Competence at Work

Rely on Good
Experiences with
From the Past to the Present and Future

“ The integration of our two companies will generate synergies and have advantages
for our clients, employees and the future development of our business. ”

This statement was made by Naoya Domoto, Managing
Executive Officer, President of Energy & Plant Operations,
IHI Corporation, at the welcoming meeting for all Stein-
mueller Engineering employees as new members of the
IHI group of companies, following the acquisition of Stein-
mueller Engineering GmbH in July 2014.
IHI and Steinmüller Engineering have a longstanding
technical relationship based on cooperation between in-
dividual employees working together on fossil-fuel power
plant equipment. Over the past 40 years, mutual activities
reach back, to a time when current Steinmüller Engineer-
ing employees worked for the former L&C Steinmüller. We
are hard at work jointly developing our technologies.
Our efforts are focussed on the diversification of fuel, im-
provement in plant efficiency and implementation of envi-
ronmentally-friendly technologies. We provide advanced
solutions to the global challenges concerning energy and
the environment. We develop sophisticated technologies by
utilizing the combined knowledge, technological strengths
and market experience gained in Germany and Japan.
Our technology in particular contributes to the effective
utilization of coal by focusing on the reduction of energy
costs and conservation of energy resources. In addition
we develop and apply environmentally-friendly technolo-
gies such as our Air Quality Control and CO2 Capture and
Storage systems.

2
 Efficiency Through Know-How

Maximum performance with minimum emissions! This
is a requirement which is simply stated, but which de-
mands exceedingly complex and thoroughly thought-
out solutions – from low emission fuel conversion in a
power plant and highest possible efficiencies up to the air
pollution control system.
of projects throughout the world. Thanks to our activities
in the planning, design, selection of suppliers, manufac-
ture, construction management and commissioning of
power plants of various kinds, we gather new experiences
every day and generate new knowledge which is utilised in
your projects.

Steinmüller Engineering is sought after throughout the

world as a consulting and plant construction company.
As employees of the former L&C Steinmüller GmbH in
Gummersbach, many of our colleagues were involved
in the development, construction and operation of the ener- Company Development
gy and air pollution control plants which are now to be
modernised. They are familiar with the construction and Since End of June 2014 Steinmüller Engineering GmbH
operation processes and know exactly where and how to is a 100% subsidiary of IHI Corporation. This is a win-
improve plant performance and efficiency. win situation, as it facilitates access to the latest
technologies and processes of the parent company,
In addition to this first-hand experience, as a customer you enables the development of further innovative designs
also benefit from our work on current new constructions and allows us to handle large-scale projects.
and refurbishments as well as our activities in a wide range

Success Through Expertise

Founded in 2003, Steinmüller Engineering GmbH rapidly The success of our company is based on our experience
developed into a key player on the local and international and passion for technology. We are engineers, who think in
markets and is in a position to handle complex and sophis- terms of facts and figures and love to solve new and chal-
ticated projects. lenging problems. But we are not dreamers. Our concepts
are based on facts, on technical possibilities and on what is
economically feasible. However, over and above all, safety
Company Development has the highest priority in our activities for the modernisa-
tion and new construction of power plants. Not question-
t€
25.000 ing every detail and closely examining every aspect of the
plant may lead to nasty surprises. You may call us pedantic.
20.000 We take that as a compliment.
15.000

94 93
10.000 83 86 88
72 Order Entry

Staff
5.000

0 Year
2009 2010 2011 2012 2013 2014

3
Dependable Support

Steinmüller Engineering GmbH is your dependable partner
through all stages of plant construction, from process
engineering and design to the management of the project.
Our engineers advise you with regard to the technical
planning, take care of the delivery of the necessary com-
ponents, supervise the installation and monitor the com-
missioning and optimization of steam generators, combus-
tion systems and flue gas cleaning systems. This holistic
approach and our unchallenged competence in all sub
areas gives you the maximum possible security, to make
your modernisation or new construction project a worth-
while investment.

FIELDS OF ACTIVITY CORE COMPETENCIES FIELDS OF APPLICATION

Process Engineering Consultancy Flue Gas Cleaning

Design Design & Planning Steam Generation

Project Management Supply Combustion Systems

4
Modify and Improve:
Process Engineering
Regardless of whether you wish to build a new plant or Use our company‘s know-how and rely on optimum solutions
modify an existing plant due to various reasons e.g. new for your needs in the fields of:
legal requirements or a change in fuel properties – the key
objective is to find a solution with optimized efficiency.
• Combustion Processes
This can be achieved either through an increase in perfor­ • Thermodynamics
mance, improved availability and/or future cost reductions.
• Flue Gas Cleaning
• Fluid Mechanics

Analyse and Implement:

Mechanical Design
Not everything that looks good on paper can be im-
plemented in reality. Rely on our experience and our • Pressure Parts in Boiler and
“up-to-date” knowledge of the latest plant technology. Apparatus Engineering
Our experience from our day-to-day work on construc-
• Components for Furnaces, such as
tion sites is included in the mechanical designs which we
Pulverized Fuel Lines, Burners and Ducts
develop for you.
• High Temperature Reactors
Together with you, we develop designs for components • DeNOX Plants (SCR)
which are subjected to high stresses such as temperature, • Electrostatic Precipitators
pressure, corrosion or erosion. • Flue Gas Scrubbers for Desulfurization Plants
• Supporting Steel Structures

Advise and Support:

Project Management
Once technical planning is complete, we ensure that the Rely on our extraordinary expertise for:
production and installation on site is implemented just as
expertly and with great care for detail. During every phase
of your project, you will be supported by people who not • Project Management
only have the theoretical knowledge, but also the practical • Manufacturing Supervision
experience. • Installation Supervision
• Commissioning
• Personnel Training

5
 Gesamtdarstellung

Bituminous Coal and Sub-Bituminous BUNKER

FUEL
SCR

Coal Combustion Systems HANDLING BOILER

TURBINE

ESP FGD

Bereich Kessel

BUNKER SCR
FUEL
HANDLING BOILER
TURBINE

ESP FGD

Bereich Reinigung

BUNKER SCR

SM V®* Coal Burner

TURBINE
FUEL
HANDLING BOILER

ESP FGD

LowNOX Emission
Efficiency Increase
Flexible Operation

Application Technical Data Scope of Supply

Power Plants and Industrial Boilers Burner Type: • Consultancy

NOX reduction, extension of fuel range, SM V®* Coal Burner • Design of burners
efficiency increase Burner Capacity: • Process engineering
15 MWth – 100 MWth
• Design of furnace
Emissions:
Benefits CO < 100 mg/m3 (STP) • CFD-Simulations of
NOX < 280 mg/m3 (STP) boiler furnace and
• Optimized engineering based on
combustion system
CFD-simulation calculations without
expensive trials Fuel Type • Supply and installation of
firing system components
• High availability and efficiency
Bituminous Coal including burners, OFA, etc.
• Increase of operational flexibility Water: 5-38 % ar
Ash: 10-40 % ar • Adaptation of I & C
• Reliable solution based on decades
VM daf: 15-45 % • Commissioning
of experience
LCV: 12-32 MJ/kg
Biomass

* ® Registered Trademark Staged Mixing Burner

www.steinmueller.com
Tel. +49 2261 78950-0
 Reference List Excerpt

Bituminous Coal Combustion Systems

Scope Client

Modification and capacity increase of LowNOx firing system, EnBW Kraftwerke AG,
Bituminous Coal, 330 MWel, Altbach PS, Germany Karlsruhe, Germany

Concept design study for LowNOX burner technology, 200 – 730 MWel, Eskom Enterprises,
Bituminous Coal, ESKOM’S fleet, South Africa Johannesburg, South Africa

Investigation and recovery scope development support after boiler Eskom Enterprises,
damage, 600 MWel, Bituminous Coal, Duvha PS, South Africa Johannesburg, South Africa

Engineering support for manufacturing, installation and commissioning Eskom Enterprises,

of PF burners, 200 MWel, Bituminous Coal, Camden PS, South Africa Johannesburg, South Africa

Boiler design review and study for future change in coal quality, Eskom Enterprises,
6 x 600 MWel, Bituminous Coal, Tutuka PS, South Africa Johannesburg, South Africa

Modernization of firing system and extension of coal range, installation STEAG GmbH,
of LowNOX burners, 500 MWel, Bituminous Coal, Herne PS Unit 4, Essen, Germany
Germany

Design study on coal range extension in supercritical utility boilers, Coastal Gujarat Power Generation,
5 x 830 MWel, Bituminous Coal, Mundra PS, India Mumbai, India

Boiler concept study for coal range extension, 465 MWel, Bituminous EnBW Kraftwerke AG,
Coal, CHP Altbach I, Germany Karlsruhe, Germany

Concept study for coal range extension at 6 x 600 MWel, Bituminous Coal, Eskom Enterprises,
Duvha PS, South Africa Johannesburg, South Africa

Boiler concept study for capacity increase and coal range extension, EnBW Kraftwerke AG,
330 MWel, Bituminous Coal, CHP II Altbach PS, Germany Karlsruhe, Germany

Modification of the firing system and installation of LowNOX burner, EnBW Kraftwerke AG,
550 MWel, Bituminous Coal, Rheinhafen-Dampfkraftwerk (RDK) PS Unit 7, Karlsruhe, Germany
Germany

Conceptual design for adaptation of firing equipment to an extension of Vattenfall Europe Hamburg AG,
acceptable coal specification, 2 x 100 MWel, Bituminous Coal, Germany
Tiefstack PS,Germany

Modification of the firing system and installation of LowNOX burner, Balcke-Dürr GmbH,
700 MWel, Bituminous Coal, Mehrum PS, Germany Ratingen, Germany, for E.ON Power

Legend:
PS – Power Station SCR – Selective Catalytic Reduction FGD – Flue Gas Desulphurization
PF – Pulverized Fuel STP – Standard Temperature and Pressure CFB – Circulating Fluidized Bed
CHP – Heat and power plant HRSG – Heat Recovery Steam Generator ESP – Electrostatic Precipitator

www.steinmueller.com
Tel. +49 2261 78950-0
 Gesamtdarstellung

Lignite Combustion Systems BUNKER

FUEL
SCR

HANDLING BOILER
TURBINE

ESP FGD

Bereich Kessel

BUNKER SCR
FUEL
HANDLING BOILER
TURBINE

ESP FGD

Bereich Reinigung

BUNKER SCR

RSM®*-Lignite Burner
TURBINE
FUEL
HANDLING BOILER

ESP FGD

LowNOX Emission
Efficiency Increase
Flexible Operation

Application Technical Data Scope of Supply

Power Plants and Industrial Boilers Burner Type: • Consultancy

RSM®* Lignite Burner • Process engineering
NOX reduction, extension of fuel range,
efficiency increase Burner Capacity: • CFD-Simulations of
30 – 150 MWth
boiler furnace and
Benefits Emissions: combustion system
• Optimized engineering based on CO < 200 mg/m3 (STP)
NOX < 200 mg/m3 (STP) • Design of burners
CFD-simulations calculations without
• Supply and installation of
expensive trials
Fuel Type firing system components
• High availability and efficiency including burners, OFA, etc.
• Increase of operation flexibility and Lignite • Commissioning
capacity Water: 25 – 70 % ar
• Furnace design
Ash: 0 – 50 % ar
• Reliable solution based on decades
VM daf: 30 – 70 % • Adaptation of I & C
of experience LCV: 3,5 – 22 MJ/kg

* ® Registered Trademark Radial Staged Mixing Burner

www.steinmueller.com
Tel. +49 2261 78950-0
 Reference List Excerpt

Lignite Combustion Systems

Scope Client

Engineering and supply of a LowNOX firing system, 350 MWel, Lignite, PE Electric Power Industry,
Kostolac PS B1, PE Industry, Serbia Belgrade, Serbia

Lignite firing system modification, 4 x 227 MWel, Lignite, ContourGlobal,

Maritza East 3 PS Unit 1 – 4, Maritza, Bulgaria Sofia, Bulgaria

Engineering for firing system retrofit, 2 x 600 MWel, Lignite, RWE AG,

Niederaußem PS Unit G and H, Germany Essen, Germany

Wall-air system detail design, 11 x 250 MWel, Lignite, Vattenfall Europe Generation AG & Co. KG,
Jänschwalde PS, Germany Cottbus, Germany

Basic engineering for LowNOX firing system modification, 11 x 250 MWel, Vattenfall Europe Generation AG & Co. KG,
Lignite, Jänschwalde PS, Germany Cottbus, Germany

Process and basic design for proposal of 500 MWel power plant, Doosan Babcock Energy Ltd.,
Lignite, Turow PS, Poland West Sussex, UK

Concept study and engineering for LowNOX burner modifications, RWE Power AG,
2 x 640 MWel, Lignite, Neurath PS Unit D and E, Germany Essen, Germany

Feasibility study of potential modifications for NOX reduction by Siemens d.o.o.,

primary measures, 345 MWel, Lignite, Sostanj PS Unit 5, Slovenia Ljubljana, Slovenia

Concept study for proposal, for 330 MWel power plant, Doosan Babcock Energy Ltd.,
Lignite, Turceni PS Unit 6, Romania West Sussex, UK

Legend:
PS – Power Station SCR – Selective Catalytic Reduction FGD – Flue Gas Desulphurization
PF – Pulverized Fuel STP – Standard Temperature and Pressure CFB – Circulating Fluidized Bed
CHP – Heat and power plant HRSG – Heat Recovery Steam Generator ESP – Electrostatic Precipitator

www.steinmueller.com
Tel. +49 2261 78950-0
 Gesamtdarstellung

Dry Lignite Combustion Systems BUNKER

FUEL
SCR

HANDLING BOILER
TURBINE

ESP FGD

Bereich Kessel

BUNKER SCR
FUEL
HANDLING BOILER
TURBINE

ESP FGD

Bereich Reinigung

BUNKER SCR

Dry Lignite Vortex Burner

TURBINE
FUEL
HANDLING BOILER

ESP FGD

High Flexibility, Availability and Efficiency

Reliable Use in Co-firing

Application Technical Data Scope of Supply

Coal Fired Power Plants and Burner type: • Consultancy

Industrial Boilers Integrated Vortex Burner • Basic engineering
Pollution reduction, extension of fuel range, Burner Capacity: • Design of burners
efficiency increase 10 – 100 MW
• Design of furnace
Ignition burner and auxiliary burner for Emissions:
CO < 100 mg/m³ (STP) • Process engineering
medium and peak loads
NOX < 190 mg/m³ (STP) • CFD-Simulations of boiler
furnace and combustion
Benefits
Fuel Type system
• High flexibility, availability and efficiency
• Supply and installation
• For reliable use in co-firing systems for Pulverized Dried Lignite of burners including all
base loads optimized engineering based Water: 10 – 20 % ar
related components
on simulation calculations without Ash: 4 – 16 % ar
VM daf: 30 – 70 % • Commissioning
extensive trials
LCV: 18 – 22 MJ/kg
• Reliable solution based on decades of
experience
• Savings on expensive start up fuel

www.steinmueller.com
Tel. +49 2261 78950-0
 Reference List Excerpt

Dry Lignite Combustion Systems

Scope Client

Engineering for C&I implementation for dry lignite test burner, RWE,
20 MWth, Lignite, RWE Ibbenbüren PS, Germany Essen, Germany

Study for integration of TBK (pre-dried Lignite) burner in anthracite RWE Service GmbH,
slag-tap firing system, 848 MWel, Bituminous Coal, Ibbenbüren PS, Nordhorn, Germany
Germany

Engineering service for support during bidding phase for design of Ishikawajima-Harima Heavy Industries Co.,
boilers including a co-firing concept, 2 x 550 MWel, Pre-Dried Lignite, Ltd., Tokyo, Japan
Niederaußem PS Unit K, Germany

Concept design study for optimization of firing system considering RWE Power AG,
dry lignite burners, 2 x 550 MWel, Lignite, Niederaußem PS Unit K, Essen, Germany
Germany

Concept study for a 1100 MWel dry lignite-fired steam generator, Ishikawajima-Harima Heavy Industries Co.,
Japan Ltd., Tokyo, Japan

Design study for a super critical steam generator fired with Pre-Dried RWE Power AG,
Lignite without flue gas circulation, Germany Essen, Germany

Feasibility study for the implementation of dry lignite burners RWE Power AG,
including test phase, Germany Essen, Germany

Legend:
PS – Power Station SCR – Selective Catalytic Reduction FGD – Flue Gas Desulphurization
PF – Pulverized Fuel STP – Standard Temperature and Pressure CFB – Circulating Fluidized Bed
CHP – Heat and power plant HRSG – Heat Recovery Steam Generator ESP – Electrostatic Precipitator

www.steinmueller.com
Tel. +49 2261 78950-0
 Gesamtdarstellung

Liquids and Gas Firing Systems BUNKER

FUEL
SCR

HANDLING BOILER
TURBINE

ESP FGD

Bereich Kessel

BUNKER SCR
FUEL
HANDLING BOILER
TURBINE

ESP FGD

Bereich Reinigung

BUNKER SCR

Oil and Gas Vortex Burner

TURBINE
FUEL
HANDLING BOILER

ESP FGD

High Combustion Efficiency

Low Emissions

Application Refineries Steel Plants Power Plants

Fuel Type Refinery gas Blast furnace gas Natural gas

Visbreaker residues Coke oven gas Light fuel oil
Vacuum residues Converter gas Heavy fuel oil
HSC-R Bio fuel
H2

Benefits • Almost total burnout

• Minimization of organic residues
• High burnout of fuel
• Reliable solutions based on decades of experience

Technical Data Capacity Gas: Capacity Oil:

0,6 – 100 MWth 5 – 100 MWth (0,45 – 9 t/h)

Scope of Supply • Consultancy

• Process engineering
• CFD-simulations of boiler furnace and combustion system
• Design of furnace
• Design of burner
• Supply of gas- and oil burners including all related components
• Commissioning

www.steinmueller.com
Tel. +49 2261 78950-0
 Reference List Excerpt

Liquids and Gas Firing Systems

Scope Client

Study for capacity increase of firing system, Coke-Oven Gas, 240 MWel, RWE Service GmbH,
CHP Hamborn 5, Germany Germany

Engineering and supply of oil atomiser lances and atomiser sprayer, MAINOVA,
Mainova, Germany Frankfurt, Germany

Engineering and supply for retrofit of burner level oil-to-gasfiring, PCK Raffinerie GmbH,
2 x 750 t/h, Refinery Residues and Heavy Fuel Oil, PCK Schwedt, Germany Schwedt, Germany

Supply of oil control valve stations, Heavy Fuel Oil and Low-Pressure- Shell Deutschland Oil GmbH,
Gas, Shell Wesseling, Germany Wesseling, Germany

Supply, erection and commissioning of 12 optimised oil burner inserts, MAINOVA,

CHP West Unit 2, Germany Frankfurt, Germany

Oil atomizer lances for an ignition system for the heat power plant Vattenfall Europe Hamburg AG,
2 x 200 MWel, Bituminous Coal, Tiefstack PS, Germany Germany

Study for capacity increase, coke gas firing system, 2 x 307 MWel, RWE AG,
Huckingen PS, Germany Essen, Germany

Engineering and supply of optimised oil lances, 340 MWel, Knepper PS, E.ON Engineering GmbH,
Germany Gelsenkirchen, Germany

Supervision of revamping at refinery steam generators, life extension MIRO,

and environmental upgrading, Germany Karlsruhe, Germany

Supply and implementation of a new oil and gas firing system at steam Shell Deutschland Oil GmbH,
generator plus retrofit of a catalytic DeNOX system, 200 t/h, Heavy Fuel Wesseling, Germany
Oil and Low-Pressure-Gas, Shell Wesseling, Germany

Basic Engineering and supply for gas connection installation, retrofit for Vattenfall Europe Hamburg AG,
additional natural gas firing system, Tiefstack PS, Germany Germany

Engineering for retrofit of a SCR-DeNOX plant, 200 t/h, Heavy Fuel Oil and Shell Deutschland Oil GmbH,
Low-Pressure-Gas, Shell Rheinland Refinery, Germany Wesseling, Germany

Babcock Hitachi Europe GmbH,

Review of firing concept for BAO Steel, 1170 t/h, Blast Furnace Gas
Oberhausen, Germany

Legend:
PS – Power Station SCR – Selective Catalytic Reduction FGD – Flue Gas Desulphurization
PF – Pulverized Fuel STP – Standard Temperature and Pressure CFB – Circulating Fluidized Bed
CHP – Heat and power plant HRSG – Heat Recovery Steam Generator ESP – Electrostatic Precipitator

www.steinmueller.com
Tel. +49 2261 78950-0
 Gesamtdarstellung

Circulating Fluidized Bed Boiler BUNKER

FUEL
SCR

HANDLING BOILER
TURBINE

ESP FGD

Bereich Kessel

BUNKER SCR
FUEL
HANDLING BOILER
TURBINE

ESP FGD

Bereich Reinigung

BUNKER SCR

Air Distribution Nozzle

TURBINE
FUEL
HANDLING BOILER

Plate Arrangement ESP FGD

Tailor Made Design

High Efficiency
Wide Fuel Range

Application Boiler Type Scope of Supply

Power Plants and Industrial Boilers • Natural circulation • Consultancy

Circulating fluidized bed boiler with direct • Once through • Sophisticated calculation
desulfurization tools for flow and heat
Fuel Type transfer
Benefits
• Engineering from
• Tailor made design to meet customer • Lignite
concept to detail
specific requests and space limitations • Bituminous coal
• Supply of core
• Sub- and super-critical boiler design with • Biomass components
and without reheater
• Waste fuels • Site supervision and
• Advanced nozzle cap design for optimized
• Pre-dried lignite commissioning
fluidization
• Refractory protection for critical zones in • Co-firing of various
furnace fuel types
• Cyclone configuration for optimal
arrangement of plant components
• Convective pass with low erosion design

www.steinmueller.com
Tel. +49 2261 78950-0
 Reference List Excerpt

Circulating Fluidized Bed Boiler Technology

Scope Client

Layout and basic engineering for heat and power CFB steam CKD Praha DIZ a.s.,
generator, 90 t/h, Lignite, Tabor PS, Czech Republic Praha, Czech Republic

Basic design review CFB boiler, 330 MWel, Lignite, Stanari PS, EFT Group,
Bosnia & Herzegovina Belgrade, Serbia

Basic design engineering for a process steam CFBC boiler, 35 t/h, Martech Boiler Company,
Bituminous Coal, new-built plant, Vietnam Ho Chi Minh City, Vietnam

Basic and partial detail design for 2 x 270 MWel CFBC boilers, Becl PS, AE&E Lentjes GmbH,
India Ratingen, Germany

Engineering for CFB Boiler, Low Rank Coal, 2 x 80 t/h, PT. ZUG Industrie Indonesia,
Indonesia Jakarta, Indonesia

Study for CFB operation boiler 6, comparison of operation values RheinEnergie AG,
with initial design parameters, Pre-Dried Lignite, 248 MWth, Cologne, Germany
Merkenich PS, Germany

Know-how transfer and training in the design of CFBC boilers, Eskom Enterprises,
Eskom Enterprises, South Africa Johannesburg, South Africa

Consultancy and supervision services – Owner’s engineer for the EFT – Rudnik i Thermoelektrana Stanari
construction of the 330 MWel lignite-fired thermal power plant Stanari, d.o.o., Belgrade, Serbia
Bosnia & Herzegovina

Know-how transfer and technical training for circulating fluidized PT. ZUG Industrie Indonesia,
bed boilers (CFB) , Indonesia Jakarta, Indonesia

Know-how transfer – Engineering for circulating fluidized bed (CFB) PJSC EMAlliance,
boiler technology Taganrog, Russian Federation

Pressure part layout and design for CFB steam generators, 2 x 250 MWel, AE&E Lentjes GmbH,
Lignite, Neyveli PS, India Ratingen, Germany

Babcock-Hitachi Europe,
CFBC Market study
Oberhausen, Germany

Legend:
PS – Power Station SCR – Selective Catalytic Reduction FGD – Flue Gas Desulphurization
PF – Pulverized Fuel STP – Standard Temperature and Pressure CFB – Circulating Fluidized Bed
CHP – Heat and power plant HRSG – Heat Recovery Steam Generator ESP – Electrostatic Precipitator

www.steinmueller.com
Tel. +49 2261 78950-0
 BUNKER SCR
FUEL
HANDLING BOILER
TURBINE

ESP FGD

Bereich Kessel

Flue Gas Desulphurization Systems BUNKER

FUEL
SCR

HANDLING BOILER
TURBINE

ESP FGD

Bereich Reinigung

BUNKER SCR
FUEL
HANDLING BOILER
TURBINE
ESP FGD

Tray Basket

Flexible Modular System for Retrofit

Removal Efficiency Increase
Reduction of Power Consumption

Application Design Scope of Supply

Power Plants and Industrial Boilers
SO2 reduction, extension of fuel
range
Benefits
• Reduction of pollutant emissions
(SO2 , SO3 , Dust)
• High availability
• Increase of operational flexibility
• Optimized consumption of
limestone
• Optimized distribution of
oxidation air
• Reduction of auxilliary energy
consumption
• Wet FGD (also with
tray technology)
• Spray Dryer Absorption
System (SDA)
• Circulating Fluidized Bed
System (CFB-FGD)
• Duct Sorbent Injection (DSI)
Technical Data
• SOX < 200 mg/m³ (STP)
corresponding to removal
efficiencies > 98 %
• Low pressure drop
Retrofit, Revamping and
New Build FGDs
• Consultancy
• Process engineering
• CFD-simulations
• Engineering, supply and
installation of components
- Nozzle position
- Tray layer retrofit
- Oxidation air distribution
• Commissioning

www.steinmueller.com
Tel. +49 2261 78950-0
 Reference List Excerpt

FGD Systems

Scope Client

Retrofit of a tray for FGD scrubber upgrade, 2 x 110 MWel, Slovenské elektrárne, a. s.,
Lignite, Novaky PS, Slovakia Bratislava, Slovakia

Retrofit of a tray for FGD scrubber upgrade, 86 MWel, Mitteldeutsche Braunkohlegesellschaft

Lignite, Deuben PS, Germany GmbH, Germany

Revamp and optimization of FGD, 660 MWel, Bituminous Coal, Nuon Power Generation B.V.,
Hemweg PS 8, Netherlands Utrecht, Netherlands

Engineering and component supply for a wet FGD, 150 MWel, LAB GmbH Germany, for Electrocentrale
Lignite, Paroseni PS, Romania Paroseni S.A., Paroseni, Romania

Retrofit of a tray for FGD scrubber upgrade, 600 t/h, Fenne PS, STEAG AG,
Bituminous Coal, Völklingen, Germany Saar-Völklingen, Germany

Detail engineering for efficiency increase of FGD scrubber, 2 x 227 MWel, ContourGlobal,

Lignite, Maritsa East 3 PS, Bulgaria Sofia, Bulgaria

Concept design study for SOX emissions reduction 200 – 730 MWel, Eskom Enterprises,
Bituminous Coal, ESKOM’S fleet, South Africa Johannesburg, South Africa

Technical specification for the FGDs, 6 x 800 MWel, Eskom Enterprises,

Bituminous Coal, Medupi PS, South Africa Johannesburg, South Africa

Study for efficiency improvement of FGD, 4 x 500 MWel, E.ON, Ratcliffe-on-Soar,

Bituminous Coal, Ratcliffe PS, Great Britain Nottinghamshire, UK

FGD optimization study, 2 x 110 MWel, Slovenské elektrárne, a. s.,

Lignite, Novaky PS, Slovakia Bratislava, Slovakia

Guizhou XingYun Environment

License, know-how transfer and cooperation agreement for FGD plants
Protection Co., Ltd., Gyiuang, China

FGD Tender evaluation, 6 x 800 MWel, Bituminous Coal, Kusile PS, Eskom Enterprises,
South Africa Johannesburg, South Africa

Legend:
PS – Power Station SCR – Selective Catalytic Reduction FGD – Flue Gas Desulphurization
PF – Pulverized Fuel STP – Standard Temperature and Pressure CFB – Circulating Fluidized Bed
CHP – Heat and power plant HRSG – Heat Recovery Steam Generator ESP – Electrostatic Precipitator

www.steinmueller.com
Tel. +49 2261 78950-0
 BUNKER SCR
FUEL
HANDLING BOILER
TURBINE

ESP FGD

Bereich Kessel

Electrostatic Precipitator BUNKER

FUEL
SCR

HANDLING BOILER
TURBINE

ESP FGD

Bereich Reinigung

BUNKER SCR
FUEL
HANDLING BOILER
TURBINE
ESP FGD

Emitter Electrode

Extremely Low Dust Emissions

High Efficiency
Reduction of Power Consumption

Application Technical Data Scope of Supply

Power Plants and Industrial Boilers Type: • Consultancy

Dust reduction, extension of fuel • Dry Electrostatic Precipitator • Process engineering
range • Wet Electrostatic Precipitator • Concept design
• CFD-simulations of flue gas
Benefits
Emissions: path and flow optimization
• Reduction of dust emissions PM < 10 mg/m³ (STP) • Optimization concepts
• Extension of fuel range
• Commissioning support
• Energy savings by optimized high Fuel Type
voltage supply
• Bituminous coal
• High availability
• Lignite
• Increase of operational flexibility
• Co-firing of biomass
• Waste
• Oil

www.steinmueller.com
Tel. +49 2261 78950-0
 Reference List Excerpt

Electrostatic Precipitator

Scope Client

Boiler and ESP design study and know-how transfer for 6 x 600 MWel, Eskom Enterprises,
Bituminous Coal, Tutuka PS, South Africa Johannesburg, South Africa

Rehabilitation and optimization of ESP, 610.000 m³/h (STP), Lignite, CET Govora,

Govora PS, Romania Râmnicu Vâlcea, Romania

Rehabilitation of electrostatic precipitator behind fluidized catalytic Raffineria di Milazzo S.C.p.A.,

cracker plant, 166.000 m³/h (STP), Milazzo Refinery, Italy Milazzo, Italy

Know-how transfer, design tools and training for firing systems, FGD, Eskom Enterprises,
DeNOx (SCR) and ESP for bituminous coal-fired power plants, South Africa Johannesburg, South Africa

Rehabilitation of electrostatic precipitator behind fluidized catalytic Ruhr Oel GmbH,

cracker plant, 90.000 m³/h (STP), BP Refinery Gelsenkirchen, Germany Gelsenkirchen, Germany

Concept engineering study for the optimization of ESPs, 6 x 600 MWel, Eskom Enterprises,
Bituminous Coal, Tutuka PS, South Africa Johannesburg, South Africa

CFD-flow simulation and optimization for ESP downstream pyrite roaster in Ion Blast Ltd.,
sulfuric acid plant, 30.000 m³/h (STP), Haldor Topsøe Plant, Denmark Helsinki, Finland

CFD-flow simulation for ESP, shale oil plant, 119.000 m³/h (STP), Ion Blast Ltd.,
Eesti Energia Narva, Estonia Helsinki, Finland

Legend:
PS – Power Station SCR – Selective Catalytic Reduction FGD – Flue Gas Desulphurization
PF – Pulverized Fuel STP – Standard Temperature and Pressure CFB – Circulating Fluidized Bed
CHP – Heat and power plant HRSG – Heat Recovery Steam Generator ESP – Electrostatic Precipitator

www.steinmueller.com
Tel. +49 2261 78950-0
 BUNKER SCR
FUEL
HANDLING BOILER
TURBINE

ESP FGD

Bereich Kessel

Selective Catalytic Reduction BUNKER

FUEL
SCR

HANDLING BOILER
TURBINE

ESP FGD

Bereich Reinigung

BUNKER SCR
FUEL
HANDLING BOILER
TURBINE
ESP FGD

SCR Shell Wesseling

Retrofitted SCR for

LowNOX Emissions

Application Technical Data Scope of Supply

Power Plants and Industrial Boilers Type: • Consultancy

NOX reduction Selective Catalytic
Reduction
Benefits
• With honeycomb catalyst
• Reduction of NOX emissions • With plate catalyst
• Process engineering
• EPC for SCR installations
• Optimization concepts

• Extension of fuel range Selective Non-Catalytic • Adaptation of boiler water-

Reduction
• High availability
Emissions:
• Increase in operational flexibility
NOX < 50 mg/m³ (STP)
• Low pressure loss
NH3 slip < 1 mg/m³
(under high dust conditions)
Fuel Type
steam cycle
• Adaptation of heating
surfaces
• Optimization of flue gas
distribution and NH3-
injection (CFD simulations)

• Bituminous coal
• Heavy fuel oil & residues
• Waste
• Lignite
• Co-firing of biomass

www.steinmueller.com
Tel. +49 2261 78950-0
 Reference List Excerpt

Selective Catalytic Reduction of NOx

Scope Client

Concept Design Study: Assessment, comparison and selection of feasible Eskom Enterprises,
NOX reduction technologies and concept engineering for a total of 10 Johannesburg, South Africa
bituminous coal fired power stations

Know-how transfer, design tools and training for DeNOX (SCR) for Eskom Enterprises,
bituminous coal-fired power plants, South Africa Johannesburg, South Africa

License and know-how transfer agreement for catalytic DeNOX system, Guizhou XingYun Environment Protection
China Co., Ltd., Guiyang, China

Owner`s engineer for 3 SCR installations, modification of 5 steam MIRO,

generators, 75 t/h, 110 t/h, 150 t/h, Refinery Residues, Oil and Gas, Karlsruhe, Germany
Mineral Oil Refinery Oberrhein (MIRO), Germany

Engineering and supply for retrofit of a SCR-DeNOX plant, 200 t/h, Shell Deutschland Oil GmbH,
Heavy Fuel Oil and Low-Pressure-Gas, Shell Rheinland Refinery, Germany Wesseling, Germany

Legend:
PS – Power Station SCR – Selective Catalytic Reduction FGD – Flue Gas Desulphurization
PF – Pulverized Fuel STP – Standard Temperature and Pressure CFB – Circulating Fluidized Bed
CHP – Heat and power plant HRSG – Heat Recovery Steam Generator ESP – Electrostatic Precipitator

www.steinmueller.com
Tel. +49 2261 78950-0
Process Gas Cooler
Downstream Secondary Reformer

HYDROGEN
SYNGAS FOR
METHANOL
OR AMMONIA
PRODUCTON
STEAM SECONDARY PGC SUPERHEATER
REFORMER REFORMER (PROCESS
GAS COOLER)

PGC Mopco Ammonia Plant

Proven Design
High Reliability

Application Product Range Scope of Supply

Heat Recovery for • Fire tube design • Consultancy

(natural circulation) • Optimization concepts
Production of ammonia, methanol,
• U-tube design
hydrogen and similar applications • Process engineering
(forced circulation)
• Steam superheater • Mechanical design
Benefits
(option) • Supply of process gas
• Tailor made design to meet customer cooler (PGC), superheater
specific requirement Technical Data and spare parts
• Capacity increase within existing footprint
• High availability • Gas temperature:
up to 1200°C
• Increase in operational flexibility
• Gas pressure:
• Reliable design based on decades of up to 40 bar
experience • Steam pressure:
up to 140 bar

www.steinmueller.com
Tel. +49 2261 78950-0
 Reference List Excerpt

Process Gas Cooler Downstream Secondary Reformer

Scope Client

Engineering of a waste heat boiler downstream secondary reformer, YARA Trinidad Ltd.,
160 t/h, ammonia plant YAT E 904 B, Trinidad and Tobago Trinidad and Tobago

Engineering and supply of a waste heat boiler downstream YARA Trinidad Ltd.,
secondary reformer, 214 t/h, E 2016 Tringen 1, Trinidad and Tobago Trinidad and Tobago

Balcke-Dürr GmbH for ThyssenKrupp

Basic and detail engineering for a process gas cooler downstream
Industrial Solutions AG
secondary reformer, Mopco Ammonia/Urea Plant, Egypt
(former Uhde GmbH), Essen, Germany

Detail engineering for a waste heat boiler downstream secondary YARA SpA,
reformer, U-tube design, 120 t/h, Ferrara plant, Italy Ferrara, Italy

Basic and detail engineering for a process gas cooler downstream Babcock Power Espana S.A.,
secondary reformer, Jinxi plant, China Valle de Trapaga-Vizcaya, Spain

Engineering and supply of a waste heat boiler downstream secondary

Yara Sluiskil B.V.,
reformer in ammonia plant, syngas flow: 135 t/h, steam production
Sluiskil, Netherlands
118 t/h, E 301 Sluiskil ref C, Netherlands

Engineering and supply of a process gas cooler downstream secondary Methanex New Zealand Ltd.,
reformer E 0205 A&B, Motunui, New Zealand Motunui, New Zealand

Engineering and supply of a process gas cooler downstream secondary Krupp Uhde GmbH,
reformer 303 E 001 and superheater 303 E 002, Suez, Egypt Dortmund, Germany

Engineering and supply of a process gas cooler downstream

Tecnimont S.p.A.,
secondary reformer 303 E 001, Al-Jubail, Saudi Arabia Fertilizer Company,
Milano, Italy
Saudi Arabia

Engineering and supply of a process gas cooler downstream secondary Uhde GmbH,
reformer 303 E 001 and superheater 303 E 002, Abu Qir, Egypt Dortmund, Germany

Saskferco Products Inc. Regina,

Engineering and supply of a process gas cooler downstream secondary
Saskatchewan, Canada
reformer 03 E 001, Belle Plain, Canada
(now Yara Belle Plain)

Engineering and supply of a process gas cooler downstream secondary Shell UK,
reformer E 2104, Stanlow, Great Britain Stanlow, Great Britain

Legend:
PS – Power Station SCR – Selective Catalytic Reduction FGD – Flue Gas Desulphurization
PF – Pulverized Fuel STP – Standard Temperature and Pressure CFB – Circulating Fluidized Bed
CHP – Heat and power plant HRSG – Heat Recovery Steam Generator ESP – Electrostatic Precipitator

www.steinmueller.com
Tel. +49 2261 78950-0
Waste Heat Boiler Downstream
Ammonia Combustion
AIR WATER (H 2O)

NH 3

AMMONIA (NH 3) REACTOR NITRIC ACID (HNO 3)

WASTE HEAT BOILER

WHB Leuna Caprolactam Plant

Proven Design
High Availability
Flexibility Increase

Application Product Range Scope of Supply

Heat Recovery for Catalytic Ammonia • Fire tube design • Consultancy

Combustion: (natural circulation) • Optimization concepts
• Water tube design,
HNO3 and caprolactam production, HCN • Process engineering
spiral and meander type
synthesis and similar processes (forced circulation) • Mechanical design
Benefits • Integrated superheater • Supply of Waste Heat Boiler
• Catalyst basket (WHB) including burner
• Tailor made design to meet customer
hood and catalyst basket
specific requirement
Technical Data • Pumps & auxiliary
• Energy savings
equipment
• High availability • Gas temperature:
up to 1200°C
• Increase in operational flexibility
• Gas pressure:
• Capacity increase within existing footprint up to 10 bar
• Reliable design based on decades of • Steam pressure:
experience up to 80 bar
• Steam temperature:
up to 500°C

www.steinmueller.com
Tel. +49 2261 78950-0
 Reference List Excerpt

Waste Heat Boiler Downstream Ammonia Combustion

Scope Client

Engineering and supply of a waste heat boiler in a nitric acid plant down- Grow How UK Ltd.,
stream catalytic ammonia oxidation, 160 t/h, Ince, Cheshire, Great Britain Ince, Chestershire, Great Britain

Engineering and supply of secondary path downstream NH3 combustion Grow How UK Ltd.,
including superheater, 160 t/h, Ince, Cheshire, Great Britain Ince, Chestershire, Great Britain

Engineering and supply of a waste heat boiler for catalytic Solvay/Butachimie,

HCN-Synthesis, 156 t/h throughput, Solvay/Butachimie, France Chalampe, France

Engineering and supply of heating surface bundles for a capacity Domo Caproleuna GmbH,
upgrade to 170 % downstream catalytic ammonia oxidation in Leuna, Germany
a caprolactam plant, Leuna, Germany

Engineering and supply of a waste heat boiler in a nitric acid plant Balcke-Dürr GmbH, Ratingen, Germany
downstream catalytic ammonia oxydation, Glomfjord, Norway for Yara Norge AS, Glomfjord, Norway

Engineering and supply of a waste heat boiler in a formaldehyde plant, BASF AG,
Ludwigshafen, Germany Ludwigshafen, Germany

Engineering and supply of a process gas cooler E 5205 Krupp Uhde GmbH,
(vertical fire tube boiler) for nitric acid plant Radici Zeitz, Germany Dortmund, Germany

Engineering and supply of a process gas cooler 30 E 005 (horizontal fire Krupp Uhde GmbH,
tube boiler) for ammonium nitrate plant, Moura, Queensland, Australia Dortmund, Germany

Engineering and supply of a process gas cooler (vertical fire tube boiler) Chemoproject A.S.,
for nitric acid plant Suslo Sala, Slovenia Prague, Czech Republic

Engineering and supply of a process gas cooler (water tube boiler) for ICF Kaiser Engineers Inc.,
nitric acid plants in Geismar and Baytown, Texas, USA Oakland, USA

Engineering and supply of a process gas cooler E 5205 (vertical fire tube Babcock-King-Wilkinson Ltd.,
boiler) for nitric acid plant Belfast, North Ireland Buckinghamshire, Great Britain

Engineering and supply of a waste heat boiler in a nitric acid plant, Didier Engineering,
Geleen, Netherlands Essen, Germany

Legend:
PS – Power Station SCR – Selective Catalytic Reduction FGD – Flue Gas Desulphurization
PF – Pulverized Fuel STP – Standard Temperature and Pressure CFB – Circulating Fluidized Bed
CHP – Heat and power plant HRSG – Heat Recovery Steam Generator ESP – Electrostatic Precipitator

www.steinmueller.com
Tel. +49 2261 78950-0
Consulting and Engineering Services

Gesamtdarstellung

BUNKER SCR
FUEL
HANDLING BOILER
TURBINE

ESP FGD

Bereich Kessel

BUNKER SCR
FUEL
HANDLING BOILER
TURBINE

Rely on our Experience! ESP FGD

Bereich Reinigung

Skills, Engineering Tools

BUNKER SCR
FUEL
and Experts for your
TURBINE
HANDLING BOILER

ESP FGD
Project Success

Application Scope of Service

Thermal Power Plants and Project Development Phase:

Industrial Energy Management • Conceptual engineering
• Owner’s engineering services • Feasibility studies
• Lender’s engineering services • Environmental and social impact assessments (ESIA)
• Management support • Fuel supply studies
• Engineering solutions • Power evacuation and grid studies

Benefits Tender and Contracting Phase:

• Concentrated know-how from experienced • Tender specifications
and skilled professionals • Bid clarifications and evaluations
• Contracting strategy
• Inhouse design capabilities and design tools
• Contract negotiations
for steam generators, heat exchangers and
flue gas cleaning plants Project Execution Phase:
• Reliable solutions based on decades of • Project management (EPCM)
practical experience • Design reviews
• QA & QM
• Erection and commissioning supervision
• Acceptance tests
• Training of personnel

Know-How Transfer /
Licensing
• Boiler and heat exchanger design
• Flue gas desulfurization and DeNOX plant design

www.steinmueller.com
Tel. +49 2261 78950-0
 Reference List Excerpt

Consulting and Engineering Services

Scope Client

Feasibity study for the retrofit of a flue gas desulphurisation plant, International Paper – Kwidzyn sp. Z.o.o.,
3 x 50 MWel, Bituminous Coal, International Paper-Kwidzyn, Poland Kwidzyn, Poland

Investigation and recovery scope development support after boiler Eskom Enterprises,
damage, 600 MWel, Bituminous Coal, Duvha PS, South Africa Johannesburg, South Africa

Plant assessment and life-ex study for a coal-fired power plant, Tübitak MRC,
22.5 MWel, Lignite, Soma A PS, Turkey Ankara, Turkey

Know-how transfer and training in the design of CFBC boilers, Eskom Enterprises,
Eskom Enterprises, South Africa Johannesburg, South Africa

Basic design review, consultancy and supervision services – Owner’s EFT – Rudnik i Thermoelektrana
Engineer – for the construction of the 300 MWel lignite-fired thermal Stanari d.o.o., Serbia
power plant Stanari, Bosnia & Herzegovina

Life time extension assessment for coal-fired boilers, 10 x 200 MWel, Siemens Ltd. South Africa for Eskom
Hendrina PS, Bituminous Coal, South Africa Enterprises, South Africa

Design study on coal range extension in supercritical utility boilers, Coastal Gujarat Power Generation,
5 x 830 MWel, Bituminous Coal, Mundra PS, India Mumbai, India

FGD optimization-study, 2 x 110 MWel, Lignite, Novaky PS, Slovenske elektrarne, a. s.,

Slovakia Bratislava, Slovakia

Design study for boiler with ultra-supercritical steam parameter and Wai Gao Qiao No.3 Power Generation
double reheat, 1350 MWel, Bituminous Coal, Co., Ltd., Shanghai, China
WaiGaoQiao PS No. 9, Shanghai, China

Boiler operation monitoring, 2 x 750 t/h steam generators, Refinery PCK Raffinerie GmbH,
Residues, Heavy Fuel Oil and Low-Pressure-Gas, PCK Schwedt, Schwedt, Germany
Germany

Design review for the steam generators, 12 x 800 MWel coal-fired power Eskom Enterprises,
station, Kusile and Medupi PS, South Africa Johannesburg, South Africa

Feasibility study for 2 x 660 MWel lignite fired power stations in E.ON Engineering GmbH,
Czech Republic Gelsenkirchen, Germany

Owner’s Engineer for 800 MWel power plant, Bituminous Coal and Essent Energie B.V.,
Biomass, Amercentrale PS Unit 10, Netherlands Netherlands

Legend:
PS – Power Station SCR – Selective Catalytic Reduction FGD – Flue Gas Desulphurization
PF – Pulverized Fuel STP – Standard Temperature and Pressure CFB – Circulating Fluidized Bed
CHP – Heat and power plant HRSG – Heat Recovery Steam Generator ESP – Electrostatic Precipitator

www.steinmueller.com
Tel. +49 2261 78950-0
After Sales Services

Gesamtdarstellung

BUNKER SCR
FUEL
HANDLING BOILER
TURBINE

ESP FGD

Bereich Kessel

BUNKER SCR
FUEL
HANDLING BOILER
TURBINE
Rely on our Experience! ESP FGD

Bereich Reinigung

Skills, Engineering Tools

BUNKER SCR
FUEL
and Experts for your
TURBINE
HANDLING BOILER

ESP FGD
Project Success

Application Scope of Service

Thermal Power Plants and Plant in Service Phase:

Industrial Energy Management
• Engineering services
• Project Management support
• Engineering solutions
Benefits
• Limitation of risks for our clients
• Concentrated know-how from experienced
and skilled professionals
• Cost savings by a safe and sound operation
of your plant
• Direct support with hands-on mentality
• Reliable communication channel
• Reliable solutions based on decades of
practical experience
• Free choice of hardware supplier and • Improvement of plant flexibility
blue color service
• Maintenance and repairs
• Upgrades
• Management support
• Appropriate supply of spare parts
• Sustainable planning and control of outage phases
Optimization Phase:
• Examination of possibilities to optimize operation
• Monitoring of operation
• Evaluation of data
• Handling and optimization of wear, fouling
and corrosion behaviour
• Improvement of part load behaviour
• Shortening of start-up times
• Trouble shooting

www.steinmueller.com
Tel. +49 2261 78950-0
 Reference List Excerpt

After Sales Services

Scope Owner/Operator

Engineering support for the optimization of the combustion system, IHI Corporation,
800 MWel, Bituminous Coal, Trianel Lünen PS, Germany Tokyo, Japan

Follow-up of boiler operation monitoring, 2 x 750 t/h steam generators,

Refinery PCK Schwedt,
Refinery Residues, Heavy Fuel Oil and Low Pressure Gas, PCK Schwedt,
Schwedt, Germany
Germany

Commissioning engineering services, 6 x 800 MWel, Bituminous Coal Eskom Enterprises,

Medupi PS, South Africa Johannesburg, South Africa

Engineering for repair works of a waste heat boiler in a nitric acid plant Grow How UK Ltd.,
downstream catalytic ammonia oxydatio, Ince, Cheshire, Great Britain Ince, Cheshire, Great Britain

Spare part supply, 200 t/h, Heavy Fuel Oil and Low-Pressure-Gas, Shell Deutschland Oil GmbH,
Shell Wesseling, Germany, Germany Wesseling, Germany

Overhaul of burners and supply of spare parts, 500 MWel, Bituminous Steag GmbH,
Coal, Herne PS Unit 4, Germany Essen, Germany

Maintenance service to the owner, 800 MWel, Bituminous Coal, Trianel IHI Corporation,
Lünen PS, Germany Tokyo, Japan

Re-engineering and supply of coal burner components, 300 MWel, Vattenfall GmbH,
Bituminous Coal, Tiefstack CHP, Germany Hamburg, Germany

Engineering and supply of 2 evaporator coils for a waste heat boiler CF Industries Nitrogen, LCC,
downstream ammonia combustion, 30,5 t/h, Donaldsonville plant, USA Donaldsonville, USA

Recalculation a waste heat boiler downstream ammonia combustion, CF Industries Nitrogen, LCC,
30,5 t/h, Donaldsonville plant, USA Donaldsonville, USA

Recalculation of gas burners, 117 MWel, Natural Gas, Lingen PS, BP Europe SE,
Germany Lingen, Germany

Engineering and supply of wall coil header pipework to heating surface

Grow How UK Ltd.,
in a waste heat boiler downstream ammonia combustion, Billingham,
Ince, Cheshire, Great Britain
Great Britain

Engineering and supply of oil atomiser lances and atomiser sprayer, Mainova,
Mainova, Germany Frankfurt, Germany

Legend:
PS – Power Station SCR – Selective Catalytic Reduction FGD – Flue Gas Desulphurization
PF – Pulverized Fuel STP – Standard Temperature and Pressure CFB – Circulating Fluidized Bed
CHP – Heat and power plant HRSG – Heat Recovery Steam Generator ESP – Electrostatic Precipitator

www.steinmueller.com
Tel. +49 2261 78950-0
PS Maritsa East 3
4 x 227 MWel, 4 x 730 t/h LowNOx Lignite Firing System

Jänschwalde

Neurath Turow
Niederaußem
Vrsany

Tabor

Voitsberg

Sostanj
Maritsa East 3
Turceni
Kostolac
Stanari

Can
Tufanbeyli
Soma

Megalopolis
Selected Lignite References of
Steinmüller Engineering

Achievements: Scope of Supply:

NOX: 150 – 180 mg/m³ • Process engineering
CO: 30 – 80 mg/m³ • 3D CFD modelling
(STP @ 6  % O2)
• Mechanical design
Fuel: Bulgarian Lignite (a.r.):
• Lignite burners
LCV: 6 – 7 MJ/kg (1.4 – 1.7 Mcal/kg)
w: 50 – 60 % • Over fire air system
a: 10 – 21 % • Sidewall air system
S: 1.5 – 3.0 %
N: 0.35 %

Literature can be provided on request

• VGB PowerTech 10 - 2013 “Revamping of a lignite fired boiler with less NOx emissions”
• VGB PowerTech 10 - 2015 “Challenges for a European Utility considering the EU Directive on
Industrial Emissions by the end of 2015”

Please contact us for further information.

www.steinmueller.com
Tel. +49 2261 78950-0
CHP Altbach, Unit 2
330 MWel, 1014 t/h LowNOx Firing System for Bituminous Coal
Astana

KAZAKHSTAN

Astana

Tiefstack KAZAKHSTAN

Mehrum
Ibbenbüren

Herne 4

Pretoria Duvha

Camden
RDK7 Altbach Kriel

Tutuka Majuba

Lesotho
SOUTH AFRICA

Pretoria Duvha

Camden
Selected Bituminous Coal References
Kriel
of Steinmüller Engineering
Tutuka Majuba

Achievements:
Capacity increase: 940 to 1014 t/h (+10 %)
NOx: 310 mg/m³ for original coal range
NOx: 420 mg/m³ for new widened coal range
CO: 100 mg/m³
(STP @6 % O2)
Fuel: Bituminous Coal (World Coal)
Boiler design: Tower type, Benson steam
generator with Steinmüller all-wall firing
system
Lesotho
SOUTH AFRICA
Scope of Supply:
• Replacement of 12 LowNOx burners
• Refurbishment of pulverisers
• Modification on forced draft (FD) fan
• Replacement of the FD drive motor inclu-
ding the addition of a frequency converter
• Refurbishment of air preheater
• All the above considering the
10 % boiler capacity increase

Literature can be provided on request

• PowerGen Europe 06 - 2013 “Combustion optimisation, efficiency improvements and emission
reduction by installation of modern LowNOX firing systems on existing bituminous coal and
lignite coal-fired steam generators”

Please contact us for further information.

www.steinmueller.com
Tel. +49 2261 78950-0
 KAZAKHSTAN

Shell Rheinland Raffinerie, Wesseling

Retrofit and Supply of LowNOx Burners and Flue Gas Treatment
Selective Catalytic Reduction (SCR) Plant

Medupi
(FGD)
Kusile
Pretoria (FGD)

Lesotho

Cottam SOUTH AFRICA

Ratcliffe on Soar Hemweg (FGD)

(FGD)

Deuben
(FGD)

Völklingen- Pocerady
Fenne (FGD)
Novaky (FGD)

Wesseling (SCR)

Trbovlje Govora (ESP)

Paroseni
Fusina (FGD)

Maritsa East 3

Selected Flue Gas Treatment References

of Steinmüller Engineering

Achievements: Scope of Supply:

NOx: < 140 mg/m³ • Feasibility study and conceptual design
CO: < 40 mg/m³ • Basic engineering for steam generator,
NH3 slip: < 1 mg/m³ furnace and SCR plant
(STP @ 3  % O2)
• Detailed planning
NH3 profile: < 3 % maldistribution at SCR inlet
• Supply and installation of new burners
Fuel: Blended heavy fuel oils and various
and SCR plant
refinery gases
• Commissioning and acceptance test
Boiler design: 2-pass boiler, natural circulation
with front wall firing system, 8 burners

Literature can be provided on request

• Presentation on Steinmüller Engineering Conference 2013

Please contact us for further information.

www.steinmueller.com
Tel. +49 2261 78950-0
 KAZAKHSTAN

CHP Govora, Unit 7

Retrofit with Efficiency Increase of Electrostatic Flue Gas Treatment
Precipitator (ESP)

Medupi
(FGD)
Kusile
Pretoria (FGD)

Lesotho

Cottam SOUTH AFRICA

Ratcliffe on Soar Hemweg (FGD)

(FGD)

Deuben
Wesseling (FGD)
(SCR)

Völklingen- Pocerady
Fenne (FGD)
Novaky (FGD)

Govora (ESP)

Trbovlje
Paroseni
Fusina (FGD)

Maritsa East 3

Selected Flue Gas Treatment References

of Steinmüller Engineering

Achievements: Scope of Supply:

Dust: < 50 mg/m³ (originally 180 mg/m³) • Flow cross-section enlarged by introducing
(STP @ 6  % O2) new roof design
Fuel: Romanian Lignite (a.r.) • Flow distribution improved by installing
LCV: 6.7 – 8.3 MJ/kg (1.6 – 2.0 Mcal/kg) guide vanes
w: 34 – 43 %
• Mechanically more robust electrodes
a: 15 – 32 % installed
S: 0.9 – 1.5 %
• High voltage system replaced
Boiler design: 420 t/h, 2-pass boiler

Literature can be provided upon request

• Presentation on Steinmüller Engineering Conference 2013
• Steinmüller Engineering Workshop 2012 “Retrofit with Efficiency Increase of ESP”

Please contact us for further information.

www.steinmueller.com
Tel. +49 2261 78950-0
 KAZAKHSTAN

NUON Hemweg 8
Retrofit with Efficiency Increase of Flue Gas Flue Gas Treatment
Desulphurization Plant (FGD), 680 MWel, 1980 t/h

Medupi
(FGD)
Kusile
Pretoria (FGD)

Hemweg (FGD) SOUTH AFRICA

Lesotho

Cottam
Ratcliffe on Soar
(FGD)

Deuben
Wesseling (FGD)
(SCR)

Völklingen- Pocerady
Fenne (FGD)
Novaky (FGD)

Trbovlje Govora (ESP)

Paroseni
Fusina (FGD)

Selected Flue Gas Treatment References Maritsa East 3

of Steinmüller Engineering

Achievements: Scope of Supply:

• SO2 removal efficiency increase • Supply of new double hollow cone and full
from 92.9 % to 95.2 % cone nozzles
• Sulphur dioxide emission reduced by • Nozzle installation based on Advanced
more than 30 % Nozzle Positioning (ANP) Technology
FGD Design: • Refurbishment of piping system
• Diameter of scrubber: 18 m • Further process optimization options
identified and proposed in additional
• Number of spray levels: 4
engineering study

Literature can be provided upon request

• VGB Workshop “Flue Gas Cleaning 2008”, Vilnius, Lithuania, 2008

“Flue Gas Cleaning research projects and their application in the NUON Power Plant Hemweg 8”
• VDI-Conference “REA-, SCR- and Dust removal in large power plants”, Düsseldorf, 2013
“Retrofit and Process Optimization for FGD”

Please contact us for further information.

www.steinmueller.com
Tel. +49 2261 78950-0
Solvay / Butachimie Chalampé
Waste Heat Boiler for Catalytic Steam Generation Technology
HCN Synthesis in a Nylon Plant

Glomfjord
SASKATCHEWAN
CANADA
Belle Paine

Uusikaupunki
USA
Syra
ATLANTIC
LOUISIANA
OCEAN

Donaldsonville
MEXICO

Billingham
Point Lisas
Ince TRINIDAD
& TOBAGO
Sluiskil
Leuna
Wesseling
Chalampé (SCR)
Ludwigs- Šaľa
hafen
Montoir
Kikinda
Selected Steam Generation References
of Steinmüller Engineering

Achievements: Scope of Supply:

• Replacement of waste heat boiler with • Design of new waste heat boiler for
improved design features the existing plant
• Capacity increase of boiler by 15 % - Process engineering
• Improved cooling of critical components - Mechanical design (basic and detail)
Boiler design: • Manufacturing and supply of boiler
• Application: catalytic HCN synthesis, steam
• Transport to site
generation and cooling of hot process gases
(> 1100°C) • Supply and installation of refractory
• Vertical fire-tube boiler with natural
circulation, 121 t/h, 26.5 bar, 227°C
• Conical design of tube sheet for improved
steam discharge
• Engineering and supply by Steinmüller
Engineering in 2013

Literature can be provided on request

• Presentation on Steinmüller Engineering Conference 2013

Please contact us for further information.

www.steinmueller.com
Tel. +49 2261 78950-0
CFB Boiler for CHP Tabor
Engineering for a Circulating Steam Generation Technology
Fluidized Bed BoilerCHINA TAIWAN

INDIA
PACIFIC
OCEAN
MYANMAR
LAOS
Gujarat

THAILAND VIETNAM PHILIPPINES India

Ho Chi Minh City Sorong Becl Mumbai

(Bombay)

Merkenich NEW
GUINEA
MALAYSIA

BORNEO

Tabor AUSTRALIA Tamil

Nadu
Neyveli
SUMATRA INDONESIA

Stanari Lukavac

Ankara

Mersin
Selected CFB References of
Steinmüller Engineering

Achievements: Scope of Supply:

• New build CFB boiler with cyclone separator • Process engineering for CFB steam
fired with indigenous lignite generator and auxiliaries
Emission limits in mg/m³ • Detailed design of pressure parts
NOX: 200 CO: 250 • Design and supply of air distributor nozzles
SO2: 200 Dust: 30
• Ash removal system
(STP @ 6  % O2)
• Field consultancy services during
Fuel: Czech Lignite (a.r.):
installation and commissioning
LCV: 16.9 MJ/kg (4.0 Mcal/kg)
w: 29.7 %
a: 9.2 %
S: 0.8 %
Boiler design: Circulating fluidized bed boiler,
natural circulation, 88 t/h, 64 bar, 465°C
• Commissioning in 2008

Literature can be provided on request

• Presentation on Steinmüller Engineering Conference 2013

Please contact us for further information.

www.steinmueller.com
Tel. +49 2261 78950-0
 KAZAKHSTAN

CFB Boiler for TPP Stanari

Owner´s Engineering for Consulting and Engineering Services
CFB Boiler Island

Kwidzyn

Amercentrale Schwedt
Medupi
Kusile
Pretoria Duvha
Niederaußem Kriel
Camden

Hamborn Tutuka
Majuba

Novaky
Lesotho
SOUTH AFRICA
Linz
Voitsberg

Sostanj
Stanari

Selected Consulting References of Canakkale

Steinmüller Engineering Soma

Achievements: Scope of Supply:

Owner´s engineering for new build • Feasibility study and conceptual design
300 MWel thermal power plant
• Expertise in lignite combustion and
• Start of concept development: 2006 desulphurization in fluidized bed boilers
• Start of site activities: 2012 • Preliminary design and tender specification
• Commissioning: 2016 • Tender evaluation and contract drafting
Fuel : Bosnian Lignite (a.r.):
• Review of Chinese design (basic and detail)
LCV: 9.1 MJ/kg (2.2 Mcal/kg)
• Chinese vs. European standards compliance
w: 49 %
check
a: 3.8 %
S: 0.13 % • QA during manufacturing in China

Boiler design: Circulating fluidized bed boiler, • Field advisory services during installation,
natural circulation, 1065 t/h, 175 bar/541°C, commissioning and testing
reheater 39 bar/541°C

Literature can be provided on request

• PowerGen Africa 2015 “Experiences with the Construction of a Chinese Power Plant in
Europe from an Owner’s Engineer Point of View”

Please contact us for further information.

www.steinmueller.com
Tel. +49 2261 78950-0
PS Herne Unit 4
Astana
500 MWel, 1512 t/h LowNOx Firing System for Bituminous Coal

KAZAKHSTAN

Astana

Tiefstack

KAZAKHSTAN
Ibbenbüren
Mehrum

Herne 4

Pretoria Duvha

RDK7 Camden
Altbach Kriel

Tutuka Majuba

Lesotho
SOUTH AFRICA

Pretoria Duvha
Selected Bituminous Coal References
Camden
of Steinmüller Engineering Kriel

Tutuka Majuba

Lesotho
SOUTH AFRICA
Achievements: Scope of Supply:
Widening of applicable coal range to “world • Process engineering for LowNOx firing system
coal” and reduction of primary NOx emissions,
• 3D CFD modelling
reducing OPEX for SCR reagent.
Emission limits: (STP @6 % O2) • Mechanical design of burners and ductwork
NOx: < 400 mg/m³ • Manufacturing and installation of
CO: < 25 mg/m³ 12 LowNOx burners
Fuel: World Coal (a.r.) • Optimization of pulverized fuel distribution
LCV: 16.7 – 26.4 MJ/kg (3.9 – 6.3 Mcal/kg)
• Installation of over fire air and side wall air
w: 7 – 18 % N: 1.2 – 1.9 %
system
a: 6.0 – 30 % VM: 21 – 36 %
• Commissioning and testing
Boiler design: Tower type, Benson boiler with
opposed firing system, 12 burners, 1512 t/h,
292 bar, 535/541°C (SH/RH)
• Commissioning: 1989 revamp by
Steinmüller Engineering 2013

Literature can be provided on request

• 26. Dt. Flammentag 2013 “Modernization of pulverized coal combustion system of steam
generator, Unit 4 at Power Station Herne” (in German)

Please contact us for further information.

www.steinmueller.com
Tel. +49 2261 78950-0
Yara Trinidad
Waste Heat Boiler downstream Steam Generation Technology
secondary reformer in an ammonia plant

SASKATCHEWAN
CANADA
Belle Plaine

USA

ATLANTIC
OCEAN

MEXICO

Trinidad & Tobago

Point Lisas
Sluiskil

Kikinda

Ravenna

Selected Steam Generation References

of Steinmüller Engineering

Achievements: Scope of Supply:

• Replacement of existing waste heat boiler
with design improvements (Bayonette-type
replaced by U-Tube heating surface)
• Application: WHB downstream secondary
reformer in TRINGEN 1 ammonia plant
• Vertical water tube boiler, forced circulation
200 t/h, 103 bar, 319 °C, 208 t/h syngas cooled
down from 980 °C to 470 °C @ 32 bar
• Engineering and supply in 2014
• Basic and detail design of waste heat boiler
• Process design, including CFD optimization
• Manufacturing of boiler, consisting
of U-Tube bundle incl. water and
steam chamber
• Pressure vessel
• Double layer refractory lining

Steinmüller Engineering Conference 2016 “Customized Process Gas Coolers and Waste Heat Boilers
for various applications” page 8–13

Please contact us for further information.

www.steinmueller.com
Tel. +49 2261 78950-0
PS Ensdorf
120 MWel, 376 t/h Steam Generation Technology Astana

KAZAKHSTAN

Gujarat

India
Becl
Mumbai
(Bombay)
Tiefstack

Mehrum
Neyveli
Ibbenbüren Tamil
Nadu

Herne

Ensdorf
Pretoria Duvha

Camden
RDK7 Kriel
Altbach Tutuka Majuba

Lesotho
SOUTH AFRICA

Selected utility boiler references

of Steinmüller Engineering

Achievements: Scope of Supply:

Flexible use of the boiler with a shorter
start-up time.
• Reduction in warm start-up time by 50 %
(<1 hour)
• Reduction in start-up oil consumption by 25 %
Boiler design:
• Once-through steam generator built 1964
• Two pass slag-tap furnace
• 120 MWel
• Main steam: 376 t/h at 535 °C and 174 bar
• Process engineering for the installation
of a recirculation on a once-through
steam generator
• Retrofitting of separation vessel and
circulation system by modifying suction
and ­discharge of pipes, fittings, pump,
expander, vents and drains, heat-up and
evaporation economizer line
• Supplement of steel structure such as
platforms, stairs, brackets
• Modification in I & C and boiler protection

Literature can be provided on request

• not applicable

Please contact us for further information.

www.steinmueller.com
Tel. +49 2261 78950-0
 KAZAKHSTAN

MIBRAG Deuben
Retrofit of a Tray Layer into a Flue Gas Desulphurization Flue Gas Treatment
Plant (FGD), 300 MWth

Medupi
(FGD)
Kusile
Pretoria (FGD)

Lesotho
SOUTH AFRICA
Cottam (FGD) Deuben
Ratcliffe on Soar Hemweg (FGD) (FGD)
(FGD)

Wesseling
(SCR)

Völklingen- Pocerady
Fenne (FGD) (FGD)
Novaky (FGD)

Trbovlje Govora (ESP)

(FGD) Paroseni
Fusina (FGD)
(FGD)
Selected Flue Gas Treatment References Maritsa East 3 (FGD)
of Steinmüller Engineering

Achievements: Scope of Supply:

• SO2 removal efficiency increase • Tray basket layer and support beams
from 95.7 % to 97.3 % • Redesign of 2 spray levels
• Sulphur dioxide emission reduced • Supply of new double hollow cone
by more than 35 % and full cone nozzles
FGD Design: • Nozzle installation based on Advanced
• Diameter of scrubber: 9.5 m Nozzle Positioning (ANP) Technology
• Number of spray levels: 4 • ID fan upgrade

Literature can be provided upon request

• Steinmüller Engineering Conference 2016 “Modernization and Optimization of Flue Gas Cleaning
Plants” page 23–36
• Kraftwerkstechnisches Kolloquium Dresden 2015, presentation “Operational experience of tray
technology for efficiency increase in existing FGDs”

Please contact us for further information.

www.steinmueller.com
Tel. +49 2261 78950-0
International Paper Kwidzyn
Technical and Economical Technology Comparison of Flue Gas Treatment
Flue Gas Desulphurization (FGD) Plant Retrofit, 420 t/h

Medupi
(FGD)
Kusile
Pretoria (FGD)

Kwidzyn
Lesotho
SOUTH AFRICA
Cottam (FGD)
Ratcliffe on Soar Hemweg (FGD)
(FGD)

Wesseling(SCR) Deuben
(FGD)

Völklingen- Pocerady
Fenne (FGD) (FGD)
Novaky (FGD)

Trbovlje Govora (ESP)

(FGD) Paroseni
Fusina (FGD)
(FGD)
Maritsa East 3 (FGD)

Selected Flue Gas Treatment References

of Steinmüller Engineering

Requirements: Scope of Supply for all Technologies:

• SO2 concentration at stack of 150 mg/m³ • Mass balances and process flow diagrams
(STP@6 % O2)
• Process description
• 33 – 100 % load
• Main equipment sizing
Technologies:
• General arrangement
• Circulating Fluidized Bed FGD
• Spray Dry Process with burnt lime • Cost estimation
• Wet Process with NaOH • Sensitivity Analyses
• Wet Process with lime or limestone

Literature can be provided upon request

• Steinmüller Engineering Conference 2016 ”Modernization and Optimization
of Flue Gas Cleaning Plants“ page 23-36

Please contact us for further information.

www.steinmueller.com
Tel. +49 2261 78950-0
Trianel Lünen PS
813 MWel, 2225 t/h After Sales Services

Ince
Tiefstack
(Hamburg)
Lingen (Ems) Schwedt

Herne Lünen
Shell Wesseling
(Köln)

Mainova (Frankfurt)

Kikinda

Selected References of
Steinmüller Engineering

Technical specifications: Scope of Supply:

SH steam pressure: 287,7 MPa
SH/RH steam temperature: 600 °C/610 °C
Fuel: Bituminous Coal
Client: Trianel Kraftwerk Lünen
GmbH & Co. KG (TKL)
Contractor: Consortium Siemens/IHI (OEM)
• Contact window for the client:
IHI via Steinmüller Engineering (SE)
• Spare parts services for TKL via SE
• Trouble shooting
• Further plant optimization
e.g. combustion tuning, CFD analysis, etc.

Benefit:
• Direct support by IHI engineers • Short distance to the client
• Full access to IHI´s documentation • Optimal communication channel for the client

Please contact us for further information.

www.steinmueller.com
Tel. +49 2261 78950-0
PS Kostolac B1
350 MWel, 1000 t/h LowNOx Lignite Firing System

Jänschwalde

Neurath Turow
Niederaußem
Vrsany

Tabor

Voitsberg Kostolac
Sostanj

Turceni

Stanari
Maritsa East III

Can
Tufanbeyli

Soma
Selected Lignite References
of Steinmüller Engineering

Megalopolis

Achievements: Scope of Supply:

NOx ≤ to 191 mg/m³ (STP) • Process engineering
CO < 200 mg/m³ (STP) • 3D CFD modelling
Fuel: Serbian Lignite (a.r.) • Mechanical design
LCV: 6.5 - 8.4 MJ/kg (1.6 - 2.0 Mcal/kg) • Lignite burners
w: 42 - 45 % • PF duct swirler
a: 20 - 26 %
• Over fire air system
S: 1.10 %
N: 0.35 - 0.5 % • Commissioning

Literature can be provided on request

• Kraftwerkstechnisches Kolloquium 2015 “Retrofit of a lignite fired steam generator
for NOx emission reduction”

Please contact us for further information.

www.steinmueller.com
Tel. +49 2261 78950-0
GrowHow Ince
Waste Heat Boiler downstream Steam Generation Technology
catalytic ammonia combustion

CANADA
Glomfjord

USA

Uusikaupunki
ATLANTIC
LOUISIANA
OCEAN

Donaldsonville
Syra
MEXICO

Ince
Ince

Leuna

Montoir

Selected Steam Generation References

of Steinmüller Engineering

Achievements: Scope of Supply:

• Replacement of existing waste heat boiler • Basic and detail design of waste heat boiler
in a nitric acid plant downstream catalytic • Manufacturing of boiler, consisting of wall
ammonia oxydation coils, spiral type heating surfaces, headers
• Application: WHB and a second path, and distributors
Ince Cheshire, Great Britain • Pressure vessel
• Engineering and supply in 2014 • Second path, consisting of superheater
and 2nd evaporator section

Literature can be provided on request

Please contact us for further information.

www.steinmueller.com
Tel. +49 2261 78950-0
 Concept/Layout: tsitrone medien GmbH & Co. KG, Cologne

Steinmüller Engineering GmbH

IHI Group Company
Fabrikstraße 5 • D-51643 Gummersbach • Germany
Tel: +49 2261 78950-0
Fax: +49 2261 78950-199
info@steinmueller.com
www.steinmueller.com Edition 2016