FAQ
Multienergy Boiler Plant
Basic information and applications
1. What is a multienergy boiler plant?
It is a multi-fuel boiler plant that can operate on many different fuels – a boiler plant fired by pellet (in the form of milled biomass dust), biogas, oil, natural gas, or even electric power. This makes it flexible and frees the company from dependence on a single energy source, while also enabling CO₂ emission reductions.
2. Where are multienergy boiler plants used?
They are implemented as part of the modernization of industrial heating plants, including those in the cosmetics, distillery, food, wood, and waste management industries. The boiler plant can operate on locally available biofuels and support the company’s decarbonization efforts.
3. What are examples of similar implementations in other industrial facilities and what results were achieved?
There are already many industrial installations on the market – for example in industrial laundries or CHP plants – using multienergy boilers based on pulverized-fuel, gas, and oil burners. These solutions have enabled plants to significantly reduce CO₂ emissions, avoid dependence on a single fuel, and optimize operating costs. The use of electric heaters in large industrial boilers is, however, new – the technology has not yet been widely deployed, but it represents the next step in the development of multienergy boiler plants. It allows full utilization of renewable electricity and even greater operational flexibility.
Fuels and operational flexibility
4. Is fuel diversification possible?
Yes, the multienergy boiler plant is designed precisely for fuel diversification. It can operate on various energy carriers. This means the plant is not dependent on a single fuel – if prices rise or availability issues occur, it can easily switch to another carrier. Diversification increases energy security and allows optimization of heat-production costs by always choosing the cheapest or most eco-friendly fuel available at a given moment.
5. What types of fuels can power the multienergy boiler plant, and can you easily switch between them?
The boiler plant can operate on:
- biomass (pellets, wood chips),
- biogas or biomethane,
- bio-oil,
- electricity (electric heaters in the boiler),
- waste-derived fuels, e.g., distillery syrups, waste oils,
- conventional fuels (natural gas, light fuel oil).
Switching between fuels can be automatic, without stopping operation – the system selects the optimal fuel in terms of price and availability.
6. What does the flexibility of a multienergy boiler plant involve?
Flexibility means the ability to quickly adapt boiler plant operation to changing conditions. The system can smoothly switch between different fuels (e.g., biomass, gas, electricity) and dynamically modulate output over a wide range – from 0% to 120% of nominal capacity. This enables the boiler plant to respond to both low loads and sudden demand spikes while maintaining stable parameters.
7. What is redundancy in a multienergy boiler plant?
Redundancy safeguards continuity of operation by duplicating equipment and enabling the use of different fuels. In practice, this means that if one fuel becomes unavailable (e.g., natural gas or fuel oil), the boiler can automatically switch to another energy source – e.g., pellets, biogas, or electricity. Thanks to such fuel diversity, the boiler plant continuously supplies process steam and the facility avoids downtime related to disruptions in a single fuel market.
8. Is it possible to co-fire several fuels simultaneously (e.g., biomass and gas) to optimize costs and operating parameters?
Yes, a multi-fuel burner allows co-firing – for example, a mixture of biomass dust and natural gas. The controller automatically regulates the fuel proportions to achieve the best economy and combustion performance. This is particularly cost-effective during periods of large fuel price fluctuations. Additionally, blending biomass with gas/oil enables more stable combustion (especially with challenging fuels).
9. Does the use of different fuels affect the quality and parameters of process steam?
No. Steam parameters (pressure, temperature, dryness fraction) are maintained regardless of the fuel. The quality of process steam meets application requirements – for example, in the food industry the steam is clean and free of contaminants.
Parameters and technology
10. What are typical operating parameters of the boiler plant?
The boiler plant can produce from several to several dozen tonnes of steam per hour, at pressures up to 24 bar(g). It can operate from 0% (electric heaters only) up to 120% of capacity (burner plus heaters), which provides high energy flexibility.
11. How does the system respond to variable demand for steam and heat?
A boiler with electric heaters and a multi-fuel burner can operate over a wide range – from 0% output (heaters only) to 120% (burner + heaters). This handles both low-load operation and demand peaks well. In addition, a steam buffer in the form of a Ruths tank enables stable operation without frequent output oscillations.
12. Does the boiler plant operate stably and reliably?
Yes, in daily operation – thanks to automation and redundancy (e.g., duplicated pumps, ability to run on different fuels) – the boiler plant ensures continuous delivery of process steam at the required parameters without the risk of sudden downtime.
13. What does the start-up process look like and how long does it take to reach full steam parameters?
Depending on the fuel type, water content, and hot/cold state, start-up typically takes from several minutes up to about 1 hour. With electric heaters, rapid warm-up and parameter stabilization are possible. In practice, a multienergy boiler plant is ready for operation faster than traditional coal-fired boilers.
14. Does the system feature predictive control (e.g., based on fuel price forecasts or production schedules)?
Yes, modern automation enables integration with forecasting and production planning systems. The controller can select the fuel depending on its current price, availability, and the facility’s demand.
15. What type of biomass mill is used in a multienergy boiler plant?
Hammer mills are used to grind pellets into wood dust. Particles must be very fine – typically below 1 mm – to ensure stable and efficient combustion in a pulverized-fuel burner. Hammer mills are often installed in process buildings next to silos, with feeders and appropriate separators. Integrated with boiler automation, the mill runs only when dust is needed and maintains a buffer inventory in a storage hopper.
16. Is compressed air required in a multienergy boiler plant?
Yes, most installations require a compressed-air system. It is used for:
- operating pneumatic actuators (valves, dampers, louvers),
- atomizing oil fuel in the burner,
- cleaning bag filters,
- automation and boiler protection elements.
Compressed air must be properly dried and cleaned to prevent corrosion and clogging. Typically, a compressor with a dryer and buffer tank is installed to provide stable supply to the entire pneumatic system.
Integration of the installation
17. Can a multienergy boiler plant be connected to an existing installation?
Yes, the boiler plant is modular and compact, so it can be tied into the facility’s existing system. This is usually done during planned maintenance outages and does not disrupt operations.
18. What are the installation requirements?
A multienergy boiler plant requires appropriate space – for example, for a 5 t/h capacity, around 450 m2. Biomass silos, bio-oil tanks (if used), a mill, the boiler, and a stack with filters are needed. A high-capacity electrical connection is also necessary if electric heaters are to be used.
19. What are the fire-protection requirements when building a multienergy boiler plant?
The boiler-house building must be designed and constructed in accordance with fire safety regulations. This includes appropriate fire resistance of walls and floors, separate fire zones for the boiler, fuel storage, and electrical installations. Ventilation and flue systems are required to prevent accumulation of explosive mixtures. The boiler plant should include a fire alarm system, appropriate firefighting equipment, and safe evacuation routes. For solid fuels (pellets), it is also important to prevent self-ignition in silos and feed systems. All these elements are agreed at the design stage with a fire-protection expert.
20. What does the water-treatment system look like in a multienergy boiler plant?
Properly treated feedwater is necessary for boiler operation. Raw municipal or well water contains salts and hardness that can cause scale and corrosion. Therefore, the boiler plant is equipped with a water-treatment station that uses, among others, iron removers, ion-exchange softeners, deaerators, and filtration systems. For steam used in food or process applications, additional purification stages (e.g., reverse osmosis or demineralization) are applied to ensure the required steam quality. The water-preparation system is fully automated and integrated with the boiler, ensuring stable operating parameters and longer service life.
21. Can the boiler plant be integrated with the facility’s current infrastructure?
Yes, it is modular and can be tied into the existing steam and water networks and the automation system (SCADA/DCS). On the plant side, connections to steam, water, and utilities piping are usually required, along with minor adaptations of electrical installations.
Expansion and cooperation with RES
22. Can the boiler plant be expanded to generate electricity?
Yes. The boiler plant can operate in conjunction with renewable energy installations, such as photovoltaic panels or wind turbines. This allows electric heaters to be powered with green energy, reducing both operating costs and the facility’s carbon footprint.
23. Is it possible to integrate the boiler plant with RES installations (e.g., a PV farm or biogas plant)?
Yes, the system can be fully integrated with RES. Electric heaters allow the use of surplus power from PV or wind farms, and gas burners can be fueled with biogas or biomethane from an in-house biogas plant. This integration maximizes the use of the facility’s own, low-cost, eco-friendly energy sources.
24. Does the system allow for expansion or power increase?
Yes, the modular design allows adding another boiler later or increasing capacity by upgrading burners and auxiliary systems.
Operation and service
25. What does boiler-plant automation look like?
The system is fully automated – it selects the fuel and controls boiler operation autonomously. Operators need not be on site around the clock; remote supervision is sufficient. In case of issues, the boiler plant automatically switches to another fuel and sends an alarm.
26. What does servicing a multienergy boiler plant involve?
It is designed to require minimal day-to-day attention because most processes are fully automated. Operators mainly perform remote supervision and periodic inspections. Regular service includes, among others: cleaning the boiler and heat exchangers, checking fuel-feed systems, inspecting water and gas system tightness, servicing the biomass mill, and checking flue-gas filtration systems. Typically, a major inspection is carried out once a year, and a more detailed overhaul every few years per manufacturers’ recommendations. Thanks to the modular design, many service tasks can be performed quickly without long downtime.
27. What does operation and maintenance look like?
The system is unattended in operating mode – requiring only remote monitoring and periodic inspections. Basic inspections are performed every few months, and main overhauls usually once a year. The supplier provides service support, spare parts, and staff training.
28. What happens if one primary heat source fails?
The boiler plant features redundancy: multiple parallel boilers, duplicated pump systems, and the ability to run on alternative fuels. Thus, even if one element of a given fuel train fails, the system continues operating and ensures uninterrupted steam supply.
29. Are multienergy boiler plants delivered “turnkey”?
Yes, they can be delivered on a turnkey basis. This means the supplier handles the entire process: design, equipment supply, installation, commissioning, and operator training. This model ensures that all components – boiler, burners, fuel systems, water-treatment station, electrical installation, automation, and fire protection – are integrated from the outset and ready for operation. The investor receives a complete boiler plant that only needs to be connected to site utilities (e.g., water, power, steam network).
Safety and environment
30. What are the environmental benefits of building a boiler plant?
Yes, the installation is equipped with flue-gas cleaning systems (bag filters, NOX – reduction systems), ensuring compliance with IED and BAT. The combustion of biomass and biomethane is CO2-neutral, so the boiler plant effectively reduces the facility’s carbon footprint and enhances its image on the global market.
31. Does the boiler plant meet all emissions standards and environmental regulations, and does it reduce CO2 emissions?
Yes, the installation is equipped with flue-gas cleaning systems (bag filters, NOX – reduction systems), ensuring compliance with IED and BAT. The combustion of biomass and biomethane is CO2-neutral, so the boiler plant effectively reduces the facility’s carbon footprint and enhances its image on the global market.
32. What measures ensure safe boiler-plant operation, and does the installation meet OHS and fire-protection requirements?
The boiler plant complies with all safety regulations (UDT, OHS, fire protection). It is equipped with automatic safety systems, a fire-alarm installation, firefighting equipment, and a building with designated fire zones and fire resistance. Additional safeguards include burner protections, ventilation systems, and fuel storage monitoring.
Finance and economics
33. What are the indicative investment and operating costs for a multi-fuel boiler plant?
Investment cost depends on installation size, required capacity and fuel set, number of installed boilers, and technical-construction conditions. Operating costs are significantly lower than for gas-only boilers because cheaper renewable fuels (e.g., biomass, biomethane) can be used, and high CO2 emission fees are avoided. For an investment quotation for a multienergy boiler plant from ICS Industrial Complete Solutions S.A., please submit an inquiry to the address provided in the Contact tab.
34. What is the expected return on investment (ROI) for such a boiler plant?
Compared to a conventional gas boiler plant, the investment typically pays back in several to about 10 years. Faster payback results from the use of cheaper renewable fuels, the absence of CO2 fees, and lower operating costs thanks to automation.
Waste gases
General and investment questions
1. What are waste gases and why is it better to burn them in boilers rather than in flares?
Waste gases are by-products of industrial processes such as metallurgy, chemicals, or petrochemicals. They have very low calorific value and often contain contaminants; for years they were treated as a troublesome waste and flared.
In this way, the chemical energy contained in the gas was irretrievably lost. Thanks to ICS installations, this energy can be recovered: waste gas is burned in dedicated chambers with burners, and the heat is used to produce steam or process heat. The facility benefits (lower fuel costs), and the environment is protected from unnecessary emissions resulting, for example, from burning natural gas.
2. Does burning waste gases reduce a plant’s energy costs?
Yes, this is one of the main benefits for the investor. Waste gases are a “free” fuel because they are produced regardless of whether we use them or not. Implementing ICS technology allows part or most of the natural gas to be replaced with energy from waste gas. This results in a significant reduction in fossil fuel purchase costs. In many cases, the share of support fuel drops to just a few percent, while the remaining energy comes from waste that was previously unused.
3. Which companies already use ICS waste-gas combustion technology?
ICS has numerous references, including at KGHM (modernizations of steam boilers in Legnica and Głogów), at Huta Cynku Miasteczko Śląskie, and at Orlen facilities. Outside Poland, there are implementations in Western Europe and Scandinavia. This shows the technology operates reliably in very different conditions and industries.
4. Does the ICS installation operate even with variable amounts of waste gas?
Yes, within the control range of the burner system; at extremely low calorific value, the share of auxiliary fuel increases. The system is designed to automatically adapt to variable composition and quantity of gas. If there is less waste gas or its calorific value drops, the system increases the share of natural gas. This ensures continuous steam production and stable combustion.
5. Can the ICS system run on natural gas only?
Yes, which is a major advantage. ICS burners are dual-fuel, meaning they can operate fully on natural gas in the absence of waste gas. This provides security and flexibility, avoiding downtime even when waste gas is unavailable.
6. Can the installation fit within an existing boiler house?
In most cases, yes. ICS specializes in modernizing existing installations rather than building everything from scratch. Burners and combustion chambers are designed to utilize existing boilers and auxiliaries. This shortens project timelines and reduces investment costs.
7. How long does design and commissioning take?
The schedule depends on project size – typically from several months to about a year. Installation and start-up are planned to coincide with standard maintenance shutdowns, minimizing production downtime and enabling rapid start of operation.
8. Does operation require special training?
Yes, but ICS provides training and manuals. The installation is fully automated, so operators do not manually control combustion. Their task is mainly process supervision via the control system (SCADA/DCS). Operation is straightforward, and additional competencies are easily acquired during commissioning training.
9. Is the installation safe?
Yes – safety is a priority. Burners feature flame detection, fast-acting gas shut-off valves, and purge procedures before ignition. If waste gas supply fails, the system immediately switches to natural gas. This prevents unburned fuel accumulation and boiler trips.
10. What are typical fuel savings?
It depends on waste-gas availability, but in many ICS projects natural gas consumption has fallen by tens of percent. In practice, this means annual savings in the millions for large plants, while also reducing the carbon footprint.
11. Does ICS guarantee emission parameters?
Yes – contractually guaranteed emission parameters comply with IED/BAT. All installations are designed in line with BAT conclusions and the IED directive. NOX and CO emissions are maintained well below legal limits, as confirmed by reference project results.
12. How often is servicing required?
ICS burners are designed for long, failure-free operation. They require routine annual inspections, typically during standard maintenance outages. Maintenance is limited to nozzle cleaning and automation checks.
13. Does ICS assist in obtaining environmental permits?
Yes. The company prepares emission reports and technical documentation that the investor can use in environmental procedures and supports interactions with authorities.
14. What are examples of similar installations?
In Poland: projects in Głogów and Legnica (KGHM), modernizations in zinc smelters, and other industrial plants. Abroad: installations in steelworks and the metallurgical industry. This shows the solution is scalable and proven under varied conditions.
15. Does the technology align with climate goals?
Yes. Utilizing waste gases reduces fossil fuel consumption and CO2 emissions, lowering the plant’s carbon footprint and reported CO2 metrics.
16. Is the system integrated with plant automation?
Yes. ICS designs control systems to work with existing SCADA/DCS. Operators supervise the installation from a single console without separate handling.
17. What does financing look like – are milestone payments possible?
Yes. ICS offers flexible settlement models tailored to project scale and schedule. Most commonly, milestone payments are linked to project phases – from technical documentation through delivery and installation to commissioning. This spreads expenditure over time, eases budgeting, and reduces the financial risk of a large industrial investment.
Technical questions
18. What minimum parameters must waste gas have?
ICS burners can combust gas with a calorific value as low as 1.5–2 MJ/Nm3. Below this, a higher share of natural gas is required, but the system remains stable – making this solution unique on the market.
19. How is combustion air preheated?
Most often via a recuperator – i.e., a heat exchanger that uses the energy of hot flue gases leaving the boiler. The flue gas transfers part of its heat to the airstream fed to the burners, so the combustion air enters the chamber preheated, typically to several hundred degrees Celsius. This improves combustion stability, facilitates ignition of low-calorific gases, and increases overall efficiency. An additional benefit is reduced stack losses, because heat that would otherwise be lost is recovered for the process.
20. Are additional NOX reduction methods used?
Usually not required because HiTAC technology keeps NOX very low. For stricter limits, ICS can apply SNCR (urea or ammonia injection) or SCR (catalyst).
21. How is oxygen in the flue gas controlled?
The installation includes measurement probes at the outlet. Burner automation regulates air supply to maintain the proper excess oxygen, keeping CO low and ensuring complete combustion.
22. Do ICS burners require water cooling?
No. Thanks to HiTAC, burner component temperatures are lower, so air cooling suffices. No water cooling means less failure risk and simpler operation.
23. What does the start-up look like?
The installation is started on natural gas or oil, heating the boiler’s combustion chamber above 750°C. Only then is the waste-gas-fired burner ignited. This ensures safe ignition and stable operation from the outset.
24. What is the efficiency of waste-gas combustion installations?
In reference projects – for example, the KP2 boiler modernization in Legnica – boiler efficiency reached at least 75% when firing waste gas and 89% when firing natural gas. This means most of the waste-gas energy is recovered with limited losses.
25. How does the burner system handle variable waste-gas pressure?
The system includes stabilization and flow-control trains that compensate pressure fluctuations, ensuring uniform burner supply.
26. What are the minimum and maximum capacities of ICS burners?
ICS burners can be engineered from a few to several dozen megawatts (MW) to suit different boilers and applications.
27. Is it possible to burn a mixture of several different waste gases in one burner?
Yes, waste-gas burners can be supplied with mixtures of gases of different calorific values, and automation adjusts combustion conditions to their composition.
28. How is the installation protected against corrosion caused by gas contaminants?
By selecting appropriate construction materials (heat-resistant steel, stainless steel, ceramic linings) and designing the system to limit dust/scale deposition and reduce steel corrosion.
29. Can ICS burners be used in different types of hot-water and steam boilers?
Yes, they can be integrated with both water-tube boilers and modern heat-recovery boilers. They can be used in both steam and hot-water boilers.
30. What are typical combustion-chamber temperatures when firing waste gas?
Typically, temperature stabilizes in the 750–1100°C range, sufficient for complete oxidation of low-calorific gases and CO burnout.
31. How is dust emission from waste-gas combustion controlled?
If gases contain metallic dust or other particulates, additional filters and dust collectors – e.g., electrostatic precipitators or multicyclones – are provided at the flue-gas outlet to the stack.
32. How does the system respond to sudden changes in the chemical composition of waste gas?
Automation measures process parameters in real time and adjusts air quantity and auxiliary fuel accordingly to maintain stable combustion.
33. Can burners be arranged in multi-burner configurations?
Yes, larger boilers are fitted with several or even a dozen burners, allowing even heat distribution and output matching to demand.
34. How long does a typical cold start of a burner take?
Depending on boiler size, on the order of tens of minutes. First the natural-gas burner is started, and after the required temperature is reached, the system transitions to waste-gas firing.
