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Forewords. 3
dena foreword.
BDH foreword.
1. Introduction. 4
1.1 Energy usage and efficiency in industry and production in Germany.
1.2 Heating systems: applications and potential savings.
2. Overview of heating system optimisation. 6
3. Optimising heating demand. 7
3.1 Analysis of current energy status.
3.2 Minimising heat losses.
4. Energy-efficient heat generation. 9
4.1 Energy-efficient plant design.
4.2 Increasing burner and boiler efficiency.
4.3 Optimisation by measurement and control systems.
4.4 Waste gas control in steam and hot water generation.
4.5 Energy generation management in heating systems.
5. Heat recovery. 16
5.1 Mode of operation of heat recovery.
5.2 Waste gas heat recovery.
6. Energy-efficient conversion and generation technologies. 19
6.1 Combined heat and power generation.
6.2 Heat pumps.
6.3 Solar thermal energy.
6.4 Heat storage.
7. Partners for greater energy efficiency in industry and production. 21
8. Best practice examples. 22
This brochure shows how all the components of a heating sys- This brochure will give you some idea of the potential energy
tem can be ideally adapted to one another, thereby enabling efficiencies lying dormant in your company. By modernising
the systematic exploitation of potential energy and cost savings. your existing systems, not only are you contributing to cli-
The brochure concludes with brief descriptions of projects mate and environmental protection, but you can also drama-
from companies which have already successfully optimised tically cut your own energy costs.
their heating systems as practical examples for others to
follow. The benefits outlined in this brochure will prove persuasive
for your company to invest in the energy efficiency of your
I hope this gives you some food for thought. combustion plants.
3
1. Introduction.
1.1 Energy usage and efficiency in industry Process heat is generated from various energy sources (e.g.
and production in Germany. electricity, oil and gas), transported by different media (e.g.
Companies from industry and production account for some warm/hot water, steam and hot air) and, depending on speci-
30 per cent of Germany‘s entire energy end-use. This amounts fic process requirements, must be provided at different tem-
to approx. 700 TWh per year (source Prognos1). The associated perature levels. As in other fields of application, considerable
expenditure is increasingly becoming a crucial cost and, thus, potential energy efficiency savings are open to companies
competitive factor for companies. For instance, according to from industry and production: looking at all thermal pro-
statistics from the German Federal Ministry of Economics, cesses, it may be conservatively estimated that there are eco-
energy costs for manufacturing industry totalled around nomically viable savings totalling 30 TWh per year of e nergy,
€36 billion in 2008. corresponding to approx. 7.5 per cent of industrial energy us-
age for process heat, to be made. Further annual savings of 17.5
Process heat accounts for some 400 TWh of energy end-use by TWh are available in space heating.
companies. This amounts to 57 per cent of total industrial ener-
gy end-use and is, thus, by far the most energy-intensive field of
application, ahead of electric motors, space heating2, lighting,
electroplating processes and biotechnology.
Figure 1: Energy end-use per field of application in Figure 2: Economically viable potential energy savings
industry and production in Germany (in TWh/year). in industrial companies by field of application (in TWh/year).
400 30.0
350 20.0
TWh/year
300 10.0
250 0.0
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1
Final Report 18/06, Potential for energy saving and energy efficiency in the light
of current price trends, commissioned by: Federal Ministry of Economics and
Technology, Prognos AG, Basel and Berlin, 31 August 2007. All data on energy
usage and potential energy efficiencies in this section are taken from this source.
2
Including hot water
Figure 3: Energy demand and potential savings for individual applications of heat.
Steam/hot water generation Chemicals and papermaking industry, production 92.9 12.0
and other thermal processes of capital goods and foodstuffs and beverages
Furnaces and processes from Production of various primary materials, iron, non- 240.1 13.3
200 to over 500°C ferrous metal and steel production, cement, cera-
mics and glass production, capital goods industry,
industrial baking
Drying and other processes Food industry processes and drying of wood, coal, 65.6 5.3
below 200°C bricks, paper, paints and coatings, fine ceramics etc.
5
2. Overview of heating
system optimisation.
Measures for optimising heating system energy usage result is to be achieved, it is advisable to take the system-
should always be taken as part of optimisation of the atic approach explained step by step in the following
overall system, as the greatest increases in energy effi- sections:
ciency can only be achieved if all the components of the
overall system are of matching efficiency. If an optimum
The first step to take when optimising a heating system‘s In a second step, the energy usage of all the system‘s com-
energy usage, is initially to obtain a detailed analysis of ponents and the overall system is optimised:
current energy consumption and to optimise heating de- checking the components and the entire heating sys-
mand. tem for energy efficiency or energy-efficient design
analysis of a system‘s current energy usage and actual replacement or acquisition of new energy-efficient
required heating demand burners and boilers
optimisation of production process energy usage boiler cascade control/multi-boiler control system
minimising heat losses burner speed control
optimisation of heating demand burner waste gas control
Heating
demand
CHP station
Boiler and
burner
Industrial heat generation and use inevitably gives rise The last step is to select the most suitable conversion and
to “waste heat”, on average 40 per cent, which is released generation technologies so as to reduce energy usage
into the surrounding environment. Heat recovery still further:
measures are a way of tapping this enormous potential: combined heat, power (and cold) generation
economisers heat pumps
condensing boiler technology solar thermal energy
combustion air preheaters heat storage
recuperative and regenerative burners
The first step in the energy optimisation of a heating sys- First of all, measures should be taken to minimise losses and pos-
tem is a detailed analysis of current heat consumption sible ways of optimising demand in production processes, for ex-
(current status) and of actual heating demand (target ample, by more efficient process technologies, should be investi-
status). The focus should be on eliminating energy losses gated. In a second step the heating system may be optimised.
from the production process.
3.2 Minimising heat losses.
3.1 Analysis of current energy status. Heat losses may occur at different points in the heating sys-
An analysis of current energy status offers an overview of tem: at the point of consumption, during transport or during
energy usage, heating demand and the overall heating sys- energy generation.
tem and its individual components. Such an audit should
also include the performance parameters of the processes In processes, i.e. at the point of consumption, energy losses
and systems – amount of heat, pressure and temperature. In can be kept low, for example, by suitably dimensioned thermal
many businesses total energy usage is known simply from insulation for tanks or furnaces, thereby reducing demand.
the cost statements for the respective energy sources which
do not give any idea of how usage is divided between the var- To limit heat losses at the point of energy generation, care
ious processes and plants. Such a breakdown is absolutely should be taken at the design stage to ensure that boilers re-
essential, however, if a temperature- and time-dependent lease very little heat and have good heat storage capacity. In
heating demand profile is to be established for processes existing plants losses can be reduced by cleaning the heating
and plants. An energy consultant can provide valuable as- surfaces and eliminating leaks in the furnace body. High losses
sistance when carrying out this analysis. Of the various op- arise during energy generation as a result of high waste gas
tions available to anyone wanting to carry out the analysis temperatures of over 200 °C. This energy can be used if heat
themselves, the Einstein Audit Guide (downloadable from recovery measures are taken.
www.einstein-energy.net) provides a useful starting point.
The total thermal energy demand process engineering pro-
cesses or of an entire company can be mapped using a pinch
analysis. The cornerstone of this analytical method is to re-
cord thermal energy streams to all a company‘s process sys-
tems and subsequently to implement measures to reduce
energy consumption.
7
To minimise radiation losses during generation and trans- Continuous maintenance of burners, boilers and the steam
port of heat, the heat generators, pipes and any heat storage and hot water distribution network may, not least, reduce
present should be thermally insulated and existing insulation energy usage and, thus, also energy costs.
checked and repaired if necessary. Boiler feed water for steam
and hot water boilers contains salts which accumulate as a re- Shutdown or standby losses can be reduced significantly by
sult of boiler water evaporation. This not only leads to corro means of control systems which prevent superfluous switch-
sion damage to the boiler, but also to energy losses. The boiler ing on and off of burners (see Section 4.3).
feed water must, therefore, be deionised. Sludge additionally
collects at the bottom of a steam and hot water boiler which
must be removed. This process likewise leads to heat losses
(see Figure 4). Good water pretreatment reduces the amount
of sludge.
Flushing losses
Sludge losses
When building a new plant, energy-efficient design of all that they are now often operated inefficiently, for example,
system components and the entire plant must be borne in with pressure-reducing valves.
mind from the outset. In the case of existing plants, the in-
dividual components of a heating system must be checked In the case of steam boilers, it is advisable to choose a boiler
for their energy efficiency and any inefficient components with a good storage capacity. In most applications, shell boil-
should be replaced with efficient ones. Fuel consumption ers are, therefore, preferable to high-speed steam generators.
and costs may be further minimised by measurement and The large water capacity means that there is an energy buffer
control systems. which can equalise fluctuations in steam demand.
4.1 Energy-efficient plant design. In many businesses, steam pressure and temperature are
Fuel selection has a considerable impact on energy costs and reduced by “deliberate” heat losses in uninsulated parts of the
CO2 emissions. Natural gas has numerous advantages in this pipework. In some cases, the desired temperature reduction is
respect, since, of all the fossil energy sources, it gives rise to even achieved by sprinkling the outside of the hot pipes with
the lowest CO2 emissions and, moreover, may be particularly water. It is substantially more efficient to reduce steam tem-
efficiently used in condensing boilers. Heating oil‘s CO2 emis- perature by condensate injection. Reducing the temperature
sion factor is only slightly higher than that for natural gas and level may also enable heat recovery or other energy-efficient
low-sulphur grades are available everywhere. Biogenic fuels conversion or generation technologies such as Combined
such as biogas and bio-oil not only conserve the world‘s finite Heat and Power generation (CHP) or heat pumps.
oil and gas resources, but also enhance a plant‘s CO2 balance.
Many heating plant components are also already designed The heat consumer with the highest temperature or pressure
to use biogenic fuels. Electricity is the most expensive and, level in a system is always decisive when it comes to defining
on the basis of Germany‘s current “power mix”, the most CO2 the design pressure of the heat generator. It may, therefore,
intensive energy source for generating process heat. Using make sense to operate a dedicated steam generator for an
speed-controlled burners and energy-efficient motors can gen individual very high pressure consumer.
erate considerable savings here. *
9
Case study: Agrana Fruit Germany GmbH.
At its Constance site, Agrana Fruit Germany GmbH ope- €10,000. Further savings of around 160,000 kWh were
rates two gas-fired steam boilers which generate the steam achieved by a multifuel burner system (see below), speed
for process heat and for sterilising the fruit. Depending on control (Page 12) and the installation of an O2- and CO-con-
base material and temperature, an anaerobic reactor produ- trolled waste gas control system (Page 14) for the new gas
ces biogas with a calorific value of approx. 6–7 kWh/Nm3 at burner. Implementing all these measures has resulted in an
a rate of approx. 20–30 normal cubic metres (Nm3) per hour. annual reduction in fuel consumption of 448,000 kWh and
Installing a new gas burner in one of the two steam boilers in costs of €19,300. Eliminating natural gas as a combustion
has meant that, instead of natural gas, a major part of the fuel has, in particular, made it possible to cut CO2 emissions
biogas produced may be used for steam generation, where- by approx. 109 tonnes. R eturn on investment on the energy
as prior to modernisation it was flared off. Annual fuel con- saving investment amounts to 30 per cent.
sumption was reduced by 290,000 kWh and costs by approx.
Reduction in energy
448,000 kWh/year
consumption
Investment €65,000
Return on investment 30 %
* All the examples are based on the following GEMIS equivalent values: natural gas
244 g CO2/kWh.
4.2 Increasing burner and boiler efficiency. the discharge momentum of the air or air mixture stream
Potential energy savings may also be made in heating systems emerging in the outlet zone to such an extent that internal
by installing more energy-efficient burner and boiler systems. flue or combustion gas recirculation takes place in the furn-
A plant‘s energy efficiency can be increased with the following ace body. This results in optimised and enlarged flame geom
types of burners and boilers: etry which leads to better heat transfer to the surrounding
furnace body and simultaneously reduces the flame temper
Multifuel burner systems with internal waste gas recircu- ature, thereby also bringing about a distinct reduction in
lation. nitrogen oxide (NOx) emissions. Biogenic fuels may also be
Modern multifuel burner systems with internal waste gas used in these systems. Burner motor power consumption may
recirculation for hot water and steam generation systems also be reduced by means of speed-controlled operation.
make use of the principle of air and fuel staged mixing sys-
tems. An increased mixing pressure additionally increases
Figure 5: Cross-section through a three-pass shell boiler by way of example of a steam or hot water boiler with burner.
Waste gas
connection to flue
Flame tube
(1st pass)
Smoke tube
Burner
(2nd pass)
Smoke tube
The boiler pressure vessel is a horizontal cylindrical tube, closed at both ends and (3rd pass)
insulated all around. This pressure vessel accommodates a flame tube (1st pass),
which is fired by a burner, and an internal reversing chamber which reverses the
direction of the waste gases and recirculates them in the 2nd pass. On the front of
the boiler there is an external reversing chamber, which again deflects waste
gases and leads them to the end of the boiler in the 3rd pass.
The following burners and processes are primarily of rele- The high outflow velocity of the combustion gases in
vance for furnaces: high-velocity or high-momentum burners ensures
Recuperative and regenerative burners are high effi- internal recirculation of the furnace body gases in the
ciency burners which use the waste gas heat directly for combustion chambers or furnace bodies and, thus, uni-
preheating the combustion air. These two types of burner form temperature distribution, as a result of which these
are explained in greater detail in the Heat Recovery Sec- burners are more efficient than conventional burners.
tion (Page 16). In comparison with a combustion process with air, com-
Flameless oxidation (FLOX®) is a high efficiency burner bustion with pure oxygen has some advantages in fur-
technology which enables compliance with stringent naces: for instance, the combustion temperature and
NOx limit values even at elevated combustion air preheat- cobustion efficiency are distinctly higher, since combustion
ing temperatures. with pure oxygen reduces the volume of waste gas and
waste gas losses are, therefore, also distinctly lower.
11
4.3 Optimisation by measurement and Blowdown flash tank and high pressure condensate
control systems. system.
Boiler cascade control and multi-boiler control. The flushing-related waste heat arising in the boiler blow-
By using boiler cascade control in steam and hot water gener down may largely be recovered by flashing and used for pre-
ation, exactly the required volumetric flow rate may be conti- heating the feed water. System efficiency may be increased
nuously conveyed in the system. As a result, only the number by up to two per cent in this way.
of boilers with appropriate capacity (speed-controlled) need-
ed for generation have to be operated. The control system not If the flash steam or vapours escape unused in an open con-
only reduces burner load and burner startups, but can imme- densate system, this results in a steam generation heat loss.
diately compensate any instabilities and faults. The boilers It is generally possible to use the vapours for preheating
can consequently always be operated at their ideal load point boiler feed water or cleaning water, for example.
and with optimum efficiency. The lowest heat losses occur if the condensate is returned
to the boiler under pressure in a closed circuit. The high
The efficiency of a plant may be further increased by installing pressure condensate system results in fuel savings of up
multi-boiler control. A “hydraulic separator” here decouples to twelve per cent and additionally reduces flushing and
all the primary circuit heat generators (generation system) sludge losses (see Section 3.2).
from the consumers in the secondary circuit. Control of volu-
metric flow in the primary circuit ensures hydraulically op-
timised operation of the plant which adapts the necessary
burner or boiler capacity to demand in the secondary circuit.
O2 probe
O2 module
Gas supply
Mixing device
Stepping
motors
Oil supply
Air supply
Visual displays
CAN bus
Firing manage-
ment system Display and Building manage-
Pulse
control unit ment system
generator
Frequency CAN
converter bus Bus system
In 2007, Teutoburger Mineralbrunnen GmbH & Co. KG car- speed control (Page 13) savings of approx. 800,000 kWh or
ried out an analysis of its steam generation boiler systems approx. €48,000 per year have been made. Measures to reduce
and had a plan drawn up for refurbishing the system. Prior demand (Page 7), such as improved insulation, weekend
to the refurbishment, despite modulated operation, the boi- power reductions and a cut in steam pressure, were addition-
lers were regularly shut down, resulting in unnecessary en- ally implemented. Further energy savings were achieved
ergy usage. Now, thanks to the use of speed-controlled by installing an O2 controller (Page 14). Taken together, all
burner motors, the burner motor speed is adapted to actual the energy efficiency measures reduced annual energy
requirements. In the event of load fluctuations, the system usage by approx. 2.4 million kWh and energy costs by
may, thus, adopt a distinctly lower power range. This €142,700. With its return on investment of 65 per cent, this
prevents unnecessary burner shut-downs. Just thanks to package of measures makes very definite economic sense.
Reduction in energy
2,378,800 kWh/year
consumption
Investment €219,000
Return on investment 65 %
* All the examples are based on the following GEMIS equivalent values:
heating oil 302 g CO2/kWh.
13
4.4 Waste gas control in steam and hot water fuels may form soot before the measurement is carried out
generation. which affects the measurement. In operation, the quantity of
Depending on fuel type and plant age, burners are operated air is reduced until the probe in the waste gas detects the pres
with 5 to 20 per cent surplus air as a safety measure. However, ence of uncombusted fuel constituents in the waste gas. The
if more air is supplied to the combustion process than is re- quantity of air is then raised again until no uncombusted con-
quired, the oxygen present in the air no longer participates in stituents may any longer be detected in the waste gas.
the combustion and the air is heated up, thereby resulting in
heat losses. These losses may be reduced by an O2 controller Energy consumption can be further reduced by monitoring
which continuously measures the O2 content of the waste gas and controlling further combustion parameters such as waste
from the boiler and adjusts the air supply accordingly. This gas temperature, soot index or furnace body pressure and by
can increase efficiency by up to three per cent. This approach installing automatic flue gas or combustion dampers. The
can also compensate the effects which occur when the boiler latter prevent the boiler from cooling down during regular,
is sited in locations with large temperature fluctuations be relatively long boiler shut-downs (e. g. over weekends).
tween summer and winter and at different altitudes. Using a
CO controller, the residual oxygen content may be reduced
back down to values of below 1 per cent by volume, thereby in-
creasing efficiency by up to 1 per cent. This approach to control
may only sensibly be applied to gaseous fuels since liquid
98
96
94
O2 content [%]
92
0
Combustion efficiency [%]
90
5
88
86
110 130 150 170 190 210
Waste gas temperature – feed air temperature [°C]
One aspect of a comprehensive program of new building ables such as weather conditions or hysteresis and op-
and expansion at the Albertinen-Krankenhaus in Ham- timises the combustion process, i.e. combustion with an
burg in 2010 involved bringing the heating and air con- optimised ratio of supplied and required air (combustion
ditioning systems up to date. One boiler was fitted with air ratio) and any excess of air is minimised. This burner set-
a low NOx dual-fuel burner for operation with heating up and combustion air preheating (Page 18) reduces losses
oil and natural gas. The other two boilers were moderni- due to the energy carried away with the waste gas: in this
sed and equipped with the latest generation of gas burn way, combustion efficiency of 97 per cent can be achieved
ers which are, for example, optimised with regard to fluid in the low and moderate power range. This comprehen-
dynamics. The quantity of heat generated is adapted to sive package of measures achieves an overall reduction in
actual demand by energy-optimised operation both of annual energy usage of more than 19 million kWh, gener-
the burners (modulating operation, Page 13) and of the ating savings of around €337,000 per year. At 69 per cent,
blowers (speed control, Page 13). Using of an O2 control- the return on investment of the energy saving investment
ler (Page 14) eliminates the influence of disruptive vari- is high.
Reduction in energy
19,150,000 kWh/year
consumption
Investment €490,000
Return on investment 69 %
* All the examples are based on the following GEMIS equivalent values:
natural gas 244 g CO2/kWh
15
5. Heat recovery.
The waste heat from heat generation and utilisation of storage technologies for interim storage of the waste heat
can be used by taking steps to recover heat. Significant arising should be looked into. In such cases, it is important for
amounts of waste heat can be recovered for further use all pipework to be provided with good thermal insulation.
from steam boiler and furnace waste gases.
If the low temperature of the waste heat makes direct heat
5.1 Mode of operation of heat recovery. recovery impossible, a heat pump can be a sensible solution.
Waste heat can be transferred directly or indirectly (via an in- Heat pumps (see Section 6) are capable of raising the temper
termediate medium) to another process by heat exchangers, ature of heat from a low to a higher level.
providing the temperature of the source of (waste) heat is above
the temperature of the consumer. In principle, heat recovery
is, therefore, more worthwhile the higher the temperature
of the available waste heat. To minimise losses resulting from
transport and storage, heat potential should always be used
locally and as directly as possible. If this is impossible, the use
In 2007, Textilveredlung an der Wiese GmbH carried out 130 °C is now achieved, where it was formerly 230 °C. This
the energy modernisation of a steam generator for tex- measure has enabled waste gas losses to be reduced by 20
tile finishing. Once heat generation energy efficiency per cent under minimum load conditions, and by around
had been enhanced by implementing an O2 control sys- 45 per cent under full load conditions. By retrofitting the
tem, it proved possible to make still further significant steam boiler with an economiser, annual fuel consump-
improvements in system efficiency by installing an econ tion was reduced by three per cent. This means savings of
omiser. In optimised operation with feed water preheat- 850,000 kWh of energy and €34,000 in operating costs per
ing by the economisers, a waste gas temperature of just year with a high return on investment of 44 per cent.
Reduction in energy
850,000 kWh/year
consumption
Percentage energy saving 3%
Investment €78,000
Return on investment 44 %
* All the examples are based on the following GEMIS equivalent values:
natural gas 244 g CO2/kWh.
Figure 8: Circuit diagram of a high pressure steam boiler plant with two waste gas heat exchanger stages (economiser/
condensing heat exchanger)
Waste gas
condenser
Steam
Pump
Economiser modules
Condensing boiler technology. pressure hot water boilers waste gas condensation can only
The “calorific value of an energy source” includes not only be used if a low temperature circuit is available.
the thermal energy released on combustion but also the en-
ergy released by condensation of the steam contained in the When selecting suitable fuels, natural gas offers the greatest
waste gas, the heat of condensation. In industry, usually potential benefits for condensing boiler technology. Natural
only the sensible heat of the waste gases (> 100 °C) is used in gas stands out from all other fuels not only in that it has the
boiler systems. The heat of condensation which arises on fur- highest steam content in the waste gas and the highest waste
ther cooling of the waste gases to below the condensing tem- gas dew point, but also in that its waste gases contain virtu-
perature of the steam is generally lost as waste gas loss via ally no soot or sulphur. However, heating oil is also a suitable
the flue. In new plants, it is generally quite straightforwardly fuel for condensing boiler technology since the low-sulphur
possible to make use of the heat of condensation since the heating oil available these days allows effective and trouble-
corrosion-resistant materials in heat exchangers and moisture- free boiler operation.
insensitive waste gas systems and flues mean this is possible
without equipment damage. Condensing boiler technology
is used primarily in hot water boilers. In contrast, for high
17
Case study: Westfalenhallen.
In the course of modernisation in 2008, the old central heat- creased from 83 per cent to 92 per cent. The intelligent in-
ing plant of the Westfalenhallen event centre in Dort- terplay between the new heating system and a modern
mund was replaced by a new heating system compri- building management system and a total of 40 heat coun-
sing a gas condensing boiler (970 kW) and three steel ters distributed over the site additionally allows flexible
boilers with different outputs (1,900, 3,050 and 5,200 and demand-based heat supply. With the assistance of
kW). By graduating the outputs of the boilers used, the the condensing boiler and the demand-based control sys-
energy-efficient gas condensing boiler runs for very tem, it was possible to reduce annual fuel consumption by
long period as the guide boiler while the three downstream 2 million kWh, the company thus being able to make sa-
boilers are operated as required. Modernisation allowed vings in energy costs of €100,000 per year. Return on in-
the efficiency of the complete heating system to be in- vestment on the energy saving investment is 20 per cent.
Reduction in energy
2,000,000 kWh/year
consumption
Investment €500,000
Return on investment 20 %
* All the examples are based on the following GEMIS equivalent values:
natural gas 244 g CO2/kWh.
Combustion air preheating. With regenerative burners, two burners are used alternate-
A combustion air preheater uses hot waste gas to preheat the ly. While the first burner is in operation, the hot waste gas is
combustion air. Heat recovery using combustion air preheat extracted by the second burner and passed via a heat storage
ing can increase combustion efficiency by five per cent. Com- medium. The waste gas releases approx. 85 to 90 per cent of
bustion air can also be preheated using waste heat from com- the heat to the regenerator. After a given burn time, the sys-
pressed air generators or from the boiler house. tem switches over to the second burner. In the process, the
combustion air flows via the regenerator and is heated to
Recuperative and regenerative burners for furnaces. a temperature which is 100 to 150 °C below the combustion
With recuperative burners, a heat exchanger is used to chamber temperature. When used in the temperature range
preheat combustion air to a temperature of 550 to 600 °C from 800 to 1,500 °C, this technology allows fuel savings of up
using hot waste gas. Burner and combustion air preheaters to 60 per cent over burners without heat recovery.
are combined into a structural unit.
The final important step involves the selection of suit- In principle, from the point of view of economic viability and
able conversion and generation technologies which plant engineering, it is best to design CHP systems as base
lower energy usage still further. load supply systems.
6.1 Combined heat and power generation. Combined heat, power and cold generation (CHPC)
Combined heat and power generation (CHP) is the genera- plants can compensate the fluctuations in heat require-
tion of power while making simultaneous use of the heat ments over the course of a year by using the excess heat in
which arises. Up to 90 per cent of the energy content of fuels the summer to generate cold (for example, for building air-
can be utilised in this way. The waste heat arising when gen conditioning). Combined heat, power and cold generation
erating power can be used as process heat for space heating can be achieved by combining any CHP technology with a
or to heat water. The prerequisite for economically viable thermal refrigeration unit, usually an absorption or adsorp-
operation of a combined heat and power plant is year-round- tion refrigeration unit. The additional cold generation then
heating demand which allows a high operating time of at allows the CHP base-load proportion and annual working
least 5,000 operating hours per year. hours to be increased, which has a positive effect on the
plant‘s economic viability.
The Rittershausen plant of Rittal International GmbH & and secondary circuit pumps were replaced with speed-con-
Co. KG operates a bio-oil operated CHP plant with a capac trolled pumps (Page 13). The volumetric flow rate meter re-
ity of 420 kW for the plant‘s thermal base load. Two cata- quired for the multi-boiler control system was fitted in the
lytic waste gas purifiers (catalytic afterburning) from the primary circuit (heating system), while the secondary circuit
production side are also available as suppliers of heat. The (secondary consumer) was decoupled by a hydraulic sepa-
main consumer is the paint shop, whose pretreatment rator (Page 12). All the energy efficiency measures together
tanks have to be maintained at a constant temperature in have reduced energy usage by approx. 1.3 million kWh and
both summer and winter. In the winter, the majority of the energy costs by approx. €270,000 per year. With its return on
energy consumed is used to heat buildings. A multi-boiler investment of 44 perc ent, this package of measures makes
control system (Page 12) was installed at the site in 2007 to very definite economic sense.
optimise the plant. In the course of this work, the primary
Investment €620,000
Return on investment 44 %
* All the examples are based on the following GEMIS equivalent values:
natural gas 244 g CO2/kWh, rapeseed oil 129.6 g CO2/kWh (German Biomass
Electricity Sustainability Ordinance)
19
6.2 Heat pumps. energy). It includes the different operating states and, there-
A heat pump brings heat flux (from the ground, water or air) fore, the many different, good and poor performance ratings
which is at a relatively low temperature to a relatively high over the year. To ensure that the energy balance of an elec-
temperature. This allows ambient heat or waste heat to be tric heat pump is positive, the annual coefficient of perfor-
used for heating purposes. mance for electrical heat pumps should achieve a value of at
least 3.0 since electricity generation in Germany is associa-
To heat domestic and industrial and commercial buildings, ted with high primary energy consumption.
low temperature heat pumps are used which can utilise
heat from air, groundwater or the ground to provide t em- 6.3 Solar thermal energy.
peratures of up to at most 65 °C. High temperature heat In Germany, thermal solar systems are used primarily to pro-
pumps offer the possibility of raising unusable industrial vide process heat at a temperature of up to an approximate
waste heat to a higher temperature so that it can be used for maximum of 120 °C. Solar thermal energy should always be
space heating, providing process water or steam or even for connected to the existing heating system at the lowest possi-
drying and distillation purposes. State of the art high tem- ble temperature since the efficiency of all collector technolo-
perature systems which operate on the basis of cold vapour gies falls with increasing temperature. Coupling solar
compression processes, can achieve temperatures from thermal energy directly to the process is suitable for: clean
80 °C to a maximum of 95 °C. Although some manufacturers ing, drying, evaporation and distillation, bleaching, pas-
offer a two-stage system with which vapour can also be pro- teurisation, sterilisation, boiling, painting, degreasing and
duced at relatively high temperatures, this additional heat cooling as well as space heating.
pump stage reduces overall efficiency. Use of an industrial
heat pump can save up to 80 per cent of energy costs. 6.4 Heat storage.
Storage technologies allow peak loads to be reduced and the
With open or semi-open heat pump systems (thermal and proportion of base load increased. For processes with pro-
mechanical vapour compressors) process steam can be used nounced temporary peak loads, supply systems and system
directly as a working medium and brought to a higher pres- components can be dimensioned for an average output lev
sure and temperature level. At source temperatures of 70 to el. The heat storage is discharged during phases with high
80 °C, these heat pumps can produce process steam or proc power requirements, while energy is stored temporarily if
ess heat with a temperature of up to 200 °C. requirements are below average output.
dena‘s “Initiative EnergieEffizienz” (“Energy Efficiency Cam- This brochure was prepared jointly by dena‘s “Initiative
paign”) is a Germany-wide information and motivation cam- EnergieEffizienz” and the Bundesindustrieverband Deutsch-
paign which promotes efficient electricity use in all consump- land Haus-, Energie- und Umwelttechnik e. V. (BDH) with the
tion sectors. support of Interessengemeinschaft Energie Umwelt Feue-
rungen GmbH (IG).
Target group-specific campaigns are used to inform end con-
sumers in private households, in industry and production and Bundesindustrieverband Deutschland Haus-, Energie- und
in the service and public sectors about the options for efficient Umwelttechnik e. V. (BDH)/Interessengemeinschaft Ener-
electricity use and to motivate them to act in an energy-effi gie Umwelt Feuerungen GmbH (IG) is an industry associa-
cient way. tion representing the commercial, technical and political
interests of its members to policy makers, government and
The campaign is funded by the German Federal Ministry of Eco- the general public. The companies in BDH manufacture in-
nomics and Technology (BMWi). “Initiative EnergieEffizienz” novative energy-efficient utility engineering systems based
also offers businesses information and practical assistance in on gas, oil and electricity and particularly for utilising
many further areas, ranging from energy management to fi- renewable energy sources focusing on heat generation for
nancing, to help them make more efficient use of electricity private households, commercial buildings and industrial
and cut costs. applications.
www.bdh-koeln.de
More details from:
www.industrie-energieeffizienz.de (in German)
Certificate Number:
164-10794-1111-1005
Image credits. www.climatepartner.com
21
8. Best practice examples.
The following companies have already successfully carried out energy optimisation of their heating systems:
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For all questions about efficient energy use
in industry and production:
E-mail: info@industrie-energieeffizienz.de
www.industrie-energieeffizienz.de
Our partners: