Combustion Systems

We offer projects and implementation of new combustion systems to burn solid alternative fuels, waste sludges from wastewater treatment plants and/or biogas stations, or various types of biomass including burning of various combinations of the above-mentioned fuels.

The combustion system burns alternative fuels while maintaining the high efficiency of the boiler as to the protection against negative effects of the combustion. Alternative fuels are burnt either in the bubbling fluid bed or on the grid. While burning in the bubbling fluid bed, hazardous wastes can also be co-burnt. Compliance with the requested emission and other parameters and requirements as requested by the customer is maintained.

We offer the following activities as the part of design and implementation of the combustion system to burn alternative fuels

• assessment of fuel properties, selection of the most appropriate combustion system, design of the engineering solution, and its implementation considering investment and operating costs
• design and implementation of fuel management
• design and implementation of the flue gas cleaning system
• installation and connection of the equipment
• putting into operation and adjustment

Benefits for the customer

• complete delivery of the combustion system including fuel transportation and flue gas cleaning as the turn-key delivery
• safe burning of alternative fuels with high operating reliability
• possibility to burn fuels with a wide range of heating values
• adjustment of the boiler output parameters to the request of the customer  

We offer projects and implementation of new combustion systems to burn bituminous  and  lignite. In addition, we also offer projects and implementation of reconstructions and modifications to the existing combustion systems. We offer systems with direct  feeding of pulverized coal to the boiler as well as indirect feeding  of pulverized coal to the boiler for boilers firing  bituminous coal.

Combustion systems fire bituminous or lignite l with maintained high efficiency of the boiler, required emission parameters, and other parameters as requested by the customer. The primary method of NOx emission reduction is designed and applied to reduce NOx emission values.

The primary method is based on the principle of sub-stoichiometric combustion of fuel in the burners

with the subsequent reduction in generated NOx. Reduction in CO and burnup of the residual coal are guaranteed by one or more levels of OFA nozzles.

The design of the combustion system to fire bituminous coal usually includes the following

• installation of new or reconstruction of the existing swirl or straight flow low-emission burners
• installation of new or reconstruction of the existing mills. The type of mill differs depending on the type of burnt coal:
  • bituminous coal: drum and ring mills
  • lignite: fan and hammer mills
• installation of new or reconstruction of the existing classifiers
• installation of pipe routes and OFA nozzles
• installation of recirculated flue gas pipe ducts
• installation of the fuel staging system of combustion (so-called reburning)
• installation of new or adjustment to the existing I+C system of the combustion system
• burning stability inspection system FLAMMON
• inspection measurement, adjustment, and setting-up of the boiler combustion system

Benefits for the customer

• compliance with NOx and CO emission limits under the applicable and/or future legislation
• improvement in boiler efficiency, reduction in operating costs
• extension of boiler operating range without stabilization
• reduction of slagging

Adjustment and optimization of the operation of the combustion system is the final activity in the sequence of implementation and putting of the combustion system into operation.

As the part of this activity, we offer

• inspection measurement of media flow through the piping duct in the point of installed airflow gauges by Prandtl probes with the subsequent calibration
• putting the combustion system into the operation, the individual functional generators adjusted in compliance with the designed air/flue gas balance
• adjustment of the combustion system to the required parameters in the entire operating range of the boiler
• correction to operating curves of the individual functional generators
• guarantee tests

FLAMMON integrates monitoring and combustion quality analysis with the security system of the pulverized coal-fired boiler. The system uses optic sensors, which monitor the radiation of the entire flame in the combustion chamber in the broad spectrum, and analyzers, which evaluate flame fluctuation range and counts flame quality to control and protect the boiler.

The combination of flame monitoring with the combustion quality analysis of the burning of the entire flame in the combustion chamber supplies information to the advanced two-stage boiler protection and safe control of the stabilization fuel supply; among others, considerable quantities of stabilization fuel are saved without the risk of boiler outage.

FLAMMON information allows for more effective operating decisions about stabilization of the burning in the boiler in the stage of boiler commissioning and operating events such as outages of fuel, mills and air distribution, pressure system failures or falls of deposits.
At the same time, the system ensures advanced boiler protection including safe shut-down of the boiler, if unavoidable, thus protecting both the boiler and the attendance staff. FLAMMON provides two levels of boiler protection if burning quality drops significantly:

1. level

The system disables the start of the stabilization if the ignition of unburnt fuel, explosion, and damage to the boiler can be encountered. 

2. level

If the flame quality massively drops, the system activates the safe shut-down of the boiler before the complete loss of the flame, thus protecting the boiler pressure system against damage.

Besides, FLAMMON allows for the automatic start of the stabilization burners if lower stability of coal-burning is indicated. For example, this function eliminates outages due to the slow response of the boiler attendance staff or sudden changes in the coal supply.

FLAMMON meets the following safety criteria

• boiler protection equipment - EN 12952-9
• SIL 3 acc. to EN 61 508
• boiler protection against the explosion of unburnt pulverized fuel
• compliance with the American standard NFPA 85

Offered services

• advisory and consulting services, studies
• design and engineering incl. engineering and installation of the protection
• delivery of the complete system, i.e., hardware and software
• installation and connection of the equipment
• putting into operation and adjustment

Benefits for the customer

• improved safety of the boiler operation
• increased reliability of the boiler
• extended boiler operating range
• saved costs for stabilization fuel
• automatic start of stabilization burners

Swirl and straight-coal burners, delivered by our company, are characterized by high technical standards, and quality of workmanship. These characteristics significantly contribute to optimal operating activity and low NOx values. Swirl burners are primarily used to burn coals with a lower content of volatile matters in the fuel. This applies mainly to bituminous coals and lignite with higher calorific value. Straight-flow coal burners are primarily used to burn lignite or low-calorific bituminous coals with a higher content of volatile matters. To meet the requested guaranteed parameters, burners can be delivered as new or, if allowed by the technical design of the existing burners, the existing burners can be optimized.

The technical design of the burner helps to achieve:

• Reduced NOx generation by optimal mixing and burning ratios with requested controlled sub-stoichiometry of the combustion air
• Proper mixing in swirl burners achieved by the optimum swirling of mixture of pulverized coal and combustion air, which is supported, in addition, by special construction of swirling terminal part of burner nozzles. The swirling intensity of the air nozzles can be adjusted.
• Proper mixing and fast ignition of the mixture in the straight-flow burners, achieved by the balanced concentration of pulverized coal at the mouth of the burner, and appropriate modification to the mouth part of the burner nozzles
• Continuously controlled distribution of the combustion air in the entire performance range of the boiler. This fact highly affects the activity of the burner as to the decreased NOx formation as well as reduced quantity of unburnt matters in the fly ash and slag
• Reduced abrasion to the stressed parts of the burner. The parts of the burner, exposed to abrasion, where the coal mixture flows, are made from an abrasion-resistant material
• Longer lifetime of the terminal part of air and coal nozzles of the burner, which can be produced from thermally resistant material or as casted parts, more resistant to thermal deformation and contributing to longer lifetime of the thermally stressed mouth of the burner

Benefits for the customer

• reduced NOx emission value
• improved boiler efficiency, reduced operating costs
• extended operating range of the boiler without stabilization
• longer lifetime of the burner’s mouth
• optimized slagging

Cast Iron Mouths of Burners

Cast iron mouths of burners are used for all types of low-emission coal burners as well as for a wide range of burnt coals. Cast iron terminal parts of the burners are designed for burners exposed to increased thermal stress. Their use - in contrast to all-welded terminal parts - significantly reduces the deformation of the geometry of the terminal parts of the burner, extends their lifetime, and maintains the quality of the mixing function of the burner in the long-term time horizon.

The technical design helps to achieve

• each cast iron terminal part of the burner is specifically produced to suit design requirements set down for the particular burner
• standardized connection of the terminal part to the burner and/or customized subject to the prior consultation with the customer
• the solution to the thermal expansion between the cast iron terminal part and the burner body excludes their mutual deformation

Benefits for the customer

• extended lifetime of the terminal part
• decreased labor demand and shorter time to replace the terminal part
• price comparable with a welded mouth
• lower probability of the deformation of the terminal part