Fuel Supply Plants and Flue Gas Treatment

Integrated "Turnkey" Solutions

Ahena Boilers positions itself as a 360° technological partner for the realization of complete industrial thermal plants:

• Custom design: analysis of specific needs and optimal sizing of each system component
• Complete plant supply: from storage units to feeding systems, from thermal generators to flue gas treatment systems
• Centralized control: electrical control panels for integrated management of the entire system
• Installation assistance: specialized technical support during all phases of assembly and commissioning
• Scheduled maintenance: customized intervention plans to ensure efficiency and operational continuity

The systematic approach to design allows for optimizing interfaces between different components, maximizing the overall plant efficiency and significantly reducing operating costs.

Advanced Fuel Transport Technologies

To ensure constant and reliable feeding of thermal generators, Ahena Boilers offers various transport technologies, selected based on the specific characteristics of the fuel and the operational requirements of the plant:

• • Screw Conveyor Systems: equipped with horizontal screw for extraction from the depot and inclined screw for fuel transport to the boiler, fitted with orthogonal axis gearmotors for excellent operational safety and high torque. This is the simplest system and is suitable for materials with particle size under 50mm and medium-sized plants

• • Belt conveyor or redler systems: suitable for plants with non-homogeneous fuel and for large-sized plants requiring high fuel flow rate. The choice between rubber belt or chain-scraper redler is influenced by the fuel type and customer needs.

Each transport solution is sized with adequate safety margins and equipped with protection systems against overloads and blockages, ensuring maximum operational reliability even under critical conditions.

Advanced Flue Gas Treatment Systems

Compliance with environmental regulations and minimization of ecological impact represent absolute priorities in the design of Ahena Boilers thermal plants. Our flue gas treatment systems are designed to ensure emissions well below the most restrictive regulatory limits:

Dust Separation Cyclones

• • High-efficiency cyclonic separatorsCoarse particulate removal
  • Multi-cyclonic configurationOptimization of separation through the use of multiple carefully sized small cyclones to maximize particulate removal while minimizing pressure losses

Bag Filters

• • Advanced textile filtration technologyFine particulate removal with efficiency greater than 99.9%
  • Automatic cleaning systemsSequential cleaning with compressed air in reverse flow
  • Selected filter materialsSpecific technical fabrics based on temperature and flue gas composition
  • Continuous monitoringDifferential pressure control to optimize cleaning cycles

All components of the flue gas treatment system are sized to ensure maximum efficiency under all operating conditions, including transient start-up and shutdown phases

Pressurized Storage Tanks

Thanks to extensive experience in the petrochemical sector, Ahena Boilers designs and manufactures high-capacity thermal storage tanks, ideal for optimizing plant energy efficiency and effectively managing demand peaks:

Technical Specifications

• • Volumetric capacityup to 200 cubic meters per single unit
  • Design pressureup to 12 bar (PED 2014/68/EU)
  • Operating temperaturescompatibility with hot water (up to 95°C) or superheated water (up to 180°C)
  • Optimized stratification coefficientmaximization of thermal storage efficiency

Advanced Construction Solutions

• • Design according to international standardscompliance with UNI and ASME standards
  • Selected materialscertified steels with complete document traceability
  • High-efficiency insulationmultilayer insulating materials with optimized thickness

Main Applications

• • District heating networksinertial storage for optimal thermal load management
  • Greenhouse heating systemsstorage to absorb evening demand peaks
  • Industrial plantsthermal storage for batch processes with high energy demand

Integrated Control Systems

The efficiency and reliability of an industrial thermal plant largely depend on the quality of the control system. Ahena Boilers designs and manufactures advanced electrical control panels for integrated management of the entire system:

Main Characteristics

• • Hierarchical control architecturecoordinated management of all plant subsystems
  • Latest generation industrial PLCshigh reliability and processing capacity
  • Touch-screen HMI interfaceintuitive and complete visualization of all operating parameters
  • Remote connectivitypossibility of remote management and remote diagnostics
  • Predictive algorithmsdynamic optimization of operating parameters

Advanced Features

• • Integrated fuel chain managementfrom storage system to generator feeding
  • Optimized combustion controlfeedback regulation based on continuous flue gas analysis
  • Advanced power modulationprecise adjustment to required load while maintaining efficiency

Operating Advantages

• • Maximized energy efficiencycontinuous optimization of operating parameters
  • Reduction of operating costsminimization of fuel consumption and auxiliary energy through the use of inverters

Distinctive Advantages of the Systemic Approach

Choosing Ahena Boilers as a technological partner for the implementation of complete plants offers numerous tangible advantages:

• • Single point of responsibilitysingle point of contact for the entire system, eliminating interface issues between different suppliers
  • Global optimizationcoordinated sizing of all components to maximize overall efficiency
  • Guaranteed compatibilityperfect integration between different subsystems, eliminating potential incompatibilities
  • Management simplificationsingle reference point for assistance and maintenance on the entire plant
  • Economy of scalerationalization of design, implementation and management costs
  • Extended warrantycomplete coverage on the operation of the entire system

Ahena Boilers' "turnkey" approach allows customers to focus on their core business, entrusting the construction and management of the thermal plant to a specialist with proven experience in the sector.