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  • As a family business, we are oriented towards sustainable industrial research and technology development and maintain our competitiveness on the international market with innovative products and services.

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Product Portfolio

  • Technology

    • POLYTECHNIK is one of the most important suppliers for combustion technology plants and is famous for the perfect planning and trouble-free delivery of turn-key biomass combustion plants for heat and power generation.

      We offer these plants with a performance range from 300 kW up to 30,000 kW (single boiler performance) as well as special waste heat boilers for wood waste recycling. Depending on the type and water content of the fuel, different firing systems are employed (underfeed system, underfeed burnout grate and hydraulic reciprocating step grate). Warm water, hot water, steam or thermal oil are used as process mediums. The plants can be used for heating and process heat, as well as for power generation. The corresponding power generation performance is within the range of 200 kWel – 20,000 kWel (single turbine performance). New in the manufaturing program are also carbonisation plants and the POLY H.E.L.D. combustion technology (high efficiency and low dust without flue gas treatment).

      Our customised plants and systems are employed in the timber industry, the public sector for municipal heat supply, by large energy suppliers and industrial energy consumers.

        • Fuels

        • Biomass is a renewable resource for cost efficient and environmentally friendly energy production.

          Polytechnik biomass energy plants provide you with safe and efficient solutions for “energy from biomass” applications. A switch to biomass technology facilitates a cost efficient energy production as well as CO2 savings of up to 100,000 tonnes per operation.

          Our combustion plants cover everything from default solutions for conventional biomass, such as fuels from the timber and forestry industry (for classifications see EN ISO 17225-1, for example: wood chips, shavings, wood dust, shredded wood), to customised plants, which meet the special requirements of your specific fuel.

          One convincing advantage of our biomass plants originates from a special design of the combustion chamber geometry, which makes it possible to use not only high-quality resources such as wood but also agricultural by-products or other biogenic resources for a low-emission energy production while reducing energy costs at the same time.

        • CHP Combined heat and power

        • With our combined heat and power plants, Polytechnik offers you the smart and economically efficient opportunity to generate heat and electricity from biogenic fuels. Combined heat and power generation is accomplished by means of either a steam turbine or an ORC turbine (Organic Rankine Cycle).
          Our cogeneration plants on the steam basis start at classic saturated steam plants with backpressure turbines and range up to high pressure steam plants with condensing turbines. We use thermal oil as energy-carrying medium for our CHP plants for ORC turbines, which is introduced to the ORC process at approx. 310°C. ORC plants are particularly suitable for customers who show a high partial load behaviour in their heat consumption.

          Polytechnik offers you the whole range, from fuel logistics to flue gas purification and implementation of the technological process as a whole.

        • Thermal Oil

        • Polytechnik thermal oil plants are not only used in cogeneration plants but also in various industrial fields which utilise thermal oil as an energy carrier for heating, drying and technological processes (for example veneer presses). We offer both thermal oil plants with mineral oil as well as with synthetic oil, depending on the requirements and operating temperature of your process.
          Your fuel determines the design of the boiler. We offer you single-pass and multi-pass boilers for the optimisation of the operating period between two maintenances (travel time) as well as for the optimal utilisation of the available biomass.
          Operational and plant safety is always our top priority. We therefore by default include safety equipment, which independently protects the operating personnel as well as the plant. Of course, equipment according to the latest DIN 4754 is fully implemented.

        • Process Steam

        • Whether it is the veneer, food or brewing industry, or from the dairy industry to the cosmetics, aviation and paper industries: Polytechnik process steam plants ensure the supply for steam-processing industries in a reliable and efficient way.
          Our process steam plants turn biogenic fuels into the required steam – in exactly the required quality and quantity. They range from low-pressure steam boilers up to superheated steam boilers and high-pressure steam boilers.

          Polytechnik offers you the whole range, from fuel logistics to flue gas purification and implementation of the technological process as a whole.

        • Warm and hot water

        • Polytechnik warm and hot water generation plants are used not only in the industrial sector (for example in the timber industry for the supply of drying chambers), but also for a large part in the local and district heat energy supply of communities and cities.
          The plants cover the whole range from 90 – 200°C for an efficient and economical use of biogenic fuels. Depending on the heat supply’s operating temperatures (low-temperature or high-temperature circuits), flue gas condensation plants can be integrated as well, in order to increase the efficiency factor.

          Polytechnik offers you the whole range, from fuel logistics to flue gas purification and implementation of the technological process as a whole.

        • Carbonisation

        • Up to now, the conventional production of vegetable carbon involved two big problems: During the carbonisation, waste gases, which do not comply with European environmental standards, develop and the energy loss amounts to up to two thirds of the used raw material.
          Both problems can be solved by means of modern plant technologies, such as those developed by POLYTECHNIK. This makes it possible to bring the production of vegetable carbon, which in large parts has disappeared in Europe, once again closer to this huge sales market at a state-of-the-art technological level and to use suitable raw materials near their place of origin.

          The most important areas of application are the production of charcoal for consumers, the production of vegetable carbon for soil improvement (Terra Preta) as well as the production of especially high-quality coal products for the industrial sector.
          Our vegetable carbon production plant is designed to produce products with a particularly high carbon content and a low amount of tarry pollutants. The pyrolysis procedure (conversion of biomass under heat and exclusion of air) is carried out here in form of a retort system in a batch procedure.

      • Products and components

        • Polytechnik offers innovative solutions and holistic systems – customised and optimised for all kinds of biogenic fuels and the highest customer demands.

          In order to convert the energy stored in the various types of biomass to different energy systems in the most efficient, energy-saving and environmentally friendly way, innovative technologies and well-tried plant components are used.

          Polytechnik’s plants are designed individually for the relevant fuel mixture and application in order to guarantee the highest efficiency and lowest emissions possible for every kind of operation. In every operating condition, computer-controlled control systems continually analyse and optimise all parameters for an efficient plant operation with the lowest emissions and the highest availability possible. All data and parameters are processed by means of process visualisation and displayed as pictures, charts and statistics.

            • FROM DESIGN TO OPERATION

            • The design and construction of biomass-fueled energy plants is not only complex from a technical point of view. That is why our experts, who can draw from their experience with over 3,000 plants and the operation of own heating plants, support our customers from the plant design up until the operation.

              Besides others, these services are carried out:
              • plant design based on the customer’s requirements, emission and authorisation rules and the available waste flows/biomass
              • combustion tests and CFD simulation (for special fuels)
              • procedural layout and planning
              • 3D detailed planning of the complete plant
              • detailed calculations of plant components
              • detail and production drawings of key single components
              • manufacturing of plant components in own Polytechnik plants and by selected long-term partners
              • suitable packaging and shipping to our customers worldwide
              • plant installation either with customer site manager(s) or at Polytechnik's overall responsibility
              • piping and electrical installation
              • plant test and commissioning
              • operator training and plant handover
              • plant service and optimisation

            • FUEL CONVEYORS AND STORAGE

            • Polytechnik’s range of services from planning to operation of the plant include the complete fuel logistics, from temporary storage to charging the combustion chamber. Based on our vast experience from thousands of plants and dozens of fuels, the silo, bunker, storage and conveyor technology are configured individually and are customer-specific.

              FUEL CONVEYORS
              Conveyor and portioning systems adjusted specifically to the relevant fuel characteristic and type of operation guarantee a trouble-free and energy efficient supply of various types biomass to the energy plant.
              • vibration, through chain and belt conveyors
              • screw conveyors and feeders
              • hydraulic conveyor and feeding systems
              • sorting and screening plants
              • magnetic separators
              • backfire safety devices

              FUEL STORAGE
              Depending on the volume, type of conveyed material and framework conditions, the following discharge systems have been used successfully, among others:
              • hydraulic push floors
              • round and square silo discharge devices
              • crane systems
              • toploaders
              • room discharge devices

            • COMBUSTION PLANT

            • COMBUSTION SYSTEMS
              • air and water-cooled horizontal and step grates
              • grateless firings and combinations
              • stationary fluidised bed


              ADIABATIC FIRING
              • co-current, counterflow and centre-flow firing
              • single-pass, two-pass and multi-pass firing
              • wood gasifier

            • BOILER TECHNOLOGY

            • In order to transfer the energy of hot flue gasses from the combustion chamber into the heat recovery system, Polytechnik provides a broad range of robust and durable boiler plants in the field of boiler technology. The heat exchangers are equipped with automatic heating surface cleaning systems in order to guarantee highest efficiency for the whole load range, low operation and maintenance costs.

              BOILER TYPES
              • water and gas tube boilers
              • thermal oil boilers
              • single-pass, two-pass and multi-pass design

              HEAT CARRIER
              • warm water (up to 105°C)
              • hot water (up to 200°C)
              • saturated steam (up to 68 bar)
              • low-pressure steam (up to 1 bar)
              • superheated steam (up to 480°C)
              • thermal oil (up to 320°C)
              • warm/hot air
              • hot gas

              OPERATION TYPES
              • with or without constant supervision

              EXECUTION STANDARDS

              • European Pressure Equipment Guideline PED 97/23/EG
              • PB10-574-03
              • EN 12952
              • EN 12953

            • ASH REMOVAL SYSTEMS

            • The ashes produced during the burning of wood and biomass are discharged form the system fully automatically by low-wear systems and transferred to containers and/or silo facilities for temporary storage.
              The following systems have proven to be especially reliable and low-maintenance with Polytechnik plants:

              • ash shut-off valves
              • vibrating, belt and through chain conveyors
              • screw conveyors
              • ash conditioning and sorting plants

            • AUTOMATION TECHNOLOGY

            • Control and regulation of Polytechnik plants
              A programmable logic controller (PLC), which translates oxygen inflows, combustion chamber temperature, flue gas recirculation, gas and combustion air temperature, material quantity and humidity, inlet and return flow temperature, steam and system pressure and consumption of the individual consumers into command signals, is used for the fully automatic control and regulation of the energy plant.
              Plant operation runs fully automatic, from the supply of biomass to the control of energy producers, tuned to the demand of consumers to whom the energy is supplied.

              Model-based regulation (MBR)
              Polytechnik is currently the only provider of a functioning model-based plant regulation worldwide.
              This regulation, which was developed by us and was already put to use multiple times, utilises a physical model of the firing and the heat exchanger in order to internally predict the required parameters (ventilators’ speeds, flap positions, fuel supply, etc.) as precisely as possible. Consequently, the regulation systems only have to compensate for the small deviations between the calculation model and the real plant, which enables a more precise adherence to the setpoint values.
              Changes in the fuel characteristics are detected and factored in automatically by the regulation, which ensures stability of the plant’s operation. During comparative measurements, savings of fuel and subsequently operating costs of 3 to 5% have been established, compared to conventional regulations.

            • PROCESS and PLANT VISUALISATION

            • The visualisation of plants and processes is also referred to as the human-machine interface (HMI). Polytechnik’s primary goal is to design the plant’s controls as user-friendly as possible for our customers. Upon request, all plant parameters are processed by Polytechnik’s process visualisation and documented in single graphics as well as intertwining charts and statistics:
               
              • fully graphic visualisation of process operations and conditions
              • combustion chamber cameras
              • plant operation via Polytechnik’s user interface with individual menu and toolbars
              • archiving of measurements and notifications in a process database
              • reporting and acknowledgement of events
              • logging of current process data and recorded archive data
              • user and access rights management

            • FLUE GAS CLEANING and CONDITIONING

            • Depending on the fuel, size of the plant and the customer’s requirement, the flue gases from biomass energy plants are cleaned before they are directed outside via the chimney system.
              Usually, the following components must be reduced or it has to be guaranteed that their value is within the corresponding limits:
              • carbon monoxide (CO)
              • particulate matter (PM10, PM2.5)
              • nitrogen oxides (NOx)
              • organic hydrocarbons (VOC / HC)
              • chlorine and sulphur compounds (HCl and SOx)
              • heavy metals
              • dioxins and furans (PCDDs/PCDFs)

              The following technologies are successfully utilised in Polytechnik energy plants for the reduction of these emissions:
              • adiabatic firing with air staging
              • centrifugal separators as well as single and multi-cyclones
              • electrostatic precipitators (e-filters)
              • tube and bag filters
              • scrubbers and flue gas condensations
              • adsorption and absorption plants with additive dosing
              • denitrification plants (SNCR and SCR)

              For some critical plant sites, the steam emissions, which are visible when wet fuels are used and the outside temperature is low, must be eliminated.
              To achieve this, dozens of Polytechnik plants employ so-called devaporisation plants, which utilise patented procedures to eliminate the steam plume at the chimney outlet.

            • RESIDUAL HEAT UTILISATION

            • In order to deprive the boiler plant’s waste gas of valuable residue energy and to save both fuel and operating costs, various downstream heat exchangers are installed after the boiler in Polytechnik plants. If designed correctly, they cool the waste gas to just above the dew point and the obtained heat is used, for instance, for feed water pre-heating, for increasing the return flow temperature and/or for pre-heating the combustion air. Depending on the design, the plant’s efficiency can be increased by 5 to 10%.
              Patented control and regulation systems in combination with various bypass systems enable our customers to adjust the efficiency to the fuel and load conditions. Once again, heat exchangers with automatic heating surface cleaning systems are installed in order to guarantee low operating and maintenance costs.

              RESIDUAL HEAT UTILISATION
              • warm and feed water economiser
              • thermal oil economiser
              • combustion air pre-heating
              • fuel dryer

            • HEAT RECOVERY

            • In order to maintain a high plant efficiency at every point of the operation even with wet fuel, flue gases can be cooled down below the flue gas dew point. Steam and accompanying substances (including particulate matter) are condensed and the released condensation heat is transferred to a heat carrier medium (low-temperature).
              These systems, which often are referred to as flue gas condensation plants, utilise the latent heat content of the fuel gas and in turn significantly reduce the fuel input and CO2 emissions.
              With Polytechnik plants, these systems are primarily used in local and district heating plants, fuel and sawdust dryers, greenhouses and often in combination with devaporisation plants. Polytechnik plants then achieve an efficiency of more than 100% with regard to the lower calorific value.