EXERGY ANALYSIS-DRIVEN OPTIMIZATION OF STEAM BOILER FURNACE PERFORMANCE: A CASE STUDY OF KADUNA REFINING AND PETROCHEMICAL COMPANY

The Kaduna Refining and Petrochemical Company (KRPC) relies on steam boilers to produce steam at the required pressure, temperature, quantity, and quality for its production processes. However, recent operational inefficiencies have led to suboptimal performance of these boilers. This study aims to investigate the causes of these inefficiencies and optimize the performance of the steam boiler furnace at KRPC using exergy analysis. The specific objectives include determining the causes of energy quality degradation, assessing the exergetic efficiency, and identifying major areas of inefficiency. The methodology involved collecting operating data from KRPC's steam generating facilities and analyzing it using Aspen Hysys Version 8.4. Key parameters such as temperature, pressure, and mass flow rates were reviewed. The exergy analysis revealed significant exergy destruction within the boiler furnace, with an exergy efficiency of 6.396% and an energy efficiency of 71.54%. The study also examined the effects of various factors, including fuel oil temperature, pressure, and composition, on exergy destruction and efficiency. The results indicate that optimizing these parameters can significantly improve the boiler's performance. The study concludes that targeted optimization strategies, such as adjusting fuel oil temperature and pressure and managing fuel composition, can enhance the exergy efficiency of the boiler furnace. These findings provide valuable insights for improving the energy efficiency and operational reliability of industrial steam boilers.