Sugar Industry 2019
Kayseri Seker Boiler Rehabilitation
CFD-driven combustion optimization achieving >99% CO reduction from 3000 ppm to <20 ppm, avoiding $21M natural gas conversion cost.
Key Results
>99%
CO Reduction
<20 ppm
Final CO Level
$21M
Cost Avoided
Before & After Comparison
| Metric | Before | After |
|---|---|---|
| CO Emissions | ~3000 ppm | <20 ppm |
| Compliance Status | At Risk | Compliant |
The Challenge
The sugar mill's three coal-fired boilers had CO emissions around 3000 ppm, risking environmental compliance and potential forced conversion to natural gas at $21M cost.
Our Solution
TABi partnered with REI (USA) for advanced CFD modeling to identify CO formation zones and flow maldistribution. Designed Over-Fire Air (OFA) control strategy with burner-level improvements and internal flow modifications.
Results Achieved
All three boilers now operate among the cleanest coal-fired units in Turkey with CO below 20 ppm. Avoided $21M gas conversion, achieved ~1.15M TRY campaign savings, and established benchmark for Turkish sugar industry.
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