Saturated steam for chemical plant in Griesheim

Lignite dust and natural gas burners for a chemical plant

In collaboration with GETEC AG, Carbotechnik supplied the combustion technology for a new steam generation plant at the ICIG (WeylChem) site in Griesheim, Germany. The plant comprises two new steam boilers that can operate with either lignite dust or natural gas. The flexible fuel concept provides a reliable and versatile solution for generating process steam in the chemical industry.

Hybrid burner technology for steam boilers

Carbotechnik supplied the complete lignite dust metering and conveying system as well as the burner technology for both fuel types. The burners feature specially designed lances for lignite dust and natural gas operation.

The scope also included the complete combustion air and secondary air supply systems. In addition, Carbotechnik supplied the flue gas recirculation systems, including fans and flow measurement instrumentation, as well as a separate natural gas control train for each boiler.

As with previous steam boiler projects, Carbotechnik was also responsible for the flue gas-side engineering, including the economizer.

27 Tonnes of process steam per hour

At full load, the two boilers generate a combined 27 tonnes of saturated steam per hour. The steam reaches a temperature of approximately 217°C and is used as process steam within the chemical plant.

The lignite dust fuel supply consists of two DN1300 dosing units, each equipped with a Carbotechnik top-mounted filter. Each dosing unit has a maximum conveying capacity of 1,595 kg/h.

For natural gas operation, each boiler train has a dedicated gas control system with a consumption rate of up to 1,000 Nm³/h.

Reliable combustion and low emissions

Following the completion of engineering and installation, Carbotechnik commissioned the plant in the summer of 2016. The commissioning process included functional testing, optimization of plant operation, and testing of all relevant safety shutdown systems.

Carbotechnik also supported the final acceptance by TÜV. Official emissions measurements confirmed that the plant remained well below the applicable regulatory emission limits across the complete load range. This result applied to both lignite dust and natural gas operation.

The successful combination of lignite dust and natural gas burners, reliable fuel supply, and integrated flue gas recirculation provides the chemical plant with flexible and efficient steam generation.

Carbotechnik scope of supply and services

The project scope essentially comprised:

• overall engineering for the steam boilers, economizers, burners, and fuel supply system
• control concept for the complete combustion system
• Carbotechnik muffle burners for lignite dust and natural gas operation
• combustion air and secondary air supply systems
• flue gas recirculation systems, including fans and flow measurement
• instrumentation and control valves
• 2 x DN1300 lignite dust dosing units with top-mounted filters
• lignite dust conveying systems
• natural gas control trains for both boiler lines
• electrical, instrumentation, and control systems
• commissioning, safety testing, and support during TÜV acceptance