Chocolate factory with a new Bosch boiler system
Modular system technology provides high efficiency and reliability
The Zvečevo chocolate factory has renewed its energy supply at its location in Pozega, Croatia with a Bosch steam boiler system. The system works especially energy-efficient and reliable due to the modular components for heat and condensate recovery, thermal water treatment and control. Compared with the previous steam generation an increase in efficiency of over 15 percent is expected.
The two new natural-gas-powered U-MB-type steam boilers replace three boiler units with a useful life of approx. 30 years. Equipped with standard integrated economizers the waste heat potential is now efficiently used. In the heat exchangers feed water is pre-heated with hot flue gases to 140 °C before it is supplied to the boilers. The fuel consumption reduces as the boilers need much less energy to heat-up the feed water. A reduction of the flue gas temperature minimises emissions and protects the environment.
The thermal deaeration of the feed water ensures a long lifetime of the system and a continuous high steam quality. This procedure protects boilers, components and piping against corrosion. In the water service module WSM-V the water is freed of dissolved gases by heating-up. Subsequently, corrosion inhibitors are added to the feed water in order to bind residual oxygen and carbon dioxide.
By recirculating condensate into the water circuit large quantities of fuel can be saved. The installed condensate service module CSM collects the warm condensate from the steam consumers and feeds it back into the water service module. The lower demand for cold make-up water reduces water and energy consumption. An integrated monitoring system prevents harmful contaminants from penetrating the condensate.
For a boiler-protecting start-up process from a cold state the system is equipped with an innovative control variant. At the push of a button or by means of an external request signal the boilers start-up automated. The operator is relieved from extensive manual activities like the stepwise opening of the main steam valve. During normal and heat maintaining mode integrated protective functions increase reliability and safety. The equipment version SUC (Start-up Control) is available via the boiler control BCO. The teleservice connection offers additional support. Upon request, a Bosch service specialist remotely analyses and optimises the operating data of the system.
The higher-level system control SCO provides for an optimal interaction of boilers and components. The integrated sequence control ensures that even at sharp fluctuations in the steam demand the boilers are always operated at the optimal operating point. Thus, an efficient operation of the multi-boiler system is ensured. Both boilers are equipped with a heat maintenance device via the burner system in order to guarantees a faster availability.
Due to the modular design of the system and the ready-to-connect control technology a fast and error-free assembly by the plant construction company Emax was possible. From consultancy, project planning up to commissioning, the team of Robert Bosch d.o.o. from Croatia competently supported the customer. In addition, Bosch offers services like regular maintenance.