Project duration: September 2024 – ONGOING
Our client POZAGAS, a. s., entrusted us with the EPC project of complex reconstruction and refurbishment of the TEG regeneration circuit for the absorption column AK1AB. The upgrade was necessary due to the technical wear and tear of the existing regeneration equipment. The project was executed as a turnkey delivery and included the following stages:
- Project design and documentation
- Dismantling of the existing technology
- Construction of foundations for the air cooler and transformer
- Reconstruction and refurbishment of steel structures
- Refurbishment of the TEG regenerators 1 A,B, installatin of new technology
- Electrical works and instrumentation & control activities
- Functional testing and commissioning into permanent operation
Execution with In-house Capacities
After dismantling the original technology, the necessary construction works followed — specifically, the construction of foundations for the overhead vapor cooler and for the electrical switchboard. Subsequently, the steel structure was refurbished and modified to include a retention basin in its lower part. The works continued with the installation of two heat exchangers manufactured in our own workshop, as well as the supplied equipment: reconcentration boiler, burner, three pumps, condensate separator, carbon filter, and all corresponding valves, pipelines, and fittings. Outside the skid (where the main technology is located), we installed the overhead vapor cooler on the prepared foundations.
Scope of our Activities:
- Project activities: detailed design documentation, 3D modeling, process, structural, and hydraulic calculations, system analysis, CED, as-built documentation, equipment testing documentation, designer’s supervision
- Dismantling works: removal of the old skid with outdated technology
- Supply and installation of new equipment: TEG regenerator, reconcentration boiler burner, heat exchangers, overhead vapor cooler, condensate separator, spray pump, TEG pump, mine water pump, carbon filter, valves, pipelines, and fittings
- Steel structures: dismantling, refurbishment, modification, and reassembly of support structures
- Electrical works: implementation of power distribution systems, lightning protection, and grounding
- Automation and control systems: installation of flow measurement for fuel gas, TEG level sensors, process temperature and pressure sensors, and control of the RK1AB burner, overhead vapor cooler, and pumps
- Insulation and coating works
- NDT testing performed in-house (VT, RT, UT, MT, PT)
- Functional and commissioning testing, including a 72-hour performance test
- Certification and development of accompanying technical documentation
Project Result
By implementing Best Available Techniques (BAT) in compliance with EU legislation, we achieved significant improvements in both the spatial layout and operational efficiency of the technological process. The original four heat exchangers were replaced by two, simplifying and streamlining the entire system. We also improved access to the boiler assembly, making maintenance much easier. The result is a modernized technological solution that ensures lower emissions and higher operational efficiency for the client.
