design and engineering pilot studies deliveries simulations process development certification testing. ICEO. pilot cogeneration plant servicing

Fuel Preparation And Combustion Laboratory

Main Activities Of The Laboratory

The fuel preparation and combustion laboratory takes leading positions in research, design, production of modern-class power-generating equipment and power units, as well as improvement of combustion systems designed for liquid and gas fuels for industrial power boilers, various types of furnaces, combustion chambers of gas turbine units and other facilities.

NPO CKTI JSC has designed standard schemes of highly-efficient low-toxicity combustion, which include:

  • using specialized new generation low-toxicity burners;
  • low-excess air combustion;
  • staging of oxidizing medium (when burning natural gas);
  • recirculation of exhaust gas.

By their features, the burners produced by NPO CKTI JSC compete with the best domestic and imported analogs. Each burner can be custom designed and produced to match the demands of each facility. Burners with central gas distribution tube are used for various types of burners in a wide range of power capacities. Burners of this type with power capacity of 4 to 20 MW are installed in the furnace chamber walls (wall mounting, single-front, opposed, stacked configuration, etc.). Burners of this type are reliable and easy to operate. They ensure proper burnout and moderate emissions.


Oil-gas burners GMU-m with central gas distribution.

Burners with adjustable tubular gas feed are installed primarily in burners with steam production capacity of more than 75 t/h. Availability of adjustable gas distribution function, as well as air feed mode adjustability (redistribution of air flow to separate channels of the burner) allows changing the length and configuration of flame (the manner of temperature distribution in the flame core), influence the emission characteristics of the flame.

Adjustment (multiple location arrangements of gas distribution nozzles of three calibers) allows significantly reducing the emission of NOx, СО, soot, influence the temperature of superheated steam. The laboratory has developed technical recommendations regarding installation angles of gas nozzles, which enable certain flame configurations.

The adjustment may be implemented by the NPO CKTI JSC experts during commissioning.

Oil-gas burner GMU-m with tubular gas distribution

Oil-gas burner GMU-m with adjustable blade row

Gas burner for burning blast-furnace and natural gases

Combined flat-flame gas burner for burning blast-furnace, coke and natural gases

NPO CKTI JSC has designed state-of-the-art burner devices for highly efficient low-toxicity combustion of blast-furnace gas, coke gas other types of associated gas in metallurgy.

Also, one of the example of using the NPO CKTI JSC burners in metallurgy is the introduction of powerful versatile pilot burner for sulfur furnace at the sulfuric acid production shop (Phosphorit plant (Eurochem Group), Leningrad Oblast, Phosphorit industrial zone).

The burners are equipped with igniters and flame monitoring sensor.

As of today, ignition control devices ZZU-ZG-01 are used in many facilities of various types. For example, our ignition devices has been used for 10 years in igniting the burners of Rostral Columns in Saint Petersburg.

The igniter works according to the “flame-transition pipe” – it does not have a high-voltage electrode and stands out of electric igniters by combustion stability, safety, reliability and durability in operation. The spark unit is installed directly into the igniter.

Ignition control device ZZU-ZG-01

Operation of ignition control device in Rostral Columns

Works performed:

  • First, installation on burners in the boiler is supervised, then, operational tests of power units are performed.
  • After installation of burners in boiler flame-out tests are performed with various pressures of gas and air.
  • NPO CKTI JSC designs and produces fuel nozzles, air valves and other auxiliary equipment and metal structures.
  • Optimization of solid fuel gasification technology based on oxygen-steam blast under pressure – as the most prospective technology for creation of powerful combined cycle gas turbines (CCGT) with closed cycle coal gasification. Experimental facilities of the laboratory allow it to perform a wide range of scientific works, which a prerequisite for design of modern-class combustion chambers and burner devices.
  • Trial operation of NPO CKTI JSC-designed solid fuel gasification unit in the pressurized oxidizer flow has confirmed a capability to obtain a high-calorie syngas suitable for using in gas turbine combustion chambers.
  • NPO CKTI JSC experts have participated in design of practically all domestic gas turbine units. We have constantly been improving our testing facilities, creating new test bays for newly designed modern units.
  • Design of burner installation on the boiler with distribution of waterwall tubes for the new burner arches.
  • Design of gas supply systems.

Dust distributor

Gasification bed, a cabinet for oxygen or nitrogen racks.

Burner module with premixed gas/air function

Combustion chamber

Burner for combustion chamber

Combustion chamber designed for starting a boiler that works with fluidized bed

Laboratory Software Base

  • TopHeat – power boiler thermal design software (proprietary).
  • Heat-KS – thermal design of boilers with fluidized bed and circulating fluidized bed (proprietary).
  • TSten-K – temperature design of convective heating surfaces (proprietary).
  • TSten-R – temperature design of radiant heating surfaces (proprietary).
  • Boiler Designer – software for creation of controlled all-mode mathematical models of heat and power facilities.
  • Autodesk AutoCAD – 2D and 3D computer-aided design system.
  • Askon COMPAS 3-D – 2D and 3D computer-aided design system.
  • Kontur – circulation design.
  • D-Pipe – design strength analysis of pipelines at heat and nuclear power plants.

Axonometric diagram for design of pipelines and installation of supports

Boiler Designer interface

TopHeat interface

Works completed:

  • Design of standard projects of boilers with circulating fluidized bed boilers for 225 MW power units with subcritical steam conditions (production capacity – 640 t/h, P = 13.7 MPa, t = 565 °C) and 330 MW units supercritical steam conditions (production capacity – 965 t/h, P = 24.2 MPa, T = 565 °C), development of testing program and operating manual for pilot plant with circulating fluidized bed; design of software for thermal design of boilers with circulating fluidized bed.
  • Conversion of Igumnovskaya Cogeneration Plant into a boiler house and readjustment of boilers No. 8–9 for lower steam conditions – to supply heat energy to Sintez OKA-ENERGO LLC and other chemical cluster enterprises at Dzerzhinsk, Nizhny Novgorod Oblast.
  • Design of fire suppression system for boiler back-end surfaces of boilers No. 2, 3, 4, 6 of Zakamskaya Cogeneration Plant – 5 as a part of conversion of power boilers of the cogeneration plant into oil burning equipment. As a part of this project, the laboratory has designed the fire suppression system for tubular air preheaters which utilizes water as the fire-prevention medium.
  • Retrofitting of hazardous industrial facility – Cogeneration PlantMondi Syktyvkar JSC – installation of new continuous blowdown flush box. Syktyvkar, Komi Republic.
  • Retrofitting of CKTI-75-39F2 boiler of plant No. 10 at cogeneration plant of SC “CHEPETSKY MECHANICAL PLANT” with conversion into natural gas burning equipment. Glazov, Udmurt Republic.
  • Retrofitting of Simon Carves boiler No. 3, NLMK Group, as a part of restoration of convection part performed with the aim to lower the temperature of flue gases and increase its cost efficiency.  
  • Modernization of continuous boiler blowdown system for Riley Stoker-type boilers at plant No. 2 and CKTI-75-39-F2-type boiler of plants No. 3–5 at the cogeneration plant of JSC EnSer. Miass, Chelyabinsk Oblast.
  • Introduction of two-stage evaporation system at plant No. 5 of CKTI-75-39-F2 type at the cogeneration plant of JSC EnSer as a part of retrofitting project aimed to eliminate the causes of damage of waterwall pipes at saline sections of the boiler. Miass, Chelyabinsk Oblast.
  • Retrofitting of heat recovery boiler of the first processing line of Melting Shop No. 1, JSC “Metallurgical plant n/a A. K. Serov” – replacement of spring-loaded safety relief valve with pulse safety device aimed to make the boiler comply with modern industrial safety requirements. Serov, Sverdlov Oblast.
  • Retrofitting of TP-87 boiler of plant No. 9, West-Siberian Cogeneration Plant, aimed to introduce the combustion of secondary gases – byproducts of metallurgical production at EVRAZ ZSMK. Novokuznetsk, Kemerovo Oblast.
  • Reestablishment of optimal hydraulic mode of LP steam/water circuit for heat recovery boiler KGT-45/6,7-450-15/0,9-270, gas turbine power plant, Novy Urengoy Gas and Chemical Complex, VIS Group. The project included selection of circulation pumps required for this circuit, design of pipeline hanger-support system of HP and LP circuits. Novy Urengoy, Yamal-Nenets Autonomous Okrug.
  • Retrofitting of E-220-9,8-540GD boilers at Utility Cogeneration Plant of NLMK Group – surface extension of second-stage water economizer, which lowered the temperature of flue gases and raised efficiency. Lipetsk.
  • Retrofitting of boiler, plant No. 6 (TP-230-2), Cogeneration Plant of NLMK Group – surface extension of second-stage water economizer to lower the temperature of flue gases and raise efficiency. Lipetsk.
  • Retrofitting of boilers at plants No. 6 and 7 (BKZ-210-140), Steam-Air-Thermal Power Plant of PAO Severstal – surface extension of second-stage water economizer and setup of condensate and feed water injection system, which extended the load range and lowered the temperature of flue gases behind boilers and raised efficiency. Cherepovets, Vologda Oblast.
  • Experimental burning of coal from Zheronsky coal deposit in the boiler plant BKZ-420-140 PT-2. Development of experimental system for monitoring circulation reliability and thermal conditions. Experimental burning of pure coal from Zheronsky coal deposit within the operating steam load range, including circulation tests and thermal conditions. Ust-Ilimsk, Irkutsk Oblast.
  • Drum replacement as a part of retrofitting of boiler at plant No. 14 (TP-82), Omsk Cogeneration Plant-3 with the aim to lower air suction, improve thermal features of the boiler, lower fuel oil consumption, increase the reliability of firing-up process.
  • Design of technical solutions for restoration of intermediate pressure evaporating circuit in the heat recovery boiler of PGU-410 unit, Krasnodar Cogeneration Plant. Taganrog.
  • Hydrodynamic research (of circulation and separation) of small-size low and medium power boilers with steam production capacity of 50.75 and 100 t/h, pressure of 1.4 and 3.9 MPa, to analyze the structure of circulation circuits and separation devices inside the drum and to issue recommendations on raising their reliability in operation. PJSC “Krasny Kotelshchik”, Barnaul branch.
  • Correction of Detailed Design Documentation for HP boilers F7701-F7901 by Hohenthurm. OOO Novy Urengoy Gas Chemical Complex, OAO VNIPIneft, Novy Urengoy, Yamalo-Nenets Autonomous Okrug.
  • Establishment of minimum load Е-2 of steam boiler BKZ-75-39FB. Vilnius, Lithuania.
  • Development of operating manual for boiler units of plants Nos. 21, 22, Pr-228/47-7,86/0,62-515/230 (PK-59), power unit No. 2. Pravoberezhnaya Cogeneration Plant, Saint Petersburg.
  • Hydraulic analysis of boiler unit P-49 with the aim to find out the cause of pipe damageability and develop a set of activities to eliminate these causes. Inspection of hydraulic and thermal conditions of front waterwall of P-49 boiler in operation, building 7A Nazarovskaya Regional SDPP. Nazarovo.
  • Introduction of boiler chemistry system at the branch of Nevinnomyssk Regional SDPP, Enel Russia. Nevinnomyssk.
  • Restoration project of 67-boiler aimed to set up operation at lower parameters within 30-120 t/h range – to supply energy to the departmentShekinskaya Regional SDPP, branch of PJSC “Quadra – Power Generation”. Sovietsk.
  • Design of drum separators with the diameter of 1600 mm and circulation analysis for the boiler TP-100, Lugansk TPP, OOO DTEK Vostokenergo. Lugansk, Ukraine.
  • Development of detailed design of separators for steam boilers F-06-5101/5102, Klaipėdos Nafta, Klaipeda, Lithuania.
  • For JSC “TYAZHMASH”, the laboratory has developed technical solutions regarding design of powerful coal mills with capacity of 80 to 120 t/h for Chinese power plants (Yimin TPP, Jiutai TPP, etc.), Laos (Honsha TPP), India (Neyveli TPP) etc.
  • The laboratory has developed technical solutions on the design of static and dynamic separators for MVS-265Ts mills designed for producing a finished product from the ground cement clinker.
  • The laboratory has developed a small-size separator for hammer mills to process high-volatile bituminous and brown coals. The aforementioned separators form a part of boilers in 210 MW and 215 MW units of Gusinoozyorskaya Regional SDPP, boilers of Blagoveshenskaya Cogeneration Plant, boilers with production capacity of 420 t/h, boilers of Nazarovskaya Regional SDPP with production capacity of 270 t/h, etc.
  • This equipment was designed based on mathematical modelling and state-of-the-art software with evaluation of full-scale models. The example can be seen at illustrations of static centrifugal separator for MVS-265 manufactured for Barh TPP(India).

The image features a coal mill with inertial separator manufactured for Honsha TPP (Laos). These separators form a part of boilers for 600 MW power units

1. Rotor

2. Mill body

3. Separator feed manifold

4. First stage of under-milled fuel return

5. Static guide blades

6. Control valve

7. Separation chamber

8. Second stage of under-milled fuel return

9. Outlet manifold for processed dust

The image features a dynamic separator for MVS 265Ts mill designed for producing a finished product from the ground cement clinker.

1. Annular inlet for milled product

2. Static guide blades

3. Rotor with blades

4. Outlet manifold for processed product

5. Under-milled product return bunker

The image features small-size inertial separator for hammer mills

1. Inlet manifold for fuel and drying agent,separator inlet manifold

2. Baffle plate

3. Static guide blades

4. Control valve

5. Separation chamber

6. Separator outlet manifold


The model design process in the gas-hydrodynamic research

The results of calculations of air-dust mixture streamlines in the separator

High-speed isosurface
of air-dust stream in the zone where the stream gets away from the separator guide vanes, which was used to further optimize the shape of the above mentioned guide vanes

Installation of continuous blowdown flush box with process piping

Installation of 06 PGVU 299-80 valves with actuators in the induced draft fan rarefaction path as a part of retrofitting of 67-SP boiler.

HP steam boilers F7701, F7801, F7901

Engineering design of boilers with circulating fluidized bed furnace on request by Minenergo (Ministry of Energy of the Russian Federation)