Products and components

Polytechnik offers innovative solutions and holistic systems – customised and optimised for all kinds of biogenic fuels and the highest customer demands.

Products and components

Polytechnik offers innovative solutions and holistic systems – customised and optimised for all kinds of biogenic fuels and the highest customer demands.

In order to convert the energy stored in the various types of biomass to different energy systems in the most efficient, energy-saving and environmentally friendly way, innovative technologies and well-tried plant components are used.

Polytechnik’s plants are designed individually for the relevant fuel mixture and application in order to guarantee the highest efficiency and lowest emissions possible for every kind of operation. In every operating condition, computer-controlled control systems continually analyse and optimise all parameters for an efficient plant operation with the lowest emissions and the highest availability possible. All data and parameters are processed by means of process visualisation and displayed as pictures, charts and statistics.

MAIN COMPONENTS and -PERFORMANCES

FROM DESIGN TO OPERATION

The design and construction of biomass-fueled energy plants is not only complex from a technical point of view. That is why our experts, who can draw from their experience with over 3,000 plants and the operation of own heating plants, support our customers from the plant design up until the operation.

Besides others, these services are carried out:

N

plant design based on the customer’s requirements, emission and authorisation rules and the available waste flows/biomass

N

combustion tests and CFD simulation (for special fuels)

N

procedural layout and planning

N

3D detailed planning of the complete plant

N

detailed calculations of plant components

N

detail and production drawings of key single components

N

manufacturing of plant components in own Polytechnik plants and by selected long-term partners

N

suitable packaging and shipping to our customers worldwide

N

plant installation either with customer site manager(s) or at Polytechnik's overall responsibility

N

piping and electrical installation

N

plant test and commissioning

N

operator training and plant handover

N

plant service and optimisation

FUEL CONVEYORS AND STORAGE

Polytechnik’s range of services from planning to operation of the plant include the complete fuel logistics, from temporary storage to charging the combustion chamber. Based on our vast experience from thousands of plants and dozens of fuels, the silo, bunker, storage and conveyor technology are configured individually and are customer-specific.

FUEL CONVEYORS

Conveyor and portioning systems adjusted specifically to the relevant fuel characteristic and type of operation guarantee a trouble-free and energy efficient supply of various types biomass to the energy plant.

N

vibration, through chain and belt conveyors

N

screw conveyors and feeders

N

hydraulic conveyor and feeding systems

N

sorting and screening plants

N

magnetic separators

N

backfire safety devices

FUEL STORAGE

Depending on the volume, type of conveyed material and framework conditions, the following discharge systems have been used successfully, among others:

N

hydraulic push floors

N

round and square silo discharge devices

N

crane systems

N

toploaders

N

room discharge devices

COMBUSTION PLANT

COMBUSTION SYSTEMS

N

air and water-cooled horizontal and step grates

N

grateless firings and combinations

N

stationary fluidised bed

ADIABATIC FIRING

N

co-current, counterflow and centre-flow firing

N

single-pass, two-pass and multi-pass firing

N

wood gasifier

BOILER TECHNOLOGY

In order to transfer the energy of hot flue gasses from the combustion chamber into the heat recovery system, Polytechnik provides a broad range of robust and durable boiler plants in the field of boiler technology. The heat exchangers are equipped with automatic heating surface cleaning systems in order to guarantee highest efficiency for the whole load range, low operation and maintenance costs.

BOILER TYPES

N

water and gas tube boilers

N

thermal oil boilers

N

single-pass, two-pass and multi-pass design

HEAT CARRIER

N

warm water (up to 105°C)

N

hot water (up to 200°C)

N

saturated steam (up to 68 bar)

N

low-pressure steam (up to 1 bar)

N

superheated steam (up to 480°C)

N

thermal oil (up to 320°C)

N

warm/hot air

N

hot gas

OPERATION TYPES

N

with or without constant supervision

EXECUTION STANDARDS

N

European Pressure Equipment Guideline PED 97/23/EG

N

PB10-574-03

N

EN 12952

N

EN 12953

ASH REMOVAL SYSTEMS

The ashes produced during the burning of wood and biomass are discharged form the system fully automatically by low-wear systems and transferred to containers and/or silo facilities for temporary storage.

The following systems have proven to be especially reliable and low-maintenance with Polytechnik plants:

N

ash shut-off valves

N

vibrating, belt and through chain conveyors

N

screw conveyors

N

ash conditioning and sorting plants

AUTOMATION TECHNOLOGY

Control and regulation of Polytechnik plants

A programmable logic controller (PLC), which translates oxygen inflows, combustion chamber temperature, flue gas recirculation, gas and combustion air temperature, material quantity and humidity, inlet and return flow temperature, steam and system pressure and consumption of the individual consumers into command signals, is used for the fully automatic control and regulation of the energy plant.

Plant operation runs fully automatic, from the supply of biomass to the control of energy producers, tuned to the demand of consumers to whom the energy is supplied.

Model-based regulation (MBR)

Polytechnik is currently the only provider of a functioning model-based plant regulation worldwide.

This regulation, which was developed by us and was already put to use multiple times, utilises a physical model of the firing and the heat exchanger in order to internally predict the required parameters (ventilators’ speeds, flap positions, fuel supply, etc.) as precisely as possible. Consequently, the regulation systems only have to compensate for the small deviations between the calculation model and the real plant, which enables a more precise adherence to the setpoint values.

Changes in the fuel characteristics are detected and factored in automatically by the regulation, which ensures stability of the plant’s operation. During comparative measurements, savings of fuel and subsequently operating costs of 3 to 5% have been established, compared to conventional regulations.

PROCESS and PLANT VISUALISATION

The visualisation of plants and processes is also referred to as the human-machine interface (HMI). Polytechnik’s primary goal is to design the plant’s controls as user-friendly as possible for our customers. Upon request, all plant parameters are processed by Polytechnik’s process visualisation and documented in single graphics as well as intertwining charts and statistics:

N

fully graphic visualisation of process operations and conditions

N

combustion chamber cameras

N

plant operation via Polytechnik’s user interface with individual menu and toolbars

N

archiving of measurements and notifications in a process database

N

reporting and acknowledgement of events

N

logging of current process data and recorded archive data

N

user and access rights management

Schematically recorded and stored plant components allow for a simple and clear overview of the condition and the functions of individual plant components and the plant as a whole. Even the smallest deviations from the preset parameters are displayed and automatically returned to the preset desired condition.

This type of visualisation facilitates not only the presentation on a monitor or control panel but also the change and setpoint change of all parameters via remote access (computer, smartphone, tablet, etc.), if required.

FLUE GAS CLEANING and CONDITIONING

Depending on the fuel, size of the plant and the customer’s requirement, the flue gases from biomass energy plants are cleaned before they are directed outside via the chimney system.

Usually, the following components must be reduced or it has to be guaranteed that their value is within the corresponding limits:

N

carbon monoxide (CO)

N

particulate matter (PM10, PM2.5)

N

nitrogen oxides (NOx)

N

organic hydrocarbons (VOC / HC)

N

chlorine and sulphur compounds (HCl and SOx)

N

heavy metals

N

dioxins and furans (PCDDs/PCDFs)

The following technologies are successfully utilised in Polytechnik energy plants for the reduction of these emissions:

N

adiabatic firing with air staging

N

centrifugal separators as well as single and multi-cyclones

N

electrostatic precipitators (e-filters)

N

tube and bag filters

N

scrubbers and flue gas condensations

N

adsorption and absorption plants with additive dosing

N

denitrification plants (SNCR and SCR)

For some critical plant sites, the steam emissions, which are visible when wet fuels are used and the outside temperature is low, must be eliminated.

To achieve this, dozens of Polytechnik plants employ so-called devaporisation plants, which utilise patented procedures to eliminate the steam plume at the chimney outlet.

RESIDUAL HEAT UTILISATION

In order to deprive the boiler plant’s waste gas of valuable residue energy and to save both fuel and operating costs, various downstream heat exchangers are installed after the boiler in Polytechnik plants. If designed correctly, they cool the waste gas to just above the dew point and the obtained heat is used, for instance, for feed water pre-heating, for increasing the return flow temperature and/or for pre-heating the combustion air. Depending on the design, the plant’s efficiency can be increased by 5 to 10%.

Patented control and regulation systems in combination with various bypass systems enable our customers to adjust the efficiency to the fuel and load conditions. Once again, heat exchangers with automatic heating surface cleaning systems are installed in order to guarantee low operating and maintenance costs.

RESIDUAL HEAT UTILISATION

N

warm and feed water economiser

N

thermal oil economiser

N

combustion air pre-heating

N

fuel dryer

HEAT RECOVERY

In order to maintain a high plant efficiency at every point of the operation even with wet fuel, flue gases can be cooled down below the flue gas dew point. Steam and accompanying substances (including particulate matter) are condensed and the released condensation heat is transferred to a heat carrier medium (low-temperature).

These systems, which often are referred to as flue gas condensation plants, utilise the latent heat content of the fuel gas and in turn significantly reduce the fuel input and CO2 emissions.

With Polytechnik plants, these systems are primarily used in local and district heating plants, fuel and sawdust dryers, greenhouses and often in combination with devaporisation plants. Polytechnik plants then achieve an efficiency of more than 100% with regard to the lower calorific value.

Contact us

You want to know more about our plants and your possibilities?

Call us at +43 2672 890-0, write an email tooffice@polytechnik.at or use the following contact form


×

This website uses cookies to deliver a pleasant and user-friendly browsing experience. If you continue to browse, we consider that you accept the use of cookies on our website. Privacy Policy

This website uses cookies to deliver a pleasant and user-friendly browsing experience. If you continue to browse, we consider that you accept the use of cookies on our website.

close