INNOVATION IN HEAT NETWORKS Franz Huelle Technical Manager REHAU DH workshop, London, 23rd March 2017

Transcription

1 INNOVATION IN HEAT NETWORKS Franz Huelle Technical Manager REHAU DH workshop, London, 23rd March 2017

2 The REHAU Group 20,000 employees worldwide experts in polymer manufacturing. Founded in 1948 in Germany. 5 divisions in the following sectors: - Window solutions - Building solutions - Industrial solutions - Furniture solutions - Automotive solutions March 2017 / F Huelle / BT GB / 2

3 REHAU - Your expert partner in district heating UK production: Only UK manufacturer of PE-Xa district heating pipes. Design service: Experts in heat network optimisation and design. Local UK sales & technical teams: Onsite support from specialist DH sales team (4 regional offices + UK head office) Quality: The renowned REHAU Everloc jointing system has been used over 850 million times. Largest UK stock & full cutting service: No 4-6 week wait for an urgent fitting. BIM: REHAU s district heating pipes have BIM models ready for download. March 2017 / F Huelle / BT GB / 3

4 REHAU are the only UKmanufacturer of PE-Xa district heating pipe. Production started in May Est. 30% reduction in CO 2 from UK manufacturing.

5 Importance of good design on the CAPEX of a heat network

6 Optimising the flow / return temperatures Modern DH systems typically use a flow temperature of ca C. Flow / return temperatures ( C) Heat load Pressure loss (Pa/m) Pipe size required 82/71 1.1MW mm 80/60 1.1MW mm 80/50 1.1MW mm 70/40 1.1MW mm 60/20 1.1MW mm March 2017 / F Huelle / BT GB / 6

7 Optimising the flow / return temperatures Flow / return temperatures ( C) Max. heat load via 160mm pipe 82/ MW 80/ MW 80/ MW 70/ MW 70/ MW 80/60 > 80/50 = 50% additional heat capacity 80/60 > 70/30 = 100% additional heat capacity March 2017 / F Huelle / BT GB / 7

8 Optimising the flow / return temperatures F/R temperatures ( C) Heat load Pipe sizing OD (mm) Heat losses (vs 82/71 C) PE-Xa lifespan (24/7 operation) 82/ MW 160 <25 years 80/ MW % lower >25 years 80/ MW % lower >25 years 70/ MW % lower >50 years 60/ MW 90 69% lower >50 years CIBSE Code of Practice: Best practice would aim to achieve return temperatures <55 C for existing buildings and <40 C for new buildings. Heat loss assumptions: 10 C soil temperature 1km distance 0.8m installation depth 1.0 W/m*K soil conductivity March 2017 / F Huelle / BT GB / 8

9 Benefits of using twin DH pipe 2x UNO 25 = 10.9 W/m DUO 25 = 7.6 W/m Heat loss reduction with DUO 30% 2x UNO 40 = 16.6 W/m DUO 40 = 11.6 W/m Heat loss reduction with DUO 30% 2x UNO 63 = 19.5 W/m DUO 63 = 13.1 W/m Heat loss reduction with DUO 33% Data at 80/50 C using RAUTHERMEX pipe. March 2017 / F Huelle / BT GB / 9

10 Optimising a 200 connection 1.2 MW DH network

11 Original Design Project details: 200 connections Total network length = 3772m 6kW per house = 1,200kW Flow / return temps = 82/71 C No diversity applied All UNO pipes List price = 725,780 March 2017 / F Huelle / BT GB / 11

12 Step 1 Check Route Layout Project details: 200 connections Total network length = 3772m 6kW per house = 1,200kW Flow / return temps = 82/71 C No diversity applied All UNO pipes List price = 725,780 March 2017 / F Huelle / BT GB / 12

13 Step 1 Optimise Route Project details: 200 connections Total network length = 3739m 6kW per house = 1,200kW Flow / return temps = 82/71 C No diversity applied All UNO pipes New List price = 711,030 Savings: 14,750 March 2017 / F Huelle / BT GB / 13

14 Step 1 Optimised Route Details Before: After: March 2017 / F Huelle / BT GB /14

15 Step 2 Check Heat Loads Project details: 200 connections Total network length = 3739m 6kW per house = 1,200kW Flow / return temps = 82/71 C No diversity applied All UNO pipes Ø160 12m lengths Ø160 Ø125 Ø75 Ø110 List price = 711,030 March 2017 / F Huelle / BT GB / 15

16 Step 2 Optimise Heat Loads Project details: 200 connections Total network length = 3739m 4.5kW per house = 900kW Flow / return temps = 82/71 C No diversity applied All UNO pipes Ø160 12m lengths Ø160 > Ø140 Ø125 > Ø110 Ø110 > Ø90 Ø75 > Ø63 New List price = 638,647 Savings: 72,382 March 2017 / F Huelle / BT GB / 16

17 Step 3 Optimise Temperatures Project details: 200 connections Total network length = 3739m 4.5kW per house = 900kW Flow / return temps = 70/40 C No diversity applied All UNO pipes Ø160 > Ø110 Ø140 > Ø90 Ø 90 > Ø63 Ø110 > Ø75 Ø63 > Ø50 Ø 90 > Ø63 New List price = 435,144 Savings: 203,502 March 2017 / F Huelle / BT GB / 17

18 Step 4 Apply Diversity Project details: 200 connections Total network length = 3739m 4.5kW per house = 900kW Flow / return temps = 70/40 C Diversity 51.4% All UNO pipes Ø110 > Ø75 Ø90 > Ø75 Ø63 > Ø50 Ø75 > Ø63 Ø63 > Ø50 New List price = 392,371 Savings: 42,773 March 2017 / F Huelle / BT GB / 18

19 Step 5 Switch to DUO Project details: 200 connections Total network length = 3739m 4.5kW per house = 900kW Flow / return temps = 70/40 C Diversity 51.4% All project in DUO pipes Ø75 UNO > DUO New List price = 311,984 Savings: 80,386 March 2017 / F Huelle / BT GB / 19

20 Heat network optimisation conclusion From these simple steps: 1) Optimising the route and using DUOs 2) Heat load correction from 6kW to 4.5kW 3) Changing flow temperature from 82/71 C to 70/40 C 4) Diversity factor of 0.51 Cost saving of 57% from the original design. Heat losses reduced from 71.9kW to 26.8kW which is 63% heat loss reduction. March 2017 / F Huelle / BT GB / 20

21 Can polymer be used for a large scale heat network? REHAU supplied 80km of RAUTHERMEX to the bioenergy village of Lathen in Germany of 11,000 residents.

22 Nexus hot tapping system world first for REHAU PE-Xa district heating pipes

23 HOT TAPPING WITH REHAU NEXUS: Hot tapping was until now only possible with polymer pipes in cold water and gas applications and with steel pipes in heating systems. REHAU NEXUS is the world s first system for hot tapping hot water and district heating networks made with orange REHAU PE-Xa pipes. Retrospective house connections / network extension Retrospective installation of air venting equipment Retrospective fitting of measuring points March 2017 / F Huelle / BT GB / 23

24 TÜV CERTIFIED TÜV Süd certified performance in combination with our orange REHAU RAUTHERM-EX pipes. Can be used with orange REHAU PE-Xa pipes in both heat networks and plant rooms. March 2017 / F Huelle / BT GB / 24

25 SAFETY & RELIABILITY No reduction in life span of pipe system Corrosion protection through encapsulated system High performance teflon coating for up to 110 C (in case of malfunctioning temperature controls) Maximum safety - simple pressure test prior to tapping provides safety Only fully trained and REHAU authorised installers March 2017 / F Huelle / BT GB / 25

26 UK Case studies - Gaunts Estate AD plant 1.6km network - Soho luxury cottages Biomass 7km network - Eleanor Social Housing Gas CHP 2km network - Tattenhall Retirement Village Gas 2km network - Dundee Social Housing Gas CHP 2.5km network - Portmeirion Village Biomass 3km network March 2017 / F Huelle / BT GB / 26

27 Contact details: THANK YOU FOR YOUR ATTENTION Any questions?