Executed a turnkey project for the installation and commissioning of a new high-efficiency, dual-fuel steam boiler system at Rajwani Denim Mills. The primary objective was to upgrade their aging steam generation infrastructure to reduce massive fuel costs and increase production capacity for their denim processing and finishing lines.
Client
Rajwani Denim Mills (Pvt.) Ltd.
Location
Karachi, Pakistan
Year
2023
A Complex Engineering Puzzle
Rajwani Denim's existing boiler was inefficient, consuming excessive fuel and unable to reliably meet the high steam demand of modern denim manufacturing. This led to high operational costs and production bottlenecks. The critical challenge was to decommission the old system and install the new one in a phased manner to avoid a complete shutdown of their 24/7 plant operations.
Innovative & Efficient
Our team engineered and installed a state-of-the-art, high-pressure fire-tube boiler with an integrated economizer to recover waste heat from flue gases. The system was configured for dual-fuel (Natural Gas/HFO) operation for flexibility and cost management. A PLC-based control system was implemented for automated, efficient combustion control, ensuring optimal steam production with minimal manual intervention.
Key Project Outcomes
Reduced fuel consumption by over 25%, leading to significant annual operational savings.
Increased steam generation capacity by 30%, directly supporting higher production output.
Eliminated production losses previously caused by frequent boiler-related downtime and failures.
Ensured full compliance with National Environmental Quality Standards (NEQS) for emissions.
“Steam is the lifeblood of our denim finishing process. The team delivered a boiler system that is not only incredibly efficient but was also integrated into our plant with minimal disruption. Our fuel costs are down, and our production is more reliable than ever. Their expertise in the textile sector is unmatched.”
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