Low-calorific waste gases
Combustion of low-calorific waste gases, such as off-gases from copper smelting, post-reduction gases, or process gases from metallurgical operations, has long been one of the major challenges in industrial energy systems. These are fuels that often have a calorific value between 0.75 and 3.0 MJ/Nm3, are contaminated with dust, moisture, or toxic chemical compounds, and are characterized by significant variability of parameters over time. In traditional systems, such fuels do not burn stably, as they require expensive support fuels (e.g., natural gas combustion), special cleaning systems, or are simply flared without energy recovery and with high CO2 and NOX emissions.
ICS technology, based on volumetric combustion in semi-adiabatic combustion chambers, provides an effective solution to this problem. Unlike conventional burners, where combustion occurs in a narrow flame zone, volumetric combustion distributes the reaction throughout a large portion of the chamber’s volume. In practice, this means a lower peak temperature, more uniform mixing of gas and oxidizer, and a stable flame even when the fuel parameters change dynamically. By using high-temperature HTB burners, it is possible to fully oxidize gases with very low calorific value—without catalysts or auxiliary fuels. The semi-adiabatic chamber design allows partial heat recovery and minimizes energy losses, resulting in high process efficiency.
Our solutions have been verified in heavy industry. An example is the Legnica Copper Smelter, where the ICS system enabled the utilization of waste gas with a calorific value of around 1.5–2.4 MJ/Nm3. The implementation allowed for the near-complete elimination of natural gas as a supporting fuel in off-gas utilization (only 1–2% in energy terms) and improved the plant’s overall energy efficiency.
The strength of ICS technology lies in its flexibility. Our combustion chambers and burners adapt to temporary changes in calorific value, pressure, or gas flow, ensuring boiler stability and complete fuel utilization. At the same time, the process operates with a low excess air ratio, minimizing emissions of NOₓ, CO, and other toxic compounds. This means that the plant not only eliminates a troublesome waste but also converts it into a valuable source of energy in the form of heat and process steam.
ICS provides solutions that enable heavy industry to reach a completely new level of energy and environmental efficiency. Where others see a problem in the form of hard-to-burn waste gases, we offer proven technology that transforms waste into a competitive advantage. High-temperature HTB burners are high-capacity units. The combustion technology applied in them (HiTAC) allows compliance with strict toxic emission limits and improves the quality of the final product by ensuring a more uniform temperature distribution in the boiler’s combustion chamber, which in turn extends the life of the refractory lining.
Why ICS?
Because our systems combine engineering reliability with measurable business results. Thanks to the flexibility of the technology and full process automation, the plant receives a solution that is reliable, stable, and virtually maintenance-free. This means:
- tangible savings through reduced fuel costs,
- a short investment payback period – optimized for each project,
- increased energy independence through the use of internal waste as an energy source,
- a competitive market advantage by meeting the most stringent environmental standards and building the image of a company investing in a circular economy.
