Efficient operation with modular Bosch technology
Following an energy analysis in 2012, Valenzi GmbH & Co. KG from Suderburg in the Lower Saxony region of Germany decided to replace its steam supply. A state-of-the-art, complete system from Bosch was installed. Through this investment, the manufacturer of preserved wild berries anticipates making annual energy savings of around 40,000 euro. It also cuts its CO2 emissions by approximately 300 tons.
The existing boilers had been in operation for up to 31 years and were replaced with two modern UL-S type steam boilers with speed-controlled natural gas firing systems, each with an output of 5,000 kg/h. The company primarily uses steam to preserve mushrooms and refine wild berries and soup ingredients. The second boiler is used as a backup and to cover peak loads.
The modular design of the Bosch system ensures energy-optimised boiler operation. Integrated economisers make efficient use of the energy from the hot boiler flue gases to heat the feed water. The efficiency of the system increases by 4.8 per cent and fuel consumption decreases by the same proportion.
Water treatment components provide optimum feed water quality. Softened make-up water is produced in the WTM softening system. To reduce susceptibility to corrosion, thermal deaeration is performed after the softening process via the WSM-V water service module. Using the compact EHB heat recovery module, thermal energy from the hot desalted water is used to preheat the feed water. This leads to an increase in efficiency and a reduction in fuel, cooling water and waste water costs.
In addition, the system is fitted with a CSM condensate service module. The module collects and stores accumulated condensate and channels it back to the water treatment system. The lower demand for make-up water reduces water and energy consumption.
The intuitive touchscreen BCO/SCO controls make it easy to operate and adjust the boilers and system. Triggered by the push of a button or an external request signal, the start-up and shut-down processes for the steam boilers are performed automatically using the integrated SUC start-up, standby and shut-down control. The sequence control applies the consumption-optimised operating mode for the multi-boiler system. The system is kept warm by means of a heating coil that is built into the boiler end. This ensures the rapid availability of the steam boilers.
The modular design of the Bosch boilers and components meant that effort for planning and installation could be kept low. Planning office Westfalia Wärmetechnik from Rödinghausen and plant construction company AME-Technik from Hamelin were commissioned to complete this work. The operator benefits from the increased degree of automation of the economically and ecologically optimised energy generation system. In addition to the new boiler system, further measures such as waste heat utilisation in the compressors and cold stores improve Valenzi's energy consumption further.