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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.

Tags: Technology, CO2, Steam, Boiler

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.

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

The Bosch Group is a leading global supplier of technology and services. It employs roughly 410,000 associates worldwide (as of December 31, 2018). The company generated sales of 78.5 billion euros in 2018. 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 460 subsidiary and regional companies in over 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. At nearly 130 locations across the globe, Bosch employs some 68,700 associates in research and development.

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

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