Thermotechnology

The brewery company, Oettinger Brauerei, modernises its central energy generation Designing steam generation more efficiently with Bosch boiler technology

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.
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  • June 05, 2014
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Intersolar Europe 2014: Bosch presents innovative solutions for decentralized energy systems Best use of renewable energy via a range of storage technologies

  • Smart connectivity for heat pumps and photovoltaic systems
  • Controlling highly efficient air/water heat pumps via smartphone
  • Electricity storage system for pioneering housing complex
Stuttgart – At Intersolar Europe 2014 (June 4-6) in Munich, Bosch will show how smart connectivity can be implemented for electrical and thermal energy using a photovoltaic system combined with the latest in heat pump technology. Bosch will be demonstrating the solution using the SWI-2 heat pump made by Bosch Thermotechnology brand Junkers. This solution allows users to consume the lion's share of the electricity they themselves generate from solar power in their own homes – which dramatically reduces their electricity costs – while also powering the heat pump so it can extract heat from air, water, or the ground and convert it into energy that can be used for heating or hot water. The Bosch system features an energy management system that knows when the heat pump requires electricity and – provided there has been enough sunshine – answers that need with solar power.

At the heart of the smart control system is e.Control, which is connected to the household's electricity meter and monitors power flows within the home. The system is designed to always prioritize supply to any home appliances currently in operation. Should the photovoltaic system connected to a Bosch inverter generate any surplus power, e.Control sends a signal to the heat pump to heat the hot water tank. This means optimum use is made of the household's solar power, since it avoids feeding any surplus electricity into the grid at too cheap a price. What's more, it relieves the public grid.

Integration of electricity storage makes consumers largely self-sufficient
Integrating Bosch Power Tec BPT-S 5 Hybrid storage into this energy system further boosts the degree to which a household can make use of self-generated electricity from the photovoltaic system. Even when the sky is overcast or after sunset, the storage system continues to provide the heat pump with a reliable supply of electricity. If the storage system has been integrated, any surplus electricity is sent to the powerful lithium-ion batteries before a signal is sent to the heat pump. When the hot water tank is heated, electrical power is converted into thermal energy, which in effect increases the stored energy. So running such a system is a large step toward achieving independence from the public grid.

Controlling highly efficient air/water heat pumps via smartphone
At Intersolar, Bosch will also be presenting the new Junkers Supraeco SAO-2 modulating air/water heat pump – one of the first on the market to feature a modulating exterior unit. Thanks to a speed-controlled compressor, the Supraeco SAO-2 always supplies only as much energy as is required. This inverter technology makes the heat pump 11 percent more efficient than previous models. Its reduced electricity consumption is reflected in a drop in CO2 emissions, and it is easily adapted to use in detached or semi-detached houses. As standard, the heat circuit's flow temperature never exceeds 62 degrees Celsius during heat pump operation. The Supraeco SAO-2 can actively cool rooms and can be operated via the internet without having to install any additional hardware. The IP gateway required for web communication is already integrated, paving the way for convenient operation via smartphone or tablet. Junkers will soon be introducing its heat pump app JunkersHome. The Supraeco SAO-2 has also been classed “smart grid ready.”

Electricity storage/battery system for pioneering housing complex
Bosch Energy Storage Solutions will also be at Intersolar, presenting a modular, safe, and turnkey storage solution for housing complexes. The Bosch turnkey storage system uses lithium-ion technology, is around 7 meters wide, 0.6 meters deep, and 1.8 meters tall, and is designed to be installed in an electrical services room. Its capacity and electronics are tailored to the requirements of the complex's power grid. Thanks to its power of 50 kilowatts, the battery can be fully charged or discharged in two hours. Its inverter enables it both to feed electricity into to the grid and to recharge from it. The means by which the battery system is controlled, in combination with Bosch's expertise in the right way to charge and discharge batteries, extends the battery's operating life. Bosch designs, develops, and builds storage systems on a variety of scales all the way up to the megawatt-hour range. Bosch is supplying just such an adaptable energy storage system to a housing complex comprising 180 row houses currently being built in Kelsterbach near Frankfurt. The storage system has an installed capacity of 135 kilowatt hours, which is enough to power ten average four-person households for a day.

Bosch booth at Intersolar Europe 2014: Hall B3, booth 310

More information is available online:
Bosch supplies energy storage system for pioneering housing complex
How electricity storage can smooth the path toward alternative forms of energy

Back to overview

Bosch Thermotechnology is a leading European manufacturer of resource-efficient heating products and hot water solutions. In fiscal 2013, the company generated sales of 3.12 billion euros (66 percent outside Germany) and employed approx. 13,500 people. Bosch Thermotechnology has strong international and regional brands and manufactures a diversified product range in Europe, America and Asia.

Further information is available online at www.bosch-thermotechnology.com.

Bosch Power Tec GmbH is a 100% subsidiary of Robert Bosch GmbH and was founded in January 2011. The business purpose is the development and sales of electronic power components for the use of renewable energies. The portfolio includes highly-efficient solar inverters, pre-fabricated inverter stations, system management solutions and pioneering electricity storage technologies. Extensive service and maintenance contracts for every product group enhance the Bosch Power Tec range.

You can find more information at www.bosch-power-tec.de.

The Bosch Group is a leading global supplier of technology and services. In 2013, its roughly 281,000 associates generated sales of 46.1 billion euros. (NB: Due to a change in accounting policies, the 2013 figures can only be compared to a limited extent with the 2012 figures). Its operations are divided into four business sectors: Automotive Technology, Industrial Technology, Consumer Goods, and Energy and Building Technology. The Bosch Group comprises Robert Bosch GmbH and its roughly 360 subsidiaries and regional companies in some 50 countries. If its sales and service partners are included, then Bosch is represented in roughly 150 countries. This worldwide development, manufacturing, and sales network is the foundation for further growth. In 2013, the Bosch Group invested some 4.5 billion euros in research and development and applied for some 5,000 patents. This is an average of 20 patents per day. The Bosch Group’s products and services are designed to fascinate, and to improve the quality of life by providing solutions which are both innovative and beneficial. In this way, the company offers technology worldwide that is “Invented for life.”

Additional information is available online at www.bosch.com and www.bosch-press.com, http://twitter.com/BoschPresse.

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  • May 19, 2014
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Mobile heating plant with integrated Bosch boiler technology 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.
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  • May 15, 2014
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