Page 16 - Bosch Modernisation of Boiler Systems

16 | Modernisation of boiler systems

Reference: Fleischwaren Sutter GmbH

In the course of a continuous plant optimisation Sutter decided to introduce an energy management
system in its main production facility in Gau-Bickelheim. The resulting tax and cost advantages are
used to compensate the increase in energy costs over the past years. In addition, many tons of CO 2
emissions are avoided.

Upon request of the Energy Manager of Sutter, Chris- In return, the natural gas supplier waived a building
tian Böhme, the savings potentials had been analysed cost subsidy for the laying of the gas pipeline. In com-
and evaluated economically. The process heat supply parison with the previous fuel oil burners with mecha-
with three oil-fired steam boilers was quickly identified nic combined group the new electronically controlled
as one of the biggest energy consumers of the plant. burners are able to modulate down to 350 kW and thus
“Prior to the modernisation we had been supplied with facilitate a significantly quieter and more efficient
around 30,000 l of light fuel oil – every week at ano- part-load operation. In addition, by using a combustion
ther price. The switch to natural gas has improved our control with oxygen sensor the losses on the flue gas
reliability of our energy cost planning. This is an advan- side could be reduced from 6 % to 5 %.
tage that we can pass on to our customers in the form
of stable prices,” explains Christian Böhme. The availability of spare parts for the boiler control
based on Siemens Simatic C7 components will fore-
In the course of the modernisation the dual fuel bur- seeably become more and more difficult in the coming
ners had been retrofitted while the existing light fuel years. Therefore a state-of-the-art boiler control system
oil supply was maintained as backup. In case of supply consisting of BCO and SCO was integrated. Besides
shortages in winter times the natural gas supplier can the automated water treatment, the SCO includes the
request the short-term operation with light fuel oil. adaptive boiler cascade control in order to avoid

Sutter’s process heat supply works with greater efficiency after the successful modernisation.