Savings in natural gas and CO2 emissions through the safe and low-emission thermal use of hydrogen, which is produced as a residual material during operation.
The potential of hydrogen (H2) for industrial decarbonization is enormous. H2, which is produced as a residual material in manufacturing processes, is also used to supply heat. For this purpose, the specialty chemicals company Nobian relied on SAACKE combustion technology and thus on proven know-how for low-emission, cost-efficient and reliable application.
Plant modernization with three SKVGD H2 burners which, thanks to external flue gas recirculation and special gas injection design, are well below the limits of the 44th BImSchV.
Hydrogen (H2) has enormous potential for industrial decarbonization. H2, which is produced as a residual material during manufacturing processes, is also used for heat supply. For this purpose, the specialty chemicals company Nobian relied on combustion technology from SAACKE and thus on proven expertise in low-emission, cost-efficient, and safe application.
Exploiting synergies: save natural gas, improve the CO2 balance
Nobian, a company of the globally active Nouryon Group, manufactures chemical products for hygiene items, construction materials and paper production at its Ibbenbüren site. With the help of SAACKE, the company has been converting its process steam generation to H2 compatibility since the 1990s. This is because the European market leader in industrial salt, chlorine trading and chloromethanes also produces hydrogen as a main and surplus by-product during chlor-alkali electrolysis. With plant modernizations, these existing residual materials can be used as a valuable substitute and heat source for the electrolysis process – and the consumption of costly natural gas as primary fuel is reduced. The operator thus exploits existing synergies and saves 577 m³ of natural gas per hour. This is achieved by three hydrogen burners from the SKV burner series, which are based on rotary atomizer technology and are flexibly suitable for gaseous fuels, but also for liquid fuels if required
Technical Data
| Boiler type: | 3 x shell boilers for generation of superheated steam (also suitable for hot water boilers or thermal oil heaters) |
| Burner type: | 3 x SKVGD |
| Burner capacity (max.) | 4,3 to 7,6 MW (depending on boiler size) |
| Fuel: | Hydrogen |
| Emissions: | 100 mg/m3 NOx, with exhaust gas recirculation even up to approx. 40 mg/m³ at 3 % vol. O2 in the dry exhaust gas |
The SAACKE solution in detail:
Compared to natural gas, hydrogen generates three times as much NOx emissions due to its higher adiabatic combustion temperature and approximately eight times higher flame speed. SAACKE addresses this problem with a sophisticated external exhaust gas recirculation system. This process ensures dilution effects and cooling of the flame by mixing exhaust gases into the combustion air. Emissions in hydrogen operation can thus be brought into line with those of natural gas. The plant significantly undercuts the limit value of the 44th Federal Imission Control Ordinance for medium-sized combustion plants, gas turbine plants and combustion engines, which stipulates 200 mg/m³ for H2. In addition, the higher H2 flame temperature places special demands on the material, which is compensated for by heat-resistant steel and a special gas injection design. To increase the safety aspect, the tube for hydrogen injection is purged with nitrogen before burner ignition.
- Synergy effects from residual material utilization and savings of 577 m³ of natural gas per hour thanks to efficient H2 utilization
- H2 combustion technology proven in practice for decades and thus ready for immediate use
- Variable burner for different fuels in any mixing ratio: natural gas, light oil (as emergency fuel) or up to 100 % pure hydrogen
- NOx emissions in gas, oil and H2 operation well below the legal limits of the 44th BImSchV
- Air volume regulation depending on fuel mix
- Special gas line with a particularly low pressure drop, to compensate for the extremely low gas pressure
- Everything from a single source: The scope of delivery also includes the SAACKE combustion management se@vis pro and a flue gas recirculation with separate fan
The industrial thermal use of hydrogen with SAACKE burners has long been “H2-ready”. Smart combustion technologies contribute to efficient, safe and comparatively environmentally friendly operation – and not only as soon as the natural gas pipelines have been converted to hydrogen on a large scale, but also today through the very specific use of residual materials.