

Technology Available

There two type of converting oil-fired boiler to biomass boiler

Internal Conversion
- This conversion requires the removal of existing burner-blower assembly, adding a grate to
burn the biomass in the same combustion chamber and the installation of an Induced Draft
fan.
Induced Draft (ID) fan

- Partially loaded boilers (40%) or boilers being fueled by only 40% with uniform load pattern
can be converted through internal conversion.
- The advantages of this conversion are: cheap, quick (can be done in 4-6 hours), no ducting
or extra space is required.
- The disadvantage of this conversion is the reduction of the existing capacity of the boiler.

External Conversion
- An external furnace must be erected with sufficient grate area for biomass fuel (wood pellet)
- Hot combustion chamber of the external furnace
- Multi-window air supply for firing and clean to be done simultaneously
- The advantage of this conversion is the retaining of over 75% capacity of the boiler
- The disadvantages of this conversion are the need of extra space, long hours of retro fitting
(6-8 hrs) and the need of large financing to erect the external furnace.
 External Furnace

Hot combustion Chamber

Boiler Conversion Methods

No. Capacity Modifications

1 40-50% Internal grate in same combustion chamber, removal of burner
assembly

2 60% External fuel fired furnace and connecting its exhaust to the
existing boilers burner assembly location

3 75% Raising the height of the boiler with water tubing arrangement
in the erected external fuel fired furnace

4 75% above New set up of boilers erected in different locations with large
thermal furnace, steam piping to the boilers
 Sample of External Conversion

Interconnecting Duct

External Furnace
with Water Wall
Boiler

Sample of Internal Conversion

 Internal Conversion Arrangement

The Induced Fan or (ID) fan is used to evacuate the gases coming from the boiler to the atmosphere
through a dust collector, cyclone separator and wet scrubber.

Cyclone Separator
 Wet Scrubber

The wet scrubber will be used to further collect the fine dust particles in the gas being emitted by the
boiler. The wet scrubber will be connected from the cyclone separator while the gas coming out of the
wet scrubber will be connected to the chimney.

Recommendation

If the required boiler capacity is 50% lower than the existing capacity, internal conversion is adequate,
and if 75% and above of boiler capacity is required, external conversion is recommended.

Pictures (External Conversion)

Feeding System of External Conversion

Ash Deposit of External Conversion

Lifted Boiler of External Conversion

 Pictures (Internal Conversion)

Removal of existing burner arrangement

Burner Chamber ready to lay firewall and firebricks