Fire-tube boilers – a turnkey solution from Carbotechnik

In close collaboration with GETEC AG, Carbotechnik recently installed a highly advanced combustion system for ICIG (Weylchem) at the industrial site in Griesheim. Specifically, this modern setup consists of two state-of-the-art steam boilers. In addition, operators can fuel these boilers with either pulverized lignite or natural gas for maximum flexibility.

Extensive scope of the combustion system

To begin with, Carbotechnik’s comprehensive scope of supply included the complete pulverized coal metering and conveying system. Furthermore, they provided the specialized burners with burner lances for dual lignite and natural gas operation. Consequently, the system controls the combustion and secondary air supply dynamically. As a result, the layout features a complete flue gas recirculation system, including individual fans and flow meters. Just like in previous boiler projects, Carbotechnik also expertly handled the entire flue gas-side design, including the integrated economizer.

Reliable process steam production

Regarding the output, the modern plant generates 13.5 metric tons of saturated steam twice per hour at approximately 217 °C under full load. Therefore, the chemical plant can utilize this reliable energy source as vital process steam. To feed the system, the supply of lignite powder relies on two DN 1300 dosing machines, each equipped with a Carbotechnik top filter. Indeed, these machines handle a maximum lignite dust flow rate of 1,595 kg/h, while the alternative natural gas line utilizes 1,000 Nm³/h.

Ultimately, following the successful completion of planning and installation work, the team successfully commissioned the entire combustion system. During this process, technicians also completed the necessary safety shutdowns and the final regulatory acceptance inspection by TÜV. Remarkably, the emissions remained well below the strict limit values across all load ranges during testing.

Key project components at a glance

In summary, Carbotechnik’s specialized scope of supply for this combustion system essentially included:

– complete engineering for the steam boilers, Eco, burners, and fuel supply, as well as the regulation and control concept
– advanced Carbotechnik muffle burners for lignite dust and natural gas, including combustion air and residual gas supply with blowers, measurement, and control valves
– highly precise lignite dust dosing systems (2 x DN1300 metering machines with top-mounted filters) and conveyance
– a fully automated natural gas control loop
– complete electrical, measurement, control, and regulation technology