Melhorias operacionais na caldeira Biochamm: uma abordagem com foco em confiabilidade e eficiência pela utilização do ciclo PDCA

Abstract

This work presents a case study on the application of the PDCA methodology in the operational optimization of a Biochamm model industrial boiler, used in a biomass-fired steam generation system. The research addresses problems encountered between June 2022 and May 2023, during which an average of 28 hours of unscheduled downtime per month was recorded. The objective of this study was to reduce boiler downtime and decrease the fixed cost per ton produced. The application of the PDCA methodology, along with other quality tools, allowed the identification of the main causes of unscheduled boiler downtime, including grate failures (resulting from material wear and excessive clearances), hydraulic system failures (presence of leaks and deficient monitoring), and low biomass quality (with high contamination by stones and sand). The implemented actions included the replacement of critical components, such as grates and ash pan doors, corrections to the sealing system, and, most importantly, improvements to the biomass feeding process, aiming to eliminate contamination and reduce equipment wear. The upgrade to the grate material was a highlight: the cast iron, which had 28% chromium, high hardness, but was brittle, was replaced by a refractory steel with better mechanical properties. The new material offers greater ductility, good corrosion resistance, and excellent creep resistance at high temperatures, resulting in a significant increase in the lifespan of these components. As a direct result of the implemented actions, a 54% reduction in average downtime was achieved, providing significant improvements in operational and economic performance. Furthermore, improved seals and the elimination of false air intakes increased the boiler's thermal efficiency by 14%, in addition to reducing biomass consumption by 70 tons per month. This case study demonstrated the efficiency of applying the PDCA methodology and quality tools in optimizing the reliability of industrial equipment. By diagnosing and addressing root causes, the project fully achieved its objectives, focusing on reducing the average monthly number of unscheduled shutdowns. In addition, other improvements were achieved that directly impacted the boiler's operating costs. Therefore, this research validates the relevance of predictive maintenance management and continuous improvement as strategic pillars to ensure greater reliability and efficiency of equipment in the industrial environment.