As part of the technical modernization of a tobacco factory in St. Petersburg, PromEnergo specialists carried out a full-cycle project including reverse engineering, equipment supply, installation, commissioning, and startup of a thermal oxidation unit (heat generator) and high-efficiency heat exchangers for process air heating.
Objectives and Tasks
- Conduct a detailed survey of the existing engineering infrastructure.
- Design and manufacture custom heat exchangers and a heat generator.
- Ensure stable supply of process air at temperatures up to 305 °C.
- Integrate new automation into the existing control system (ACS TP).
- Complete installation within the limited window of a planned production shutdown.
System Operation Principle
Natural gas and gaseous waste are burned in a new fan burner. The combustion products pass through three sequentially installed heat exchangers, heating process air up to 305 °C. The heated air is then used to warm the tobacco and subsequently returns to the heat exchangers. Airflow regulation is performed by the existing dampers and fans.
- Process air temperature: 305 °C (± 20 °C)
- Airflow velocity: 19–21 m/s
- Pressure differential: 20 ± 10 mm H₂O
- Duct diameter: 500–1000 mm
Project Highlights
- Integration of new equipment into the existing technological line without loss of productivity.
- Development and implementation of an upgraded automation and control system with extended logic and emergency algorithms.
- Short installation time thanks to pre-launch testing and debugging at a test site.
- Certification and supervision support in compliance with Rostekhnadzor requirements.
Project Stages
- Inspection of existing heat exchangers, heat generator, and gas equipment.
- Analysis of the support and suspension system for pipelines (temperature range 100–550 °C).
- Study of production processes and operational modes.
- Examination of building engineering systems and utilities.
- Diagnostics of existing automation and control systems.
- Thermal, hydraulic, and strength calculations.
- Development of detailed design documentation for custom-made equipment.
- Certification of gas-using equipment in compliance with national standards.
- Preparation of documentation for gas distribution system modernization.
- Obtaining a positive expert review and official approval.
- Manufacturing, painting, and delivery of equipment.
- Installation and network connection during scheduled downtime.
- Full-cycle commissioning and functional testing.
- Final approval and authorization from Rostekhnadzor.
- Development of operating manuals and delivery to the client.
Results and Benefits
- Reduced energy consumption through efficient heat recovery.
- Increased reliability of production processes due to upgraded automation.
- Improved environmental safety through gaseous waste utilization and emission reduction.
- Fast ROI achieved through minimized installation time and reduced downtime costs.
This reverse-engineering project and implementation of a thermal oxidation and heat recovery system for a tobacco factory in St. Petersburg once again demonstrated PromEnergo’s ability to execute complex technical upgrades without production interruption and in full compliance with safety and regulatory standards.