Veolia in Lodz enhances CHP boiler performance and reduces emissions with Valmet's combustion optimization

The Lodz Heat Power Station EC4 supplies heat and power to Lodz, a city located 120 km southwest of Warsaw, Poland and its surrounding areas. Operated by Veolia in Lodz, the cogeneration plant consists of seven units with a total output of 404 MW_e and a thermal output of 1,360 MW_t and is connected to the national grid.

Veolia’s EC4 cogeneration plant in Łódź, Poland, supplies electricity and heat to the city and surrounding areas with a total output of 404 MWe and 1,360 MW_t.

Solution based on pure engineering and expertise

To explore potential solutions for improving boiler efficiency and reduced operational costs, Veolia met with several suppliers who offered tools based on artificial intelligence. Some were predictive decision-support systems for boiler operations and others were systems capable of calculating the calorific value of the fuel burned in real time.

Valmet surprised us because their solution was not based on artificial intelligence. Instead, they suggested the Valmet DNA Combustion Manager, which is based on pure engineering, expert knowledge, fuzzy logic and a set of advanced master controllers. Another benefit of Valmet was that the DNA Combustion Manager could become an integral part of our existing Valmet DCS for the K7 boiler.”

“We also decided to ask Valmet, the distributed control system (DCS) supplier for our K7 boiler, if they could help,” says Kuba Malecki, Main Engineer for Automation and Control System of the Heat and Power Plant, Veolia in Poland. “Valmet surprised us because their solution was not based on artificial intelligence. Instead, they suggested the Valmet DNA Combustion Manager, which is based on pure engineering, expert knowledge, fuzzy logic and a set of advanced master controllers.”

Valmet proposed conducting a feasibility study at the start to assess the potential of the boiler and ensure the success of the specified optimization indicators.

“Another benefit of Valmet was that the DNA Combustion Manager could become an integral part of our existing Valmet DCS for the K7 boiler,” says Malecki.

In the picture, from left to right: Kuba Malecki, Main Engineer for Automation and Control Systems of the Heat and Power Plant, Veolia in Poland, and Krzysztof Jedrzejczak, Head of EC4 CHP Plant.

‘A virtual operator’ with top-level expertise

Krzysztof Jedrzejczak, Head of EC4 CHP Plant describes what the boiler optimization solution means to Lodz. “Most of us in the energy sector believe that to operate a unit efficiently, you only need a well-designed DCS, qualified personnel and technically sound actuators.”

But over time, equipment and elements wear out. And with boilers, many interdependent factors influence performance. Meeting required steam parameters and maintaining appropriate emissions levels are necessary while still ensuring the highest possible efficiency.

“It’s not possible to tune the controllers for every potential boiler configuration or fuel type without skilled operators to make adjustments. But operators differ in their knowledge, experience, risk tolerance, and eventually, commitment,” he says.

Most of us in the energy sector believe that to operate a unit efficiently, you only need a well-designed DCS, qualified personnel and technically sound actuators. It’s not possible to tune the controllers for every potential boiler configuration or fuel type without skilled operators to make adjustments. But operators differ in their knowledge, experience, risk tolerance, and eventually, commitment.”

The Valmet DNA Combustion Manager continuously adjusts the controllers to match the changing boiler operating conditions. It tunes them in real time to achieve the best possible performance at any given moment.

“I like to compare it to driving a sports car with two different drivers. Both will get you from A to B. But the Valmet’s optimizer lets you make that trip like a professional rally driver,” Jedrzejczak explains. “Since its implementation, every operator becomes a rally driver – regardless of road conditions, mood or other limitations.”

I like to compare it to driving a sports car with two different drivers. Both will get you from A to B. But the Valmet’s optimizer lets you make that trip like a professional rally driver. Since its implementation, every operator becomes a rally driver – regardless of road conditions, mood or other limitations.”

Valmet DNA Combustion Manager solution now ensures that we have a ‘virtual operator’ on the boiler 24/7, combining the best skills of all our operators. The tool constantly adjusts the boiler’s parameters for greater operating stability.”

“Valmet DNA Combustion Manager solution now ensures that we have a ‘virtual operator’ on the boiler 24/7, combining the best skills of all our operators,” he continues. The tool constantly adjusts the boiler’s parameters for greater operating stability.

Win-win teamwork

Collaboration with Valmet has been extremely smooth. “We always had a fantastic, amazing team! They were knowledgeable, committed and available at practically any time of the day or night,” Malecki says.

We always had a fantastic, amazing team! They were knowledgeable, committed and available at practically any time of the day or night.”

An additional factor that led Veolia in Lodz to select Valmet was a special “success fee” contract model, which allowed Veolia to share not only the risks but also the benefits with Valmet.

“This was a first for Valmet, but we felt so strongly that we could achieve the KPIs, we were willing to create a win-win situation for both parties,” says  Krzysztof Jonik, Sales Manager of the Automation Solutions business area at Valmet.

Veolia agrees that this level of flexibility helped strengthen the trust and collaboration between the two companies to reach the objectives.

The plant’s operators are also happy with the optimization and have given good feedback. Smooth and efficient training helped lower job-related stress, making the transition easier for everyone involved.

Lowering NOx and CO₂ emissions

Measurable benefits for Lodz include reduced fuel consumption, urea consumption and CO₂ emissions, along with increased boiler efficiency. The combustion process is ammonia-free, as confirmed by data on the NH₃ content and ash quality.

We’re also seeing improved combustion process stability and better boiler dynamics. Today, we have a virtual operator who gives 100% every minute to ensure that the K7 boiler operates as optimally as possible.”

“We’re also seeing improved combustion process stability and better boiler dynamics,” Kuba Malecki says. “Today, we have a virtual operator who gives 100% every minute to ensure that the K7 boiler operates as optimally as possible.”

When asked how Valmet’s boiler optimization solution has helped their work – Krzysztof Jedrzejczak has a simple answer: “It has completely changed our lives!”

Valmet’s boiler optimization solution has completely changed our lives!”

“We are especially proud of this project, as it demonstrates our ability to help even smaller CHP plants utilize boiler optimization to meet tightening emissions regulations without investing in plant rebuilds,” Jonik says.

We are especially proud of this project, as it demonstrates our ability to help even smaller CHP plants utilize boiler optimization to meet tightening emissions regulations without investing in plant rebuilds.”

Thanks to the success of the first project, and the strength of the collaboration, a contract has now been signed for a second boiler optimization project - continuing the joint effort toward greater efficiency and sustainability.

For more information, Krzysztof will be happy to assist you:

Krzysztof Jonik, Sales Manager, Valmet

krzysztof.jonik(at)valmet.com