System solutions and dosing technology for power plants

Untreated boiler feedwater is one of the most common causes of malfunctions and efficiency losses in power stations and waste-to-energy plants. Corrosion caused by dissolved oxygen, deposits and scale, as well as incorrect pH levels, attack boilers, pipework and valves, and impair heat transfer and the operational safety of the plant. The consequences are increased maintenance costs, unplanned downtime and higher operating costs. Targeted chemical treatment of the boiler feedwater is therefore a key prerequisite for safe and economical boiler operation. sera’s dosing systems enable the precise, automated and demand-driven addition of oxygen scavengers, corrosion inhibitors, phosphates, and acidic and alkaline chemicals. This ensures stable water chemistry, reliably protects plant components and guarantees the long-term, efficient and low-maintenance operation of the boiler plant.

Microbiological growth in boiler feedwater is an often underestimated but highly critical risk for boiler operation in power stations and waste-to-energy plants. Bacteria and biofilms promote corrosion, encourage the formation of deposits and can significantly impair heat transfer and operational safety – with direct consequences for the plant’s efficiency, availability and service life. Inadequate or uneven biocide dosing further exacerbates this risk. sera’s dosing systems ensure the precise, automated and continuous addition of biocides to boiler feedwater – thereby guaranteeing consistently stable water quality, protected boiler components and safe, economical operation.

Cooling towers in power stations are constantly exposed to extreme chemical and biological stresses. Without targeted water treatment, corrosion, deposits and microbial growth inevitably lead to poorer heat transfer, reduced efficiency and increased maintenance costs – and, in the worst case, to unplanned shutdowns. Unstable pH values and fluctuating water chemistry further exacerbate these effects. sera’s dosing systems ensure the precise, automated and demand-driven addition of inhibitors, hardness stabilisers, acids and alkalis – thereby guaranteeing consistently stable cooling water quality, protected plant equipment and reliable, cost-effective cooling tower operation.

Microbial growth in the cooling circuit poses a serious operational risk in power stations. Algae, bacteria and biofilms impair heat transfer, promote corrosion and deposits, and lead to efficiency losses, increased maintenance costs and, in the worst case, unplanned outages. Inconsistent or manual biocide dosing further exacerbates these problems. sera’s dosing systems ensure the precise, automated and continuous addition of biocides to the cooling circuit – thereby ensuring stable water quality, reliable cooling performance and economical, trouble-free power plant operation.

Water vapour is the key working medium in power stations and waste-to-energy plants – and at the same time one of the most sensitive areas of the entire plant. Without targeted chemical treatment, corrosion, deposits and unstable water-vapour chemistry inevitably lead to efficiency losses, increased maintenance costs and, in the worst case, unplanned shutdowns. High pressures and temperatures further exacerbate these effects. sera’s dosing systems ensure the precise, automated and demand-driven addition of corrosion inhibitors and oxygen scavengers – thereby ensuring permanently stable water-steam chemistry, protected boiler and turbine systems, and safe, efficient and economical plant operation.

Compliance with statutory emission limits is one of the key requirements for the operation of power stations, waste incineration plants and chemical production facilities. Flue gases contain pollutants such as sulphur dioxide (SO₂) and nitrogen oxides (NO_x), which, without effective purification, cause environmental pollution and can jeopardise operating licences. Fluctuating flue gas compositions, insufficient dosing accuracy and the cumbersome handling of reagents make stable process control difficult and increase operating and maintenance costs. Precisely controlled flue gas cleaning is therefore a prerequisite for safe and economical plant operation. In DeNOX systems, nitrogen oxides are specifically reduced to nitrogen and water, whilst in flue gas desulphurisation plants, sulphur dioxide is reliably removed or – for example in sulphuric acid production – returned to the production process. sera’s dosing systems enable the precise, automated and demand-driven dosing of reagents such as ammonia, urea or lime milk, thereby ensuring stable purification processes, consistently low emissions and compliant, cost-effective plant operation.

Even power stations with low wastewater volumes generate process wastewater that must be treated appropriately before being discharged back into the environment. In particular, the concentrated cooling water that is regularly discharged often needs to be neutralised with soda to regulate its pH level and composition.

Further wastewater is generated, for example, during flue gas cleaning, condensate treatment or residue dewatering. Here, precise dosing of precipitants, neutralising agents or flocculants is essential – a task for sera’s precise technology.

sera offers complete dosing systems, preparation and dosing units for polymers, accessories and high-performance dosing pumps for this purpose. This ensures efficient, legally compliant and cost-effective wastewater treatment – reliably and in a resource-saving manner.

River water is widely used as a source of raw water in waste-to-energy plants and power stations, but it places high and constantly changing demands on the plant’s engineering systems. Suspended solids, organic contaminants, chemical residues and highly fluctuating water qualities place a strain on heat exchangers, pipework and boilers, promote fouling and corrosion, and lead to efficiency losses, higher maintenance costs and, in the worst case, unplanned downtime. At the same time, environmental regulations and requirements for water cycles are constantly increasing. Process water treatment using system solutions from sera ensures targeted, automated and reliable conditioning of the raw water – thereby safeguarding plant equipment, ensuring stable processes, reducing operating costs and enabling the economical, permit-compliant operation of waste-to-energy plants and power stations.

Self-sufficient energy and heat supply using hydrogen

We offer power stations and waste-to-energy plants integrated energy supply solutions designed to make efficient use of surplus renewable electricity. Surplus energy is converted into hydrogen via electrolysis, compressed using the sera piston compressor, and stored.

When required, we use the stored hydrogen for power generation or direct heat production – whenever photovoltaic systems and battery storage are insufficient. In this way, we enable a largely self-sufficient, secure and predictable energy and heat supply whilst simultaneously reducing the use of fossil fuels.