Boiler technology from Bosch saves 90 megawatt hours a year

Thomas Pelizaeus >


CO₂ emissions reduced by 21 tons per year

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 CO2emissions 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, part of the Bosch Thermotechnik GmbH, has stood for innovation in industrial boiler technology for more than 145 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.

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The Bosch Group is a leading global supplier of technology and services. In fiscal 2012, its roughly 306,000 associates generated sales of 52.5 billion euros. Since the beginning of 2013, its operations have been 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. Bosch spent some 4.8 billion euros for research and development in 2012, and applied for nearly 4,800 patents worldwide. 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.”

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Bosch Thermotechnology is a leading European manufacturer of energy-efficient heating products and hot water solutions. In fiscal 2018, the company generated sales of about 3.5 billion euros (66 percent outside Germany) and employed approx. 14,200 people. Bosch Thermotechnology has strong international and regional brands and manufactures a diversified product range in Europe, America and Asia.

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The Bosch Group is a leading global supplier of technology and services. It employs roughly 400,000 associates worldwide (as of December 31, 2019). The company generated sales of 77.7 billion euros in 2019. Its operations are divided into four business sectors: Mobility Solutions, Industrial Technology, Consumer Goods, and Energy and Building Technology. As a leading IoT provider, Bosch offers innovative solutions for smart homes, Industry 4.0, and connected mobility. Bosch is pursuing a vision of mobility that is sustainable, safe, and exciting. 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 facilitate connected living with products and solutions that either contain artificial intelligence (AI) or have been developed or manufactured with its help. 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 subsidiary and regional companies in 60 countries. Including sales and service partners, Bosch’s global manufacturing, engineering, and sales network covers nearly every country in the world. The basis for the company’s future growth is its innovative strength. Bosch employs some 72,600 associates in research and development at 126 locations across the globe, as well as roughly 30,000 software engineers.

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