The modern boiler room for Duslo Šaľa is in full operation
The construction and commissioning was carried out by the PPA CONTROLL group as the general contractor.
We have completed the complex and demanding implementation of another major energy project, this time in the chemical industry, which significantly contributes to a more modern and environmentally friendly operation. As a general contractor, we are in PPA CONTROLL group implemented the complex construction and commissioning of the new K8 boiler house for the company Duslo, as. For many years, it has been one of the most important chemical industry companies in Slovakia and during its existence has developed into a fertilizer producer of European importance.
Investment worth millions of euros
All competitive businesses today must be able to respond flexibly to market demands while meeting ever-tightening emission standards. Moreover, in a dynamic industrial production environment where efficiency and reliability are key success factors, modernizing energy infrastructure is becoming a necessity.
Duslo realized the need to strengthen its production capacity and ensure stable energy supplies. Subsequently, our company PPA CONTROLL played a key role in this context, as the general contractor, embarking on a challenging project, namely the construction of a new K8 boiler house for this chemical plant. The total investment required costs of more than 3 million euros.
Under the direction of PPA CONTROLL until the start of operation
However, the entire process, from project preparation to the final launch of K8, which was comprehensively covered by our PPA CONTROLL group, was not easy. It took several years and had to face several significant complications. Before the end of 2021, a contract was concluded between the companies, which represented a significant milestone for both parties. The entire order included the comprehensive construction of a new boiler house, including the installation of cutting-edge technology and the integration of the new K8 boiler into the existing pipelines of this chemical giant.
These have a complex structure, as natural gas, steam, feed water, air and demineralized water flow through them. The demanding challenge required precise planning and coordination of all phases of the project, starting with the development of project documentation and ending with the final handover of the K8 boiler into full operation. As a general contractor, we not only provided technical expertise, but also managed complex processes and ensured their compliance with current strict standards and regulations.
"We received the building permit in mid-2022 and excavation work soon followed. We continued with the completion of the piles, concreting, installation of the chimney and the entire steel structure of the boiler room. Shortly after this, the main boiler technology was delivered to Duslo and the boiler was inserted into the boiler room. Less than a year after the start of construction, we started the first individual tests, continued with comprehensive testing and handing over the K8 to trial operation, and we successfully completed the final approval for full operation from this year 2025," says Michal Pogač, project manager at PPA CONTROLL, calculating the range of activities.
We have thus managed to implement another challenging and significant energy project, which will contribute to a more efficient and ecological operation of one of the key chemical industry companies in Slovakia.
Modern gigantic boiler weighing 35 tons
The central component and, so to speak, the heart of the new boiler room was the K8 natural gas steam boiler, featuring a regulated steam output of 6 to 30 tons/hour, a steam pressure of 3,8 MPa, and a boiler efficiency of 96% at nominal output. This equipment meets the strictest emission limits, thereby contributing to reducing the environmental impact of Duslo Šaľa's operations.
The new technological equipment is also more reliable and efficient to operate. The total weight of the main boiler body, which is up to 35 tons, is also evidence of how large the project was. Of course, it was the largest and heaviest part of the boiler technology that was inserted into the new boiler room.
"After the previous modernization of other boilers already operating in Dusla and the latest addition of the K8 boiler, the company effectively covered their combined output and steam supply at the start of ammonia production. The latest K8 boiler is used to produce lower steam consumption and therefore older boilers with higher output no longer have to be operated at certain times. This saves operating costs and ultimately reduces emissions," Michal Pogač delivers for PPA CONTROLL.
The entire project also includes a 45-meter chimney.
In addition to the installation of the K8 boiler, the entire project also included the construction of a new 45-meter chimney, equipped with state-of-the-art emission measurement probes, as well as the sophisticated implementation of extensive external pipe routes. These components ultimately play a key role in ensuring the safe and efficient operation of the newly built boiler house at the chemical plant.
During the construction of the modern boiler house itself, several problems had to be solved, for example, due to the delayed delivery of the main boiler from the manufacturer. Nevertheless, under the leadership of our company PPA CONTROLL, work continued on the construction of the structure and the outer shell of the boiler house, into which the 35-ton boiler was inserted after delivery using specially built rails. Handling such huge weights and oversized bodies required the use of many special technologies and equipment. Two cranes with a lifting capacity of up to 100 tons also helped in the installation of the boiler body of the new boiler house.
More efficient and environmentally friendly production
"The construction of new infrastructure in the form of a modern boiler house has brought significant benefits to Duslo, in particular an increase in the availability of resources necessary for the start-up of the Čpavok 4 production plant and optimal provision of steam in the summer months. This strategic step allows us to manage production processes more efficiently and reliably, thereby strengthening the competitiveness of our company on the market," says Roman Protuš, Technical Director and Member of the Board of Directors of Duslo, as.
With the comprehensive implementation of this project, we, together with the PPA CONTROLL group, once again confirmed our position as a reliable and competent partner for demanding energy projectsOur ability to successfully handle complex engineering and construction work, from project documentation to final handover, demonstrates a high level of expertise and professionalism.
