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

Thermal processing systems

Efficiency meets environmental responsibility

Whether thermal exhaust air purification, industrial drying, or energy-optimized

heat generation—SAACKE thermal process systems stand for maximum energy 

efficiency, minimal emissions, and maximum operational safety.

Our customized solutions combine state-of-the-art combustion technology with

intelligent heat recovery—ideal for demanding industrial processes in the chemical,

food, or heavy industries.

Thermal exhaust gas and exhaust air cleaning.

Efficiently clean industrial exhaust gases and recover heat – with SAACKE

solutions for thermal exhaust air cleaning.

SAACKE offers tailor-made solutions for thermal exhaust and exhaust air

purification that meet the highest environmental standards while reducing

energy costs. Our systems combine decades of industry experience with

state-of-the-art technology – ideal for demanding industrial applications.

Shell boiler.

MODERN LOW-NOX BURNERS FOR ALMOST ANY FUEL

SAACKE’s portfolio includes:

Burners and combustion systems for standard and special fuels,

such as hydrogen, biogas, lean gas, glycerine or animal fat

(e.g. the ROTONOX series)

Burners and combustion systems with minimal emission values

(e.g. TEMINOX)

Customized complete solutionsand various measures for modernizing

and increasing the efficiency of your plant

With their typically large control range and minimal excess air,

SAACKE burners are particularly efficient and highly available.

In plants that are already equipped with SAACKE burners, it is often

not necessary to replace the combustion technology in order to increase

efficiency and reduce emissions. For example, the control and regulation

of a plant can be improved with a seavis control system from SAACKE,

and retrofitting a flue gas recirculation system can optimize your plant

in terms of emissions.

SAACKE also offers measures to increase energy efficiency: Retrofitting

economizers, O2 controls, and air preheaters allows for more efficient

utilization of your plant, while a frequency converter for blowers reduces 

power consumption.

SAACKE GreenDock

ZERO EMISSION ENERGY IN PORT.

Electrify your steam supply – zero fossil fuels & zero emissions during port stays.

SAACKE GreenDock provides local emission free heat supply to your vessel as a

retrofit  solution for all kinds of heating media such as steam, thermal oil and hot

water. The technology used is compatible to boiler and heat generator systems

from all makers and can be provided by SAACKE on a turn-key basis.

ZERO EMISSIONS AT HIGH EFFICIENCY MAKING THE EXISTING FIRED

BOILERS FUEL TYPE IRRELEVANT IN PORT.

SAACKE GreenDock provides clean  energy throughout the whole port stay,

completely emission-free, while operating on shore power instead of fossil

marine fuels. Integrated into the existing system by means of a circulation pump,

the electrical economizer provides the existing auxiliary boiler with clean energy

while the burner remains switched off.

Efficiency and compliance:

Lower emissions and lower OPEX through steam generation from shore power

instead of marine fuels. Resulting  in significantly lower CO2  emission charges

and port fees.

Compact design

Series design with vessels layout in mind. Low footprint vertical solution and low

height horizontal solution available.

Retrofitting existing systems

Can be retrofitted in any steam, thermal oil and hot water system regardless of

original maker. Installation envoyage or during docking.

Optimized load control

Intelligent modulating load control by thyristor controllers, resulting in smooth

operation without overloading the shore connection terminal.

SEEMP Action

Capacity range from 150 to 2000 kW (Steam production of 250 to 2500 kg/h),

design pressure of 12.0 bar(g), accessories and outfittings  selected to comply

with all major marine classification societies.