New boiler system improves efficiency and conserves resources
Beck+Heun GmbH offers innovative roller shutter casings and breakthrough solutions for windows. In 2013, the company modernised its machinery at its headquarters in Mengerskirchen, Germany. In addition to new production facilities, a steam boiler system from Bosch Industriekessel was also purchased. The aim was to increase capacities and guarantee a more energy-efficient and resource-conserving production strategy.
The previous steam generation facility comprised three boilers with a total capacity of 5,500 kg/h, the oldest boiler dating back to the nineteen seventies. The steam is used to pre-foam the polystyrene granulate that is subsequently required to produce roller shutter casing shells. To accommodate the additional pre-foaming station, the new boiler system was rated for a steam capacity of 8 tonnes.
The two type UL-S Bosch boilers are fitted with integrated economisers. To thermally exploit the flue gases even further, two stainless steel condensing heat exchangers were used; an efficiency exceeding 100 percent is achieved. The boilers are fired by modern gas firing systems with energy-saving speed controls. An oxygen control was also installed. This continually measures the oxygen content in the flue gas and controls the air supply accordingly. This reduces fuel consumption and ensures low emissions.
The feed water is degassed by the water service module WSM-V. Further Bosch equipment components contribute to a highly economic operation of the overall system: The vapour cooler VC uses the thermal energy contained in exhaust vapours and returns them to the water service module. The hot desalting water is expanded via the heat recovery module EHM. The expansion steam produced in this process helps to heat up the feed water tank.
The PLC-based boiler and system controls BCO/SCO offer transparent operation in line with demand. Energy consumption, emissions and wear are minimised, simply by optimising all measuring and control functions. All operating messages and the latest process data for the overall boiler system are transmitted via the link to the company's process control centre by means of Profibus-DP.
The new boiler system technology from Bosch permits energy-efficient and environmentally-friendly steam production. The efficiency of the overall system was improved by approximately 20 percent, the CO2 and NOx emissions have reduced accordingly. The installation of the boiler system was entrusted to the experienced plant construction company AGO AG Energie + Anlagen from Kulmbach. The boilers were commissioned by Bosch Customer Service.
The modern Universal steam boilers UL-S with oxygen and speed-regulated natural gas firings.
The water service module WSM-V for feed water treatment and degassing.