Songrui Completes 3000t/a Activation Line Energy-saving Retrofit
Company News
Songrui completed a 3000t/a activation line energy-saving retrofit, reducing comprehensive energy consumption by 25% and saving approximately 800,000 RMB annually in steam costs.
Project Overview
| Info | Detail |
|---|---|
| Client | Coal-based activated carbon producer |
| Capacity | 3000 t/a |
| Scope | Rotary activation furnace and auxiliaries |
| Duration | 45 days |
| Investment | ~1.2 million RMB |
Pre-Retrofit Issues
- Wall temperature 130-150℃
- Manual burner, excess air 2.0+
- 850℃ tail gas discharged without recovery
- Energy consumption 5.2 t steam/t
Retrofit Content
Burner Upgrade
Replaced with ratio-adjusting automatic burner with oxygen analyzer.
Waste Heat Recovery
Added gas-gas heat exchanger for steam preheating and raw material preheating.
Insulation Retrofit
Ceramic fiber modules + lightweight castable composite insulation.
Results
| Metric | Before | After | Improvement |
|---|---|---|---|
| Energy consumption | 5.2 t steam/t | 3.9 t steam/t | -25% |
| Wall temperature | 130-150℃ | 65-75℃ | -50% |
| Excess air | 2.0+ | 1.2 | -40% |
| Iodine fluctuation | ±80 mg/g | ±30 mg/g | -62% |
| Annual steam cost | ~3.2M RMB | ~2.4M RMB | -25% |
ROI
Investment 1.2M RMB, annual savings ~800K RMB, payback ~1.5 years. Product quality stability improved significantly with 60% reduction in customer complaints.