Power plant technologyInnovative and customized energy plantsfor waste, biomass and thermal recovery

Oschatz is a globally operating plantconstructor with over 160 years‘ experience,more than 1,400 employees as well as subsid-iar ies, representative offices and branches aroundthe world. Our plants for cooling waste gasesand converting recovered heat into industriallyutilizable steam are used throughout the worldin the following industries:

■ Iron and Steel Metallurgy■ Non-ferrous Metallurgy■ Chemical Industry■ Power Plant Technology

2 3

Our Market is the World

At home in the worldOschatz – best technology backed by experience

Our portfolio:Turnkey power plants and component solutions

Customized solutionsNo two Oschatz plants are the same. Each plantconcept is customized to ensure the highestlevels of productivity, economic efficiency andoperational safety for our customers. Oschatz plants are environmentally friendly

and still work reliably even after many years oftough continuous operation. Depending on theirdestination, the plants are fabricated in our twoextremely modern production facilities in Kocaeli,Turkey, and Nanjing, China. Needless to say, wecomply with all quality standards, such as ISO9001, the ASME standard, the Pressure Equip -ment Di rec tive, EU standards, etc.

Oschatz is present in about 20 countries all over the world.For details please use the QRcode or www.oschatz.com.

Power Plant TechnologyIron and Steel Metallurgy Non-ferrous Metallurgy Chemical Industry

Biomass power plants: thermal utilization ofrenewable fuels such as green and waste wood,olive pits, rice husks or similar➜ see p. 10

Industrial waste treatment plants: thermalutilization of residues from the paper industry,sewage sludge, plastics and recycling residues➜ see p. 10

Thermal recovery of liquid and gaseousresidues from chemical and industrial processplants➜ see p. 11

Directly fired power plants using fuels suchas natural gas, oil, hydrogen, coke-oven gas andCO gases➜ see p. 11

Oschatz designs and manufactures plantsfor the efficient, ecological and sustainable useof municipal and industrial residues, applyingthe very latest energy conversion technologiesto meet specific customer requirements.On the following pages, we would like to pro-

vide an overview of the various solutions Oschatzoffers in the field of power plant technology,ranging from individually designed core compo-nents to turnkey power plants:

Grate firing systems➜ see p. 4/5

Boiler systems➜ see p. 6/7

Waste-to-energy plants: combustion of municipal and household waste➜ see p. 8/9

Refuse derived fuel (RDF) plants:combustion of sorted and pre-treated waste➜ see p. 8/9

This refuse derived fuel (RDF)power plant in Hagenow,Germany, was handed over by Oschatz as a turnkey plant in 2009.

Biomass power plant in Italy,handed over ready for operationin 2012

One of the world‘s largest one-piece boilers forthe combustion of hydrogen and natural gaswas built and delivered by Oschatz in 2009.

Our Market is the World4 5

Grate firing systemsCore component for optimal combustion

The grate brand Oschatz is the further devel -opment of the horizontal DES grate technology ofour subsidiary Danish Energy Systems, which hasbeen in operation for decades. The Oschatz grateconsiders the specific requirements of wastefuels, such as low heating value (LHV), high ashand water contents.

Top picture: View onto a combustion grateBottom picture: Grate in operation

Assembly of an Oschatz gratefor the combustion of biomass

Air- or water-cooled grate – a matter of heating valueOschatz offers air-cooled grates as well as gratesin a water-cooled application. The main criterionfor the choice of the appropriate cooling methodis the heating value of the fuel and the resultingheat output on the grate surface. LHVs higherthan 13 MJ/kg (typically RDF and waste wood)require a water-cooled grate, for lower LHVs(natural biomass or municipal waste) an air-cooled grate is generally sufficient.To improve the efficiency of the water-cooling

system, the extracted thermal energy can bere-fed into the water-steam cycle, e.g. by pre-heating condensate or air.

Layout and functionality of the grateTo control the combustion process, the grate isdivided into several carriages. Stroke velocity,stroke length and stroke reverse points of eachcarriage can be adjusted individually. In a similarway, the grate is divided into several air zonesto adapt primary air and recirculated flue gasflow to the combustion characteristics of the fuel.The fuel is fed to the grate continuously by

means of an individually designed feeder. Thegrate bars, bolted together to a grate bar row,

*Capacities below 25 MW can behandled by our subsidiary DES.

are made of special heat- and wear-resistantalloy steel with high chrome, silicium and nickelcontents. Primary air is fed to the grate frombe low together with recirculated flue gas.Secon d ary air is blown into the furnace abovethe grate and provides the required oxygen foroptimal burn-out.

Benefits:■ Excellent mixing of the fuels■ Perfect burn-out with lowest C content■ Minimal CO emissions in accordance with the waste incineration directive (WID/EU)

■ Homogenous combustion air distribution to the different grate zones

■ Long availability, low maintenance costs

Characteristics:■ Capacity range: 25 – 90 MW* per unit■ Grate load: ~ 750 kW/m²■ Hydraulic drives■ Individually adjustable carriage speed and return points

■ High fuel-poking capability

Fuel

Moving grate bar row

Not moving grate bar row

Primary air

Secondary air

Ash,slag

6 7

Our Market is the World

■ Cooling of the flue gases to less than 650 °C before entering the convection bundles → Protection against corrosive flue gases and caking of sticky dusts

■ Protection of tubes which are exposed to most critical corrosion conditions by high-alloy cladding

■ Cleaning of the heating surfaces by most recent systems, e.g. water spraying, soot blowers, hammering and rapping devices as well as shot cleaning

■ Optimal integration of our boilers into the furnace and combustion chamber to ensure excellent cooling and reduced slagging of the walls

■ Optimization of the boiler and bundle geometry to ensure optimal flue gas velocity and to reduce flue gas pressure losses

■ Increase of the boiler’s radiation area with screen wall heating surfaces to reduce overall boiler dimensions

Boiler systemsEfficient solutions for a wide range of applications

Two pass directly fired boiler

The RDF boiler at the power station in Andernach,Germany, is lifted into position.

Boilers for solid fuelsDownstream of grate firing, e.g. of waste, RDFor biomass, Oschatz provides water tube boilerconcepts with state-of-the-art vertical, horizontalor combined arrangements. Relying on ourwide-ranging experience, our waste heat boilersystems are designed conservatively and reliablyin terms of corrosion resistance and minimizeddust fouling to ensure maximum efficiency.

Special features■ Both hanging and supported boiler arrangements

■ Feed water preheating or external super-heaters to achieve higher steam parameters, improving electrical efficiency

Based on long time experience, Oschatzhas built up specific know-how and developedtheir own proven technologies for waste heatboilers and steam generators. Boiler concepts for solid as well as liquid and gaseous fuels aredesigned and built.

One-pass tower type boiler asspace-saving application

Characteristics:■ Thermal capacity: 20 – 200 MW■ Steam capacity: 20 – 250 t/h■ Steam pressure: up to 150 bar■ Steam temperature: up to 550 °C■ Flue gas flow: up to 350,000 Nm³/h

Benefits of all Oschatz boilers:■ Reduction of maintenance costs■ Longer operation periods■ Generation of higher steam parameters to increase electrical efficiency

■ Space-saving plant layouts■ Permanent monitoring from design to start-up thanks to production of the boiler systems in our own state-of-the-art workshops in Turkey and China

Steam generators for liquid and gaseous fuelsOschatz provides tailor-made thermaltreatment plants for liquid and gaseousfuels as well as directly fired steamgen erators for the chemical and oil andgas industry. Depending on the fuelproperties, steam parameters, emissionrestrictions, the available area and othersite conditions, Oschatz designs appro-priate water tube boilers. Space-savingone-pass vertical ”tower“ type or com-pactly arranged multiple pass boilersystems in a combined vertical /horizon-tal arrangement are available eitherwith natural or forced water circulation.

Cross-sections of a vertical (top)and horizontal (bottom) boilersystem downstream of grate firing

8 9

Our Market is the World

Waste-to-energy / RDF plantsAll services from a single source

In view of current political guidelines onnational, European and international levels, suchas legislation for power generation from renew-able sources, concepts for ”energy change“ orlimitations of greenhouse-gas emissions, the useof biogenic fuels and fuels from waste gains inim portance.

Economically and ecologically worthwhileOschatz plants for waste and refuse-derived fuels(RDF) offer a wide range of advantages:

■ Cost savings for primary fuels■Waste and residues do not have to be stored nor landfilled

■ Flue gas is cleaned in accordance with the local legislation

■ Combustion residues are aseptic, inodorous, problem-free to dump and can even be reused in some cases, e.g. grate slag for roadworks.

All services from a single sourceThanks to our extensive know-how in combustionand steam generation, we are your one-stop supplier for turnkey plants. We offer:

■ Individual design of your customized plant■ Engineering of grate and boiler as well as procurement in-house

■ Production of the components in our own manufacturing facilities

■ Delivery, assembly and commissioning■ Excellent after-sales service all around the world

Our competence does not only cover the technol -ogy from chute to stack, but the electric powergeneration and, if desired, even the process anddistrict heat generation.

1

2

3

4

5

6 7 8

9

10

11

12

13

14

16

17

18 19 20

22

23

24

25

15

21

1 | Tipping hall2 | Waste bunker3 | Waste crane4 | Feed hopper and feeder5 | Primary air preheater6 | Primary air fan7 | OSCHATZ water-cooled grate8 | Wet ash conveyor9 | Bottom slag transport10 | Ash box11 | OSCHATZ 4 – pass vertical boiler12 | OSCHATZ steam drum13 | OSCHATZ super-heater14 | OSCHATZ economizer15 | Water treatment16 | Silos for lime hydrate and

activated carbon17 | Baghouse18 | Induced draught fan19 | Turbine20 | Generator21 | Switch board22 | Air cooled condenser23 | Residue silo24 | Stack25 | Control room with crane

control station

Reference plant: Rudolstadt-Schwarza, GermanyWaste-to-energy plant providing energy from industrial waste and paper mill residuessince 2008

■ Capacity: 60,000 tons/a ■ Fuel heat input: 33 MW■ Steam flow rate: 32 t/h■ Steam pressure: 33 bar g■ Steam temperature: 420 °C

Reference plant: Andernach, GermanyCombined heat and power (CHP) plant with electrical power generation, furthermore servinga nearby production site with process steam

■ Capacity: 120,000 tons/a■ Fuel heat input: 54 MW■ Steam flow: 65 t/h■ Steam pressure: 70 bar g■ Steam temperature: 525 °C(with external super-heater)

■ Electrical power generation: 16.5 MW

Flow chart to illustrate thefunctionality of a waste-to-

energy / RDF plant

Our Market is the World

Industrial waste treatment plantsThermal utilization of low calorific residues

Biomass is one of the key renewable en-ergies for the transition to a more sustainableenergy production. Use of this energy is, therefore,a sensible, environmentally friendly and carbondioxide-neutral method of resource recovery. In our turnkey biomass plants fuels such as

green and waste wood, arundo, lignin, olive pits,pomace/marc residues or rice husks are incinerat -ed in our own, individually designed combustionsystems and converted efficiently to energy.

Special features:■ Depending on the fuel’s heating value our custom-made air-cooled or water-cooled incineration grate will be most suitable.

■ Steam parameters are chosen in order to receive high electrical output.

Since the late 1980s, Oschatz has built sev-eral tailor-made plants for the thermal utilizationof liquid and gaseous residues, suitable e.g. foracrylic acid, butanediol and THF plants.Specific and complex tasks from these chemical

processes have been solved and transferred toreliable and successfully operating plants.

Major design features are:■ Individually designed burner system able to incinerate several liquid and gaseous residues in parallel

■ Combustion process designed to achieve low emission values in accordance with the emission regulation

■ Integration of necessary NOx reduction measures such as flue gas recirculation or SNCR systems

Oschatz offers tailor-made plants for thetreatment of industrial residues like waste wood,paper and sewage sludge, hazardous waste orrecycling waste. The thermal utilization of such very low calor -

ific industrial waste is connected with a highlyefficient combined heat and power generation(CHP) process. This concept results in the consid -erable saving of primary energy, the reductionof landfill waste and costs, and is therefore ahuge benefit for industries with a high demandfor energy, e.g. the paper industry.

An overview of the process:■ Incineration of residual materials on a reciprocating grate■ Special conditioning of the low calorific value residual materials■ Use of gas turbine exhaust gases as combustion air for pre-drying of the residues

■ Conversion of the energy from the high-pressure steam to electric power via steam turbine and process steam (CHP)

■ Use of residues from the combustion process (slag) and flue gas cleaning (gypsum) as saleable materials

Biomass power plantsEnergy from renewables

Biomass power plant in Italy, built in 2012:■ Fuels: lignin, wood■ Capacity: up to 180,000 tons/a■ Fuel heat input: 47 MW■ Steam flow: 54 t/h ■ Steam pressure: 80 bar g■ Steam temperature: 480 °C

Waste heat boiler and rawmaterial utilization at the Weigpaper mill in Mayen, Germany

Thermal utilization plant for chemical processes

10 11

Directly fired power plants Designed for high efficiency

■ Auxiliary and supplementary firing ■ Latest flow modelling techniques■ Low flue gas temperature ensuring high efficiency

The high quality requirements on material andconstruction are achieved by our full service policy: design, engineering, manufacture andassembly of the boiler parts take place in-house.

Thermal recovery of liquid and gaseous residues Solutions for the chemical industry

■ A combined heat and power (CHP) process can be set up in accordance with project-specific demands.

■ State-of-the-art flue gas cleaning systems are applied in accordance with local and current legislation.

This gas power plant in Germany has produced steam from hydrogen and natural gas since 2011.

■ Combustion chamber as part of the boiler or as separate brick-lined chamber depending on the fuel properties

■ Possibility of additional firing in order to generate steam output independently from residue heat input

■ Combustion air and waste gas pre-heaters which improve the combustion process in case of low calorific fuels

■ Process control system for the highest level of plant safety and availability

Specially designed combustion process

for the efficient use of CO gas in metallurgical

processes

Directly fired waste heat recovery plantsmade by Oschatz achieve maximum thermal effi-ciency with the lowest emission values. Referencesfor the following fuels are in operation:

■ Natural gas■ Fuel oil■ Hydrogen■ Coke-oven gas or CO gas

Each plant is tailored individually to the cus- tom ers’ needs and operating modes, securingmaximum flexibility, smooth change between the operating modes and high availability. This is achieved, amongst others ways, by:

Production plant in Kocaeli, TurkeyOschatz has been producing boilers and wasteheat systems in the Turkish region of Kocaeli,close to Istanbul, since 1997. In 2011, productionwas expanded and relocated to a new site:

■ Site area: 60,000 m² (646,000 ft²)■ Production area: 10,000 m² (108,000 ft²) ■ Four production workshops up to 22 metres high

■ Deep-water port close by■ Production in accordance with ASME standards, the Pressure Equipment Directive, TRD/AD standards and ISO 9001

■ Second stage of construction (four additional workshops /10,000 m²) in progress

Production plant in Nanjing, ChinaTo serve the markets in Asia, Australia andOceania quickly and cost-effectively, Oschatzhas operated a production plant in Nanjing,China, since 2005 (second stage of constructionin 2008):

■ Site area: 50,000 m² (538,000 ft²)■ Production area: 15,000 m² (161,000 ft²)■ Seven production workshops■ Link to the port of Changjian■ Production in accordance with Chinese GB standards, ASME standards, TRD/AD standards and ISO 9001

Production plant in Prague, Czech RepublicThe Oschatz production location in Prague was established in 2012 for the production of pipe work, smaller boiler components and spare parts:

■ Production area: 1,650 m² (17,760 ft²)■ Certified in accordance with SCC** 2006 and EN 3834-2■ Centrally located, and well connected to international highways

Head office:Oschatz GmbH Westendhof 10-12 45143 EssenGermany

Phone +49 201 1802-0Fax +49 201 1802-165info@oschatz.comwww.oschatz.com

Oschatz Kraftwerkstechnik Hamburg GmbH & Co. KGLeverkusenstraße 54 VII22761 HamburgGermany

Phone +49 40 1812 90-0Fax +49 40 1812 90-108kraftwerkstechnik@oschatz.com