Project Information
Project:
Optimizing Biomass Briquette Handling for Boiler Efficiency in Sticky Material
Client:
ITC
Project Location:
Bangalore
Background of the Challenge
The client was facing operational inefficiencies due to poor material flow through the existing dump hopper. The briquettes, being sticky and prone to bridging, failed to flow consistently—resulting in:
1. Irregular fuel supply
2. Inefficient boiler performance
3. High manual intervention and operational costs
The core issue stemmed from the static dump hopper design, which caused briquette bridging and ratholing. This interrupted the fuel feed, forcing operators to manually intervene and reducing the effectiveness of downstream equipment.
Our Solution
After a thorough study, Turbovent proposed a straightforward yet effective mechanical upgrade.
Root Cause Analysis
Flow blockages were traced back to poor geometry and the lack of active discharge mechanisms within the dump hopper.
Design Modifications & Equipment Upgrade
1. Hopper Redesign
Geometry was modified (slope or exit profile) to improve passive flow.
2. Vibrating Feeder Installation
Added to the hopper base to ensure consistent discharge by actively breaking up briquette bridges and maintaining uniform flow into downstream conveyors.
Results & Client Benefits
1. Improved Operational Consistency
The boiler now receives a continuous and reliable fuel supply, improving combustion efficiency and reducing operational fluctuations.
2. Reduced Labor & Handling Costs
Manual feeding was significantly minimized, lowering overall manpower requirements and associated costs.
3. Enhanced System Throughput
Downstream briquette handling systems now operate at optimal load without blockages or jamming, increasing system reliability.
Key Learnings
1. Understand Material Flow Properties
Sticky biomass briquettes require specially designed hoppers with flow-aiding geometry and discharge mechanisms.
2. Use Active Discharge for Challenging Materials
Vibrating feeders or similar solutions are essential for ensuring reliable, uninterrupted flow in bulk handling systems.
3. Fixing One Bottleneck Improves the Entire System
Optimizing the dump hopper enhanced performance across the fuel handling line, including boiler efficiency, manpower optimization, and reduced downtime.