Project
LPG AND CNG PARALLEL SYSTEM AT THE ALUMINUM PLANT
DATA Energy designed and installed a dual fuel supply system comprising an LPG system (17-ton tank, 3 x 500 kg/h vaporizers) and a CNG system (1,500 Sm³/h PRU station, 3 filling stations) to serve production at an aluminum plant.
- Field: Aluminum Production / Non-ferrous Metallurgy
- Timeline: 45 days for survey, design, installation, and completion
1. The situation
The existing aluminum plant uses LPG (liquefied petroleum gas) as the primary fuel source for its aluminum smelting furnaces and heating equipment in the production line.
With plans to expand capacity and optimize fuel costs in the long term, the plant decided to add a CNG (compressed natural gas) system to operate in parallel with the existing LPG system. This parallel solution allows the plant to flexibly manage fuel supply according to market prices, ensuring continuous production even when one source is interrupted.
2. System Specifications
- LPG System:
- 1 LPG tank with a capacity of 17 tons
- 3 vaporizers with a capacity of 500 kg/h/unit – total vaporization capacity of 1,500 kg/h
- Pressure regulating valve system, safety valves, and distribution pipelines to the burners
- CNG System (New Installation):
- 1 PRU (Pressure Reducer Unit) with a capacity of 1,500 Sm³/h
- 3 CNG refueling stations for periodic gas supply to tanker trucks
- Automatic flow metering and control system
3. Site Preparation and Infrastructure Construction
DATA Energy conducted a site survey and designed an optimal layout for both systems, placing them close together while ensuring safe distances according to current QCVN standards. Renovation work includes leveling, pouring concrete foundations, constructing protective fences, installing a lightning protection grounding system, and safety signs according to fire safety standards.
4. Fabrication, Installation, and System Integration
- The PRU station is fabricated according to pressure standards, with a multi-stage pressure reducer, flow meter, and automatic ESD (Emergency Shut Down) system.
- Three CNG filling stations are directly connected to the high-pressure distribution pipeline, each with a separate meter for consumption management.
- DATA Energy performs inspection and calibration of all equipment, conducts parallel testing of both sources, and delivers the equipment along with technical documentation, operating procedures, and periodic maintenance guidelines.
5. Benefits
- Optimized fuel costs: CNG is generally cheaper than LPG, helping to reduce the production cost per ton of aluminum.
- Ensures continuous production: Two independent sources eliminate the risk of downtime due to fuel shortages.
- Flexible operation: The plant can adjust the LPG/CNG usage ratio according to market price fluctuations at any given time.
- Meets capacity expansion needs: Total gas supply capacity is doubled, ready for subsequent production increases.
See more:
CNG system installation process (CNG station)
Realistic Pictures
