Task: Determining plant efficiency through a combustion calculation

Combustion in waste incineration plants can be influenced if the composition of waste alters or changes occur in the process, an example being a change in the combustion temperature. This results in increased wear and maintenance costs and altered energy efficiency. A recalculation of combustion using available parameters is recommended here. Combustion calculation is also of assistance, in the case of a planned modification of existing plant components, in determining influences on combustion in advance.

Solution: Independent combustion calculation

We compile an independent combustion calculation based on FDBR Directive RL 7 (FDBR – Association for Steam Boiler, Pressure Vessel and Piping Construction). The usual losses are taken into consideration during this calculation. A transparent combustion calculation can be produced on this basis, with reliable calculating of boiler efficiency, adiabatic flame temperature, required volumes of air, flue gas quantities, the oxygen concentration and many other parameters. This balance sheet can also be utilised to determine the current waste-to-energy value from process data.

Implementation: Optimisation based on the combustion calculation

The initial step involves recording current process data for the plant. The combustion calculation produced on this basis enables a comparison of the current state and combustion and energy efficiency of the plant with the initial design. The results can be used to improve combustion through appropriate optimisation measures. These may involve adjusting the air-fuel ratio and oxygen set point or configuration of combustion control.

Task: Determining inaccuracies through network measurement

Measuring the volume of gases may result in major inaccuracies. This may be the consequence of an irregular flow profile. A network flow measurement provides an overview of existing air and exhaust measurements or collects data where process measurements are not available.

Solution: Precision network measurement

At EnergieLink we can conduct an accurate network measurement that records numerous measuring points in the line cross section. We have appropriate measurement instruments at our disposal for temperature, flow and differential pressure measurement and suitable calculation and evaluation sheets for all conventional ducts and pipelines.

Implementation: Network measurement according to customer specifications

We prepare the network measurement to our customers’ specifications. This includes the following:

• Determining the measurement position (e.g. in a pipe or duct)
• Specification of the number of measurements and measuring points
• Definition of measuring points and their documentation on the data sheet and Prandtl probe
• Conducting measurements
• Evaluation of measurement

We are more than happy to compile a report in addition to the measurement log.

Task: Heat balance determination and optimisation of energy use

Efficient use of energy plays an increasingly important role in waste incineration. Many plant operators would like to expand their systems through, for example, heat extraction or the installation of additional heat exchangers to enhance energy efficiency. We examine different options in the heat balance.

Solution: Calculation of the water-steam cycle

EnergieLink calculates the water-steam cycle in a heat balance. This means the actual state of the plant can be determined and different optimisation options simulated. EnergieLink strives at all times to achieve practical solutions when it comes to optimisation, an approach which is aided by the varied experience we have gained with existing systems.

Implementation: Calculation in close consultation

Numerous parameters need to be taken into consideration when calculating a water-steam cycle. We are more than happy to discuss potential applications with you and help you find the ideal way to optimise your industrial plant, while also taking economic aspects into account.

Task: Determination of primary air distribution

Distribution of primary air over the combustion grate is a significant criterion when it comes to optimum combustion. Original parameters may alter due to grate adjustments or wear, reducing the efficiency of air distribution. This must be improved to ensure optimum combustion in the plant.

Solution: Pressure measurement via the grate siftings hopper

The distribution of primary air over individual grate parameters is determined through pressure measurement in the grate siftings hopper. Important conclusions regarding combustion can be drawn as a result and the ideal optimisation of settings determined. Determination of primary air distribution over the grate elements decisively improves the efficiency of combustion and reduces plant wear.

Implementation: Measurement according to customer specification

We arrange the measurement to our customers’ specifications. For example, primary air distribution can be measured before and after a grate overhaul. This measurement illustrates how the grate changes its behaviour over the uninterrupted operation period. EnergieLink has the appropriate evaluation sheets at its disposal. The state of the primary air system is also recorded during measurement (e.g. the position of the blanking plates used for fine adjustment of the air). We recommend corrective measures for our customers to improve the process in the event of deviations.

Task

Major projects in the area of overhaul and modification or the procurement of spare parts are put out to tender above a defined investment volume. The defined general terms and conditions of purchase of the company issuing the invitation to tender apply in this respect. However, technical performance is always tailored specifically to suit the order and, ultimately, guarantees that the extremely complex tasks involved will be resolved without compromise.

Solution

Together with our customers, we define the precise technical performance specification – from the selection of materials to all necessary warranties. This ensures that fulfilment of the order coincides exactly with the customers’ expectations in the event the contract is awarded.

Implementation

Perfect specification documents, including all technical performance descriptions and commercial calculations, significantly increase the probability a contract is awarded and guarantee optimum results during implementation. We also provide clients with support when it comes to the examination and assessment of the tender documents submitted.

You too camake the perfect choice.

Task: Determination of parameters, enhancement of energy efficiency

According to EU Directive 2008/98/EC, industrial plants classified as R1 recovery operations must have an R1 factor of at least 0.6 (approval prior to 01.01.2009) or 0.65 (approval after 31.12.2008). The R1 factor can be improved through energetic optimisation.

Solution: Determination of parameters

EnergieLink has templates for calculating the R1 code pursuant to EU Directive 2008/98/EC and experience of energetic optimisation of plants. The experience we have gained on numerous plants enables us to support plant operators by proposing solutions and with their implementation. We analyse and test combustion parameters on your plant, along with combustion control and the water-steam system. During this process, we also identify possible measures to enhance energy efficiency, such as the installation of additional heat exchangers.

Implementation: Optimisation measures

The existing energy indicator of the plant is determined in the initial step. We then ascertain the impact of possible optimisation measures on this indicator. Possible optimisation measures and a further course of action are then discussed in close consultation with our customers. Essential cost and feasibility aspects are taken into consideration here.

Task

Do you operate an industrial plant with complex process chains and numerous technical assemblies with, in part, diverse configurations? In the event of an overhaul or modification, we will find the optimum solution for your application together – both in economic and technical terms.

Solution

Good ideas reduce downtimes. Our specialists are drawn from every plant engineering discipline and will thoroughly inspect your system in every detail, providing you with an optimum plan of action based on this.

Implementation

We provide you with project support from start to finish, beginning with a technical appraisal and budget planning and continuing with the selection of suppliers and subcontractors until the final project management step and on-site commissioning. Our expert team consists of well-versed specialists in every discipline, including highly qualified process engineers and experienced project managers.

You alone decide how and in which field you require our assistance.