Solutions for generating energy in industry and

Solutions for generating energy in industry and commerce
Contents
High pressure steam boiler
2/3
Contents
Steam
up to 120t/h
Electricity
up to 50 MWel
All part of the service
Page 4
Industrial systems for steam, power, heating and cooling are
developed from a single source for each individual customer, and
extended with a comprehensive range of services.
Heat
up to 116 MWth
Cooling
up to 2 MWth
Energy generators and system modules
Page 6
Steam boilers up to 120 t/h, power stations for generating power
up to 50 MW, hot water boilers up to 116 MW and heat pumps
for heating and cooling up to 2 MW.
The Viessmann range of services:
Everything from a single source
Page 11
From consultation and the design concept right through to
maintenance, the focus is on the complex life cycle of the energy
system.
Systematic approach: Sample applications for hospitals
and the paper industry
Page 12
By renewing or replacing an energy centre, savings of up to 30 %
can be achieved.
International references
Page 14
International references provide evidence of Viessmann's
expertise. The six systems presented here include ones that use
both mono and multi mode operation.
Always nearby
With sales companies and agents in 74 countries, it is quick and
easy to get in touch with Viessmann anywhere in the world.
Page 20
Industrial energy systems
Steam
up to 120 t/h
Power
up to 50 MWel
Heating
up to 116 MWth
Cooling
up to 2 MWth
Consultation/design concept
Implementation
Maintenance/service
In the four energy areas of steam,
power, heating and cooling,
Viessmann offers a comprehensive
range of products and services for
PYROVENT
industry and commerce
Heat pump
Combined heat
and power unit
Biomass boiler
Flame tube boilers
Double flame
tube boiler
Special boiler
Water tube boiler
4/5
Industrial systems
for steam, power, heating and cooling
The energy efficient and clean provision of
energy, delivered with high operational safety
and reliability, are essential requirements
for energy generating systems employed by
industry and commerce.
Overview of the product range
The following outputs refer to the largest type
of boiler or energy generator. Higher outputs
can be achieved by linking individual boilers into
cascades.
Viessmann is the technological trailblazer
for efficient energy systems. Matching
components and systems are developed from
a single source for each individual customer,
and extended with a comprehensive range of
services.
„ Industrial boiler systems for:
Steam up to 120 t/h
Power up to 50 MW
Heating up to 116 MW
„ Biomass plants for:
Steam up to 50 t/h
Power up to 15 MW
Heating up to 50 MW
„ CHP units for:
Power up to 401 kW
Heating up to 549 kW
„ Heat pump systems for:
Heating and
cooling up to 2 MW
Waste heat
boiler
Biomass plant
Steam up to 120 t/h
Double flame tube boiler for steam generation
Steam generation up to 120 t/h with renewables,
fossil fuels and waste heat utilisation
Steam boiler with biomass
combustion
Waste heat boiler for steam
generation
Thanks to their excellent equipment level,
Viessmann steam boilers meet the criteria
for a variety of application areas. The boilers
are robust and require only a low level of
maintenance. They form part of a tailor made
boiler house concept designed as a system
solution for industrial steam generation.
Steam boiler systems
„ Steam output up to 120 t/h per boiler
„ Operating pressure up to 130 bar
„ Hot steam temperatures up to 540 °C
„ Systems with shell boilers or water tube
boilers
„ Broad range of fuel types
„ Waste heat boilers to utilise process heat;
they can be combined with gas turbines
and CHP units
„ Modular design
System modules
All of the components Viessmann supplies are
matched to the relevant steam boiler system.
„ Boilers and superheaters
„ Flue gas heat exchangers
„ Thermal and chemical treatment plants for
feedwater
„ Combustion including fuel storage and
charging
„ Regulating and control systems
„ Flue gas scrubbing
„ Steam storage
„ Boiler platform
Power up to 50 MWel
Combined heat and power units
Power generation for on-site requirements and for
exporting to the public grid up to 50 MW
Viessmann offers four types of system for
industrial power generation which cover a
broad output range. They are designed for
environmentally responsible CHP operation.
The user benefits from reduced costs for
power and heat.
Combined heat and power units (CHP)
„ Output range up to 401 kWel
„ CO2 neutral operation with bio natural gas
„ Equipped as standard for mains substitution
mode in the case of power failure (island
mode)
„ Stringent connection conditions
(AR-N 4105) issued by the power supply
utility are met
Steam turbine power stations
„ Output range up to 30 MWel
„ Industrial steam turbines for use with
continuous steam processes
„ Suitable for efficient power generation
ORC systems
„ Output range up to 2 MWel
„ Power generation in a thermal oil-based
process
„ Use in industrial waste heat processes
„ Utilisation of waste heat from ORC process
up to 90 °C
Gas and steam turbine power stations
„ Output range up to 50 MWel
„ High electrical efficiency in excess of
50 percent
„ Flexible operation due to rapid load changes
ORC system for power generation
6/7
Heat generation
up to 116 MWth
Hot water boiler with gas burners
Heat generation up to 116 MW with biomass, oil,
gas and natural heat
Viessmann offers the right solution for industry
and commerce with its energy systems. Users
have a choice of high efficiency hot water
boilers, CHP units and heat pump systems.
Biomass boiler
If a system is needed quickly, ready-to-connect
container solutions are available for most of
the energy generators.
Heat source
„ Hot water boiler with an operating pressure
of up to 50 bar
– Fired with oil or gas up to 116 MW
– Fired with biomass up to 50 MW
– Waste heat boilers up to 116 MW to
utilise process heat; can be combined
with gas turbines and CHP units
„ CHP units up to 549 kW
„ Heat pumps up to 2 MW per unit (cascades
possible)
System modules
„ Boiler
„ Combustion equipment, fuel storage and
charging
„ Flue gas heat exchanger
„ Intermediate flow piece with safety
equipment
„ Regulating and control systems
„ Return temperature raising facility
„ Boiler platform
Cooling up to 2 MWth
Large heat pump for heating and cooling
Economical cooling
with heat pumps up to 2 MW
Customer-specific large heat pumps are
available for industry, large residential
premises, office buildings and hotels. For
industrial and commercial applications, the
cooling function of the heat pump is just as
important as its heating function – for example,
for cooling food storage rooms or providing air
conditioning in production rooms.
This energy system has the particular
advantage of being able to heat and cool at the
same time.
Large and special heat pumps
„ Individually designed heat pumps
with outputs up to 2 MW/unit (cascades
possible)
„ Able to be installed even in the most
awkward spaces
„ Implementation of dual mode heating
systems in combination with an oil or gas
condensing boiler to cover peak loads
System modules
„ Ice store
„ Dry cooler
„ Collectors
Ice store system with 1800 m3
storage capacity
8/9
Services
3D boiler house design
10/11
The Viessmann range of services:
Everything from a single source
The Viessmann comprehensive range stands
for innovative and efficient technology at its
best. From consultation and design concept
right through to maintenance, attention
remains focused on the complete life cycle of
the energy system.
Consultation/design concept
Viessmann treats all projects individually, with
each and every aspect of the design concept
being geared towards high efficiency:
„ Impartial consultation on technology and
fuel type
„ Best solution recommended from an
ecological and economical standpoint
„ Information about national and international
legislation
„ System analysis
Professional project design concept
Implementation
Coordination with all technical departments
while the system is under construction to
ensure timely delivery and installation:
„ Manufactured with a high level of
pre-assembly to minimise time on site
„ Trouble-free commissioning
„ Comprehensive output tests
„ As-built documentation
Large number of matching components are pre-assembled
Maintenance/service/training
Reliable operation is ensured through
customer-specific service concepts with
guaranteed spare part supply, regular
maintenance and boiler checks:
„
„
„
„
„
24/7 customer service
Remote monitoring and diagnosis
Conversion and modernisation
Boiler hire
Training at the Viessmann Academy
Professional maintenance and service concepts
System solutions
Systematic approach: Sample applications for
hospitals and the paper industry
High cost pressure forces many companies
to seriously examine their energy expenditure
and take steps to realise potential energy
savings. By renewing or completely replacing
an energy centre, savings of up to 30 % can
be achieved.
This means that new technology pays for
itself quickly and eases the burden of current
expenditure.
Expertise in multi mode heating systems
Viessmann's comprehensive range offers
innovative and powerful technology that can be
tailored to the system user's own aspirations
and requirements.
Multi mode systems are increasingly
being used for commercial applications,
combining renewables and fossil fuels. For
this, Viessmann offers the necessary system
expertise. For covering the base load, biomass
boilers, heat pumps or CHP units are deployed;
peak loads are covered by oil or gas boilers.
Combined heating system with a high
output and a high level of supply security
The graphic on the left shows a sample
system solution: In a hospital, two Vitobloc 200
combined heat and power units (4) generate
some of the required power. For heating water
and domestic hot water, there is also a Pyrotec
biomass boiler (2) and two Vitomax 200-LW
with Vitotrans 300 (7). Pure steam for clinical
applications, e.g. for sterilisation, is produced
by the Vitomax 200-HS high pressure steam
boiler (8).
For perfect interaction and therefore the
highest level of efficiency, Viessmann
combines all of the system components in
accordance with individual requirements.
Power
grid
1
2
3
1
2
3
4
5
6
7
4
5
6
Woodchip store
Pyrotec biomass boiler
Heating water buffer
cylinder
Twin Vitobloc CHP unit
DHW cylinder
Distributor
Cascade with two
Vitomax 200-LW with
Vitotrans 300 flue gas/
water heat exchanger
7
8
8
Vitomax 200-HS high
pressure steam boiler with
thermal and chemical water
treatment systems and a
pure steam generator
12/13
High pressure
steam
Feedwater
Natural gas
1
2
3
4
5
6
7
Electrical power
1
2
3
4
Efficient solutions for steam
and power generation
Typical applications for steam generation in
large volumes can be found in paper mills
(above). Here, the associated power station
generates steam and electricity. A generator
(1) driven by a gas turbine (2) supplies the mill
with power. The heat from the combustion gas
is used in a waste heat boiler (3) to generate
hot steam. A separate high pressure steam
boiler (4) supplies the redundancy required for
the production process and covers possible
peak loads. The output of the power station is
equivalent to the energy required for a town of
around 50,000 inhabitants.
The greater the energy demand, the more
positive the impact of the savings achieved by
Viessmann's highly efficient energy systems.
5
6
International references provide evidence of
Viessmann's systems expertise. Six systems
are presented on the following pages,
including ones that use both mono and multi
mode operation.
7
8
8
Generator
Gas turbine
Waste heat boiler with
water tube design
High pressure steam
boiler with water tube
design
Economiser
Feedwater pumps
Feedwater tank with
integral deaerator
Paper mill
References
Sembcorp Utilities, Wilton (United Kingdom)
Steam production for the chemical industry
Sembcorp Utilities, Wilton
(United Kingdom)
The international energy group, Sembcorp,
provides up to 60 t/h steam for several
chemical companies on an industrial site.
HKB, one of the Viessmann Group companies,
was the general contractor responsible for
the construction of the steam boiler system
for this project in 2009, based on an individual
design. Due to industrial requirements, four
Vitomax D HS double flame tube boilers were
installed, each with a steam output of 30 t/h.
Two of these are kept for redundant backup
to ensure high operational reliability. Preassembled system modules helped to reduce
the installation time.
Specification
Double flame tube boilers
Fuel type
Steam output/boiler
Hot steam temperature
Operating pressure
Feedwater temperature
Boiler efficiency
Commissioned
4 x Vitomax D HS
Natural gas
30 t/h
300 °C
17 bar
105 °C
91 % (without
economiser)
2009
Standard delivery
„ High pressure hot steam boiler
„ Burner
„ Superheater
„ Feedwater system
„ Main pipelines, steel structure and platforms
„ Chimney stack
„ Control unit
14/15
Natural heat for modern architectural concepts
Lotte World Tower, Seoul (Korea)
The "Lotte World II" skyscraper complex will
be 555 m tall. Energy for the building is to
be supplied by environmentally responsible
technology. Twelve KWT heat pumps will
provide the renewable part of the building's
heating and air conditioning supply.
Six brine/water heat pumps, each with 1.7 MW
heating output and 1.9 MW cooling capacity
will be supplied by 720 geothermal probes
sunk 200 m into the ground. In addition,
six water/water heat pumps will be installed,
each with 2 MW heating output and 1.7 MW
cooling capacity. The latter use water from the
river that runs past the tower. All twelve heat
pumps will be operated in a cascade, which is
controlled by a higher ranking control centre.
Specification
Heat pump type
Total cooling capacity
Total heating output
Flow temperature
Cold water temperature
Due to be commissioned
12 x special heat
pumps
20.4 MW
22.2 MW
up to 55 °C
up to 7 °C
2015
Standard delivery
„ Brine/water heat pumps
„ Water/water heat pumps
KWT heat pump
Lotte World Tower, Seoul
(scheduled for completion in 2015)
References
Bioheating centre at E-Werke Frastanz, Austria
Bioheat for regional energy supply
E-Werke Frastanz (Austria)
E-Werke Frastanz chose to invest in a
bioheating plant to supply the Vorarlberg
region in Austria with energy from renewable
resources. Consumers are now benefiting
from the more stable price of biomass
compared to crude oil. The plant supplies
private, public and commercial buildings with
natural heat from woodchips all year round.
The chippings are automatically transported
from the silo to the combustion chamber using
a pushrod discharge system. A flat moving
grate (FSB) with variable speed ensures
optimum combustion of fuels that have a high
water and ash content.
Specification
Biomass boiler
Fuel type
Water temperature
Boiler efficiency
Commissioned
Standard delivery
„ Wood combustion system
„ Push floor
„ Trough chain conveyor
„ Hydraulic feed
„ Multi cyclone separator
„ Electrostatic filter
„ Bunker cover
„ Control unit
2 x Pyroflex FSB
(1100, 550 kW)
Biomass
95 °C
85 %
2009
16/17
Heating plant in Gräfelfing with biomass boiler (right) and hot water boiler for peak loads
Multi mode heating centre for local heating supply
Bio-Wärme, Gräfelfing (Germany)
The heating centre at Bio-Wärme Gräfelfing
GmbH meets all the demands for quality,
efficiency and optimum interaction between
component modules. The particular focus is on
a long service life and ease of maintenance.
Both of these factors make a significant
contribution to the continuous yet economical
operation of the plant, which stands at more
than 8000 hours per year.
The Pyroflex boiler used here is notable for the
minimal demands it makes of its fuel – wood,
which with a water content of w60, can be
combusted reliably and cleanly. The boiler's
modulating operating mode matches the
system output to the actual heat demand. If
required, a Vitomax 200 peak load boiler is also
started up.
Specification
Biomass boiler
Flame tube boiler
Total output
Fuel type
Commissioned
Pyroflex SRT
Vitomax 200-LW
3650 kW
Biomass, gas
2012
Standard delivery
„ Wood combustion system
„ Hydraulic direct feed (fuel transport)
„ Pushrod discharge (fuel discharge)
„ Flue gas dust extraction using multi cyclone
separator
„ Hot water boilers
„ Control
Model view of the heating plant
References
Tropical atmosphere at the
Badeparadies Schwarzwald leisure
complex
Tailored system solutions
for swimming pools
CHP unit (left) in the leisure complex.
Two Vitoplex boilers cover peak loads
when required.
Badeparadies Schwarzwald leisure
complex, Titisee (Germany)
A Vitobloc 200 CHP unit was installed in the
Badeparadies Schwarzwald leisure complex to
provide low cost power and heat. The system
is operational for around 8000 hours per year
and primarily produces power for use by inhouse consumers.
The simultaneously generated heat is used
for central heating and DHW, resulting in an
energy utilisation level in excess of 90 percent
for this CHP system. The Vitobloc 200 provides
the base heat load that is required all year
round.
In the warm summer months, the CHP unit
takes over sole provision of power and heat.
During the winter, a Pyroflex woodchip
system covers the additional heat demand. For
redundant backup and possible peak loads,
two Vitoplex 200 low temperature boilers were
installed.
Specification
CHP unit
Low temperature boiler
Wood combustion system
Fuel type
Commissioned
Vitobloc 200 EM
(401 kWel/
549 kWth)
2 x Vitoplex 300
(3200 kW)
Pyroflex FSR
(2100 kW)
Natural gas, oil,
biomass
2010
18/19
The DGUV energy centre with five
CHP units in St. Augustin
CHP units for power supply and
air conditioning in office complexes
DGUV, St. Augustin (Germany)
At the head office of the German Social
Accident Insurance Institution (DGUV) in St.
Augustin near Bonn, five Vitobloc 200 CHP
units generate the power that is used in the
building itself. If there is a public grid power
failure, the system can provide emergency
power in island mode and safeguard the
necessary power demand. The mains
substitution management this requires is
provided by the Viessmann multi module
management system 300.
The heat generated by the CHP plant is mainly
used for operating absorption refrigeration
machines and for heating the building. If
required, a Vitoplex 300 low temperature boiler
supplies additional heat.
Specification
CHP unit
Low temperature boiler
Fuel type
Commissioned
DGUV administration building
5 x Vitobloc 200 EM
(238 kWel/363 kWth)
Vitoplex 300
(1250 kW)
Natural gas, oil
2012
Standard delivery
„ Combined heat and power units
„ MMM 300 multi module management
system for mains substitution management,
including active load distribution
„ Low temperature boiler
Industrial energy
systems
Further information can be found
in the engineering and product
brochures.
Easy to order from
www.viessmann.de/Industrie
Product and engineering brochures
20/21
All of the information you need is just a click away:
online at www.viessmann.de/Industrie
With just a few clicks of the mouse, trade
partners, design engineers and operators
can go online to discover Viessmann's entire
range of products and services for industry,
commerce and local heating networks.
System examples
More and more companies in the industrial
and commercial sectors are now choosing
multi mode systems when they invest in new
energy systems.
Numerous system examples with graphic
illustrations and an economic viability
calculation make all of the individual solutions
clear.
Viessmann references
Advanced and efficient energy systems from
Viessmann are in use in many large buildings,
making an important contribution to the
sustainable exploitation of energy reserves.
The website for
Detailed information on international reference
systems can be found in the database on the
Viessmann website.
industrial energy
systems provides
information about all of
our products (above) and
shows example system
Engineering software
Vitodesk is the complete software support
package for trade partners and design
engineers. All programs support automatic
data exchange.
Further details are available in the information
area for Viessmann trade partners.
solutions.
Viessmann international
Viessmann is represented by sales
offices and agents in 74 countries.
Always nearby
Proximity to customers and rapid availability
are important criteria for the professional
design and implementation of energy systems
for industry and commerce. Viessmann is
represented in major industrial countries with
its own sales offices and experienced experts.
They ensure that every energy system,
whether it is for steam, power, heating or
cooling, is individually tailored to the required
application. This includes ongoing support after
successful commissioning.
www.viessmann.com
All members of the Viessmann Group are
represented here, along with a short summary
of each company, to provide insight into the
wide variety of powerful energy systems that
are on offer.
22/23
Europe
Belgium
Viessmann Belgium BVBA
Hermesstraat 14
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info@viessmann.be
Bulgaria
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Denmark
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Germany
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Estonia
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France
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United Kingdom
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Spain (mainland)
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ul. Karkonoska 65
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Romania
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Spain (Balearics)
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Czech Republic
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info@viessmann.cz
Turkey
Viessmann Isı Tek. Tic. A.Ş.
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Ukraine
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Dimitrova Street 5, Building 10A
03680, Kiev
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Hungary
Viessmann Fűtéstechnika Kft
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Süssen u. 3.
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Belarus
OOO "Vistar"
ul. M.Bogdanovitcha 153b,
Room 302
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info@viessmann.by
Africa & Middle East
Dubai
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FZE E-Wing, Office 603
HQ Building
Dubai Silicon Oasis
United Arab Emirates
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America
USA
Viessmann Manufacturing Company
(U.S.) Inc.
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Warwick, RI 02886
Tel: +1 (401) 732-0667
Tel: (800) 288-0667 (toll free)
info@viessmann-us.com
Canada
Viessmann Manufacturing Company Inc.
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Waterloo, ON N2V 2G5
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Tel: (800) 387-7373 (toll free)
info@viessmann.ca
Asia
China
Viessmann Heating Technology
Beijing Co., Ltd.
Beijing Tianzhu Airport Industrial
Zone B
No. 26 Yumin Street, Shunyi District
Beijing 101318
Tel: +86 (0)10-80490888
info@viessmann.cn
Hong Kong
Viessmann China Ltd.
Unit 16, 17th Floor,
Millennium City 2
378 Kwun Tong Road
Kwun Tong, Kowloon
Tel: +852 25440807
info@viessmann.hk
Viessmann Industrie
Deutschland GmbH
35107 Allendorf (Eder)
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