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SAACKE Boiler-house log bookSAACKE service contract customers will receive their next SAACKE Boiler-house log book in November ready for 2017. We would welcome any feedback regarding this benefit. If you are not a service contract customer and would like to order a log book, or you would like to order additional copies, please get in touch with us.

SCanView goes from strength to strength

SCanView, SAACKE’s combined burner management and combustion control system, has now achieved over 500 units in the field. With its unique Safety Test System and maintenance aids, it is a market leader in the UK and Ireland. As well as enhancing the safety of the burner and plant, it enables better performance and greater control. Speak to our Service team to find out more.

SAACKE Combustion Services Ltd.Telephone: +44 (0) 23 92 333900Email: ukadmin@saacke.com

What’s inside this issue

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Spotlight Issue 2 - 2016For owners and operators of heat generating plants in the UK and Ireland

Bernie’s hot tips

SAACKE & SSE Enterprise partnershipThe turnkey solution for Micro-CHP systems

2016 Energy & combustion conferencesEssential industry guidelines and legislation updates

SAACKE LONOX UCC systemAlready complies with future Chinese emissions limits

SAACKE UK team snippetsCongratulations – at work and outside of work!

We are pleased to announce an exclusive partnership between

SSE Enterprise, part of one of the leading energy suppliers

in the UK and Ireland, and SAACKE Combustion Services

Limited, the leader in innovative solutions for combustion and

heat generation, to bring substantial savings to local markets by

using SAACKE’s proven micro gas turbine CHP system utilising

gas turbine flue gas burner technology.

You can generate your own electricity, feed-in the surplus to the

National Grid AND use 100% of the turbine exhaust gases as

combustion air in a unique burner firing on a conventional new

or existing boiler/furnace, thereby maximising overall plant

efficiency. SSE bring their design and turnkey project

management expertise to bear together with project funding and

attractive payback options.

Direct use of gas turbine flue gas for combustion – with over 90% overall efficiency at the turbine

The idea of using excess heat from generating electricity that

would otherwise be lost, for raising process steam or hot water,

is not new. It could better be described as a logical step, because

the hot flue gases of a block heat and power plant or gas turbine

contain great quantities of valuable energy.

While the hot flue gas of a traditional combined heat and power

plant (CHP) is directed immediately through a heat

exchanger or waste heat boiler, in the solution now available

from SAACKE the gas turbine exhaust gases supply a DDZG-GT

series gas turbine flue gas burner as combustion air.

SAACKE & SSE Enterprise partnershipThe turnkey solution for Micro-CHP systems

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In this way SAACKE not only opens the way to new

high-temperature processes for CHP plants, but also makes

production more flexible and profitable overall. The system can

achieve overall efficiencies of over 90%, and is not only very

economical, but also environmentally friendly.

Conventional CHP plants have most commonly been

implemented in the low and medium load range with block heat

and power plants, and are very maintenance-intensive.

However, SAACKE is now offering an alternative: an extremely

low-maintenance combination of micro gas turbine with proven

SAACKE burners known as “micro CHPs”. A gas turbine

generates from 50 to 200 kW of electrical current, with its flue

gas used to supply a SAACKE gas turbine flue gas burner, which

fires in the downstream heat generator.

Depending on the layout and configuration of the heat

generator, a CHP plant of this type produces heat, steam or hot

water with conventional heat generators – and also produces

valuable electrical energy.

Direct use of gas turbine flue gas for combustion – with over 96% efficiency

With the “micro CHP” principle, SAACKE introduces a highly

cost effective method for generating electricity for conventional

heat generators.

Initial systems have been based on a Capstone micro gas

turbine. These proven electricity generators were originally

developed for use by the US army. They combine turbine,

generator and line synchronisation in one compact sound-

proofed housing. They are typically operated with natural gas,

but are also able to use biogas, fuel oil or biogenic oils.

Because all movable parts of the electricity generator run on a

single (air-cushioned) shaft, the maintenance intervals of the

micro gas turbine are extremely long, with a total service life of

up to 80,000 hours for the turbine.

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Typical Plant

45-59%Efficiency

Typical Plant

Boiler

Electrical Power Generation(Grid Energy Supplier)

TypicalSAACKE CHPPlant 91-96%

Efficiency

Typical CHP Plant

67-80%Efficiency

SYSTEM EFFICIENCY EXAMPLES

30 - 17% heat losses

1.4 - 1.75 MWh Electrical Power

3.5 - 4.15 MWh Steam/Hot water

Energy user

72 – 65% heat losses5 MWh NATURAL GAS

5 MWh NATURAL GAS

8.18 MWh NATURAL GAS

1.82 MWh NATURAL GAS

5% Heat losses

0.6 MWh Electrical Power

8.5 - 8.9 MWh Steam/Hot water

9 - 4% heat lossesEnergy user

1.12 MWh Waste heat

SAACKE Micro Gas TurbineCHP System

Micro Gas Turbine

Steam/HW generator with SAACKE DDG-GTM

Typical CHP Gas engine

Waste heat boiler

10 MWh NATURAL GAS

Energy user

10% heat losses

23 - 10% heat losses2.9 - 4.7 MWh Steam/Hot water

3.8 MWh Electrical Power

5.2 MWh Waste Heat

Start-up takes only a few seconds. Then, depending on the size,

between 50 and 200 kW of line-synchronous electrical power

is available. The turbine features infinitely variable operation

over a very wide control range with both heat and current guided

mode.

The current that is generated can be fed back into the electrical

network or used solely internally. Firing systems featuring high

operating hours and continuous heat consumption are naturally

suited to CHP solutions, however, the turbine and burner can

optionally be operated independently of each other.

Products from the proven SAACKE DDZG-GT series are used

as burners. They develop firing rates between 2 and 20 MW

(depending on the size of the turbine) and fire directly into the

downstream heat generator.

In principle these robust lance burners work with practically all

liquid and gaseous fuels and are even suitable for thermal

utilisation of auxiliary fuels and by-products. The proven

combination of turbine and burner guarantees the lowest

emission values, and also reliably exceeds the requirements

across the entire range of EU regulations.

SSE Enterprise brings extensive experience in turnkey project

delivery from HV through to full mechanical and electrical

engineering services, management and maintenance of critical

energy services.

From feasibility study, through funding/finance options via direct

or third party lending to implementation of a full O & M regime

over an agreed contract period, customers can be assured of the

best available support in addition to the best available

technology for their plant going forward.

SAACKE & SSE Enterprise – turnkey Micro-CHP systems continued

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For further information on turnkey Micro-CHP systems and the

SAACKE and SSE Enterprise partnership, you are invited to

attend our regional conferences.

You will also learn about the latest guidelines and legislation

covering the essential aspects of operating a boiler plant.

We are partway through the 2016 programme but there are still

places available at the following venues:

Thursday 15th September

Cork: Radisson BLU Hotel

Tuesday 4th October

Perth: Murrayshall House Hotel

Thursday 6th October

Bradford: Cedar Court Hotel

For more details and to apply for tickets, visit www.ukcombustionseminar.co.uk

You can also contact Susie Bell via s.bell@saacke.com or on+44 (0) 23 92 333831

Free places are offered to holders of SAACKE Service Contracts

(number dependent on level of contract/membership). Otherwise

cost per delegate is £85/€110 (including VAT).

Energy, Efficiency, Emissions, Expertise

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Elite

“Good day - always come away with further knowledge.”

“Attended to ensure I’m up to date with what’s happening in the industry.”

Energy & combustion conferences

From 2017, particularly strict emission guidelines will apply in selected urban areas in China, such as Beijing.

New heat generation plants and power stations will then be subject to a NOx limit value of a maximum of 30 mg/m³ based on 3.0% dry O2, while the regulation enters into force in five years for existing plants.

The optimised SAACKE LONOX UCC (Ultra Clean Combustion) system, based on burner technology that has proven its worth over decades, already complies with the future guideline values in all areas – without expensive additives or secondary measures.

This was verified by the German TÜV (Technical Inspection Authority) in January 2016, based on measurements at a test facility at the SAACKE research and development location in Bremen.

The new statutory regulations are the Chinese government’s response to rising air pollution and smog formation, especially in urban areas. These are the result of released nitrogen oxides, which are unwanted by-products of combustion processes that use high temperatures in many sectors of industry or are also released by motor vehicles in traffic.

“We want to use our technology to contribute to a better climate and better living circumstances for

the inhabitants”

says Dr Norbert Schopf, Director, Business Development at SAACKE. “The guidelines for new plants may only enter into force from 2017, but they also affect power stations that supply heat. The goal is to be able to commission the first SAACKE Low NOx burners at the start of the 2016/2017 heating period.”

Plants that are already in operation can also be fitted with the technology, so that they can continue to be used.

Cost-effective and efficient compliance with limit values

The reduction of nitrogen oxides in industrial processes is generally achieved by cooling the flame temperature in the burner, such as by installing cooling fins or water injection.

NOx reduction measures of many SAACKE competitors often lead to a high amount of excess O2 or a high level of CO. Significant reductions in the released nitrogen oxide can often only be achieved using expensive, catalytic (SCR) or non-catalytic (SNCR) processes.

“Just keep sending John to us and there’ll be no complaints. He’s one of the best and most helpful people we deal with.”

“SAACKE always provide us with a first class service and respond as quickly as possible to our requirements.”

“SAACKE is a very good organisation. We always get a response to enquiries without having to chase.”

“Have always found SAACKE technicians to be very helpful and willing to advise on/solve any problems that arise throughout the whole year on any boiler/burner at our sites.”

“Staff always pleasant and willing. Great to work with – never an issue. Exceptional service to our company which is greatly appreciated.”

“As always first class service from SAACKE.”

“I would like to take this opportunity to thank you personally for all your help over the last few days with regard to the boiler at the DVLA. I totally understand your team were under contractual pressures and had some major installations to complete. They however managed to make the time to help us out during this very difficult situation. Can you please pass on my thanks to your engineer Chris Ball. He was absolutely fantastic and worked tirelessly to resolve the issue we had. My engineer spent a lot of time with him yesterday and was blown away by Chris’s knowledge and skills. I cannot stress how grateful we are for all your help.”

Denise Laing - Contract Manager, CBRE

Customer comments

SAACKE LONOX UCC system already complies with future Chinese emission limitsNitrogen oxide emissions < 30 mg/m³ based on 3.0% dry O2 certified by the German TÜV

However, all of these options increase fuel consumption, material costs and the use of necessary additives at the operator’s expense.

By contrast, the SAACKE LONOX UCC system is based on an internally developed technology, whose core elements are a swirled and particularly stable spherical flame as well as a specially-engineered flame control. “This function has proven itself in practice over many years and has undergone constant optimisation”, explains Dr Norbert Schopf.

The SAACKE burner fires all gaseous fuels cost-effectively and efficiently in compliance with the limit values of 30 mg/m³ NOx based on 3.0% dry O2 – with a low flue gas recirculation rate of < 30%. Specifically, measurements by the TÜV Nord, under low, partial and full load, resulted in NOx values (averaged over half an hour) of < 19 mg/m³ at an output of 1 MW, < 28 mg/m³ at 4 MW and < 24 mg/m³ at 8 MW. The CO value is below 100 mg/m³.

The SAACKE LONOX UCC system does not require any external measures for NOx or CO, and has a capacity range of 8 to 64 MW, making it suitable for plants with shell boilers or water-tube boilers with capacity ranges between 10 and 80 tons per hour. The burner solution is also ideal for extremely short furnaces due to the special flame geometry.

The SAACKE LONOX UCC system can be customised to customer requirements and the local infrastructure. Besides the test plant at the research and development location in Bremen, a 32 MW demonstration plant is also in planning at SAACKE’s Chinese site in Qingdao.

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If you are reading this newsletter but don’t receive your own personal copy and would like to be sent one directly, please contact Susie Bell via s.bell@saacke.com or on 023 92 333831

David Turner (Service Technician, Midlands) and his wife Dee ran the Stafford Half Marathon on Sunday

20th March. They both finished in 2 hours, crossing the finish line together and raised a fantastic £1167.75 for Parkinson’s UK, a charity that has supported David’s father and House of Bread, a Stafford based charity that assists the homeless locally.

This was a real challenge for both David and Dee as neither of them had done any exercise in the last 10 years post children. According to David, the plan is to do a full marathon next year – although apparently Dee is not overly keen at the moment!

Barbara Diplock (Service Administrator, Havant) and her family including her son, Mark Diplock (Stores/Spares Technician, Havant) took part in The Rowans Hospice Moonlit Memories Walk on Saturday 18th June.

The local charity supports people with cancer and other life-limiting illnesses. They selected to walk the full 12 miles and gathered at 11pm ready to go. Following some dreadful weather, the night was warm with hardly any breeze which made it perfect for walking.

Barbara and her husband Roger did it in 3 hours and 35 minutes. Mark and his brother Darren together with girlfriend Laurita all finished in 3 hours and 22 minutes, so all quite close together.

Portsmouth Cathedral stayed open during the event for the walkers to light candles and remember loved ones. Apart from a spell of tiredness at the 10 mile point (and dreams of a soft, warm bed!), Barbara enjoyed the challenge. The tea and bacon rolls on Southsea Common at 2.35am were very welcome!

Laurita, Darren, Roger, Barbara, Mark

UK team snippets

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Adam Hartin (Aftersales Engineer, Havant)

Lee Cornwell (Spares Co-Ordinator, Havant)

who have both recently celebrated 10 years with SAACKE UK Companies.

Luke Brooks from Walkden High School spent a week on work experience in the Northern office in June assisting Jo-Ann Szysz (Regional Office Administrator) and Jim Nee (Regional Service Manager).

Luke had a great time learning new skills. He enjoyed finding out about burners and was amazed at all the different parts. He said that he would like to come back to learn more so it must have been a good week!

Jo-Ann Luke Jim

Congratulations

SAACKE Combustion Services Ltd.Langstone Technology Park,Langstone Road, Havant,Hampshire, PO9 1SA. England

Telephone: +44 (0) 23 92 333900Website: www.saacke.com

Paul Drury (Service Technician, Midlands)

who retired on 1st August 2016 after 16 years with SAACKE UK.

Good luck

Congratulations