The Challenge
A recovery boiler was consuming an average of 49 kiloliters of furnace oil per month, significantly above what the process should have required. The excess consumption was adding approximately $49,000 CAD annually to the cost of production and pointed to combustion inefficiencies that also carried implications for boiler reliability and environmental performance.
The Approach
The improvement effort focused on understanding the conditions driving excessive consumption. Firing patterns, air-to-fuel ratios, liquor temperature profiles, and startup procedures were all analyzed. Data trends revealed inconsistent firing behavior and over-reliance on furnace oil during operational transitions. The initiative then:
- Developed optimized operating practices based on data analysis
- Adopted new control settings to stabilize combustion and reduce excess oil use during transitions
- Coached staff on improved sequencing and monitoring techniques
- Established practices to ensure the gains were understood and maintained rather than gradually eroded by reverting to old habits
The Outcome
Furnace oil consumption dropped from 49 kiloliters per month to 35 kiloliters per month, a 29 percent reduction. The savings totaled $49,000 CAD annually.
Boiler stability improved, reducing the risk of unplanned trips, and the reduction in oil consumption also lowered the environmental load associated with the operation.