Middlepressure Boilers

Universal Steam Boilers

Specifications

KU boilers are flue fire-tube, large-capacity boilers with natural circulation of boiler water for the combustion of liquid and gaseous fuels. The combustion chamber size is designed so as to minimise emissions. The maximum design pressure of KU line boilers is 1.8 MPa. The maximum temperature of superheated steam t = 450°C. According to the temperature required, a specific type of super-heater is installed in the boiler. The boilers are supplied on a standard frame, including insulation with sheeting and a service platform. The supply includes the respective fittings, boiler valves and instruments and gauges. Upon the client’s request, the boiler is also equipped with a feed pump and feed water control (modulated or ON-OFF). The boilers are fitted with fire-tube or water-tube economisers of feed water, thus increasing the boiler efficiency by 2 to 4 %. Condensation exchangers may be added next to the boilers, using condensation heat of water vapour contained in flue gases. The design, manufacturing, testing and additional equipment of boilers are done according to the CSN technical standards.

Boiler Characteristics

The boiler has excellent accumulating capacity, allowing for reliable operation even in the case of fluctuating steam extraction. This feature, however, does not restrict the boiler output and start-up (start-up time in cool state is from 15 to 20 minutes). The boiler construction facilitates maximum cooling of flue gases at a minimum heating surface and maximum reliability and service life. This feature is also connected with reduced quality requiments for water treatment. The output regulation scope is limited by the regulation scope of the combusting equipment.

Boiler Modulation

The basic modification is a steam boiler with saturated moderated-pressure steam extraction. The boiler can also be supplied in a modification for super-heated steam or hot water.

Equipment for steam-boiler plants operating without constant supervision

The boiler is ready for the installation of equipment for steam-boiler plants operating without constant supervision made by Gestra (supervision intevals every 2 – 24 – 72 hours according to TRD 602 and TRD 604).

TESTING AND CERTIFICATION

The transportable moderated-pressure boiler room is designed and produced according to the CSN standards in force, and the boiler holds a certificate of approved design, issued by the Safety Standards Inspectorate. The construction and the first pressure test in accordance with CSN 070623 are performed in the production plant, and the result is recorded in an inspection book, which is part of the technical documents supplied with the boiler room, together with a certificate of tests carried out on materials used in accordance with CSN 420090.

Technical Parameters – Universal Steam Boilers 200 kg/hour – 8000 kg/hour

Parameters Units KU 200 KU 600 KU 1000 KU 2000 KU 4000 KU 5000 KU 6000 KU 7000 KU 8000
Rated output kg/hr 200 600 800 2000 4000 5000 6000 7000 8000
Rated thermal capacity
Saturated steam
Super-heated steam (220°C)		 kW 131
144		 392
433		 521
676		 1303
1352		 2606
2704		 3258
3380		 3910
4056		 4561
4732		 5213
5408
Maximum steam overpressure MPa 1,4 ; (0,6 ; 0,9 ; 1,8)
Minimum steam overpressure** MPa 0,2 – 0,4
Nominal temperature of superheated steam* °C do 450 °C
Boiler efficiency: Natural gas / LO % 91/89
Boiler efficiency with economiser: Natural gas / LO % 92 – 94 / 91 – 92
Nominal temperature of feed water °C 105 (70) 105
Nominal temperature of sucked air °C 20
Maximum fuel consumption:
– Natural gas
– LO		 Nm3/h
kg/hr		 14,5
14,7		 43,6
44,2		 76,7
68,7		 154
137		 300
275		 375
354		 466
412		 554
481		 621
550
Maximum of air for combustion (lambda=1,1) Nm3/h 155 465 860 1720 3400 4250 4900 5660 6500
Amount of flue gases Nm3/h 169,3 508 970 1940 3880 4850 5820 6790 7760
Electrical wiring 3 x 380 V/50 Hz
Input of electric appliances (burner, feed pump) kW 6,5 9 6,5 9 11 11 14,5 18,5 22,5
Noise level dB Max.80
Emissions***
Natural gas:
– standard
– low emission		 mg/Nm3 NOx – 160, CO – 100
NOx – 100, CO – 100
LO mg/Nm3 NOx – 450, CO – 175, SO 2 – 1000, solid substances – 100, smoke rate < 2
KU Boiler weight
Boiler weight without superheater kg 1600 2230 3050 7000 12500 13500 15500 17000 19500
Boiler weight with superheater kg 1800 2470 3400 8100 13500 14300 16400 18000 20600
Boiler operating weight kg 2300 3870 5800 11100 19500 20500 26500 27000 29500

* The nominal temperatureof superheated steam can be changed, depending on the client’s request and the fuel used.
** According to the economiser used.
*** Emission relate to 3% of O2 in dry combustion products at t = 0°C and barometric pressure.
The given emission levels may be mainained only provided that the liquid fuel contains (except for values according to CSN 656506) maximally: S < 5 000 mg/kg, N < 1 000 mg/kg, asphaltenes < 3 %.

Technical Parameters – Univesal Steam Boilers 10000 kg/hour – 20000 kg/hour

Parameters Units KU 10000 KU 12000 KU 14000 KU 16000 KU 18000 KU 20000
Rated steam output kg/hr 10000 12000 14000 16000 18000 20000
Maximum steam output kg/hr 11000 13200 15400 17600 19800 22000
Temperature of output steam* °C Saturated or superheated steam (to 450°C)
Design overpressure MPa 1,4 (or 0,6 ; 0,9 ; 1,8)
Minimum operating overpressure MPa 0,2 – 0,4
Rated thermal capacity:
Saturated steam
Super-heated steam (220°C)		 MW 6,5
6,7		 7,8
8,4		 9,1
9,4		 10,4
10,7		 11,7
12,1		 13
13,4
Maximum thermal capacity:
Saturated steam
Super-heated steam (220°C)		 MW 7,2
7,4		 8,6
8,8		 10
10,3		 11,4
11,8		 12,9
13,3		 14,3
14,7
Minimal temperature of feed water °C 105
Combustion air temperature °C 20
Efficiency with economiser % 92 – 94,5
Fuel consuption:*
– Natural gas
– LO		 Nm3/hkg/hr 673
605		 808
726		 943
848		 1077
968		 1212
1090		 1347
1211
Max. of air for combustion* Nm3/h 7191 8629 10068 11506 12944 14382
Amount of flue gases max.* Nm3/h 7861 9433 11005 12577 14149 15721
Boiler resistance at flue gas side-max. Pa 1250 1350 1350 1350 1350 1400
Temperature of flue gases at boiler output °C 120 – 180
Boiler water volume
At pressure test
Operating – up to medium water level
Of water heater		 m3 14,9
10,8
1,1		 17,8
12,8
1,3		 19,2
13,8
1,4		 20,7
14,9
1,5		 22,5
16,2
1,6		 24,3
17,5
1,7
Sludge discharging – about 15s – Min. once every 8 hours depending on the quality of water
Maximum noise level of boiler dB 80
Emissions***
Natural gas:
– standard
– low emission		 mg/Nm3 NOx – 160, CO – 100
NOx – 100, CO – 100
LO mg/Nm3 NOx – 450, CO – 175, SO 2 – 1000, solid substances – 100, smoke rate < 2
Transport/operating weight
(Applies for design pressure of 1.4 MPa)		 t 24,5 / 42,4 32,7 / 51,8 34,6 / 55,1 37,8 / 58,5 40,5 / 46 / 76,1 46 / 76,1
Technical changes are reserved

* The nominal temperatureof superheated steam can be changed, depending on the client’s request and the burned fuel.
** The values relate to the maximum boiler output at the steam pressure of 1.4 MPa, superheated steam temperature of 220°C and efficiency of 92%.
*** Emission relate to 3% of O2 in dry combustion products at t = 0°C and barometric pressure.
The given emission levels may be mainained only provided that the liquid fuel contains (except for values according to CSN 656506) maximally: S < 5 000 mg/kg, N < 1 000 mg/kg, asphaltenes < 3 %.

Universal Steam Boilers KU 200 – 1000 kg/hr

Universal Steam Boilers KU 200 - 1000 kg/hr

PROPORTIONS (mm)
BOILER A B C D E F G H J K
KU200 2250 1680 1000 800 1375 545 1365 1744 1800 2276
KU600 3500 1750 1900 900 1535 595 1525 2005 2450 3250
KU1000 3700 1800 1900 1000 1720 630 1705 2200 2830 3450
Technical changes are reserved

Universal Steam Boilers KU 2000 – 8000 kg/hr

Universal Steam Boilers KU 2000 - 8000 kg/hr

PROPORTIONS (mm)
BOILER A B C D E F H Ø D
KU2000 4120 2550 2590 1200 2370 950 3230 320
KU4000 4900 2980 3250 1500 2812 1165 3670 505
KU5000 5655 2995 3430 1500 2812 1165 3711 505
KU6000 6055 3035 3630 1500 2812 1165 3725 505
KU7000 6400 3055 3800 1500 2812 1165 3725 636
KU8000 6610 3110 3930 1500 2812 1165 3765 636
Technical changes are reserved

Universal Steam Boilers KU 10000 – 20000 kg/hr

Universal Steam Boilers KU 10000 - 20000 kg/hr

PROPORTIONS (mm)
BOILER A B C D E F H Ø D
KU10000 6600 3600 4600 2350 6400 600 4850 799
KU12000 6800 3600 4600 2350 6400 600 4850 799
KU14000 7095 3600 4600 2350 6600 600 4850 799
KU16000 7900 3750 5700 2400 7200 600 4855 799
KU18000 8785 3950 5700 2400 7400 800 5000 896
KU20000 9670 3950 5800 2400 8000 800 5000 896
Technical changes are reserved

Electric-Heating Boilers KUE 120, 200, 500 kg/hr

niversal Electric-Heating Boilers KUE are suitable sources of heat for technological and heating use. Boilers are supplied in the following performance:

KUE Middle pressure steam boilers
KUE-H Hot-water boilers
KUE-T Warm-water boilers
KUE-A Low presser steam boilers

Description of boiler

The boiler is large space boiler with electric heating. The pressure system is composed by cylindrical welded drum horizontally placed on supporting structure. There are resistance heaters plugged in into drum securing heat-up of heat transfer fluid. Boilers are supplied together with encasing and insulation and necessary fittings. Boiler switchboard including power part, mounted water level control including boiler output control and monitoring flue gas and water temperature is within the supply. On-off feed water control from Gestra enables boiler operation in the mode with periodical supervision 1x in 2 hours.

It is possible to extend the supply with Gestra equipment for boiler operation without constant supervision in the mode 1 x in 24 hours and with automatic intermittent blowdown.

Design, fittings and garniture, production and documents are in conformity with the requirements ČSN.

KUE – Technical parameters

Technical parameters Units KUE 120 KUE 200 KUE 500
Nominal output kg/hr 120 200 500
Rated thermal capacity kW 78 130 325
Maximum heating output kW 90 150 360
Maximum steam pressure MPa 0,17 ; 0,6 ; 0,9
Nominal temperature of feed water °C Min. 70
Number of heaters – 3 5 12
Type of heaters 404795260, 30 kW, 3x 400V
Volume of water m3 0,84 0,84 1,6
Boiler weight-transportation kg 1020 1064 1600
Weight of accessories kg 300 300 400

Electric-Heating Boilers KUE

Electric-Heating Boilers KUE

Boilers for combustion of wood waste

Technical Specifications

Wood waste is generally perhaps the cheapest fuel, which is in our conditions accessible. Recently there has been higher demand of it. Like at another fuels, wood waste combustion has its own characteristics and especially observing emission limits requires meeting either general conditions of combustion so fulfilling all conditions specific for wood waste combustion. Transport and dosing of chemicals into the combustion chamber is solved with use of auger with frequency convertor. By change of auger speed, it is possible to change exactly transported amount of fuel. Maximum size of fuel particles, i.e. wood chip is 30 – 50 mm. Moisture of fuel is up to 60%.

Great emphasis is to care for solution of furnace and separation of combustioned air with possibility of regulation in couple of ranges independently to each other. The fuel poured out by auger slides down into the combustion chamber. There is heating surface of the boiler in connection to the combustion chamber. The boiler is performed as combined large spatial flame-tube boiler with combustion chamber integrated in the body of the boiler or put forward. Boilers are supplied in performance middlepressure steam KUD, lowpressure steam KUD-N, hotwater KUD-H and warmwater KUD-T. Boilers are supplied with encasing and insulation and with necessary fittings. As part of supply, there is boiler switch board consisted of power part, integrated feed regulator from GESTRA and including output regulator and monitoring of combustion and water temperature. It is possible to extend the supply with equipment GESTRA for operation of boiler without constant supervision of a boiler in intervals 1x in 24 hours, and equipment GESTRA for automatic blowdown. Design, accessories and equipment, production and documents are in correspondence with requirements ČSN. Offer is not limited only for supply of a boiler, but consists of whole fuel treatment and transport technology, technology of bins, cleaning of flue gas at outlet, air ventilator.

Technical Parameters

Type of boiler Warmwater boilers KUD-T Middlepressure hotwater boilers KUD-H Middlepressure steam boilers KUD
Heating output 1 – 5 MW 1 – 5 MW 1 – 5 MW
Design pressure 0,6 (0,9; 1,4) MPa 0,6 (0,9; 1,4; 2,0) MPa 0,6 (0,9; 1,4; 2,0) MPa
Boiler efficiency at nominal output 80 – 86 % 80 – 86 % 80 – 86 %
Regulation range of boiler 50 – 100 % 50 – 100 % 50 – 100 %
Temperature inlet water – min 70 °C 70 °C –
Temperature of outlet water – max for pressure 1,3 MPa 110 °C 180 °C –
Temperature of feed water – min – – 105 °C
Temperature of superheated steam – – 220 – 350 °C

Supplementary equipment:

  • Transporting and dosing equipment
  • Equipment utilizing pressure drop of produced steam for cogeneration of electric energy (steam turbine or steam engine)
  • Homogenizator, fuel breaker and its connection to the combustion equipment
  • Water heater
  • for steam and hotwater boilers
  • Steam superheater
  • GESTRA equipment for operation of hotwater and steam boilers without constatnt supervision in intervals 1x in 24 hours, 1x in 72 hours
  • Complete supply of boiler house technology including water treatment and control system as a whole or supply of particular components
  • Heat reservoirs

Guaranteed emission limits 
Emission limits according to provision FVŽP to the law no. 309/91.

Arrangement of technology of a boiler for combustion of wood waste

Fuel is brought onto receiving and dosing launder (1), which is connected to breaker mill (2), the wood chips made by the breaker mill are transported by air ventilator (3) into the bin (4), the picking equipment (5) takes the chips into the feed auger(6), which feeds the combustion chamber (7), which is connected to the boiler (8). Behind the boiler there is placed equipment for separation of solid particles from flue gas (10). Dust draw-off from filter secures conveyor (9). There is combustion ventilator (12) behind the filter (11).

KUD - container boiler house

Sketch of container boiler house for combustion of biomass KUD with output 600 kW

KUD - container boiler

LEGEND: 
1. fuel bin  |  2. burner and after-combustion chamber 600 kW  |  3. boiler KUD 600 kW  |  4. flue gas cleaning  |  5. tensile ventilator  |  6. chimney  |  7. boiler 45 kW  |  8. water treatment  |  9. ash pit

Universal Steam Water-Tube Boilers KU-V 8000, 12000, 16000, 20000, 25000 kg/hr

Technical Specifications

These are water-tube boilers with membrane walls, an overpressure furnace and natural circulation for the combustion of liquid and gaseous fuels. The pressure part is formed by steam and sludge cylinders, enclosed by dished heads, laid in horizontal position, connected with the membrane walls and the tube convection bundle. The disk heads are fitted with holes for the boiler pressure system control. The burner is fixed to a burner plate in the front membrane wall of the boiler. The boiler includes an economiser designed for natural gas or LO combustion. The economiser is supplied in blocks according to the boiler efficiency required, differing according to the type of fuel employed. For boilers burning natural gas, economisers from ribbed tubes are applied, whereas for those burning liquid fuels economisers from bare tubes are used. The boiler equipment includes a superheater with the superheated steam output temperature range specified by the client.The boiler is fitted with all the fittings and gauges and thermometers. The supplied set also includes a service platform. The boiler and economiser are fitted with insulation covered by sheeting. The boiler manufacturing, design and equipment comply with CSN 07 0240.

Boiler Modulation

The boiler can also be supplied in a hot-water modification. The boiler is ready for the installation of GESTRA equipment for steam-boiler plants operating without constant supervision (supervision intervals every 2 – 24 – 72 hours according to TRD 602 or TRD 604).

Technical Parameters

Parameters Units KU-V 8000 KU-V 12000 KU-V 16000 KU-V 20000 KU-V 25000
Rated steam output kg/hr 8000 12000 16000 20000 25000
Rated thermal capacity kW 6216 9324 12432 15540 19425
Construction overpressure MPa 1,6 / 2,5 / 3,8
Temperature of superheated steam* °C do 450
Minimum temperature of feed water °C 105
Nominal temperature of combustion air °C 20
Efficiency at rated power:
– Natural gas
– LO
%		 94 – 94,5
92 – 93
Amount of fuel:
Natural gas
LO
Nm3/h
kg/hr		 665
612		 997
918		 1330
1224		 1662
1530		 2077
1913
Max. of air for combustion for lambda – 1,1 ** Nm3/h 7261 10891 14522 18522 22691
Amount of flue gases – output max** Nm3/h 7932 11898 15864 19830 24788
Boiler resistance at the flue gas side Pa 2000 – 3500
Noise level dB max.80
Flue gas temp. at the boiler output °C 120 – 180
Emissions***
Natural gas – standard / low emission mg/Nm3 NOx – 160, CO – 50 / NOx – 100, CO – 50
LO mg/Nm3 NOx – 450, CO – 175, SO 2 – 1000, solid substances – 100, smoke rate < 2
Boiler weight
Transport weight
(Applies for design pressure of 1,4 MPa)		 kg 20000 23000 28000 30000 32000
Technical changes are reserved

* The nominal temperatureof superheated steam can be changed, depending on the client’s request and the burned fuel.
** The values relate to the maximum boiler output at the steam pressure of 2.5 MPa, superheated steam temperature of 400°C and efficiency of 92%.
*** Emission relate to 3% of O2 in dry combustion products at t = 0°C and barometric pressure.
The given emission levels may be mainained only provided that the liquid fuel contains (except for values according to CSN 656506) maximally: S < 5 000 mg/kg, N < 1 000 mg/kg, asphaltenes < 3 %.

Universal Steam Water-Tube Boiler KU-V

Universal Steam Water-Tube Boiler KU-V

PROPORTIONS (mm)
BOILER A B C D E
KUV 8000 4800 4340 3500 3100 3980
KUV 12000 5190 4730 3720 3375 3980
KUV 16000 5990 5530 3720 3375 3980
KUV 20000 8500 8040 4040 3695 3980
KUV 25000 8810 8350 4040 3695 3980

Utilisation Boilers

Utilisation boilers are designed for the exploitation of heat from flue gases or gases coming from glass furnaces, brick making lines, refuse incinerating plants etc. These boilers are supplied within the output range from 100 kW to 15 MW. The boilers are supplied in hot water and steam modifications for saturated or superheated steam production. Their maximum design pressure is 3.8 MPa. The superheated steam temperature is adapted to particular requirements, reaching the maximum of 450°C.

The boilers may be supplemented with fuel-burning equipment using high-quality fuels to maintain the output required in the case of a flue gas input temperature drop or a decrease in the input flue gas flow. The boiler is supplied as a unit, including the necessary fittings and devices for its operation according to CSN standards and its water control. All types of boilers may be fitted with additional heat exchangers to pre-heat feed water or heat hot utility water.

Equipment for boiler plants operating without constant supervision

The boiler is ready for the installation of equipment for steam-boiler plants operating without constant supervision made by Gestra (supervision intevals every 2 – 24 – 72 hours according to TRD 602 and TRD 604).

Testing and certification

The transportable moderated-pressure boiler room is designed and produced in accordance with the CSN standards in force, and the boiler holds a certificate of approved design, issued by the Safety Standards Inspectorate. The construction and the first pressure test according to CSN 070623 are performed in the production plant and the result is recorded in an inspection book, which is part of the technical documentation supplied with the boiler room, together with a certificate of tests carried out on materials used according to CSN 420090.

Block Design Steam Boiler Room

Description

Steam boiler rooms in the block design technology are suitable sources of middle pressure steam of small output for heating and technological purposes. The use of block design boiler rooms are especially suitable in the cases, where it is necessary to realize the erection of heating source in the shortened period or with limited space with minimum requirements for construction adjustments. The boiler room is in the company plant mounted into one or more blocks, which are assembled at the customer during short time into functional unit of steam boiler room. The boiler rooms are supplied in the performance – for combustion especially natural gas or extra light and light heating oil. In the basic offer the boilers are equipped with BoB device for the operation without constant supervision with periodical control in the mode 1 x in 2 hrs.

Range of supply

As a part of block design boiler room is besides the boiler itself with a burner also water treatment, feed water tank, system of measuring and control and heavy current electroinstallation (optionally after-cooler of waste waters). The proposal of water treatment technology is performed according to individual specific conditions at the customer. The whole technological block is placed and eventually assembled in the reserved part of the boiler room and is made the connection to the external distribution system and connection to the mediums. The boiler rooms can be in the whole output range supplied also in the performance for low-pressure steam. A part of supply is also prescribed tests and revisions, put in operation, training of the supervision staff and documents.

Optionally is possible to add the boiler room with the equipment like e.g. economizer, steam superheater, continues feed water control, BoB in the mode 1x in 24 hrs. or 72 hrs., automatic continues blowdown od intermittent blowdown, superior control system etc.

Basic technical parameters

Parameters Units BPK 200 BPK 600 BPK 1000 BPK 1500 BPK 2000 BPK 2500
Rated steam output kg/hr 200 600 1000 1500 2000 2500
Rated thermal capacity kW 130 390 650 975 1300 1625
Nominal steam pressure MPa 1,4
Nominal temperature of steam at saturation point
Boiler efficiency –
Natural gas / LO		 % 91 / 89
Electrical wiring 3 x 400V / 50 Hz
Noise level dB max. 85
Maximum fuel consumption Nm3/hr 14,5 43,5 77 125 168 210
Informative dimensions
L1 mm 2590 2790 3290 3420 3930 4180
B1 mm 1480 1750 1950 2250 2450 2500
H1 mm 3390 3640 4110 4570 4640 4790

Block Design Steam Boiler Room

Block Design Steam Boiler Room

LEGEND:
1. El. switchboard  |  2. Burner  |  3. Steam outlet  |  4. Feed water tank  |  5. Feed pump  |  6. Feeding  |  7. Diameter of flue gas duct  |  8. Start-up  |  9. Chemical dosing  |  10. Thermic deaeration  |

Fluid Boilers for Solid Fuel Combustion

Fluidized bed boilers equipped with fluidized bed combustion technology EFDM are suitable sources of heat for technological purposes and heating systems especially for economical operation, high efficiency (85 – 88%), good control ability, “en block” arrangement and also for wide range of usable fuels.

Fuels

Basic fuels of the fluidized bed boilers FK are additived brown coals hp1, hp2 and hp3. After recharge of additive bin with the fuel and additive dosing into boiler, it is possible to burn nonadditived brown coal too. Other usable fuels are black coal, wooden chips, biomass but also some wastes (solid, pasty, liquid). The boiler is equipped with appropriate device for flue gas cleaning according to type of combusted waste. The boiler is designed in order to enable (after a simple adjustment) combustion of several types of fuels alternately or at once. The boiler is able to combust natural gas too after adjustment.

Description

The “en block” arrangement of FK boilers with EFDM technology enables a simple and quick assembly, supplementary addition of other equipments (additive dosing, additive bin, supplementary fuel storage and transport, wet flue gas cleaning, dosing of pasty and liquid wastes). The technology also enables an increase of installed output or whole technology (including separate fuel transport and storage bins). The boilers are supplied in performance “steam”, “low-pressure steam”, “hotwater” and “warmwater” including accessories and fittings necessary for safety and reliable operation, with automatics controlling fluidized bed furnace operation and enables communication with superior control system. Design, manufacture, tests, accessories and fittings fulfill all ČSN requirements and other directives related to operation of such equipments.

Diagram of Fluidized bet boiler FK 2MW

Fluid Boilers for Solid Fuel Combustion

Technology arrangement of fluidized bed boilers and scope of basic supply
(see the picture above)
Fuel is brought into the storage tank of unmodified-fuel (9). From there the fuel is transported by a screw feeder (7) into the mill (11), from which the fuel falls into the storage tank of modified-fuel (10). From there the fuel is conducted by fuel conveyor (8) into the pneumatic feeder (7). By transport air the fuel is brought into the fluidized furnace (14). The fluidized furnace consists of the bottom with nozzles for inlet of fluidizated and combusted air. The furnace walls create water cooled boiler walls (13) welded from the diaphragm walls. Air for transport and combustion of the fuel is secured by high-pressure fan (17). For reaching the operation temperature of the fluidized bed is the boiler equipped with start-up device (12) – burner for liquid fuels (possible to supply also a burner for natural gas, propane butan, etc.), which its warm flue gas will fire the fuel in the fluidized bed. After fuel burn-off in the fluidized bed is the fly ash wafted by flue gas into the convection part of boiler, where its first separation occurs. The separated fly ash falls into the dump, from where the fly ash is by fly ash conveyor (19) brought onto the place of storage eg. into a container (20). Behind the convection part is placed the flue gas filter (21) or other type of flue gas cleaning (separation) from the solid particles (e.g. wet cleaning). The fly ash caught in the flue gas fabric filter is by the conveyor brought on the place of fly ash storage. Behind the filter, there is placed the flue gas fan (22), which carries the flue gas into the chimney.

The outputs and performance of fluid boilers FK

Boiler output Heat output [MW]
Nominal Max
FK 1 MW 1 1,2
FK 2 MW 2 2,3
FK 2x 2 MW 2 x 2 2x 2,3
FK 3 MW 3 3,8
FK 2x 3 MW 2 x 3 2 x 3,8

Technical parameters

Type of boiler Warmwater boilers VFK Middlepressure hotwater boilers HFK Middlepressure steam boilers SFK
Design pressure 0,6 MPa 1,4 MPa 1,4 MPa
Max. provozní tlak 0,6 MPa 1,3 MPa 1,3 MPa
Boiler efficiency at nominal output 80 – 85 % 80 – 85 % 80 – 85 %
Control range of boiler 50 – 100 % 50 – 100 % 50 – 100 %
Temperature inlet water – min 70 °C 70 °C –
Temperature of outlet water – max for pressure 1,3 MPa 110 °C 180 °C –
Temperature of feed water – min – – 105 °C

Supplementary equipment

  • Equipment for fly ash pelleting – ability to utilize the pellets from the fly ash in the building industry (sub-base material)
  • Flue gas cleaning (washer)
  • Water heater – for steam and hotwater boilers
  • Steam superheater
  • GESTRA equipment for operation of hotwater and steam boilers without constant supervision in intervals 1x in 24 hours
  • Complete supply of boiler house technology including water treatment and control system as a whole or supply of particular components

Operation characteristics of boiler
The fluidized bed boilers with EFDM technology are characterized by these features

  • Fast realization of heat source – due to “en block” layout
  • Easy operation (operational comfort approaches to a high-quality boiler operation)
  • Meeting emission limits (in case of prescribed fuel combustion)
  • Minimum needs for maintenance
  • Quick output adjustment
  • Quick boiler start-up (boiler start-up while cold stand-by approx. 30 minutes, while warm stand-by approx. 5-10 minutes). The boiler enables a start without using start-up burner until 6 hours from shut-down.
  • High operational reliability
  • Wide control range
  • The boiler enables combustion of two fuels alternately (supplementary fuel is admixed) or it is possible to alternate the fuels.
  • The boiler enables additive dosing control according to specific composition of used nonadditived fuel
  • In case of requirement it is possible to extend the supply with fuel feeding into unmodified fuel bin.

On the base of requirement, we are able to supply boilers with design pressure 2,5 MPa. Outlet water temperature from hotwater boiler must be at least 10°C lower than boiling temperature within operation pressure. It is possible to equip the boilers with water heater. It is possible to extend the supply of boiler accessories with GESTRA equipment for boilers operation without constant supervision in intervals 1x in 24 hours. It is possible to equip the boiler with steam superheater.

Guaranteed emission limits 
Emission limits according to provision FVŽP to the law no. 309/91.

Universal Hotwater Boilers

TKU-E boilers are flue fire-tube, two-tensile, large-capacity boilers determined for the combustion of liquid and gaseous fuels. The combustion chamber size is designed so as to minimize emissions. The design pressure of KU line boilers is 0,6; 1,0 or 1,6 MPa. The boilers are supplied on a standard frame, including insulation with sheeting and a service platform. The supply includes the respective fittings. The boilers are equipped with economizers (eco). It is possible to place behind the boiler condensate exchangers, which utilizes the vapour heat included in the flue gas. The design, manufacturing, testing and additional equipment of boilers are done according to the CSN technical standards.

Standard boiler equipment:

  • Safety valve – 2x
  • Closing valve – water inlet DN 250 – 1 x
  • Closing valve – water outlet DN 250 – 1x
  • Air relieve valve DN 40 – 1x
  • Intermittent blowdown valve DN 40 – 1x
  • Manometer – 1x
  • Thermometer measuring on water piping inlet – 1x
  • Thermometer measuring on water piping outlet – 1x
  • Thermometer for outlet flue gas measuring – 1x
  • Manometer for water pressure (min.,max.) – 2x
  • Temperature sensor (max. outlet water temperature) – 1x
  • Thermostat (min. inlet water temperature) – 1x
  • Emergency thermostat max. outlet water temperature – 1x

Technical Parameters – TKU 6000-E

Parameters Units         TKU 6000-E          
Rated thermal capacity kW 6000
Maximum thermal capacity kW 6600
Maximum overpressure MPa (0,6 ; 1,0 ; 1,6)
Minimum steam overpressure** MPa 0,2 – 0,4
Nominal temperature of superheated steam* % 92
Efficiency – with eco % 96
Flue gas temperature – boiler without eco °C 180
Flue gas temperature – boiler with eco °C
Minimum temperature of circulated water-inlet °C 60
Maximum outlet temperature of water °C 110
Minimum allowed temperature drop of circulated water °C 10
Temperature of sucked air °C 20
Maximum fuel consumption – natural gas Nm3/hr 759
Amount of combusted air (lambda=1,1) Nm3/hr 8045
Amount of flue gases Nm3/hr 8880
Overpressure in the furnace – boiler without eco Pa 650
Overpressure in the furnace – boiler with eco Pa 150
Middle volume load of combustion chamber MW/Nm3 1,1
Water volume of boiler m3 8,6
Water volume of eco with connecting piping m3 0,5
Heating surface of boiler m2 176
Heating surface of eco m2 277,6
Noise level dB Max.80
Emissions***
Natural gas mg/Nm3 NOx – 100
CO – 100
KU Boiler weight
Boiler weight kg 18600
Eco weight kg 2400
Boiler operating weight kg 30 850
Boiler dimensions
Boiler length mm 6500
Boiler width mm 2300
Boiler width with eco mm 2400
Boiler height without eco mm 2460
Boiler height with eco mm 3750
Diameter of flue gas branch mm 700
Diameter of inlet and outlet water branch DN 250
Safety branch 2xDN80
Intermittent blowdown branch DN 50
Eco drainage branch G1“
Condensate outlet branch G1“
Assembly hole – boiler without eco mm 2,6 x 3
Assembly hole – boiler with eco mm 2,6 x 3,7
Space on right side (in direction from burner) mm 600
Space on left side (in direction from burner) mm 1200
Space behind boiler mm 800
Space in front of boiler
Possible to put gate or make assembly hole		 mm 5000

*** Emissions relate to 3% O2 in dry combustion products at t = 0°C and barometric pressure.

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