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New Bosch boiler system for herbal medicines from Bionorica

A new Bosch steam boiler system has gone into operation at Bionorica SE in Neumarkt in Bavaria (Germany). With a total output of ten tons of steam per hour, the two single-flame tube boilers are supremely able to meet the increased requirement for process heat for manufacturing the company's herbal medicines. The process heat in the form of steam is used for example to extract the herbal raw materials and to concentrate and dry them, as well as for preparing cleaning agents. The modular constructed system extends over two levels in the new boiler house and, thanks to the maximum recovery of process-related waste heat, it achieves an overall efficiency rate of over 100 percent based on the calorific value.

The engineering consultants, Farmbauer, planned the new steam supply system with due consideration for the company's environmental philosophy. A major challenge was how to build the new boiler house: due to the building situation at the Neumarkt site, the amount of floor space available for construction was limited. But there was plenty of vertical space available, and so Petry AG, the plant construction company, installed the modules for water treatment and the downstream flue gas heat exchangers on a second level, directly below the boiler house roof. The two natural gas-fired UL-S steam boilers were sited on the ground floor.

In order to get the most out of the flue gas heat produced during steam generation, and hence keep fuel consumption as low as possible, it was decided that two flue gas heat exchangers per boiler would be used. These components alone save over 800,000 euros in natural gas costs over the course of 10 years. Additionally, the environment is spared through a saving of 21 tons of CO2 emissions, which equates to the emissions of more than 12,000 passenger cars. The boilers are equipped with combustion controls to further enhance their efficiency and reduce flue gas losses. These work in a similar way to the Lambda control in a passenger car.

The system's own consumption is also reduced thanks to complementary modular technology. An installed vapour heat exchanger uses the energy from the exhaust vapour to preheat make-up water for the thermal deaeration unit. For the deaeration process the WSM water service module is used. The module heats the make-up water up to 103 °C in order to eliminate corrosive substances like carbon dioxide and oxygen. The water vapour (exhaust vapour) mentioned above also escapes during the process. A further significant saving is achieved by condensate recovery. If the process steam has released a large part of its energy in production, it accumulates as condensate. This still contains however considerable residual heat and can be used instead of cold fresh water. This reduces fuel and water requirements significantly.

Other equipment, such as Bosch control systems, completes the overall system. They automatically control all the processes from desalting through to condensate technology and right up to the adaptive change of master and slave boilers. Bionorica benefits from an improved operating mode thanks to the high degree of automation and the optimum coordination of all the components. In addition to this, the company also saves large quantities of fuel and emissions thanks to the intensive measures for heat recovery.

Bosch Industriekessel GmbH, part of the Bosch Thermotechnik GmbH, is setting the benchmark for industrial boiler technology over 150 years. Boiler systems for steam, hot water and heating, manufactured to customers' specification, provide efficient heating and process heat for all applications. Boiler house components, which are modular in design and perfectly coordinated, together with intelligent regulation and control technology, significantly simplify the planning, installation and commissioning of the complete system. Comprehensive service support from one source rounds off the innovative product portfolio.

Additional information is available online at www.bosch-industrial.com

The Bosch Group is a leading global supplier of technology and services. It employs roughly 390,000 associates worldwide (as of December 31, 2016). The company generated sales of 73.1 billion euros in 2016. Its operations are divided into four business sectors: Mobility Solutions, Industrial Technology, Consumer Goods, and Energy and Building Technology. As a leading IoT company, Bosch offers innovative solutions for smart homes, smart cities, connected mobility, and connected manufacturing. It uses its expertise in sensor technology, software, and services, as well as its own IoT cloud, to offer its customers connected, cross-domain solutions from a single source. The Bosch Group’s strategic objective is to deliver innovations for a connected life. Bosch improves quality of life worldwide with products and services that are innovative and spark enthusiasm. In short, Bosch creates technology that is “Invented for life.” The Bosch Group comprises Robert Bosch GmbH and its roughly 440 subsidiaries and regional companies in some 60 countries. Including sales and service partners, Bosch’s global manufacturing and sales network covers nearly every country in the world. The basis for the company’s future growth is its innovative strength. At 120 locations across the globe, Bosch employs some 59,000 associates in research and development.

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