Low-energy gases
Waste gases with very low calorific value represent one of the greatest challenges in industrial energy systems. Although these gases are relatively clean in composition (typically a mixture of nitrogen with a small fraction of methane or other hydrocarbons), their calorific value often falls below 0.75 MJ/Nm3—dozens of times lower than that of natural gas. Such fuels cannot burn stably in conventional burners, and their disposal without proper technology typically involves flaring (using support fuel such as natural gas) or direct release into the atmosphere, which results in energy losses and environmental impact due to the direct emission of methane into the air.
ICS has developed a solution that allows this untapped energy potential to be recovered while simultaneously eliminating the emission problem. The key lies in the use of volumetric combustion in chambers specifically designed for low-energy fuels. In this process, there is no single flame zone—combustion occurs throughout a large portion of the chamber volume, ensuring stable and complete oxidation. Additionally, both the waste gas and combustion air are preheated to very high temperatures, lowering the ignition threshold and ensuring complete combustion of methane even at extremely low concentrations in the fuel.
With these solutions, it becomes possible to utilize gases that traditional technologies consider “non-combustible.” The process runs stably, without the need for auxiliary support fuels, and the generated thermal energy can be used to produce process steam or industrial heat. This simultaneously reduces methane emissions—a greenhouse gas with 28 times higher warming potential than CO2 – and lowers conventional fuel consumption costs, such as natural gas, within the plant.
In one of ICS’s projects, waste gas from a natural gas denitrogenation process—with a calorific value just above 0.5 MJ/Nm3 – was successfully utilized. Using volumetric combustion technology with preheating of gas and air to high temperatures, a stable oxidation process, full methane conversion, and recovery of over 5 MW of the chemical energy contained in the gas were achieved.
ICS – energy from what others write off as waste
Our technologies redefine the concept of waste. What was once a problem and a cost, we transform into a source of clean energy, savings, and competitive advantage. Thanks to ICS, even the lowest-calorific waste gases become the fuel of the future – safe, stable, and economically viable. Combustion of low-calorific waste gases.
