Fuel flexibilization as the key to adaptation

Flexibilization of combustion plants

The flexibilization of combustion plants describes the adaptation of existing combustion plants to changed operating conditions, such as different fuels or load requirements. The aim is to operate plants efficiently, stably and reliably even outside the original design range. The CONENGA Group develops customized concepts for this and implements them directly in existing plants .

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.

Key Takeaways

The flexibilization of combustion plants enables them to adapt to changing fuels, load requirements and operating conditions.
Fluctuating fuel qualities, especially with biomass and waste, require dynamic control and adapted plant technology.
Measures such as adjusting the fuel supply, automation and control improve stability, efficiency and system availability.
The CONENGA Group analyzes existing systems, defines technical and economic limits and develops individual flexibility concepts.
CONENGA implements optimization measures step by step or as a complete package and ensures reliable operation with extended requirements and load ranges.

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Bernhard Kronberger is your expert concerning more flexible combustion systems !

The CONENGA Group makes firing systems more flexible through data-based analysis and customized adaptation of control and system technology.

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 optimization path together with the client

Optimization 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 equalization 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 optimization measures

Implementation is carried out step by step or as a complete package – depending on the extent and scope of the approval situation – and of course in close coordination with the plant in order to make optimum 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 equalization 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.

Our services

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

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, minimized emissions, long travel times