The boiler units feature dual-fuel burners developed in-house by ZiO. The burners provide stable operation on natural gas from the Sakhalin field as the primary fuel and heavy fuel oil as the backup fuel. The equipment was designed to fit into the plant’s existing building, so a new boiler house was unnecessary. Each new ZiO boiler unit has a steam output of 540 t/h and will replace two boilers that have reached the end of their service life, each rated at 210 t/h. The units can operate in the plant’s cross-connected thermal circuit or as part of a dedicated unit with a steam turbine generator. ZiO’s design reduces specific fuel consumption for steam generation and cuts pollutant emissions.
Boiler unit No. 1 has been installed and commissioned. Performance guarantee tests confirmed the unit’s reliability and environmental performance, with measured figures exceeding design targets. Gross efficiency reached 95.2%, compared with a guaranteed 94.5%. Nitrogen oxide concentration in the exhaust was 118 mg/m³, 5.6% below the 125 mg/m³ limit. Carbon monoxide concentration was 49 mg/m³, 83.7% below the guaranteed value of 300 mg/m³.
Boiler unit No. 2 is undergoing performance guarantee tests. Installation of boiler unit No. 3 is under way, with commissioning scheduled for 2027.
Background
ZiO Group, headed by Podolsk Machine-Building Plant JSC, is a vertically integrated group of power engineering companies. It handles the entire project cycle, from feasibility studies, engineering and manufacturing through turnkey construction, commissioning and maintenance.
Designing and manufacturing steam boilers for power generation are among ZiO Group’s core activities. Its engineers develop each design around the facility’s process configuration, operating requirements and installation conditions. In-house engineering capabilities and years of experience supplying equipment allow the Group to deliver complex projects and provide technical support for the equipment.