News - Bosch Industriekessel GmbH, Stammhaus

News - Bosch Industriekessel GmbH, Stammhaus

Bosch Industriekessel GmbH, Stammhaus

GermanyGunzenhausen

 

News - Bosch Industriekessel GmbH, Stammhaus

Newsgrafik #34743
 01.03.2019

ISH Energy: Enter a digital networked future with Bosch   (Company news)

At ISH Energy, the world's leading trade fair for sanitary, building, energy, air conditioning technology and renewable energies, Bosch is continuing to promote digitalisation and networking in the commercial and industrial sectors. Fast, simple, unbureaucratic and agile – customers in project business have high expectations for reaction times, flexibility and planning support. Bosch therefore relies on smart tools and uses intelligent configurators. One brand new example is the automatic preparation of project-specific 3D data and P&I diagrams. Being available in very early stages of projects this makes work simpler for planners and plant engineers. This enables them to perform more precise calculations and avoid later changes.

Bosch is launching their new planning guide for steam boiler systems as an interactive digital version. The fundamental idea: Make planning of complex process heat systems easier and make expert knowledge comprehensively available. With programmed calculation tools, checklists and practical error prevention information, the new interactive document is more than a typical planning handbook. "It doesn't just provide beginners with the information they need – it also serves as an efficient working tool for experienced planners," emphasises Daniel Gosse, Head of Marketing and Academy at Bosch Industrial.

Smart control technology and AI assistants for Industry 4.0 applications
Preventing production downtimes and reducing energy costs to a minimum are key drivers for businesses and industries. The energy management solutions from Bosch Energy and Building Solutions enable overall optimisations including energy generation, distribution and whole production lines. The Energy Platform at the trade fair booth gives you a live view of selected Bosch production sites. Recorded energy and process data is transformed into significant figures in order to increase energy and resource efficiency. What's more, Bosch Rexroth is presenting control solutions for this type of future-proof automation system for buildings and factories.

With artificial intelligence specifically designed for industrial boilers, the digital efficiency assistant MEC Optimize really stands out from the crowd. Predictive maintenance features monitor and present operating data. Additionally, the smart algorithms interpret the data and inform users in advance about potential downtime risks. With individually determined information and recommended actions, system operators are assisted in maximising their system availability and minimise their energy costs.

Product innovations for steam, heat, power and compressed air
Highly efficient, compact and easy to operate – at the ISH trade fair, Bosch will present the new CSB Universal steam boiler (compact steam boiler), which is available in a power range from 300 to 5,200 kilograms steam per hour. The CSB steam boiler will be presented at the Bosch trade fair booth as a complete boiler system with low-NOx burner, modules for waste heat recovery and the compact steam control CSC mounted on the boiler. The boiler achieves a high efficiency of more than 95 per cent and enables sustainably low emissions. Its innovative design additionally provides easy accessibility for servicing and maintenance work.

At the ISH 2019 the Bosch booth features the largest boiler of the entire trade fair. The ZFR double-flame tube boiler generates up to 55 tons of steam or up to 38 megawatts hot water. Visitors can actually step inside the boiler or even go upstairs to the VIP lounge on its top floor. Besides the process heat systems, Bosch will also present innovative combined heat and power systems. In this sector, the customer focus is also on digitalisation through control technology or remote access in order to optimise reliability and operating costs. At their ISH booth, Bosch will show a combined heat and power unit from the latest motor generation. It is optimised to provide particularly high overall efficiency and future-proof low emissions. The compressed air and heat system is another highlight. It produces compressed air using a natural gas motor and simultaneously provides waste heat for additional processes and heating applications. This enables CO2 emissions savings of up to 50 per cent and lowers operating costs.

International industry solutions
Bosch offers reliable energy solutions in more than 140 countries worldwide. Typical applications include the food and beverage industry, production industry, energy suppliers and large buildings or public facilities. Availability, efficiency and seamless integration into the customer's processes are essential. Bosch demonstrates these qualities at the ISH trade fair at different information points. Additionally, visitors can see real boiler houses and energy centres from a range of industries using a 360° virtual reality headset.
(Bosch Industriekessel GmbH)

Newsgrafik #34386
 14.11.2018

Smart steam boiler technology from Bosch - Digitisation and networking in a traditional brewery  (Company news)

Heiko Doppler, a Bosch customer service engineer, and Thomas Steffes, Project Leader at Kramer & Best, have recently handed over a new steam boiler system to André Ködel, master brewer of Park & Bellheimer's brewery in Pirmasens, south-west Germany. Park & Bellheimer expects to save around €80,000 a year in energy costs by installing this upgrade. Furthermore, the brewery in Rhineland-Palatinate is employing an Industry 4.0 solution in the form of MEC Optimize, meaning that in future it will benefit from digitised data collection, intelligent analysis and maximum energy transparency.

MEC Optimize from Bosch is a digital efficiency assistant that helps boiler attendants and operators to locate potential energy losses quickly and suggests concrete measures to address them. The efficiency assistant even detects critical situations immediately and analyses the state of components based on the operating mode. The reliable prognoses enable Ködel, who is also Head of Operations at the Pirmasens plant, to schedule maintenance timely according to the brewery's capacity. Leading-edge predictive maintenance is consequently being brought into a traditional brewery while making its workers, machines and processes more efficient.

The data for MEC Optimize is collected and saved locally by an industrial computer built into the control cabinet. Bosch offers two different systems for transferring and visualising data, which make use either of standardised interfaces to a process control system or of a PC/tablet via WLAN. At the brewery in Pirmasens, authorised persons can view the statistics and analyses via the central control station, gleaning all the important information about the system's energy consumption, load profile and performance, and digitally entering the results of the boiler tests at the same time. Being networked with the secure Bosch MEC Remote monitoring system enables data to be called up from any location, including outside of the brewery. A further advantage of remote access is that, if requested by the operator, Bosch experts can assist with troubleshooting, parametrisation and programming – cost effectively and without having to travel to the site. "Uninterruptible yet economical process heating is absolutely essential to running our brewery," says Ködel. The networked solutions from Bosch will help to make response times faster and make work more productive overall.

The new Bosch boiler system supplies the brewing house with steam for processes such as mashing and boiling – up to five tonnes of steam per hour are available. Components for heat recovery, a modulating natural gas burner, speed-controlled fans and various items of automation equipment help to provide the steam in a flexible and energy-saving way. The new system was planned and installed by Kramer & Best Anlagenbau GmbH in collaboration with Bosch Industriekessel GmbH.
(Bosch Industriekessel GmbH)

Newsgrafik #32009
 28.10.2016

New brewing site for traditional Gaffel Kölsch beer: Production extension with Bosch steam boiler  (Company news)

For the extension of its production, the privately owned brewery Gaffel Becker & Co. OHG decided to implement a new steam boiler plant from Bosch. The production capacities at the Eigelstein location in the centre of Cologne were too small for satisfying the production demands. Up to four million litres are produced every month, trend increasing. The portfolio ranging from the traditional Gaffel Kölsch beer up to liqueurs and refreshing soft drinks. The new brewing site in the South-Eastern part of town, Porz-Gremberghoven, is a better location in terms of logistics, but also provides more effective production conditions. The new process heat supply also contributes to this: With the more efficient Bosch boiler system and the improved brewing equipment, the steam consumption could be reduced by 50 per cent. Intelligent data recording and analysis keeping energy costs constantly low. In addition, the brewery can profit from an evenly high steam quality and efficiency at all load ranges. The installation of the entire steam boiler plant was done by the engineering company Dankl Dampfsysteme.

The selected Bosch boiler type UL-S can provide up to 8 000 kg steam per hour for the high process heat requirements in the brewery. And there are also further energy consumers, such as CIP plants for cleaning and the dealcoholisation plant. The industrial boiler is designed for the sudden load changes of the steam consumers, typical for a brewery. Due to the large control ratio of 1:10 of the natural gas burner, the plant operates flexibly and efficiently at every operating point, even low loads are covered efficiently. Another advantage is the speed controlled burner fan. Electricity savings are the result for the brewery, thanks to a reduction of the fan speed depending on the current burner output.

High efficiency is a very important aspect in the energy-intensive brewing process. With the integrated flue gas heat exchanger of the boiler, the steam demand for heating the feed water and thus the fuel consumption during steam generation are reduced. The boiler efficiency is around 96 per cent. In order to keep emissions low, the natural gas burner has an internal flue gas recirculation. Part of the flue gas is returned from the combustion chamber to the burner mixing device. This lowers peak temperatures in the flame and thus considerably reduces the thermal formation of nitrogen oxide – a contribution to the environment. In addition, the integrated oxygen probe enables evenly high burner efficiency and reduced fuel consumption.

The high degree of automation of the steam boiler plant offers optimum user comfort and allows intelligent data analysis. The SPS based boiler control BCO records and saves all important operating data, such as for example the amount of burner starts, cold starts or desalting values. With the software Condition Monitoring, this data can be displayed and evaluated efficiently. Consequently, the operating personnel at the Gaffel brewery and the responsible Bosch service technician can react immediately, e.g. in case of high energy losses during desalting. Also the feed water deaeration and chemical dosing are completely automated and designed to demand.

In summary, the Gaffel brewery profits from an dynamic steam supply, that is entirely energy-efficient and customer-specific configured. But not only in the technical range, also in design, Bosch shows flexibility. Instead of the common red/grey combination, the boiler is designed in the Gaffel corporate colour dark blue. The control cabinets are in stainless steel, just as required by the customer.
(Bosch Industriekessel GmbH)

Newsgrafik #30741
 04.11.2015

New steam boiler from Bosch saves up to 16 percent energy costs  (Company news)

Traditional art of brewing meets environmentally-friendly efficiency
Pivovar Klášter brewery renews its steam supply

Photo: Director Zdenek Prokupek of Pivovar Klášter brewery relies on traditional brewing in combination with state-of-the-art engineering.

Mashing, boiling or keg and bottle cleaning: The production of beer is an energy-intensive process and thus needs an efficient and reliable steam supply. In the Pivovar Klášter brewery in the Czech Republic a steam boiler operated for over 30 years. In order to increase the reliability of supply and to reduce the running costs Pivovar Klášter decided to renew its existing energy system. With the new UL-S steam boiler from Bosch not only the reliability increased thanks to numerous automation equipment, the steam boiler also saves around 47 m³ of natural gas per hour. Around 75 percent of these savings are realised by the recovery of waste heat from flue gas. In total, the brewery saves up to 16 percent on fuel costs with the new system.

The first flue gas heat exchanger, the economizer, is used for preheating the feed water. Thus, the need for fuel for heating up and evaporation of water in the boiler is reduced. In the downstream heat exchanger the flue gas is additionally condensing. Due to the low temperature of this waste heat it is used for preheating the brewing water.

The shell boiler can provide 4,000 kilogram of steam per hour. The natural gas firing with modulating control ensures an elastic operating behaviour. The burner capacity can be adjusted continuously to the actually needed steam demand. It is thus possible to reduce the number of burner starts resulting in higher efficiency and prolonged lifetime of the boiler and burner. After downtimes the boiler can be started very gently from the cold state by using the intelligent automatic function SUC (start-up control).

The boiler control BCO provides easy access to important operating data like fuel consumption, boiler and burner operating hours or the number of burner switches. Further optimisation possibilities can be derived from this data. Furthermore, the BCO automatically controls desalination and blow-down. In comparison to a manual operation the demand-controlled process saves energy and water. In addition, the water service module from Bosch provides the boiler with deaerated feed water. This protects the system from corrosion and ensures a continuous high steam quality.

The perfectly matched components from Bosch provide a reliable system and allowed a quick and smooth installation. Zdenek Prokupek, director of Pivovar Klášter, is pleased about the good result and the cooperation with Bosch: "With the new system we have managed to reduce our energy costs significantly and thanks to the high degree of automation we can now completely focus on beer brewing. Both the quality as well as the local service from Bosch in the Czech Republic have convinced us."
(Bosch Industriekessel GmbH)

Newsgrafik #30350
 17.07.2015

Bosch Industriekessel is celebrating its 150th company anniversary  (Company news)

From a boiler manufacturer to a system supplier

This year Bosch Industriekessel is celebrating its 150th company anniversary. The company started as a small boiler manufacturer under the Loos family name. In the past decades it developed to a the leading global system supplier for industrial boilers. Since its foundation the company time and again revolutionised the heat and process energy technology in the large performance range: New and further developments continuously improved the efficiency and the durability of boiler systems.

The product range today comprises in addition system combinations with integration of combined heat and power units and renewable energies as well as products for waste heat utilisation. Internally developed, intelligent controls and web-based remote functions facilitate a higher energy efficiency and provide for an optimum interaction of different energy generators. Passion for power – this is our guiding principle. "We are building on a solid foundation that we have created in the past decades. For the future it is of high importance to use and to network energy much more efficiently. To achieve this we are developing concepts, we are offering system solutions and we are conducting research and development," explains Markus Brandstetter, managing director of Bosch Industriekessel GmbH.

The history of the company begins in 1865, when Philipp Loos founded the "Dampf-Kessel-Fabrik PH. LOOS" in Neustadt an der Weinstraße (Palatinate). In 1917 today's headquarters in Gunzenhausen (Bavaria) came into being in order to develop a series production of vertical steam and hot water boilers. The boilers from Loos proved to be successful on the market. New production locations were established in Schlungenhof near Gunzenhausen in 1958 and four years later in Bischofshofen, Austria.

Advantage through innovation
In 1952 Loos developed and patented the horizontal three-pass flame tube/smoke tube boiler with internal water-flushed rear flue gas reversing chamber – today market standard worldwide. During the course of its history the boiler manufacturer brought further innovations on the market that today still are setting benchmarks in the industry. In 1977, for example, the company developed a fully automatic water level control for a 72-hour operation without permanent supervision. Further procedures and boiler system modules e.g. for water treatment, heat recovery and PLC-based control technology followed. These components optimised not only boiler operation but also greatly facilitated system planning and installation.

High quality boilers from Germany and Austria
In the past, boiler pressure vessels were laboriously joined with rivets. The introduction of the welding technique at the beginning of the 20th century lead to significant quality improvements and optimised working processes. In 1966 Loos introduced automation into production and as the world's first boiler manufacturer the company used an numerically controlled flame cutting machine for plate cutting. Today state-of-the-art-manufacturing and testing facilities, welding robots, laser cutting machines and X-ray chambers in connection with the expertise of the specially trained employees ensure the highest in quality and perfection. Up to 1 800 customised industrial boilers per year with transportation weights of up to 108 tons leave the production facilities in Germany and Austria.

Globally active
Over 115 000 systems in more than 140 countries: When Bosch Industriekessel talks about its market today, then this is a trip around the world. In the 1980s already first sales subsidiaries were established outside Europe, for example in Asia. Due to the continuous expanison of our sales and service networks at home and abroad the export share currently makes up more than 60 percent.

The 150th anniversary – a joint success
150 years after the foundation of the company Bosch Industriekessel looks back with pride on this eventful history, characterised by technical revolutions and innovations. The partnership and the trustful cooperation with planners and plant construction companies as well as the expertise and the passion of around 700 employees have significantly contributed to this success.
(Bosch Industriekessel GmbH)

Newsgrafik #29882
 11.03.2015

Bosch presents Energy generation 4.0   (Company news)

ISH Energy 2015 in Frankfurt, hall 8.0, stand B31
Modular efficiency concept and intelligent controls

-Interactive demonstration of the energy system control MEC
-Live connection to real plants with Bosch remote technology
-Interactive efficiency configurator for heating and process heat

On the ISH Energy, the World’s leading trade fair for the sanitary, building, energy, air conditioning technology and renewable energies Bosch completely focuses on the subject Energy generation 4.0 for large systems. With the new product family Master Energy Control (MEC System) steam, hot water and combined heat and power (CHP) products from Bosch can be combined to intelligent systems. Direct communication between system components like CHPs and steam boilers ensures higher system efficiency and a long system liftetime. Maximum availability and 24/7 remote service are additional benefits of energy generation plants networked with the MEC System. The intuitive user interface allows to view and evaluate the state of systems quick and effective. With the optional remote connection MEC Remote users can safely access their systems from everywhere. If required, experts from Bosch online provide advice and suggest optimisations on demand at any time.

Thus, Bosch sets a new standard in terms of system availability, reliability and service level. At the ISH Energy visitors can interactively experience the system: A Bosch expert will give live demonstrations of the secure access to test systems, for example, in Kazakhstan.

Interactive efficiency configurator for heating and process heat
Another highlight on the trade fair are the interactive configurators for efficient heating and process heat. Whether it is the retrofitting of a heat exchanger, switching from oil to gas operation or the preheating of combustion air with waste heat, here, trade visitors can acquire an impression of the economic efficiency of different modules and combinations.

When and for whom does a combined heat and power unit pay off? What benefit does the use of waste heat from cooling units have? And which increase in efficiency can intelligent system controls and efficient hydraulics provide? At the Bosch stand on the ISH Energy interested persons receive information about the hidden saving potentials in their current system.

Industry-specific energy concepts and system solutions
With 150 years of experience Bosch has unique knowledge in the area of specific requirements of different industries and users. More than 110 000 successful projects in more than 140 countries are a clear proof of the high competence in the area of energy generation systems.

Highly specialised configuration tools and experienced experts ensure extraordinarily quick and precise customer-specific offer generation. Therefore, one of the focal topics at the Bosch stand are energy concepts for different industries. Besides technical information on thermal system solutions, our experts will demonstrate advantages of Bosch technology by providing insight into innovative reference projects.
(Bosch Industriekessel GmbH)

Newsgrafik #29311
 02.10.2014

Designing steam generation more efficiently with Bosch boiler technology: The brewery company, ...  (Company news)

... Oettinger Brauerei, modernises its central energy generation

Oettinger Brauerei has modernised its steam generation at its North Oettingen site with Bosch boiler technology to the latest standards for efficiency and environmental protection. The modernisation involved an economizer, firing systems with speed and oxygen control, intelligent boiler control technology and other system accessories from Bosch Industriekessel. Thanks to these measures, the brewery has reduced its CO2 emissions by more than 650 tonnes per year and also its energy usage, which means an annual reduction in fuel costs of around 20 percent.

The two three-pass boilers under the Loos brand name (which has now become Bosch) have been providing the brewery company with steam very reliably since 1991 and 1993. One of the boilers had not yet been equipped with an economizer. In order to use the heat potential in the boiler flue gases, which are around 230 degrees Celsius, an economizer was installed downstream from the steam boiler as part of the modernisation. The flue gas temperature is reduced by almost 115 degrees Celsius through preheating the feed water. This increases the boiler efficiency by around six percent and reduces the fuel usage, as well as helping to keep emissions low.

The replacement of the existing dual burners with modern, modulating natural gas burners resulted in a further increase in efficiency. Thanks to the use of speed control, the motor speed is reduced depending on the burner output. The electrical power consumption in the partial load range is therefore considerably lower – and at the same time there is also a significant reduction in the sound pressure level. Even the oxygen content in the flue gas is continually recorded. If this is too high, making combustion ineffective, the volume of combustion air is reduced. This optimises the efficiency of the burner system and reduces the environmental impact as well as energy costs.

In order to guarantee that there is always the optimum water quality in the boiler, automatic desalting and blow-down devices were retrofitted. The installed feed water regulation modules ensure that there is a constant water level in the boiler. In addition to increasing the degree of automation, these measures provide a more even level of operation with less material stress, as well as ensuring that energy losses are reduced.

Thanks to the integration of the boiler controls BCO, all the available control functions can be called up, and the actual and setpoint values can be visualised or altered on the touchscreen display. With the integrated software Condition Monitoring basic, the operating company benefits from a consistently high level of efficiency and availability for the boiler system. The widest range of data, such as for example flue gas temperature, desalting quantity or boiler load, is analysed and evaluated by the forward-looking monitoring system for operating conditions, and the data is then depicted clearly for the operating personnel by means of a traffic light model. The teleservice connection offers additional support and rapid elimination of faults.

The consulting engineers, Harald Moroschan from Muhr am See, were entrusted with the planning of the modernisation project. The plant construction company, Sell Haustechnik GmbH from Helmbrechts, installed the equipment.

Thanks to the project experience it has gained from supplying over 110,000 systems worldwide, Bosch offers the drinks industry individually tailored boiler systems for efficient and environmentally-friendly energy provision. You can find out all you need to know about boiler system technology and other solutions from the areas of combined heat and power, waste heat utilisation, heat pumps and solar thermal energy on the Bosch stand at the BrauBeviale trade fair in Nuremberg from 11 to 13 November 2014, in Hall 4, Stand 313.
(Bosch Industriekessel GmbH)

Newsgrafik #28758
 15.05.2014

Mobile heating plant with integrated Bosch boiler technology   (Company news)

Efficient heat supply by means of condensing heat exchanger

Hotmobil, a supplier of mobile energy plants for heat, cooling and steam, has presented a technical innovation in the area of mobile heating plants: the six-metre long Hotmaster MHC 1.500 container system, which weighs 8,500 kilograms, with integrated Bosch heating boiler and condensing heat exchanger features a high standard utilisation efficiency of up to 104 percent at an output of 1,500 kW.
“This mobile heating plant with condensing technology, which is the largest on the market, is yet another result of the many years of successful cooperation between Hotmobil and Bosch Industriekessel”, says Reto Brütsch, Technical Director of Hotmobil. The Bosch heating boiler UT-L in 3-pass design, which is built into this heating plant, has already proven its worth thousands of times in practical use. The integrated condensing heat exchanger ensures that the system operates particularly economically. It reduces the flue gas temperature below the flue gas dew point and uses the condensation heat, which is released. The efficiency increases, emissions and fuel use decrease. The dual oil/gas firing system ensures that there is the greatest possible flexibility.
The new Hotmobil container system with integrated Bosch boiler technology has three sides, which can be opened completely. This makes operation easier and enables maintenance to be carried out quickly and efficiently. Another advantage is the extremely compact construction, which means that the logistics costs remain at a very low level. In emergencies the plant can be made ready within a few hours. The possible applications of the mobile energy plant are very varied. As a mobile and modular solution, which is also capable of being upgraded, it can be used for office buildings, hospitals, large residential complexes, local and district heat supply and for a wide range of applications to provide process heat.
(Bosch Industriekessel GmbH)

Newsgrafik #28075
 04.12.2013

Efficient operation with modular Bosch technology   (Company news)

Preserves manufacturer saves 40,000 euros per year in energy costs

Following an energy analysis in 2012, Valenzi GmbH & Co. KG from Suderburg in the Lower Saxony region of Germany decided to replace its steam supply. A complete system from Bosch was used, which could be matched exactly to the customer's requirements thanks to the numerous modules available. The manufacturer of forest fruit preserves expects an energy saving from the new system of around 40,000 euros per year. The CO2 emissions are also reduced by approximately 300 tons.

The modular design of the Bosch system ensures energy-optimised boiler operation. The existing boilers had been in operation for up to 31 years and were replaced with two modern UL-S type steam boilers with speed-controlled natural gas firing systems, each with an output of 5,000 kg/h. The company primarily uses steam to preserve mushrooms and refine wild berries and soup ingredients. The second boiler is used as a backup and to cover peak loads. Integrated economisers make efficient use of the energy from the hot boiler flue gases to heat the feed water. The boiler efficiency increases by 4.8 per cent and fuel consumption decreases by the same proportion.

Water treatment components provide optimum feed water quality. The WTM water treatment plant produces softened make-up water. To reduce susceptibility to corrosion, thermal deaeration is performed after the softening process via the WSM-V water service module. The water is heated to 103 degrees Celsius, causing the gases contained in the water to be released. Using the compact EHB heat recovery module, thermal energy from the hot desalted water is used to preheat the feed water. This leads to an increase in efficiency and a reduction in fuel, cooling water and waste water costs.

In addition, the system is fitted with a CSM condensate service module. The module collects and stores accumulated condensate and channels it back to the water service module. The lower demand for make-up water reduces water and energy consumption.

The intuitive touch-screen BCO/SCO controls make it easy to operate and adjust the boilers and system. Triggered by the push of a button or an external request signal, the start-up and shut-down processes for the steam boilers are performed automatically using the integrated SUC start-up, standby and shut-down control. The sequence control applies the consumption-optimised operating mode for the multi-boiler system. The steam boilers are kept warm by means of a heating coil built into the end of the boiler, and this ensures that there is rapid availability.

The modular design of the Bosch boilers and components meant that effort for planning and installation could be kept low. Planning office Westfalia Wärmetechnik from Rödinghausen and plant construction company AME-Technik from Hamelin were commissioned to complete this work. The operator benefits from the increased degree of automation of the economically and ecologically optimised energy generation system. In addition to the new boiler system, further measures such as waste heat utilisation in the compressors and cold stores improve Valenzi's energy consumption further.
(Bosch Industriekessel GmbH)

Newsgrafik #27893
 22.10.2013

Bosch steam boiler system cleverly combined with solar heat  (Company news)

Picture: The solar thermal system supports feed water preheating.

An increase in production capacity provided Fixkraft Futtermittel GmbH, a producer of animal feed based in the Danube port town of Enns, Austria, with the opportunity to restructure its energy supply. A system concept from plant construction company Ing. Aigner Wasser – Wärme – Umwelt GmbH in Neuhofen/Krems, Austria was introduced. It comprises a Bosch steam boiler featuring modules for increased efficiency combined with a solar thermal system. With the new energy supply, Fixkraft is able to reduce its CO2 emissions by around 85 tons per year and make energy cost savings of approximately 15 per cent compared against the old system.

The Universal UL-S steam boiler from Bosch with an output of 2,500 kg/h provides the process heat required to produce the animal feed. The saturated steam is introduced directly into the product, meaning that the amount of condensate that is returned is very low. A solar thermal system with an installed collector area of 320 m² is used to help preheat the feed water.

The fresh water needed is taken from the company's own well, treated and then supplied to a 6,000-litre heat storage tank. The solar collectors absorb the sun's energy and pass it on to the water in the heat storage tank via a heat exchanger.

The WSM-V water service module deaerates the make-up water. It is heated to 103 °C. The gases contained in the water dissolve and leave the deaeration system with a small quantity of steam, known as exhaust vapour. The VC vapour cooler uses the thermal energy contained in the exhaust vapour and feeds it back to the water service module. Heating-up steam is saved and the energy efficiency of the system increased.

The feed water itself is heated further in the economiser, reducing the flue gas temperature of the boiler. In order to make additional use of the flue gas condensate, a condensing heat exchanger made of stainless steel is installed downstream of the economiser. The make-up water preheated by solar heat absorbs the condensation heat before it is supplied to the feed water tank via the exhaust vapour heat exchanger and deaerator dome.

The boiler equipment also includes the low-emission natural gas firing system with oxygen control. This continually measures the oxygen content in the flue gas and controls the air supply accordingly. Modern touchscreen controls with a teleservice connection enable the system to be operated reliably and based on individual requirements.

Thanks to the use of solar energy and heat recovery facilities, Fixkraft benefits from a highly efficient and environmentally-friendly steam supply. Energy use is reduced and efficiency increased.
(Bosch Industriekessel GmbH)

Newsgrafik #27590
 12.08.2013

Wildbräu brewery modernises steam generation  (drinktec 2013)

Boiler technology from Bosch saves 90 megawatt hours a year
CO2 emissions reduced by 21 tons per year

Picture: The modernised steam boiler at the Wildbräu brewery with the oxygen and speed-regulated firing. The retrofitted economizer makes efficient use of the energy from the boiler flue gases.

The Wildbräu Grafing brewery opted to modernise their steam generation using components from Bosch Industriekessel in order to bring the energy efficiency of the system in line with modern standards. Thanks to the measures taken, Wildbräu Grafing GmbH is able to reduce the energy consumption of the system by approximately 90 megawatt hours per year. The CO2 emissions are reduced by 21 tons per year. The modernisation and switch to natural gas saves the brewery around €36,000 in running costs per year. The return on investment is 40 per cent.

A UL steam boiler from Loos (now Bosch) with an output of four tons of steam per hour has been responsible for supplying the process steam since 1978. For efficient use of the hot flue gases, which are up to 230 degrees Celsius, an economizer from Bosch Industriekessel is now in use. The boiler feed water is preheated while the flue gas temperature is reduced by around 100 degrees Celsius. The boiler efficiency is increased by a reduction in flue gas losses of approximately five per cent, the fuel consumption is likewise reduced at full load.

The replacement of the existing light oil burner with a modern dual burner resulted in a further increase in efficiency. Natural gas is used as the main fuel and light fuel oil is only used during peak load operation or in an emergency. An electronic compound control now ensures correct dosing of the fuel/air ratio. In comparison to the mechanical compound control of the old burner, this achieves a more precise setting for the air supply and reduces the fuel consumption accordingly. In addition, the new firing enables completely infinitely variable operation. Combined with a high turndown ratio, switching the burner on and off, which goes hand in hand with energy loss, is considerably reduced.

The motor speed is reduced in relation to the burner capacity through the use of speed regulation. The electrical power consumption in the partial load range is considerably lower and at the same time there is also a significant reduction in the sound pressure level. Even the oxygen content in the flue gas is continually recorded. If this is too high, and the combustion is thus ineffective, the volume of combustion air is reduced. The oxygen regulation thus optimises the efficiency of the burner system, reduces its environmental impact, and helps to save energy costs.

The newly integrated boiler control BCO comes with all the necessary information and functions for operation according to need. An intuitive touchscreen display indicates operating states, operating data, and measured values as well as operating settings.

The retrofitting project was planned by the IGS Ingenieurbüro in Hallbergmoos while the Ernst Huber Wärmetechnik GmbH in Rott am Inn carried out the installation.

All you need to know about the innovative boiler system technology along with further solutions from the fields of combined heat and power, waste heat recovery, heat pumps, and solar heat can be found at the Bosch stand at the Drinktec trade fair in Munich between September 16-20, 2013 in Hall B6, Stand 100.
(Bosch Industriekessel GmbH)

26.03.2013

ISH Energy 2013 in Frankfurt - Bosch presents "Conditon Minitoring basic" ...  (Company news)

... for industrial boilers

Preemptive condition monitoring

Photo: “Condition Monitoring basic” facilitates preemptive action: The new function for consistently high efficiency and availability of industrial boiler plants can be accessed via the BCO Boiler Control.

Other trade fair highlights included:
 Efficient combination of a combined heat and power unit with a 4-pass boiler cuts costs by up to 40 percent
 Utilising waste heat potential with ORC technology
 A glance into the future of system controls

At ISH Energy in Frankfurt, the world’s leading trade fair for sanitary, heating and air conditioning technology, Bosch presented its new preemptive condition monitoring solution for large boiler plants. “Condition Monitoring basic” has a positive effect on ensuring consistently high system efficiency and availability of steam boilers, hot water boilers and heating boilers. It analyses and evaluates the system data and displays them in a transparent way using a traffic light model. The calculation algorithms also produce forecasts. Modes of operation which lead to inefficiency, increase wear or cause unplanned downtime can thus be identified at an early stage and avoided.
“Condition Monitoring basic” recognises, for example, unfavourable start-up conditions, emerging water and waste gas contamination or corrosion risks. Additionally, it can generate maintenance reports on request. Excellent data transparency facilitates optimum boiler operation. The display of the boiler load profile over the course of time as well as the measurement and display of energy losses highlight optimisation opportunities.

A perfect matc: CHP plant with a 4-pass boiler system
Another innovation presented by Bosch at ISH Energy was the conventionally fired 3-pass boiler with an additional integrated fourth smoke tube pass. This allows the very efficient combination of a combined heat and power unit with a large boiler; the flue gas from the CHP plant is used directly in the fourth pass of the steam boiler. This reduces the costs for the system operator by 20 to 40 percent compared to a separate waste heat boiler. Bosch can offer its customers all the components of this complete solution from a single source.

Utilising waste heat potential with ORC technology
At ISH Energy, Bosch also showcased an Organic Rankine Cycle (ORC) system. ORC solutions convert waste heat into electrical energy and are suitable for all situations where large quantities of otherwise unusable waste heat are produced, e.g. in conjunction with a combined heat and power unit.

A glance into the future of system controls
An important issue for the future is the development of multifunctional system controls for large-scale systems. Bosch exhibited a prototype solution in this area at ISH Energy. The new control unit makes it possible to combine various products such as a boiler, combined heat and power unit and accumulator to form an efficient energy system linked by a single operating interface. It has been designed with a focus on energy monitoring: energy flows and costs can be monitored and recorded with ease. Standard web browsers provide access to the system from any standard PC, laptop, tablet PC or smartphone.
In addition to these new solutions, Bosch demonstrated its outstanding system expertise and experience at ISH Energy, taking its inspiration from the theme “Leaders in large thermal plants”. Bosch has accumulated extensive project know-how by supplying more than 110,000 systems for industrial, commercial, residential and public buildings as well as local and district heating suppliers worldwide. Bosch’s modular systems extend from heat supply systems in industrial boiler plants, large-scale solar energy systems and heat pumps to combined heat and power units and ORC systems for waste heat utilisation. Bosch is a strong partner to its customers at every stage of the project, from planning and support to after-sales.
(Bosch Industriekessel GmbH)

Newsgrafik #22401
 09.11.2011

Bosch Industriekessel at Brau Beviale 2011  (Company news)

Join Bosch Industriekessel with innovative brand Loos at Hall 4, Booth 315/410
(Bosch Industriekessel GmbH)

Newsgrafik #21353
 13.10.2011

Six Loos boilers for biogas plant in Szarvas  (Company news)

In July 2011, Hungary's largest and most state-of-the-art biogas plant was put into operation. The project was implemented by r.e Bioenergie GmbH from Regensburg via its Hungarian subsidiary in close cooperation with the food processing company Gallicoop Pulykafeldolgozó Zrt based in Szarvas. Bosch Industriekessel was responsible for the innovative boiler technology in this outstanding project, supplying six Loos manufactured boilers and a WSM-V water service module to Hungary.
The plant produces approximately 12,500,000 Nm³ of raw biogas annually from organic waste and energy crops. The waste heat, which accumulates in the process of generating electricity from the biogas, is used to produce heating and cooling for Gallicoop.
A combined heat and power (CHP) module and two Unimat UT-L boilers fired with LPG or biogas supply the heat required to operate the fermenters for biogas production. The second boiler serves primarily as a redundancy and covers peak load. The boilers are equipped with low-emission burners and integrated flue gas heat exchangers for maximum energy utilisation. Efficiencies of nearly 97 per cent can be achieved even at very low loads.
A gas line four kilometres long transports most of the biogas produced to the Gallicoop premises. Three further CHP modules transform the gas into electrical energy. To provide the process steam base load for poultry production, three Loos heat recovery boilers use the waste heat from the CHP modules. About 1,820 kilogrammes of saturated steam can be produced per hour. An additional Loos steam boiler with an integrated economiser and two further steam generators already on site cover the peak load and at the same time ensure redundancy for the highest level of supply reliability. The Universal UL-S steam boiler features an output of 5,000 kilogrammes of steam per hour and is fired with natural gas or biogas.
The Loos boilers were commissioned by Kazantrade from Hungary, a longtime partner of Bosch Industriekessel. The biogas plant will go into full-load operation this autumn. The EU has declared the complex concept to be trend-setting and eligible for funding.
(Bosch Industriekessel GmbH)

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