Oettinger Brauerei modernises its central energy generation
Designing steam generation more efficiently with Bosch boiler technology
Oettinger Brauerei (Bavaria) 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 overall responsibility for the modernisation of the steam system lay with Sell GmbH from Helmbrechts.
The downstream economizer reduces fuel usage and provides higher efficiency.
The boiler controls BCO with a forward-looking monitoring system for operating conditions guarantee a high level of transparency and simple boiler operation.