Flexibilization of combustion plants

The long-term use of combustion systems requires continuous adaptation to changing fuel properties and operating conditions.

Originally planned assumptions regarding fuel properties and fuel availability can change during operation, as can the required output range. This leads to the previously defined design range of the system being exceeded.

To ensure the flexibility of combustion plants and maximize their efficiency and reliability, we offer two main options: Fuel flexibilization and load range extension. Both approaches are aimed at optimally utilizing your plant and ensuring smooth operation. A key component of this is the EPOC®, which supports you in running your plant stably to its limits, depending on your current requirements.

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DR. Brenhard Kronberger, Exprete für verfahrenstechnische Innovationen bei Voigt+wipp / Conenga group

Bernhard Kronberger

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Bernhard Kronberger is your expert when it comes to process engineering innovations!

Fuel flexibility

The change in fuel properties is much more likely with biogenic and waste fuels than with fossil fuels. The change in both physical and calorific fuel properties can cause problems and have a negative impact on the smooth, trouble-free operation of a combustion plant.

Particular attention must be paid to the change in ash softening temperature, which can lead to caking in the combustion chamber and thus to a reduced travel time.

We offer the following services in the area of fuel flexibilization:

Our services

Overall analyses for fuel flexibilization with the determination of the actual practical limits of an existing system
Examination of the permissible limits of the permit, the plant technology, the ecological impact and the economic efficiency
Comparison of the limits thus determined with the extended/future requirements (e.g. by extending the waste wood fraction) – if the extended requirements exceed the actual limits, we design an optimisation path together with the client

Optimisation path concept

Implementation takes place step by step or as a complete package – depending on your requirements and the scope of the approval situation. We work in direct coordination with your company in order to make optimum use of planned shutdowns. We also ensure that all measures are coordinated with the plant safety concept.

Frequent measures that we take are:

Adaptation of the fuel conveying and dosing technology
Increase of the degree of automation, e.g. by additional level sensors for equalisation of the delivery, dynamic speed adjustment of screw dosing to avoid fluctuating delivery rates.
Design of the higher-level control by, for example, renewing the firing rate control – for example with EPOC®
Expansion and renewal of sensors and actuators

Implementation of optimisation measures

The implementation is carried out step by step or as a complete package – depending on the extent, scope of the approval situation – and of course in close coordination with the plant in order to make optimal use of planned shutdowns. All measures are coordinated with the plant safety concept. We frequently carry out the following measures:

Design of the higher-level control, renewal of the firing rate control – for example with EPOC®
Extension of sensor technology, repair or renewal of actuator technology
Avoidance of air leakage
Adaptation of fuel conveying technology
Increase of the degree of automation, e.g. by additional level sensors for equalisation of the delivery, dynamic speed adjustment of screw dosing to avoid fluctuating delivery rates.
Adjustment of the combustion chamber pressure to prevent burn-back

Load range extensions

An expansion of the load range is often the result of a change in the energy user’s requirements. In the area of heat supply, the need to expand the load range often arises due to seasonal fluctuations or network expansion. In summer, for example, the typically reduced heat consumption often requires a reduction in the minimum sustainable load. In addition, new requirements in continuous operation can lead to different load requirements. This means that the firing system must be able to react flexibly to both a minimum load and an increased continuous load.

The task of expanding the load range is related to the task resulting from fuel flexibilization. Extending the design load range of the boiler system involves extensive work to understand and revise the firing system.

The following measures take place frequently. All measures are of course coordinated with the plant safety concept.

Our services

Analysis to determine the limits of the existing system technology, recognizing the possibilities for adapting the furnace and boiler
The consideration of the firing system includes the combustion chamber incl. the system technology and the firing rate control as the “intelligence of the firing system”.
Development of a concept for adapting or renewing the firing rate control(EPOC®) and for utilizing the procedural possibilities that exist according to the analysis of the combustion chamber
Derivation of the specifically suitable bundle of measures – in addition to all measures on the furnace control system, the following are frequent: adaptation of refractory lining, adaptation of air preheating, change in recirculation gas quantity, fuel or air trimming.
Requirement: maximum firing efficiency, minimised emissions, long travel times