Modernisation of boiler systems - Reduce operating costs
20Pages

Reduce operating costs

2 | Modernisation of boiler systems Foreword For many companies, the efficient use of energy has become a key competitive factor. Energy prices have risen constantly over the past decades and more than doubled in the last 10 years. According to research by the German Heating Industry Association (BDH), there is a considerable modernisation backlog in the sector of heat and steam generating systems. In Germany, for example, more than 80 % of the existing systems are operated inefficiently. In average the energy efficiency can be increased by 20 to 30 % with common technical measures. This...

Modernisation of boiler systems | 3 Expertise and quality Bosch Industriekessel is renowned worldwide as a specialist supplier of boiler systems in all sizes and output categories. A driver of innovation in industrial boiler technology for more than 150 years. Expertise – the basis of our quality We have specialised in industrial boiler construction since our company was founded in 1865. In over 150 years we have developed extensive specialist expertise and a deep understanding of the specific requirements of our customers. Engineering, manufacturing and service – the expertise of our...

4 | Modernisation of boiler systems Modernisation pays off The average service life of boiler systems that are used for industrial purposes is between 20 and 40 years. Many measures which previously were not possible or financially justifiable pay off nowadays after a very short period of time. Five good reasons to modernise your energy generating system Reduce operating costs Structural adjustments optimum operation ▶ Spare parts availability ▶ Modifications with regard to the available fuel quality Laws, directives and requirements ▶ Increase in the service life of the system ▶...

Modernisation of boiler systems | 5 Our offer Services for your project Project phase Energy Quick Check – free of charge, without obligation, individual Not everything pays off for everyone – the individual setting and load profile are crucial. Our specialists evaluate potential modernisation measures on the basis of your specific situation. Energy Quick Check Quotation and project management A detailed feasibility study based on your data offers you a solid basis for making the decision. Our experts configure the desired modernisation package in high quality. Project management Production...

6 | Modernisation of boiler systems Smart energy saving Our modular system and components portfolio enables modernising your existing system quick and easy. Outdated components are removed and the boiler pressure vessel is equipped with modern system technology such as heat recovery devices. Economizer  up to 7 % fuel saving Flue gas condenser  up to 7 % fuel saving Air preheating  up to 2 % fuel saving Feed water cooling  up to 1.8 % fuel saving Settings and maintenance  up to 3 % fuel saving  extended service life  process reliability  impro

Water treatment ► higher water quality ► improved steam quality ► lower desalting rate Modulating firing ► up to 1 % fuel saving ► wear reduction Speed-controlled fan ► up to 75 % electrical saving O2/CO burner control ► up to 1 % fuel saving Modernisation of boiler systems | 7 Condensate systems ► up to 12 % fuel saving ► make-up/raw water saving ► waste water reduction ► up to 90 % savings on chemicals Thermal degassing system ► up to 80 % savings on chemicals Expansion and heat recovery module ► up to 1 % fuel saving ► up to 1 % make-up water saving ► up to 100 % cooling water saving ►...

8 | Modernisation of boiler systems Modernisation measures in detail Save fuel costs through heat recovery ... ... from flue gas up to 14 % The flue gas temperature can be reduced by more than 100 Kelvin through the use of a flue gas heat exchanger (economizer). A downstream condensation heat exchanger extracts further energy from heat and condensation. ... from condensate up to 12 % Condensate is water that has already been treated A 10 % fuel saving in a system with 10 t/h steam capacity means a saving of up to 150,000 euros per year. and that also contains energy. By feeding it back to...

Modernisation of boiler systems | 9 Reduced operational costs and increased reliability by automation. Minimising mandatory supervision thanks to automation equipment (EN 12953) ... ... with continuous measurement of conductance Measuring the conductance in the boiler makes it possible to significantly reduce desalting losses. Combined with automatic desalting less fresh water has to be heated and pre-treated. ... with automatic desalting and blow-down Automatic blow-down and desalting increase convenience of operation while reducing fuel and water consumption. High levels of automation...

10 | Modernisation of boiler systems MEC Optimize for high efficiency and availability Optimum system efficiency and a high level of system availability are important factors for industries to reduce production costs and to increase competitiveness. In this field the use of state-of-the-art data acquisition and analysis is very beneficial and gives information about the operating performance and efficiency of energy-generating systems. With MEC Optimize, Bosch offers operators of steam and hot water boiler plants a new, innovative system for energy monitoring and operational safety. MEC...

Modernisation of boiler systems | 11 Remote access using MEC Remote for boiler systems Using MEC Remote, operators can now gain remote access to their hot water and steam boiler systems conveniently and securely. This means the entire boiler and system control can be visualised using standard Internet-enabled devices. MEC Remote is the ideal solution for all companies: ▶ which the supervising personnel cannot be in on-site constantly ▶ operating multi-boiler systems requiring supervision ▶ with on-call service, e. g. at the weekends Using the overview map, multiple systems around the world...

12 | Mod ernisation of boiler systems Load profile of industrial operation Boiler load in % Annual operating hours Key data Steam boiler with an output of 10 t/h and an operational pressure of 10 bar, using light fuel oil and a burner with mechanical linkage, without an economizer and with a condensate rate of 2,000 kg/h: 6 % oxygen-free, 50 % with oxygen, average load 3,900 kg/h, 5,000 operating hours per year following the shown load profile. Fuel and power prices ► Light fuel oil: 0.44 euro per kg (0.375 euro per l) ► Water price: 2 euro per m3 ► Waste water price: 2 euro per m3 The...