Aeras handed over to the customer the second electrostatic precipitator after a general repair in December last year. The key part was to increase the efficiency of dust removal at the electric heating plant in Chorzow, Poland, on a 110 MW unit burning a mixture of biomass and coal. In addition to mechanical repair, the project also included the replacement of collecting and discharge systems on the first section and the delivery of a Coromax® pulse system to increase the efficiency of dust removal. We asked the head of implementation, Mr. Jakub Štech, how the project progressed and what the results were.
What are the results of the project with respect to the requirements and have the investor’s expectations been met?
The required guaranteed parameter for PM outlet was set at 11 mg/Nm3; now we reach an outlet of 4 mg/Nm3. The requirement was fulfilled and we even exceeded the investor’s expectations. These output parameters are not only the result of ESP short-term monitoring since its commissioning in the autumn of 2022, but above all, they are proven by the operation of the electrostatic precipitator on block I, which has been in operation since the autumn of 2021. Thus, for more than a year, we achieve lower outlets and save electrical energy to operate the equipment at the same time.
What was the most challenging part of the project?
Here I would divide the answer into I. and II. stage.
I. The stage took place during the period of covid and related measures, which required a number of administrative actions during the implementation of the international project. Furthermore, an unpredictable situation with a lack of overseas transport capacities during the delivery of the equipment from the production plant threatened the deadline for putting the equipment into operation.
In 2022, during the implementation of the second block, assembly work was carried out within a narrow space between the buildings, where we had to cooperate with another contractor as part of the general repair of block II.
Thanks to the professional cooperation of colleagues, our suppliers and the investor, it was possible to overcome all obstacles and successfully hand over both electrostatic precipitators into operation on time.
Is it possible to transfer these experiences to other projects?
You take away new experiences from every project implemented, and it was no different here. In addition, it was the first implementation abroad for Aeras, during which we established contacts with potential customers and began to cooperate with new suppliers.
How was the cooperation with ČEZ?
I rate the cooperation with CEZ Chorzow very positively, because during more than two years of cooperation we were able to find constructive solutions together in various situations and phases of the project.
Aeras in konsorcium with Mostecká montážní a.s. and in collaboration with Steinmüller Engineering GmbH delivered Tray layer in FGD for B6 in Počerady Power Plant. Thanks to this technology the guaranteed dust emissions < 8 mg/Nm³ (6%O2, dry) have been achieved with a significant margin with very reasonable CAPEX.
Aeras participated on a traditional gathering of energy experts in Poland, also this year under the patronage of Czech Trade Agency as well. Many interesting meetings and contact have been conducted with an attendance of Mr. Jakub Rudy, Ministerial Counsellor and Mr. Ivo Šipl, Director CzechTrade Poland. Thanks to both gentlemen for their support on Polish market and hope to meet us there soon again. Personal attendance of Mr. Kirk Larsen as a FLSmidth Coromax® representative was also warmly welcomed.
We want to thank CzechTrade office in Warsaw for preparation of Czech booth where we presented together with Mads Kirk Larsen from FLSmidth ESP upgrade. The feedback from our Polish partners was great. More about the venue:
Aeras will this year in cooperation with Czech Trade agency and FLSmidth company hold an exhibition in symposium “Energetyka Belchatów”. You are cordially invited to visit our presentation or take part on the lecture “ESP Upgrade to reach valid BAT/BREF limits”.
Aeras has signed a contract with ČEZ for a complete repair and efficiency increase of two electrostatic precipitators. Each will be refurbished and equipped with a brand new Coromax to ensure compliance with new BAT/BREF regulations.
ČHMÚ Ostrava started a project to answer a still open question: „What is the real share of air pollution of local industry, municipal heating, transport, pollution import from Poland and other sources?”
The project will focus on benzo[a]pyrene and particulate matter pollution. To solve that there will be eight measuring stations established. Based on meteo conditions and modern math modelling tools (receptor model PMF) we acquire aggregate yearly assessment of air quality. The answer to basic project question shall be available in the second half of the year 2022.
Anythyng we do, we strive to do it as good as we can. If there are procedures and processes which help us in our effort, there is no reason to avoid them. That is why we have undertaken the certificate audit – and passed excellently. It is another step in our cause to deliver solutions, which are technically advanced, reliable and creating maximum value for the customer.
ESP in Plzenska Teplarenska enjoyed reconstruction consisting of improvement in flue gases control and distribution, new high voltage micropulse Coromax® tanks and mechanical repairs. It remunerated us with PM emissions in range 2,2 – 7,9 mg/Nm3.
Final dust emissions in stack are according to guarantee measurement in range 1,4 – 1,8 mg/Nm3. Considering 23 years old technology, not bad, is it?
As a part of processes improvement and standardization , Aeras has deployed Kvados MyTeam software tool for project management and consulting. We expect to further improve project management skills thanks to the Prince2 methodology on which the system is based. More information at the https://myteam.akce.kvados.cz/.
Quality, improvement and best practices are not just empty words for us, which stay locked on QM desks. We strive to improve and learn. We believe that Centrum for Excellence founded by Czech quality association is a way how to learn from the best. We are convinced that improvement in processes, procedures and final quality will be reflected by our customers, suppliers and partners soon.
For curious – CfE issued 2020 version of EFQM model, you can download it here (in Czech). It is a complex tool for management improvement via self assessment of key areas.
Thanks to the signing of the representation contract with Enfit, Aeras is active on the market with our northern neighbours, especially in the field of municipality heating plants and a construction of new biomass boilers.
Contact at the Polish representation is ENFIT Sp. from o.o., Mr. Czeslaw Kominek, +48 601 246 578.