NUK-HP®

High pressure steam boiler system

for closed steam/condensate cycle

for process heating plants

Virtually no maintenanceThere are no pumps, no con-densate fittings and no feed-water system, nor is clarificationrequired. There is no danger ofcorrosion due to entry of oxygenfrom the ambient air into thesystem is not possible.

Other advantages• Efficient, non-toxic pro-

cessing heating system.

• Very low flow resis-tance in the verticalevaporator pipes toguarantee high watercirculating rates.

• Low radiation load inthe combustion cham-ber and a large con-vection heating surface.That means steam bub-ble formation in the pipesystem is therefore verylow. Controlled heattransmission at the heat-ing surfaces is guaran-teed and high combus-tion efficiency is achieved.

• No refractory material inthe combustion chamber,thus preventing heatstorage and uncontrolledevaporation in the eventof an emergency shut-down.

• Bursting disc and safetyvalve as the systemprotection against over-pressure and vacuum.

• 72-hour operation withoutsupervision. Pressure, boiler-water minimum level and fluegas temperature are perma-nently monitored by a safetycontrol system.

• The reliability of operation ofthe NUK-HP® is verified in anexpertise by internationallyrecognised specialists.

NUK-HP® product series hasbeen developed and gives fol-lowing additional advantages: • Differentiated, customized

capacity grading• free space and area around the

burner, and therefore goodworking during commissioningand maintenance

• Substantial reduced numberof welding seams at the pro-duction of the tube system, by that a higher operationalreliability and durability

Reduced operating costsThe NUK-HP® is a high-pressurenatural circulation boiler operat-ing by the gravity circulationprinciple. Therefore circulatingpumps are not required to oper-ate the NUK-HP®. Boiler water isused as the heat carrier. Thewater is evaporated in this boiler within a hermetically closed cir-cuit. The steam flows to the heatexchanger and the condensateflows by gravity back to the boiler.

No steam bubble blockage in theNUK-HP®. Water circulation isalways guaranteed in all opera-ting modes, even with rapidlychanging operating pressures.No steam bubble blockages ari-se in the vertical rising tubes.The heating surfaces consist ofvertical, coaxially arranged risertubes which form a high-efficien-cy 3-pass flue gas system.

Alternating load states in boilersystems consisting of pipe coilsin a spiral arrangement canresult in steam bubble blockageswhich, in turn, can interrupt thewater circulation. This invariablyresults in critical operating statesin the boiler pipe system.

The hermetically closed steam-condensate-circuit system

• Equipped and produced inaccordance with the EuropeanCommunity technical rules(PED 97/23/EC), and otherworld-wide acceptance organ-izations (e. g. SELO, ASMEGOST-R, ROSTECHNADZOR).

GekaKonus® natural circulation boiler in a palm oil refinery for 700 TPD

Application

Food industry Distillation and fractioning of fatty acids, esterification of fattyacids, distillation of glycerine,deodorising edible oil and fat

splitting. Applicable in all processheating plants in which plant-relatively a natural circulation canbe implemented in the heatingsystem.

V 3

SV 1PIASH

RP

PIC

XZA

TE

PE

V 2

LASL LE

LASL LE

V 4

PI

V 1V 6M22

SV 3

PASH

PE

TSAH

M22 filling pump

V 1 filling and draining valve

V 2 check valve low level

V 3 flushing and venting valve

V 4 pressure gauge valve

V 5 non-return valve

PI 5 pressure gauge

SV 1 safety valve

SV 3 safety valve

PASH pressure limiter

PE pressure transmitter

PIC pressure controller

RP rupture disc-pressure switch

PIASH pressure indicator-alarm switch

LE water level electrode

LASL water level limiter

XZA burner

TSAH flue gas temperature

limiter

Design

Capacity range

150 up to 5700 kW / 95 bar, steam flow volume up to14.000 kg/h

DesignThe NUK-HP® consists of verticalrising tubes connected to a topand bottom collector. The risertubes are welded to cylindricaltube baskets. Two baskets andthe boiler shell are the basis ofthe boiler system. Flue gas flowis conducted in the 3-pass-flueparallel-counter-flow principle.

Monitoring instrumentsThe NUK-HP® is equipped withall the necessary safety devicesspecified by the correspondingsafety regulations. This equip-ment guarantees safe and relia-ble operation and ensures thatthe boiler is shut down in theevent of a fault.

Standard equipment • 2 electrodes in self-controlled

mode to monitor the minimumwater level, redundant wired

• 1 pressure switch to monitormaximum operating pressure

• 1 flue-gas temperature sensorto limit the maximum flue gastemperature

• 1 spring-loaded safety valve • 1 rupture disc with pressure

monitoring device • 1 pressure gauge with shut-off

valve and testing flange

All safety equipments are cor-responding to the rules of the European Community and aretested by the notified body TÜV.

Moreover, any items of equipmentcan be adapted to the regulationsin force in the country in whichthe boiler is to operate.

BurnerThe NUK-HP® can be equippedwith burners for high speed die-sel, heavy fuel oil, natural gas,LPG, biogas and bio diesel orusing a dual fuel burners.

The choice of burner dependsupon the boiler capacity, the fueland the demands expected ofcapacity control.

The capacity can be controlledby different controlling systems: 2-stage: High / low / off or modulating

ControlThe capacity can be controlledby different controlling systems.• Pressure control:

The capacity of the NUK-HP®

and the saturated steam pres-sure is controlled independ-ently of product temperature (e. g. vegetable oil).

• Cascade control:The capacity of the NUK-HP®

is controlled according to pro-duct temperature (e. g. vegeta-ble oil). The saturated steampressure is adapted in a defined range of controlaccording to the heat require-ment of the heat exchanger (e. g. vegetable oil) the product temperature.

Permanent Monitoring • Boiler water minimum level• Steam pressure • Flue gas temperature• Burner control

Your energy/system advantage

Complete workshop pre-assembling

The NUK-HP® is supplied as acomplete boiler system readyfor operation. Boiler assemblingon site is not necessary. Theburner, controls and safety de-vices and the switchboard arealready pre-mounted on theNUK-HP® ready for operation.All the electrical connectingcables between the burner, theinstrumentation and the switch-board are fully pre-wired oncable bars ready for operation.

The freestanding switchboardcan be set up near the GekaKonus® NUK-HP®. The electric connection occursabout marked industry plug-inconnector.

Before the NUK-HP® leaves ourworkshop, the boiler with allequipment is checked by logicand electrical functional test. This test ensures that all possi-ble faults in the equipment aredefinitely eliminated.

GekaKonus® GmbH

Siemensstr. 10 · D-76344 Eggenstein-Leop. · Phone +49 (0) 7 21/9 43 74-0 · Fax +49 (0) 7 21/9 43 74-44info@gekakonus.net · www.gekakonus.net

Continuous partnership

• Since 1954, more than 50 years experience

in heating technology

• More than 45 years experience with High Pressure

Natural Circulation Steam Boilers

• Product design accepted by many international

notified bodies

• World-wide operating success in the edible

oil industry and a wide range of other industries

which need process heat energy

• World-wide successful with more than

12.000 operating systems

in all industral heating processes

GekaKonus® business segments

• Thermal Oil Heater

• High Pressure Natural Circulation Steam Boiler

• High Pressure Steam Boiler for open

steam condensate cycle

• Steam Generator, thermal oil heated

• High Pressure Quick Steam Generator for open

steam condensate cycle

• Exhaust Gas Thermal Oil Heater

• Project management and engineering for

process heating plants

• Commissioning, training, maintenance,

spare parts, service

OCCHIPINTI GmbH

Welding Technology,

Heater, Boiler, Pressure Vessel,

Steel Chimney

GekaKonus® GmbH

Office

Manufacturers