Forced Draft TEG Reboiler

Reducing NOx by Transforming a Natural Draft Gas Processing Plant Reboiler to Forced Draft. Tell us more about your project

Project Highlights

+70 NOx ppm to Sub-20 NOx ppm Reduction
+20% Natural Gas Savings
Natural to Forced Draft Reboiler Conversion
Reduced Callouts & Maintenance Costs
Local, State, & Federal Regulation Adherence
PF3100 BMS Controller Powered
Complete Turnkey Profire Solution
Expert Consulting & System Analysis
System Integration & Servicing
Post-Installation Reporting

Industry Oil & Gas – Midstream
Customer Gas Processing Plant
Application(s) TEG Reboiler

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The Problem

One of our long-term customers faced the serious risk of regulatory penalties at the local, state, and federal levels due to excessive NOx emissions. They needed to reduce their NOx emissions below 30 ppm to meet compliance standards. The stakes were high, and time was running out with the threat of heavy fines looming over their operation.

Their existing setup included a natural draft, multi-burner firetube reboiler with non-modulating ON/OFF controls and a gas pressure of approximately 18 psi. The system was generating NOx emissions of 60-70 ppm and CO emissions between 300-400 ppm—well outside the limits.

With tight regulatory deadlines in place and an outdated system incapable of meeting modern emissions standards, the customer needed an urgent and reliable solution. Addressing emissions compliance while improving operational efficiency required a trusted partner with proven expertise to deliver a pre-built, tested system that would ensure long-term stability and success.

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Before Profire

The Profire Solution

After a thorough analysis of the application and burner management system, our team concluded that upgrading the natural draft system to a forced draft system was essential. To implement this, we paired the PF3100 BMS Controller Panel with a low emissions burner, incorporating high-quality peripheral components, actuators, and safety shutoff valves.

This resulted in an exceptionally safe and reliable forced draft solution that provided:

Sub-20 ppm NOx emissions (exceeding the sub-30 ppm requirement) with independent fuel/air control,
<1 ppm CO through improved burner efficiency,
Lowers maintenance costs from reduced downtime & fewer callouts,
Streamlines system servicing with first out annunciation, AND
Maintains an operating gas pressure of approximately 14″ W.C.

This solution not only meets the strict sub-30 ppm requirement but surpasses it, achieving emissions below 20 ppm. Additionally, it delivers significant benefits, including ~20% reduction in natural gas consumption. These savings result from lower emissions of NOx, CO, volatile organic compounds (VOCs), and unburned hydrocarbons, effectively combining regulatory compliance with enhanced cost efficiency.

Thanks to the PF3100’s Modbus capabilities, the facility’s team can now access critical system data faster, respond quickly to issues, and get their operations back online with minimal downtime. Using either Modbus or local displays, combined with first out annunciation, the customer has significantly cut down the number of callouts required for system restarts.

By successfully reducing emissions, the customer not only achieved regulatory compliance, but also avoided costly penalties. The new system minimizes downtime, maximizes efficiency, and delivers significant operational improvements.

We’re proud to have delivered this project on schedule, while successfully managing the complexities of local, state, and federal environmental regulations. This accomplishment underscores our commitment to precision and reliability, ensuring every solution we provide aligns with the customer’s operational goals and compliance needs.

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