ENGLISH
INTELLIGENT FIRE
for grate fired waste
and biomass plants
Technikgruppe is a provider of cutting-edge control systems of
leading manufacturers and offers worldwide integration support
for incineration plants.
Especially for waste incineration based on grate technology
Technikgruppe can rely on more than 20 years of expertise in
mechanical inspection, process evaluation, process optimisation
and operational support.
Our network of suppliers enables us to combine the products
of different suppliers in order to offer individual solutions to
our customers worldwide and to achieve excellent results in
operation through a high level of automation.
Efficient and environmentally friendly
plant operation through WIC
What is WIC?
How does WIC work?
WIC is a universally applicable electronic combustion manager
The combustion system usually consists of feeder, grate, primary air system, secondary air system and sometimes
developed for optimisation of combustion on moving grates.
recirculation air system (see figure 1). The feeder pushes the waste on the grate. The grate‘s movement transports
WIC is primarily used in waste- and biomass-to-energy plants.
the waste during the combustion with primary air (in the burning chamber) and secondary air (in the after
WIC was successively developed over the past years using
burning chamber).
the experience on nearly all grate combustion technologies to
provide considerable profit enhancement for our customers.
WIC uses about 40 process signals from the existing control system, permanently analyses the combustion process
and combustion conditions with appropriate and well proven process equations (remember! 6500 functional
The difference to classic
combustion control systems?
diagrams). The output of the WIC manager is about 30 signals to manage about 30 controls, that influence the
combustion process.
Just an example: The majority of the various combustion
control systems on the market can be described with less than
Main controls are:
50 functional diagrams. For a reliable and effective combustion
• Stroke length of the feeder
management much more functional diagrams are needed.
• Speed of the feeder
WIC is based on more than 6500 functional diagrams. This
• Stroke of the grates
big difference is only one foundation of the WIC’s technical
• Speed of the grates
leadership.
• Primary air flow
• Secondary air flow
• Recirculation air flow
Secondary
air
Feeder
& Grate
Combustion Management
=
Intelligent Fire
=
more than just combustion control
Primary air
Fig. 1: Combustion management with WIC optimisation system
Unveiling the reserves of your plant!
Measurements
(40 signals)
from existing
system
Control of
30 devices
FEEDER
GRATE
PRIMARY AIR
SECONDARY AIR
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Basic function
Model calculation
The WIC manager monitors the combustion process on the grate and manages the steam production in the
WASTE-TO-ENERGY
steam boiler.
ENERGY EFFICIENCY
Saving up to ¤ 1,200,000/year with a thermal
waste treatment plant
• More steam production
Nearer to the goal
• Stability of steam flow
• Higher incineration
capacity
• Less corrosion
• More profit
300,000 t p. a. waste throughput
8,000 operating hours p. a.
5-8 % more waste throughput
5-8 % more electricity generation
5-8 % more district heating generation
0.03 ¤/kWh electricity generation revenue
0.015 ¤/kWh district heating generation revenue
- CO2, NOX, SO2
60 ¤/t waste incineration revenue
¤ 1.2 Mio. additional receipts/year
The further target is a stable combustion air flow as a precondition for smooth and economic combustion.
The WIC manager holds the produced steam flow constant
over time, avoids over or undershooting and hence optimally
utilises the plant.
• Stabilisation of
combustion air flow
„stable = less wear off“
Advantages
• Less additives in flue
gas cleaning process
• Less energy and less
mechanical forces on fans
• Higher burn out rate
• Enhancement in steam production
• Stabilisation of steam production
• Enhancement in plant capacity
• Less oil/natural gas consumption
• Less CO, CO2, NOx, SO2 ... emissions
• Better burn out in flue gas and bottom ash
• Less chemical additives in flue gas cleaning process
The primary control variables of the WIC manager are the steam flow, the temperature in the combustion chamber
Operation modes of combustion controls
and the O2 concentration. The highly sophisticated parameters out of the WIC manager enables the feeder to
deliver the appropriate amount of fuel without overloading the grate.
The WIC manager offers all typical operation modes:
• Power control (steam flow control)
By optimising the combustion system the waste throughput will remarkably increase and the steam flow will be
• O2 control*
stable. The WIC manager, furthermore, automatically adapts to the changing fuel quality and supports the plant
operator in every decision-making process.
Cost reduction through an automated management
The application of the WIC manager leads to a smoother and automated operation combined with the saving of
feed stocks and additives, low-wear operation and a reduction of necessary operator interventions.
*O2 control
In case the steam flow measurement does not work, the O2 control can be employed. In the O2 operation mode,
the combustion process is stabilized and hence a very smooth plant operation is achieved. The O2 control is also
the perfect tool if, for example, a downstream turbine causes fluctuations in pressure which significantly affect the
steam flow produced in the boiler. In this case the O2 control stabilises the process.
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Coupling to every process control system
(DCS and PLC) possible
The WIC manager communicates with the underlying process
The WIC manager can be delivered with redundant components and — consequently — it can also be used in
control system via the following industrial-compatible interfaces:
high-availability applications.
The operator at any time has the possibility to switch off the WIC manager in order to operate the combustion
process with DCS set points or manually.
Simple integration, safe operation
PLANT MANAGEMENT & OPERATION
The configuration of the underlying process control system or
WIC
Combustion
Manager
the programmable logic controller remains unchanged when
employing the WIC manager. The WIC manager does not replace
the existing DCS-PLC system or influence the plant protection
system. Interlocks such as the boiler protection and other
protection units are always superior to the WIC manager and
remain unchanged as well.
Plant
Operator
DCS
PLC
Manual
Unmanaged
Managed
All control parameters continuously utilised by the WIC manager
DCS
are determined from easily measurable process values.
Reliable communication
The input signals required for the combustion control (i. e.
combustion chamber temperature, O2 concentration at boiler
end, steam flow, combustion air flows, …) are processed in the
Set points
WIC manager. The computed output signals (control commands,
Existing DCS / PLC
Combustion
Control System
set points) are returned to the process control system.
Plant
Protection
Automatic storage of process data
The transfer functions required for controlling are determined
from the plant’s real process data; these provide the parameters
for the state controllers of the WIC manager. All required
parameters, algorithms and other necessary process data are
Plant
Process
Field
FEEDER, GRATE
PRIMARY AIR
SECONDARY AIR
safely stored in the WIC manager.
Fast and secure implementation
WIC can be connected to any DCS or PLC system. With a software or hardware switch it is easy to determine,
The commissioning of the WIC manager is very user-friendly as
which system should control the feeder, the grate and the combustion air.
the different processes and algorithms of combustion control
have already been pre-tested. The cold commissioning work
comprises the coupling of the input and output signals to the
control system.
Tried and tested hardware
The WIC manager is manufactured in Austria meeting the
highest technical industrial standards including CE-conformity.
Necessary infrastructure on site: interface to DCS (PLC) via Profibus/
Modbus/OPC; power supply 20 VDC - 33 VDC or 110 VAC - 250 VAC.
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20 years of data archiving
WIC packages
The AutoDyn Industrial software, which serves as an analysis
The following packages of the industry-trusted, tried and tested hardware and software are currently available
system, is delivered together with the WIC manager.
and can be easily and individually configured in order to fit the plant:
This user-friendly program enables easy and fast logging (Excel,
PDF & SAP), a comprehensive data acquisition as well as an
WIC manager
excellent long-time data archiving and reporting.
An instant and secure data access is possible anywhere and
anytime via a firewall with every web browser.
WIC 850 + AutoDyn Industrial
WIC 870 + AutoDyn Industrial + DMC (Data Management Console)
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Free* plant audit
Worldwide lifetime support
During the plant audit, possible faults regarding control, mechanical and process engineering can be detected.
Technikgruppe offers a variety of service contracts in order to keep the system up-to-date throughout its operating
On the basis of the examination, individual solutions are developed which will sustainably optimise the overall
time.
efficiency of the plant. Wishes and targets for improvements are always similar:
In addition to the on-site service support, an online support* with a secure Internet remote connection is
established.
More waste troughput?
Better performance?
Stable load?
Better burnout?
Wishes/
Targets?
Lower emissions?
Higher availability?
WIC keeps you informed 24/7
Less wear?
Less operating costs?
References
The WIC manager is a classic example of technical progress and currently runs in successful commercial
operation in about 40 incineration plants (trend rising sharply) in Europe and North America. A detailed
reference list is available upon request.
Time-efficient implementation
The maintenance-free WIC manager can be implemented in every plant in less than one month.
Audit
Feasibility
study
1 Month
Control
strategy
Delivery
2 - 3 Months
Installation,
commissioning
and training
Test Run
1 Month
1 Month
The comprehensive operator training is performed in collaboration with the plant management in order to provide
the operators with the necessary knowledge of the implemented control strategy.
*The plant audit is free upon purchase of the WIC manager.
* Multilingual 24/7 support in Chinese, English, French, German, Italian, Russian, Spanish (alphabetical order)
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24/7 SERVICE & SUPPORT
E N V I R O N M E N TA L T E C H N O L O G Y
I N T E R N AT I O N A L
TG Mess-, Steuer- und Regeltechnik GmbH
Hauptstraße 229 | 8141 Premstätten
Österreich
Telefon: +43 (0)316 255536-0
[email protected]
www.technikgruppe.com
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description of our products and are not considered as a sign or characterizing feature of our products.
All rights reserved © Technikgruppe
The content in this publication is presented for informational purposes only, and while every effort has been made to
ensure its accuracy, it is not to be construed as warranties or guarantees, express or implied, regarding the products
or services described herein or their use or applicability. All sales are governed by our terms and conditions, which are
available on request. We reserve the right to modify or improve the design or specification of our products at any time
without prior notice.
EN-WIC-P-03