Research and implementation work

The Thermal Processes Department has extensive experience in conducting research and implementation work aimed at the needs of industry. The work carried out is mainly focused on:

measurements and diagnostics of power equipment,
numerical modeling of thermal and flow processes,
technical consulting.

Examples of completed or ongoing work in the above fields are presented below.

Measurements and diagnostics of power equipment

Boiler operation optimization tests

Combustion process optimization tests in the OP-650 boiler no. 8 at the Dolna Odra Power Plant after the modernization of OFA nozzles
Optimization of the operation of OP-230 boilers no. 1 and 5 at VHP EC Żerań after the installation of low-emission burners
Combustion process optimization tests in OP-430 boilers no. 10, 14, 15, OP-230 no. 3 and 4 and OP-380 no. 11 at VHP EC Siekierki
Optimization of the operation of OP-140 boilers no. 1 and 2 at EC Poznań Karolin after the installation of low-emission burners
Optimization tests of the WP-120 boiler no. 2 at EC Pomorzany
Optimization of the operation of OP-230 boilers no. 7 and 8 at EC Białystok S.A., OP-650 No. 4 in Jaworzno III Power Plant, OP-150 No. 5 and 6 and WP-120 boiler No. 8 in EC Elbląg as well as WP-70 and WP-120 in EC Lublin-Wrotków after installing low-emission burners
Optimization of the operation of the OP-650-050 boiler No. 2 in Dolna Odra Power Plant with B&W burners and analysis of the possibilities of improving the production efficiency of unit No. 2
Research and analysis of solutions aimed at improving combustion conditions in the combustion chamber in order to solve the slagging problem and increase the efficiency of the OP-230 boiler No. 5 in Ostrołęka Power Plant
Performance of research and development of the modernization concept of the OP-100 boiler No. 3 in Ostrołęka Power Plant

Warranty measurements

Warranty measurements of the WP-200 boiler No. 4 in VHP EC Kawęczyn
Warranty measurements of the OP-230 boiler No. 1 in VHP EC Siekierki
Guarantee measurements of air heaters of the OP-650 boiler no. 1 at Dolna Odra Power Plant

Mill installations

Modernization concept of the WP-120 boiler mills no. 5 and 6 at Kraków Power Plant
Measurement of coal grinding in the boiler mills no. 10 and 11 at VHP Siekierki Power Plant
Measurement of the mill installation of the OP-140 boiler no. 6 at Białystok Power Plant
Post-modernization tests and optimization of the operation of the mill installation of the OP-140 boiler no. 4 at the FRANTSCHACH Świecie Paper Plant
Modernization of the MWK-16 mill separators at VHP Żerań Power Plant
Optimization of the operation of the MWK-12 mills to improve the grinding quality at ZEC Stomil-Olsztyn S.A. Corrosion hazards

Identification of the level of low-oxygen corrosion hazard of evaporator tubes and indication of means of its minimization in OP-650-030 boilers in Ostrołęka Power Plant
Monitoring of the low-oxygen corrosion hazard of the walls of the BP-1150 boiler of unit no. 3 based on continuous measurement of oxygen content in the boundary layer in the Opole Power Plant

Installation and burners for biomass combustion and co-combustion

Design of an installation for biomass combustion bypassing mills for unit no. 5 in Dolna Odra Power Plant
Concept of modernization of the OP-230 boiler for biomass co-combustion using WIR technology in the Konin Power Plant
Conceptual study for adapting the OP-140 boiler no. 5 in SM Świecie for biogas co-combustion
Design and biomass burner for Koniecpolskie Zakłady Płyt Pilśniowych S.A. for OSR-32 boilers no. 1 and 2
Production of 4 BIO-5 type biomass burners for the autonomous biomass combustion installation in the OP-650 boiler no. k5 at PGE Dolna Odra S.A.
Design of a biomass swirl burner and construction of secondary air channels for burners for OP-650 boilers no. 1 and 2 at Ostrołęka Power Plant
Manufacture, delivery and start-up of 2 burners for burning biomass dust in the OR32-N boiler at Knurów Power Plant

Other

Explanation of the causes of damage to the screen tubes of the OP-430 boiler no. 14 at VHP EC Siekierki based on tests of the combustion process and composition of wall exhaust gases and optimization of the boiler operating conditions

Determination of the causes of slagging of OP-230 boilers at VHP EC Żerań and indication of remedial measures
Tests of the temperature distribution and composition of exhaust gases in the wall layer of the combustion chamber screens of the OP-650 boiler no. 6 at Dolna Odra Power Plant
Tests of the tightness of the rotary air preheater of the BENSON A and B boiler at Pomorzany Power Plant
Modernization of OFA nozzles on boilers no. 7 and 8 at Dolna Odra Power Plant
Studies of temperature distribution and flue gas composition in the boundary layer of the combustion chamber screens of the OP-650 No. 7 boiler at the Dolna Odra Power Plant in connection with biomass combustion
Modernization of the flue gas recirculation system of the OP-650-050 No. 6 boiler at the Dolna Odra Power Plant in order to reduce the asymmetry of operating conditions
Concept of modifying the first-stage secondary steam superheater in order to reduce the asymmetry of operating conditions of the OP-650-050 No. 5 boiler at the Dolna Odra Power Plant

Numerical modeling of thermal and flow processes

Reducing NOx emissions

Adapting the combustion system of the OP-650 boiler no. 1 to work with the lowest possible NOx level at the Dolna Odra Power Plant
Technical and economic analysis of non-catalytic methods in relation to catalytic methods allowing for the optimal selection of the installation reducing the NOx level on the OP-650 boiler at the Dolna Odra Power Plant - numerical studies of the possibilities of reducing NOx emissions of OP-650 boilers at the Dolna Odra Power Plant using primary and non-catalytic methods
Performing a technical and economic analysis of the combustion process related to the reduction of NOx emissions, i.e. reducing low-oxygen corrosion and reducing emissions below 200 mg/mn3 in the BP-1150 boiler at the Opole Power Plant using numerical simulation tools
Simulation of the use of low-temperature vortex technology in the combustion chamber of the BB-1150 boiler in order to reduce NOx emissions at the Bełchatów Power Plant
Numerical studies of the combustion process low-emission in the OP-230 boiler no. 7 at the Białystok Power Plant

Optimization of boilers and auxiliary devices

Numerical simulations of the OP-650 boiler no. 4 at the Dolna Odra Power Plant in order to meet the applicable emission standard, taking into account the maximum use of existing devices
Optimization of OFA nozzles in the 300 MWel boiler no. 5 in Ruien, fired with coal dust and equipped with corner swirl burners - contract for Electrabel, Belgium
Simulation of the combustion chamber and optimization of the flue gas recirculation system in the 200 MWel boiler equipped with low-emission burners and OFA nozzles at the Dolna Odra Power Plant
Optimization of the combustion chamber of the BB-1150 boilers (360 MWel block) fired with brown coal at the Bełchatów Power Plant
Performance of simulation tests of a steam boiler with liquid slag removal (360 t/h) in Kakanji Power Plant in order to optimize modernization solutions (new swirl burners and OFA nozzles)
Numerical studies of the combustion process in the WP-120 boiler no. 2 in Pomorzany Power Plant in order to optimize modernization solutions
Simulation of the combustion chamber of the OP-130 boiler in EC Elbląg - optimization of the combustion process after the applied modernization
Simulation of the combustion chamber of the OP-70 boiler in EC Olsztyn - selection of burners, OFA nozzles, wall nozzles - optimization of the combustion process after the applied modernization
Simulation of the combustion chamber of the OP-650 boiler in EC Ostrołęka in order to determine the causes of corrosion of the screens and find ways to eliminate this problem
WP-120 steam boiler fired with coal dust with a tangential burner system producing hot water for heating purposes EC Lublin-Wrotków - optimization of combustion after the use of new low-emission burners
Simulation of the combustion chamber of the CKTI boiler 75 in Janikowskie Zakłady Sodowe - combustion optimization after using low-emission HTS type swirl burners
OP-140 steam boiler fired with coal dust with a tangential burner system equipped with low-emission burners - EC Poznań Karolin - combustion optimization after using new low-emission burners
Simulation of the combustion chamber of the OP-100 boiler in EC Ostrołęka in order to determine the causes of low boiler efficiency and find ways to eliminate this problem
Analysis of the BB-1345 boiler operation in order to determine the causes of hopper slagging and explosions in the slag trap

Other

Numerical modeling of the combustion process of low-quality gases in a gas boiler in Ravenna, Italy

Technical consulting

Development of a multi-variant concept containing an overview of the flue gas denitrification technologies available on the market and development of tender documents for the construction of a flue gas denitrification installation for block boilers in VHP EC Siekierki. Technical and economic consultancy for the tender procedure aimed at selecting the contractor for the project entitled “Reduction of NOx emissions from BP-1150 boilers in the Opole Power Plant.”
Technical and economic analysis of the profitability of the implementation of a coal firing installation for the BB-1150 boiler in the Bełchatów Power Plant.
Concept for the implementation of a biomass transport, storage and processing installation as part of the project of direct co-combustion of a large amount of biomass in the Kraków CHP plant.
Programmatic and spatial concept of the installation for co-combustion of sludge from the municipal sewage treatment plant in the BB-1150 boiler in the Bełchatów Power Plant
Technical and economic concept for the use of renewable fuels in order to improve the economic efficiency of the Starogard CHP plant
Development of a technical program for increasing biomass energy production in the companies of the PGE capital group to at least 4 TWh/a in 2012, together with a logistics model ensuring the implementation of the program