Category: SAACKE

Industry overview

• Energy and heat supply

• Chemicals

• Refineries

• Food industry

• Waste recycling

• Steel and metal processing

• Building materials industry

• Wood processing

• Consumer goods

Benefits

• Robust design with maximum availability, low maintenance requirements, and long service life.

• Minimal operating costs thanks to low auxiliary energy consumption.

• High efficiency due to low residual oxygen in the flue gas, even with the most stringent emission requirements.

• Short planning phase, simple installation and commissioning thanks to modular design.

• Small installation diameter generally requires no changes to the boiler pressure vessel during modernization.

• Future-proof with Best Available Technology (BAT).

• Ideal for new construction or modernization.

• Flexible burner concept thanks to modular design.

• Ideal system concepts for new construction or modernization.

• Version for air preheating (optional).

• Future-proof for industrial decarbonization (“H2 ready” ≤ 100 vol.% hydrogen).

• Bio and synthetic fuels.

• No or only minimal external exhaust gas recirculation required.

• Significant savings.

• Low installation and operating costs.

• Compatible with various control concepts (se@vis, Siemens, etc.)

ATONOX

THE ULTRA-LOW-NOX BURNER FOR YOUR LARGE-SCALE COMBUSTION.

With its outstanding performance and innovative concepts, the SAACKE ATONOX

is already laying the foundation for a livable environment for future generations.

This is achieved through the use of both conventional and future fuels.

Its success is based on a modular burner design that allows for easy configuration

to different installation situations. This makes the ATONOX extremely flexible and

reduces not only the commissioning effort but also the costs.

Fuels

• Natural gas

• Liquid gas,

• Hydrogen

• Light fuel oil,

• Synthetic fuels

• Special fuels (biogases, bio-oils, etc.)

Applications

• New construction and modernization of industrial plants:

• Shell boilers

• Water-tube boilers

• Thermal oilheaters

• Thermal processing systems

Pulverized fuels.

Although fuel dusts are a very economical alternative to natural gas or heating oil,

they are often overlooked. This is particularly unfortunate when dusts are produced

as by-products in industrial processes and could directly replace valuable

(and expensive) standard fuels.

In this context, dust is defined as a solid material with a maximum particle size of

up to 0.5 mm. Apart from this definition, however, dusts differ fundamentally in their

water and ash content, their calorific value, and their ignitability, which is directly

related to the proportion of volatile components. For example, lignite dust and hard

coal dust are not very far apart in terms of calorific value, at 20-22 MJ/kg and 25-30

MJ/kg respectively. However, lignite dust has significantly more volatile components

and is therefore more flammable overall. An extreme example is petroleum coke:

this dust contains very few volatile components and therefore places increased

demands on the combustion process despite its high carbon content.

In addition to ground coal, there are numerous biogenic dusts whose utilization

relieves the budget twice over:

• Wood dust/wood grinding dust

• Sugar beet pulp dust

• Rapeseed extraction meal

• Fermentation substrate

• Coffee husks

The SSB swirl burner series is used for all types of dust. Not only does it offer a wide

control range with maximum burnout, it can also be operated in both combustion

chambers and water tube boilers. It reliably falls below even the most stringent emission

limits and impressively demonstrates the possibilities of dust firing.

SPECIAL GASES.

In addition to natural gas, which is the standard fuel, there are a whole range of special gases with high calorific values that are often flared or burned with the aid of a support fuel. Typical gases in this group include landfill gas, sewage gas, refinery gas, coal mine gas, vent gases, and coke oven gas. All of these can be easily utilized thermally, but place increased demands on the combustion system.

In contrast to lean gas, these gases have a significant energy content of more than 15 MJ/m³, but they occur in fluctuating quantities or with fluctuating calorific values. Vent gases from fuel storage facilities are a good example: the tank contents consist of volatile, highly flammable hydrocarbons, so the tanks are inerted with nitrogen during refueling. During loading and unloading, therefore, not only the volume and quantity of gas fluctuate, but also the composition of the gas between pure fuel gas and pure nitrogen.

While the combustible components of refinery gas consist of hydrogen to butane, methane is the main component of landfill gas, sewage gas, or coal mine gas. These also contain significant proportions of carbon dioxide and nitrogen.

Numerous contaminated by-products of the chemical industry, such as biphenyl acetate (BPA), styrene, or toluene

While some of these substances are produced specifically as primary raw materials for thermal recycling, many are by-products or even genuine “problem substances” that have a negative impact on the balance sheet and must be disposed of. All of them have a high calorific value, but differ in their chemical and physical properties. Numerous special fuels must be preheated in order to achieve a viscosity suitable for combustion or to become liquid in the first place. Many are contaminated and place high demands on the combustion process due to their fluctuating chemical composition.

A ROTNOX GL, for example, is ideal for this purpose. Because its parts that come into contact with the fuel are made of stainless steel, it reliably utilizes even highly viscous and contaminated liquids with a high acid number and ensures the best possible emission values with excellent burnout.

Regardless of which burner is used for which fuel, the utilization of special fuels is usually a worthwhile investment. This is especially true if this material previously had to be disposed of at great expense or with the use of auxiliary fuel instead of being used to generate energy. This new energy source not only eases the strain on the budget, but also protects the environment.

SPEcial liquid fuels.

In addition to the standard liquid fuels light oil and heavy oil, there are a number of substances with a calorific value of more than 15 MJ/kg that contain so much energy that thermal utilization is worthwhile. These include, for example:

• Animal fat

• Rapeseed oil

• Soybean oil

• Palm oil/fat

• Fish oil

• Glycerin

• Frying fat

• Biodiesel

• Sulfur

• Silicone oil

BIOFUELS.

Biogenic fuels can be of plant origin or a product of fermentation or digestion of organic material. The chemical and physical properties vary considerably depending on the fuel. Some substances are solid at room temperature, others are liquid or gaseous.

Typical biofuels are:

• Rapeseed oil

• Soybean oil

• Palm oil

• Biodiesel

• Biogas

• Bio natural gas

• Sewage gas

• Gas from biomass gasification

• Wood dust

All of these fuels have a high calorific value of more than 15 MJ/kg (15 MJ/m³) and a neutral CO2 balance when burned. If sewage gas or biogas was previously released uncontrolled, thermal utilization can reduce the impact on the climate even further: these gases contain a lot of climate-damaging methane, which is converted into CO2 during combustion.

Even though the combustion of rapeseed oil, soybean oil, or biodiesel works largely in the same way as the use of light or heavy oil, each individual fuel poses a particular challenge for combustion: All substances differ in terms of calorific value, pour point, viscosity, and ignitability. Because palm oil is solid at room temperature, it must be preheated to a greater or lesser extent, depending on the burner used, in order to be able to convey and atomize it. In addition, most biogenic liquids contain a certain amount of free fatty acids, which are highly corrosive. In this case, all parts that come into contact with the fuel must be made of stainless steel.

IGNITION AND SUPPORT BURNERS.

On rust-fired waste incineration plants and biomass boilers,

as well as on active coating boilers

The SAACKE portfolio includes:

• Robust burners for light oil and natural gas in the power range

between 5 and 60 MW individual burner output for the safe start-up

of waste incineration plants and to ensure the necessary combustion

temperature in waste operation

• Associated fuel lines and control switchgear for this special area of

application

The advantages of SAACKE burners for this area of application are safe,

stable, and low-emission flame formation, homogeneous mixing of all

flue gas streams with the burner flames in all load ranges, and very low

cooling air requirements during standby operation.

WATER TUBE BOILERS.

INCREASED EFFICIENCY AND OPTIMAL EMISSION VALUES.

The SAACKE portfolio includes:

• Burners and combustion systems for standard fuels

(e.g., natural gas or light fuel oil) and special fuels

(e.g., hydrogen, biogas, lean gas, converter gas, or bio-oils,

HVO, molasses, etc.)

• Burners and combustion systems with minimal NOx emissions

• Support and ignition burners for grate-fired or fluidized bed

boilers (e.g., in waste-to-energy plants)

• Modernization of existing boiler systems through the installation

of new burners, new control systems, and/or other modernization

measures.

For water tube boilers, SAACKE supplies both individual burners

and complete fuel valve lines, burner controls, and fully integrated

combustion systems. Whether you are building a new plant or

modernizing an existing one, SAACKE has the right products and

services to make your industrial combustion system future-proof,

energy-efficient, and environmentally friendly. All system elements

used are designed to operate your plant with maximum efficiency

and minimum emissions.

The SAACKE portfolio includes:

• State-of-the-art industrial burners and combustion chambers in various

designs

• Thermal exhaust air purification systems as integrated system solutions

• Technologies for energy saving and heat recovery

• Emission reduction in accordance with legal environmental requirements

• Customized engineering and planning expertise for every industry

Advantages at a glance:

Thermal exhaust air purification is the most widely used method for exhaust

air treatment – and for good reason:

• Maximum reliability in continuous operation

• Low maintenance costs thanks to robust design

• Effective destruction of pollutants through oxidation (e.g., of hydrocarbons)

• Use of the heat energy generated in the production process

• Long-term compliance with legal limits