Oil and gas solutions Unicon boiler plants for steam and hot water production
Contents Pages 6-9 Unicon WF Boiler plants equipped with fire tube boilers that use oil or natural gas. Pages 10-13 Unicon WT Boiler plants assembled on-site and equipped with water tube boilers. Pages 18-21 Unicon SF Boiler plants equipped with fire tube boilers that use oil or natural gas. Pages 22-23 Unicon ST Boiler plants assembled on site and equipped with water tube boilers. Pages 26-29 Unicon MST Unicon MST boiler plants with transferable modules and equipped with horizontal water tube boilers. 2
With decades of experience in energy projects, KPA Unicon provides responsible energy solutions and life-cycle services We specialize in boiler plants that use fossil fuels and biofuels. We optimize each project scope and technology according to our customer s needs and offer solutions from pre-studies to services throughout the plant s whole life cycle. Our main clients on the global markets include: - Oil and gas industry - Energy companies - District heating companies - Municipalities - Process industry - Food industry - Nuclear power enterprises - Construction industry - Chemical industry - Paper industry - Forest industry - Metallurgy industry Mission Vision We deliver responsible energy solutions in order to drive customer success and the well-being of our people. We are the forerunners in the business and closely involved in the customers energy production. 3
Responsible energy solutions 4
Unicon boiler plants Oil and gas solutions» Unicon WF - water boiler plant, capacity range 5-300 MW th» Unicon WT - water boiler plant, capacity range 20-500 MW th» Unicon SF - steam boiler plant, capacity range 7-300 t/h» Unicon ST - steam boiler plant, capacity range 30-600 t/h A modular boiler structure minimizes costs without compromising on quality The high-quality Unicon boiler plants can be delivered for on-site assembly or manufactured as modules. They can be partly or fully pre-assembled at our workshop in Finland. The modules can be transported by rail or road. At the assembly site, they are attached to each other, and the plant is commissioned.» Unicon MST - steam boiler plant, capacity range 20-300 t/h 5
Unicon WF boiler plants for hot water production Unicon WF boiler plants are equipped with fire tube boilers that run on oil or natural gas. They can be assembled on site or manufactured as modular and transferable plants in a capacity range from 5 to 300 MW th. At combination plants, water and steam boilers can be placed in the same building. These boiler plants are typically used in district heating networks to balance out peak loads or to supply hot water. They are also suitable for process facilities where hot water is needed. 6
Technical data Model Unicon WF Capacity 5-300 MW th Boiler Three-pass fire tube boiler Boiler capacity 1-40 MW th Pressure (max.) 20 bar Temperature (max.) 205ºC Fuel Natural gas, light and heavy fuel oil Operating efficiency 90-95% Burner equipment One or two automatic modulating burners per boiler Flue gas temperature 80-250ºC (depending on fuel and economiser) Typical emission levels (in dry flue gases) Natural gas Natural gas Light oil Heavy oil Oxygen content Low NO x О ² 3.0% 3.0% 3.0% 3.0% Carbon monoxide content CO <63 mg/m³n <63 mg/m³n <63 mg/m³n <63 mg/m³n Nitrogen oxide content NО ² <144 mg/m³n <80 mg/m³n <206 mg/m³n <800 mg/m³n Particle emissions <18 mg/m³n 18 mg/m³n <50 mg/m³n 100 mg/m³n 7
Unicon WF The plant with a three-pass fire tube boiler The core of the Unicon WF plant is a threepass fire tube boiler. The fuel burns in the furnace flue. A cooled reversing chamber at the end of the flue sends the flue gas back to the front section of the boiler. From the front section, the flue gas is directed through the fire tubes to the flue gas duct oreconomizer at the back end of the boiler. Our boiler design is based on a low furnace heat load and low flue gas velocity of in the convection part. This way, combustion in the furnace is complete and NO x emissions, for example, are reduced. Also the boiler s pressure loss is low. Due to its structure, the boiler does not get dirty easily, and the heat transfer surfaces can be cleaned during maintenance. The Unicon WF boiler capacity ranges from 1 to 40 MW th. Typical boiler values for Unicon WF Unicon-Danstoker-Global No. 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Heat output kw 2500 3000 3500 4250 5000 6000 7500 8500 10.000 12.000 13.500 15.000 17.500 20.000 Length mm 4075 4350 4500 4850 5150 5450 5750 5950 6700 6615 7315 7615 7815 8015 Width mm 2040 2200 2290 2370 2480 2660 2830 2900 2980 3310 3410 3410 3810 3910 Height mm 2370 2530 2630 2710 2820 3000 3170 3240 3320 3750 3900 3900 4280 4380 Furnace length excl. reversing chamber mm 3225 3425 3550 3900 4200 4450 4650 4750 5500 5223 5904 6204 6300 6500 Furnace length incl. reversing chamber mm 3600 3800 3950 4300 4600 4850 5150 5350 6100 5723 6404 6704 6800 7000 Furnace diameter mm 900 960 1022 1080 1130 1208 1310 1360 1410 1550 1630 1630 1730 1850 Flue gas resistance* mbar 7 7,5 8 8 8 8 10 11 12,5 11 10 12 13 13 Flue gas temperature* C 205 205 205 205 205 205 205 205 205 195 210 210 205 195 Pressure loss Δt 30 C mbar 35 50 35 50 25 30 50 25 35 40 40 35 35 35 Water capacity m³ 5.2 6.8 7.45 8.55 10.2 12.6 14.9 15.1 19 23.6 27.1 28.4 39.3 41.2 Flue gas volume * m³ 4 4.6 5.6 6.9 7.7 9.3 11.5 12.3 15.5 16.6 20.3 21.4 26.8 30.4 Pressure 4.0 bar(g) ton 5.2 6.3 7 8.5 9 10.9 13.2 14 16.6 20.1 21.9 22.8 27.7 30.3 Pressure 6.0 bar(g) ton 5.4 6.6 7.6 8.7 9.8 11.8 13.7 15.2 18.1 21.8 24.2 25.2 31.8 35.0 * Natural gas / light fuel oil О ² dry = 2.1% T:75/60 C 8
Take a look at some Unicon WF references Unicon WSF92 at a chemical weapons destruction complex for Parsons Built as a joint project between the Russian and U.S. governments, the boiler plant generates steam and hot water for demanding industrial processes. Location: Shchuchye, Kurgan oblast, Russia Steam/hot water boiler plant: 3 x 23 MW th + 2 x 12.5 t/h + 2 x 2,6 t/h Fuel: Natural gas, light fuel oil Unicon WSF26, Lahti Energy The plant produces hot water and steam for Lahti Central Hospital. Location: Lahti, Finland Hot water/steam boiler plant: 2 x 12 MW th + 2 x 1.5 t/h Fuel: Natural gas, light fuel oil 9
Unicon WT boiler plants for hot water production The Unicon WT boiler plants are assembled on-site and equipped with water tube boilers. Their main fuels include light or heavy fuel oil, or natural gas. It is also possible to have parallel boiler plants with several boilers connected together in a capacity range from 20 to 500 MW th. These boiler plants are typically used in district heating networks to balance out peak loads or to supply hot water. They are also suitable for process facilities where hot water is needed. 10
Unicon WT Technical data Model Unicon WT Capacity 20-500 MW th Boiler Natural circulation water tube boiler Boiler capacity 20-60 MW th Pressure (max.) 25 bar Temperature (max.) 205ºC Fuel Natural gas, light and heavy fuel oil Operating efficiency 93-95% Burner equipment One or two automatic modulating burners per boiler Flue gas temperature 80-160ºC (depending on fuel and economiser) Typical emission levels (in dry flue gases) Natural gas Natural gas Light oil Heavy oil Oxygen content Low NO x О ² 3.0% 3.0% 3.0% 3.0% Carbon monoxide content CO <63 mg/m³n <63 mg/m³n <63 mg/m³n <63 mg/m³n Nitrogen oxide content NО ² <144 mg/m³n <80 mg/m³n <206 mg/m³n <800 mg/m³n Particle emissions <18 mg/m³n 18 mg/m³n <50 mg/m³n 100 mg/m³n 11
Unicon WT A combined water tube and fire tube boiler Unicon WT is a combined water tube and fire tube boiler in which the furnace and the reversing chamber have a gas-tight water tube membrane wall structure and the convection part has a fire tube structure. The burner is mounted on the roof of the furnace, and the flame is directed from the roof towards the bottom of the boiler. Flue gas passes through the opening in the back wall of the furnace to the convection part where the convection tubes are located. The convection tubes are a non-finned design, which helps keep the boiler clean for a long time and also makes cleaning easier. The gap between the furnace and the convection part is cooled down by water throughout the entire area. The heat load of the furnace and the velocity of flue gas in the convection part are low, making combustion in the furnace complete and reducing NO x emissions, for example. Also, the boiler pressure loss is low. Thanks to its structure, the boiler does not get very dirty and can be cleaned with a system installed for cleaning purposes. Typical boiler values for 40-60 MW th Unicon WT boilers are shown in the table below Unicon WT No. WT-40 WT-50 WT-60 Heat output, max kw 40000 50000 60000 Length, furnace mm 3600 4000 4000 Convection Ø 2800 3150 3420 Width mm 3600 3600 4000 Height, furnace mm 9000 10400 10400 Convection mm 5020 5020 6500 Flue gas temperature C 150 140 150 Pressure loss Pa 2100 2100 2100 Water capacity m³ 30.7 42.7 56.0 Weight (total) ton 65 71 100 Furnace/Convection part ton 19/44 21/49 27/71 Economizer incl. incl. incl. 12
Take a look at some Unicon WT references Unicon WT282 in Almaz-Antey The boiler plant supplies district heat to new industrial buildings in Almaz-Antey. Location: Nizhny Novgorod, Russia Hot water boiler plant: 6 x 47 MW th Fuel: Natural gas, light fuel oil Unicon WT94 at Vantaan Energia The plant produces hot water for the local district heating network and serves as a backup and peak load plant. Location: Vantaa Finland Hot water boiler plant: 2 x 47 MW th Fuel: Natural gas, light fuel oil 13
Unicon WT Unicon WF 14 15
Unicon ST Unicon SF 16 17
Unicon SF boiler plants for the process and food industries The Unicon SF boiler plants are equipped with fire tube boilers that are usually fired with oil or natural gas. The plants in the capacity range from 7 to 300 t/h can be either delivered to the site as prefabricated modules or built at the customer site with short delivery times. These economical and flexible plants are suitable for the process and food industries where steam is needed and loads vary. The investment costs of the plants are low and their deliveries fast. The power control range of the boilers is wide and they operate reliably with high efficiency also in different load changing situations. 18
Unicon SF Technical data Model Unicon SF Capacity 7-300 t/h Boiler Three-pass fire tube boiler Boiler capacity 1-55 t/h Pressure (max.) 20 bar Temperature (max.) 300ºC Fuel Natural gas, light and heavy fuel oil Operating efficiency 90-95% Burner equipment One or two automatic modulating burners per boiler Flue gas temperature 80-250ºC (depending on fuel and economiser) Typical emission levels (in dry flue gases) Natural gas Natural gas Light oil Heavy oil Oxygen content Low NO x О ² 3.0% 3.0% 3.0% 3.0% Carbon monoxide content CO <63 mg/m³n <63 mg/m³n <63 mg/m³n <63 mg/m³n Nitrogen oxide content NО ² <144 mg/m³n <80 mg/m³n <206 mg/m³n <800 mg/m³n Particle emissions <18 mg/m³n 18 mg/m³n <50 mg/m³n 100 mg/m³n 19
Unicon SF The boiler with 99% steam dryness The Unicon SF plant s core is a three-pass fire tube boiler that has one or two fire tubes depending on the boiler size. The fuel burns in the furnace. A cooled reversing chamber at the end of the flue sends the flue gas back to the front section of the boiler. From the front section, the flue gas is directed through the fire tubes to the flue gas duct or economizer attached to the back end of the boiler. Because of the large steam chest, steam generation is reliable despite load changes, and the boilers can reach a steam dryness of 99%. A superheater can be integrated into the boiler s front section. With the superheater, the steam temperaturecan be increased to 300 C. Typical boiler values for 5-30 t/h Unicon SF boilers Unicon-Danstoker OPTI Nr. 500 600 700 800 1000 1200 1400 1600 1800 2000 2500 3000 Steam output kg/t 5000 6000 7000 8000 10000 12000 14000 16000 18000 20000 25000 30000 Length mm 5425 5550 5585 5750 6300 6725 7025 7925 8025 8100 8120 8120 Width mm 2500 2580 2700 2760 3000 3050 3350 3375 3550 3710 4010 4210 Height mm 2965 3080 3200 3260 3500 3550 3850 3875 4050 4100 4195 4395 Water capacity m³ 10.8 11.6 12.8 13.5 17.2 19.0 24.1 27.2 30.0 32 35.1 40 Steam chest m³ 2.14 2.37 2.79 3.15 3.99 4.68 5.31 6.36 6.99 8.2 9.4 11 Furnace diameter mm 975 1000 1025 1050 1200 1200 1375 1425 1550 1675 1825 1825 Furnace length mm 4000 4100 4100 4250 4750 5100 5300 6200 6250 6300 6300 6300 Flue gas volume m³ 5.3 5.9 6.4 7.0 10.0 11.0 14.6 18.0 20.7 23 27.5 31.5 Flue gas temperature C 240 240 240 240 240 240 240 245 245 240 240 245 Flue gas resistance mbar 9.5 10.0 10.0 11.5 10.0 12.5 11.0 10.0 10.5 11 10 13.5 Weight 13.0 bar ton 12 14 16 18 20 22 24 28 32 35 42 50 20
Take a look at some Unicon SF references Unicon-WSF130 in Antipinsky NPZ The plant produces steam for refinery processes and hot water for heating the buildings. Location: Tyumen, Russia Hot water/steam boiler plant: 3 x 50 t/h+ 3 x 9.3 MW th Fuel: Natural gas/refinery gas, light fuel oil Unicon-SF60 at Chernomortransneft/Transneft The plant produces steam for refinery processes. Location: Novorossiysk, Shesharis, Russia Steam boiler plant: 3 x 20 t/h Fuel: Natural gas, heavy fuel oil 21
Unicon ST steam boiler plants The Unicon ST boiler plants are assembled on site and equipped with water tube boilers. Their main fuels are light or heavy fuel oil, or natural gas. They are also available as parallel boiler plants with several boilers connected together in a capacity range from 30 to 600 t/h. In combination plants, both water and steam boilers are placed in the same building. These plants are suitable for steam production in the process and power generation industries, among others. 22
Unicon ST Technical data Model Unicon ST Capacity 30-600 t/h Boiler Natural circulation water tube boiler Boiler capicity 30 100 t/h Pressure (max.) 50 bar Temperature (max.) 480ºC Fuel Natural gas, light and heavy fuel oil Operating efficiency 90-95% Burner equipment One or two automatic modulating burners per boiler Flue gas temperature 80-250ºC (depending on fuel and economiser) Typical emission levels (in dry flue gases) Natural gas Natural gas Light oil Heavy oil Oxygen content Low NO x О ² 3.0% 3.0% 3.0% 3.0% Carbon monoxide content CO <63 mg/m³n <63 mg/m³n <63 mg/m³n <63 mg/m³n Nitrogen oxide content NО ² <144 mg/m³n <80 mg/m³n <206 mg/m³n <800 mg/m³n Particle emissions <18 mg/m³n 18 mg/m³n <50 mg/m³n 100 mg/m³n 23
Unicon ST A natural circulation boiler with a sturdy structure Unicon ST is a natural circulation boiler with a sturdy and simple structure, suitable for meeting the demanding requirements at power plants and in various industrial processes. The reliable boiler only needs minimal maintenance as its pressure body provides a durable framework. Downcomers, headers and tube walls are welded together to form a gas-tight construction. The burner is installed on the roof of the furnace, and the flame is directed from the roof towards the bottom of the boiler. Flue gas circulates through the screen between the furnace and the second pass to the convection part where the convection tubes are located. All the convection tubes are plain, which keeps the boiler clean longer and makes cleaning easy. The heat load of the furnace and the velocity of the flue gas in the convection part are low. This makes combustion in the furnace complete and reduces NO x emissions, for example. Also, pressure loss in the boiler is low. 24
Take a look at some Unicon ST references Unicon ST70 at Pori Energia, Aittaluoto The boiler plant delivered to Aittaluoto produces process steam and hot water for the district heating network. Location: Pori, Finland Steam boiler plant: 70 t/h, 13 bar, 220 C Fuel: Heavy fuel oil Unicon ST40 at Storuman Värme AB The steam boiler plant utilizes pellet dust as fuel and produces steam for pellet production, among others. Location: Storumen, Sweden Steam boiler plant: 40 t/h, 82 bar, 500ºC Fuel: Pellet dust 25
Unicon MST steam boiler plants for industrial processes and power plants The Unicon MST boiler plants are manufactured as transferable modules and equipped with horizontal water tube boilers. The modules are easy to transport and quick to assemble. The main fuels are light or heavy fuel oil, or natural gas. The plants are also available as parallel boiler plants with several boilers connected together in a capacity range from 20 to 300 t/h. In combination plants, both water and steam boilers are placed together in the same building. These boiler plants are used for steam production, for example, on oil fields. 26
Unicon MST Technical data Model Unicon MST Capacity 20-300 t/h Boiler Natural circulation water tube boiler Boiler capacity 20 50 t/h Pressure (max.) 50 bar Temperature (max.) 480ºC Fuel Natural gas, light and heavy fuel oil Operating efficiency 90-95% Burner equipment One or two automatic modulating burners per boiler Flue gas temperature 80-250ºC (depending on fuel and economiser) Typical emission levels (in dry flue gases) Natural gas Natural gas Light oil Heavy oil Oxygen content Low NO x О ² 3.0% 3.0% 3.0% 3.0% Carbon monoxide content CO <63 mg/m³n <63 mg/m³n <63 mg/m³n <63 mg/m³n Nitrogen oxide content NО ² <144 mg/m³n <80 mg/m³n <206 mg/m³n <800 mg/m³n Particle emissions <18 mg/m³n 18 mg/m³n <50 mg/m³n 100 mg/m³n 27
Unicon MST Unicon MST A reliable horizontal natural circulation boiler The heart of the Unicon MST plant is a horizontal natural circulation boiler. The reliable boiler has low maintenance needs. The pressure body is a durable framework, and downcomers, chambers and tube walls are welded together forming a gas-tight construction. The burner is installed in the front section of the boiler, and the flame is directed horizontally towards the back of the boiler. Flue gas flows from the furnace to the superheater and further to the convection part and economizer, which are all placed horizontally in a row. The design is based on a low furnace heat load and low flue gas velocity in the convection part. This way, combustion in the furnace is complete, and NO x emissions, for example, are minimized. Also, the pressure loss of the boiler is low. Thanks to the boiler structure, the boiler stays relatively clean. Typical boiler values for Unicon MST 20 t/h 25 t/h 30 t/h 50 t/h Steam output kg/h 20000 25000 30000 50000 Heat output MW 16 20 24 40 Lenght mm 9500 12900 16200 22800 Width mm 2840 3150 3235 3600 Height mm 4510 4510 4575 4600 Water capacity m3 10 12 13 22 Steam temperature (superheated) C 300-440 300-440 300-440 300-440 Steam pressure bar(a) 39-46 39-46 39-46 39-46 Efficiency % 94-95 94-95 94-95 94-95 Furnace height mm 2260 2260 2260 2900 Furnance width mm 2240 2240 2240 2900 Furnance lenght mm 6960 6960 9120 8960 Flue gas temperature C 115-135 115-135 115-135 115-135 Flue gas resistance mbar 9 11 13 15 Weight ton 44 50 52 74 28
Take a look at some Unicon MST references Unicon MST125 at Sahalinmorneftegaz/Rosneft The plant produces steam for processes on the oil field. Location: Sahalin, Russia Steam boiler plant: 5 x 25 t/h, 40 bar, 400ºC Fuel: Associated oil gas Unicon MST50 at Lukoil The plant produces steam for processes on the oil field. Location: Jarega, Russia Steam boiler plant: 2 x 25 t/h, 25 bar, 270ºC Fuel: Natural gas 29
Auxiliary modules Pumps and piping The steam and water pipes in the boiler plants are designed in accordance with all valid regulations and recommendations so that the actuators and field instruments are placed efficiently for service. When necessary, the pipes are insulated with mineral wool and coated with metal sheets. The main pumps in the Unicon water boiler plants are the circulation pump for district heat water, the shunt pump for the boiler, and the pressure maintaining pump. In the Unicon steam boiler plants, the main pumps are the feed water pump and the condensate pump. The pumps are dimensioned according to each plant for the best possible operating efficiency during varying loads. Larger pumps can be equipped with frequency converters. Building All Unicon boiler plants can be placed in an existing or a new building. Environmental requirements are the starting point for the new boiler building design, and the color and materials are chosen on a case-by-case basis. The most common material is a steel structure with sandwich element walls. If the plant consists of more than one boiler, the boilers are placed side by side. Each boiler s equipment and systems are placed according to the same layout to provide efficiency from an operation point of view. HVAC and building electrification are also important for the boiler plant s operation. A smart service platform design ensures easy and safe operation during inspections and maintenance. The modular plants are manufactured and tested in Finland before they are transported to the customer s site. Water treatment Good water treatment is essential for the boiler plant s long operating life. The Unicon water boiler plants are equipped with make-up water treatment equipment and an expansion system. Unicon steam boiler plants, too, can be equipped with make-up water treatment equipment, if necessary. A feedwater tank and a deaeration system ensure good quality and adequate feed water. Electrification and automation Electrification includes the plant s main control center and auxiliary control centers from where power is distributed to the equipment. The automation degree is determined by each customer s needs. Small boiler plants are usually designed for unmanned operation, as they can be remote controlled and operated from the main control room via a PlantSys control system. In larger plants, the control room can be housed in the boiler building. In some cases, critical automation components or the whole system can be duplicated. This guarantees even better efficiency and uninterrupted operation, also during problem situations. In addition to the PlantSys system, KPA Unicon offers solutions for a customers existing automation systems, as well as customer-specific packages. We also offer operation and maintenance related life-cycle services for small and medium-size boiler plants. Customer s own process automation system Boiler plant equipment PLC PlantSys system Customer s own equipment 30
Fuel auxiliary modules Fuel handling The Unicon boiler plants use gas or liquid fuels and their combinations: - light or heavy oil - natural gas - waste gas - cox gas - bio-oil A boiler plant usually has one burner per boiler. In addition to the burner, the burner package generally includes a combustion air fan and the required equipment for fuel treatment and feeding. An important part of the burner is its automation that controls the fuel and air volume, air distribution and fuel pressure. Burner automation is part of the plant s main automation system. The best possible combustion efficiency, low emission levels, high usability and operational safety are achieved with a modern control system. Oil handling The oil can be atomized with steam, compressed air, a pressure jet or a rotary cup. The boiler can also be equipped with a combined burner, allowing the use of natural gas and light or heavy fuel oil as fuel. The oil burner package often includes oil filters, a pumping unit and an oil pressurizing unit. The oil pumping unit for heavy fuel oil is equipped with preheaters that operate either with district heat water or electricity, or even both. An oil tank with accessories can also be included in the boiler plant delivery. Gas handling The gas burner package includes gas filtration and required pressure reduction equipment. The gas equipment is designed according to all requirements from the authorities. 31
KPA Unicon Oy Myllykatu 12 FI-76100 Pieksämäki, Finland Tel. +358 207 749 200 Fax +358 207 749 201 info@kpaunicon.com www.kpaunicon.com 2014 KPA Unicon