The energy supplier ELCEN Bucharest faced the challenge of increasing the energy efficiency of its hot water production while complying with the EU's strict emission limits.
The goal was to reduce NOx emissions to a maximum of 30 mg/Nm³ and CO emissions to a maximum of 15 mg/Nm³.
At the same time, full boiler capacity of 116.3 MW had to be guaranteed even with one burner out of service (N-1 operation).
Use of 6 SAACKE ATONOX 280G burners, with an individual output of 25.2 MW on a total of 3 water tube boilers, each with an output of 116 MW.
The burners operate with an exhaust gas recirculation rate (FGR) of 27%, which has resulted in a drastic reduction in NOx emissions.
By using this highly efficient low-NOx technology, ELCEN reduced emission values to NOx < 30 mg/Nm³ and CO < 15 mg/Nm³ – even at full boiler capacity. The company is thus not only making a significant contribution to air pollution control in the Bucharest region, but also increasing the operational safety and efficiency of the plant.
Despite the difficult conditions – in particular a narrow combustion chamber and strong boiler vibrations – SAACKE was able to ensure stable, low-vibration operation by specifically optimizing the gas nozzles and reinforcing the boiler construction.
The SAACKE solution in detail
The burner system is based on the ATONOX series, which was specially developed for ultra-low NOx emissions. The use of internal steam pressure atomization, precise air-fuel control, and controlled exhaust gas recirculation creates a particularly homogeneous flame structure with an even temperature profile.
This combination enables complete and stable combustion with minimal pollutant formation. The structural conditions of the boilers posed a particular challenge: the combustion chamber was very narrow and the distance to the rear wall (diaphragm wall) was extremely small. This meant that there was a risk of a flame that was too long placing a thermal load on the rear wall.
To avoid this risk, SAACKE developed an optimized burner geometry with a shortened flame that still ensures complete and stable combustion. In addition, the engineering team developed customized adjustments to the gas nozzles to significantly reduce vibrations in the boiler.
Commissioning took place in close cooperation with the Romanian SAACKE service team, which took care of the fine-tuning on site, thus ensuring reliable implementation of the demanding project goals.
- Ultra-low emissions: NOx < 30 mg/Nm³, CO < 15 mg/Nm³
- Full capacity with one burner out of operation (N-1)
- Safe operation despite narrow combustion chamber
- Modified gas nozzles and reinforced boiler construction reduce boiler vibrations
- Support from the Romanian SAACKE team on site
- ATONOX burner technology with exhaust gas recirculation for maximum efficiency
The ELCEN Bucharest project impressively demonstrates how SAACKE can meet the highest requirements for efficiency and emission reduction through customized engineering solutions and close cooperation between international teams.
Despite difficult technical conditions, reliable, low-emission, and efficient plant operation was achieved—another example of SAACKE's expertise in industrial combustion technology.