Although adjusting boiler burner for optimal combustion efficiency is a very tedious and painstaking process, the MIEEIP team at the Kajang Tritex Containers Sdn Bhd has proved that if the same process can be well coordinated, it will not only achieve the ultimate objective but can also be carried out without any interruption to the on going production activities.

The MIEEIP team headed by the Energy Audit Programme Manager, En Hishamudin Ibrahim, under the respective guidance and assistance from the international consultant, Mr Povolny and the factory staff members, Mr Kunasegaran and Mr Ang successfully conducted this process on the 9th of November, 2001 at the factory site.

The team was divided into three sections, namely boiler operation, boiler setting and emission measurement. The first two sections were headed by the factory staff, whereas Mr Ramvir Sharma of the MIEEIP team took charge of the third team.

The boiler operation team's responsibility is to make sure that the process does not cause any interruptions to production and the other two team members are to coordinate the instructions given by the team leader once the decision was taken based on the emission measurement results.

The aim of burner adjustment is to optimise the combustion efficiency by reducing the 02 content in the flue gas for the three firing steps (high/medium/low). The accepted range of 02 in the flue gas is 1-2 % with an excess air ratio of 1.00-1.11 for diesel fuel.

Starting from current setting parameters of the burner, the team adjusted the combustion air quantity and fuel quantity at each firing step to achieve the desired 02 content in the flue gas. After 18 steps of adjustment, the teams were able to finally set the correct setting for optimal burner efficiency. They succeeded to reduce the average 02 content of the flue gas to 1.6 with excess air of 1.1. Since the whole process was very well coordinated, the various team members were able to carry out the assignments entrusted to them smoothly without any interruption to the production.

At this setting the annual fuel saving was calculated to be 6,563 liters which is approximately RM 5,000 per annum as compared to the fuel consumption of the boiler prior to the adjustment.

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