Natural gas. Dreyer & Bosse. Profitable Power and Heat

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1 Natural gas Dreyer & Bosse Profitable Power and Heat

2 Dreyer & Bosse: Profitable Power and Heat Dreyer & Bosse Gorleben, Lower Saxony founded 1997 around 100 employees certified to DIN ISO 9001 Member of the Wolf Group wide product range Dreyer & Bosse is a technological leader among system suppliers for decentralised heat and power generation. Our range includes tailormade combined heat and power units (CHP) for biogas and natural gas, as well as plants for gas scrubbing and upgrading. highest availability As a pioneer in combining heat and power generation, Dreyer & Bosse can draw on more than 15 years of CHP experience. We are trailblazers in new technologies, such as gas scrubbing with two-stage activated carbon filters or our oil management system, both state of the art. Our innovations guarantee high plant availability and ensure our clients become even more competitive. Contents Function: efficient, environmentally friendly energy supply Applications: viable solutions for every demand Construction and control: top performance from an ideal combination

3 Overview everything from a single source Dreyer & Bosse provide not only reliable, innovative products but also well conceived complete solutions. The open design of our systems in particular paves the way for flexible options to suit almost any requirement. From initial feasibility studies, through planning and engineering, via construction and commissioning right up to repairs and maintenance of your CHP unit, with us you re in good hands. excellent efficiency Dreyer & Bosse pay particular attention to the optimum sizing of its plants, aligned to your requirements and local conditions. This is the only way to fully utilise the technical potential of the individual CHP components and to achieve high system efficiency. Excellent efficiency means faster payback for your plant. Standing still is not what this business is about. Everything is in forward motion, being developed and growing. And that s as it should be, as demands made are constantly increasing. We can all share the pride of having held our position in the market right from the start. This is only achieved with strength, courage and the determination of rising to meet new challenges. Felix Fröhlich, managing director Components: High efficiency through sophisticated technology Engineering: the right size matters Service: maximum yield through maximum availability

4 efficient, environmentally responsible energy provision seperated energy production approx. 52 % 100 % gas approx. 48 % 100 % gas electricity generation n el = 36 % heat production n th = 85 % approx. 19 % electricity approx. 41 % heat Cogeneration cogeneration heating plant exhaust approx. 50 % heat approx. 40 % electricity approx. 40 % loss approx. 10 % loss Combined heat and power makes it possible to use the provided fuels efficently. For example you can produce 50 % more heat and power with the same input of primary energy. combined heat and power generation Dreyer & Bosse natural gas-based CHP units are designed to generate heat and power in a single process. By adding an absorption refrigeration unit, the heat can be converted into cooling capacity (trigeneration). These plants are therefore ideal for any consumers wishing to reduce their energy costs whilst having a high demand for power and heat or cooling. The high efficiency of our systems guarantees you reliable energy provision along with added financial benefits. utilising energy efficiently In our CHP units, a gas engine drives a generator. The power generated by this can be used on site by the plant operator or exported to the grid for appropriate remuneration may differ depending on country laws and regulations. The waste heat generated scheme cogeneration by the process, from the engine coolant and exhaust gas, is extracted by heat exchangers, making it available for heating purposes, for heating DHW or as process heat. advantages for the environment The combined generation of heat and power makes best use of the energy contained in natural gas. High overall efficiency levels are achieved. Compared to the separate generation in a power station and a boiler, the Dreyer & Bosse CHP units use up to 40 % less primary energy. This saving in gas cuts your energy costs and it reduces climate-damaging CO 2 emissions significantly. exhaust gas engine cooling heat exchanger absorption refridgeration cooling or airconditioning engine integration in existing heating system electricity for own use or feed into national grid generator exhaust heat exchanger 4

5 Function The lubricant manufacturer ROWE MINERALÖLWERK GMBH in Worms requires huge amounts of heat for mixing oil with additives. This heat is generated by a Dreyer & Bosse CHP unit (600 kwel) and made available to the process at the required temperature by means of thermal oil. All of the generated power is used on site. This concept reduced energy costs significantly. Benefits of combining heat and power generation in summary: u reduced energy costs through the combined generation of energy (heat + power) u greater independence from the energy market u in many countries, public subsidies for the energy generated by combined heat and power units (feed-in tariffs, tax credits) u fewer noxious emissions (carbon dioxide, nitrogen oxide) u ecological use of resources with a reduction in primary energy consumption of up to 40 % compared to conventional energy generation 5

6 viable solutions for every demand Industry and commerce For industrial concerns, a CHP unit from Dreyer & Bosse is an excellent investment. Manufacturing demands a lot of power, for processing machines as well as filling and handling plants. Waste heat, brought to the required temperature level, can be utilised for the most diverse processes. CHP units that deliver hot water at around 90 C are particularly suitable for use in different parts of the food processing industry, such as dairies and breweries, both of which have a high demand for hot water. In paper mills or chemical plants that require heat at a higher temperature level, CHP units from Dreyer & Bosse generate process heat via either steam or thermal oil. Other industries require heat for air conditioning plants or for cooling products. For these applications it is appropriate to combine the CHP units with an absorption refrigeration unit. This converts the heat generated by the CHP unit into cooling capacity without the use of environmentally threatening refrigerants. Hospitals In hospitals, CHP units can reduce the cost of energy by a significant proportion. Ventilation plants, pumps for central heating and DHW provision, lighting and specialised working areas, such as operating theatres, kitchens or laundries are all heavy users of power. In addition to space heating demand, a high heat demand for DHW heating must also be covered all year round. In the summer months, the cooling demand for central air conditioning rises. Swimming pools Swimming pools also provide excellent conditions for economical operation of CHP units. Showers and heating the pool water requires huge amounts of hot water. Ventilation plants and circulation pumps create a largely constant demand for power. further applications: Shopping centres Airports Hotels Retirement homes Commercial nurseries Residential complexes Grain dryers

7 Application More than 700 CHP units worldwide bear our logo. The majority of Dreyer & Bosse CHP units have been installed in Germany. In other countries too, we have scored notable successes. To date, our CHP units have been commissioned successfully in the following countries: Brazil, Bulgaria, France, Greece, Great Britain, Italy, Kenya, Netherlands, Poland, Sweden, Slovakia, Czech Republic, Hungary, Uruguay, USA and Cyprus. The gear manufacturer Pritzwalk GmbH saw the opportunity of generating cooling capacity economically by means of a 400 kwel CHP unit from Dreyer & Bosse with downstream absorption plant, as an important motivation in favour of this investment. All of the generated power is used on site. The Salzgitter Maschinenbau AG installed a 600 kwel Dreyer & Bosse CHP unit, thereby making its energy provision more flexible and economical. All of the generated power is used on site. The generated heat provides space heating for the production facilities in winter, and supplies the paint shop all year round. The heat not required in summer will in future be used to generate cooling. 7

8 top performance from an ideal combination reliability The efficiently operating CHP unit is the result of reliable and matching technology. Consequently, Dreyer & Bosse only uses system components that have proven themselves in practical applications, developing some technologies inhouse and optimising their interaction. In doing so, we ensure that your plant functions perfectly and can achieve plant availability levels of up to 99 %. You, as plant operator, can enjoy high efficiency and rapid payback. easy to service CHP units made by Dreyer & Bosse stand out on account of their open design. All mechanical elements are easily accessable for adjustment, checking and regular servicing. This results in a reduction of the frequency for servicing, and the associated costs. A minimum transfer of engine vibrations reduces structureborne noise and the use of costly sound attenuation. flexible installation The open design of our CHP units also offers you many individual opportunities for linking your system into the wider plant. Whether installing in a new power station or in an existing building complex, the layout of components can be adapted and designed according to preference and purpose. Alternatively, all relevant system components can be fitted inside a container and delivered as one unit ready for installation. We will manage any space challenge you may face. Dreyer & Bosse natural gas CHP-series Terra Type/ Terra-Pico CHP Terra-Grandis CHP unit Electrical output kw Thermal output max. kw Electrical efficiency % 37,2 36,5 41,4 37,5 42,3 40,8 42,0 42,4 41,0 41,0 43,7 Thermal efficiency % 47,4 51,8 48,9 45,6 44,4 42,8 45,5 45,0 46,1 45,1 43,0 Cylinders R6 R6 R6 V8 V8 V12 V12 V16 V12 V16 V20 Energy input kw Built up L/B/H m 6,0/2,45/2,6 9,0/3,0/2,9 12,0/3,0/2,9 15,0/3,2/3,2 Standard reference conditions according to ISO 3046 (1000 mbar, air temperature, 298 K, relative humidity 30%). Performance tolerances 7%. Specific data are given in the CHP data sheet.

9 Design and control LICA: Advanced control system Operation is quick and intuitive - on site, from your office or via smartphone. Call up current process parameters, such as temperature and pressure Runtime history with long term database free zoom function in historical trends Economy monitor Help function with support User management automatic SMS and despatch for information exchange (fault and warning messages You have complete control of your power station from anywhere advanced control The control system is the brains behind our CHP units, which we continuously develop inhouse. It handles the specific differences of each individual plant and thereby ensures the smooth running of all processes. Various interfaces are available for linking the plant by means of commercial fieldbus systems. our head-start The Dreyer & Bosse PLC (Programmable Logic Controller) can easily transmit signals to higher control systems. This means that linking up to virtual power stations will be quick and easy, paving your way to lucrative direct selling of exported power. easy operation Our most advanced LICA control system comes with display and control elements. You can make adjustments directly and easily via a touchscreen that provides you with all relevant parameters. 9

10 high efficiency through sophisticated technology power At the core of our plants lies an extremely robust and powerful gas engine. It is designed for the highest electrical and thermal efficiency, low operating and service costs as well as high reliability and availability. low service requirements Our oil management system is a further in-house development from Dreyer & Bosse. High oil volumes guarantee a high buffering of pollutants that enter the engine oil from the gas. The process affords a continuous replacement of the engine oil. As a result, the engine only requires an oil change every 3000 hours run (max.). environmentally responsible Our specifically sized oxidation catalytic converters (OxiKat) are used to treat the exhaust gas prior to emission. The OxiKat reduces formaldehyde and carbon monoxide emissions: Country-specific limits are complied with. noise reduction Sound packs tailor-made to your needs reduce noise emissions to the minimum necessary. We design each cooler, container wall and exhaust silencer to individual requirements. Where required, we even meet emissions of 40 db(a) at 10 m distance. Typical heat exchange function Smoke exhaust cross counterflow principle exhaust water / thermal oil water / thermal oil exhaust Economical deployment 10 In order to make sensible use of the waste heat generated by the engine, Dreyer & Bosse will fit an exhaust gas heat exchanger for you to generate steam and heating water or to heat thermal oil. You benefit from the improved heating output of your CHP unit as well as higher overall efficiency.

11 Components In industry, hospitals and swimming pools, our open design and modular control allows our engineers to match your CHP unit perfectly to your company demands and requirements. Benefits of the Dreyer & Bosse CHP: u reliable components and an easy to maintain, open design reduce costs for service and repair u high plant availability (up to 99 %) and excellent system efficiency levels lead to long-term financial benefits u efficient utilisation of heat through a combination with a thermal oil heat exchanger, a steam generator or an absorption refrigeration unit u expansion with additional control elements is all it takes to make integration into a virtual power station possible 11

12 tailor made for your application economical in design The more hours the CHP unit operates each year, the quicker the payback. As a rule, therefore, your plant unit should run as evenly as possible and achieve the highest possible utilisation level. By engineering and sizing your plant carefully and accurately, we will design your CHP unit as economically as possible. accurate engineering Calculating the right output for your needs is the focus of our engineering and sizing. To match the heat and power generation of a CHP unit to the relevant demand, we analyse the general conditions for heat and power sides for each project individually. CHP units will deliver power and heat in a fixed ratio to each other. Whilst you can export surplus power against attractive remuneration into the grid, generated heat can only be stored to a limited degree. Consequently, we generally design our CHP units with a heat bias. Your heat demand then becomes the control variable for the operation of the CHP unit. annual load duration curve One commonly used instrument for sizing the CHP unit and calculating the efficiency is the annual load duration curve. It represents the output demand of a project based on the respective utilisation time. Well engineered - maximum profit Our plants are individually sized in order to establish optimised operation for best economy and process.

13 Engineering we go one step further Using new intelligent software, we calculate the very best CHP unit for you. This software is characterised by a complete integration of all relevant operating parameters and magnitudes as well as current and trend market data. This permits an accurate calculation of parameters for every operating hour over the entire life cycle of your CHP unit. Through this unique accuracy in simulation and the associated calculations of the viability of the CHP unit, Dreyer & Bosse offer you a significantly more viable investment in your CHP unit. Your benefit - reliability and realistic planning. annual load duration curve actual time of energy need source: asue.de Perfectly sized - quicker payback. Our advanced sizing program also delivers Viability analysis with annual load duration curve and realistic energy demand curve Data of an optimum CHP unit Operating and finance data over a 10 year period Cost comparison with conventional energy generation 13

14 maximum yield through the highest availability All of us are trained specialists. Every one of us at Dreyer & Bosse has their place and tasks to perform. Together, we are a rapid response team that works hand in hand with our customers. Our motto: As soon as a call comes: off we go! Everything we do is done without delay. We know that time is money. And, when everything runs smoothly, success can be real fun too. regular service & maintenance On-going quality assurance and high grade components guarantee an extraordinarily long service life and the highest availability. In order to safeguard both in the long term, our service specialists provide our clients with appropriate expert servicing and maintenance. individual support We prevent unscheduled downtimes and repairs with maintenance and service contracts that are individually tailored to the requirements of your plant. In this, we go beyond the recommendations of engine suppliers. Instead, we also apply our own experiences. Your benefits are predictable costs and successful plant operation. immediate help If, nevertheless, your plant should suffer a fault our service team, which you can contact via our hotline, is available to you 24/7. Most problems can be determined and solved quickly by our team of experts through remote dial-up. rapid on-site service Our service department runs more than 20 vehicles, which are well equipped with all required tools as well as many wearing and spare parts. In emergencies, our team will be with you at short notice and will restore your plant to operational status as quickly as possible. Roman Brillowski, Dreyer & Bosse employee You can reach our service team any time. We answer your questions and assist you quickly.

15 Benefits of maintenance and service in summary: u 24/7 emergency service and troubleshooting u Technical hotline: Remote dialup and diagnostics, telephone consultation on technical questions u individual maintenance and service contracts, designed to meet your needs precisely u well sorted spare parts stock at Gorleben guarantees a quick delivery for missing material u highly qualified engineers with more than 20 service vehicles on the road u advanced precision and test equipment for rapid diagnosis u training of operators in the maintenance and repair of CHP units The professional assistance by our service team ensures you of consistent output at the highest level. You can count on us! 15

16 Dreyer & Bosse Development and construction of bespoke CHP systems for biogas and natural gas + Gas scrubbing plants with the innovative Vita-Mundus system + Biomethane plants for upgrading biogas into energy-rich biomethane + Professional planning with optimum sizing + Engineering and commissioning by highly qualified personnel + appropriate maintenance and servicing + highest plant availability (up to 99 %) + excellent system efficiency = Heat and power with PROFIT Should you still have questions or if you have an interest in using a CHP unit or a gas scrubbing or upgrading plant... So do give us a call. We d be happy to advise you! Dreyer & Bosse Kraftwerke GmbH I Subject to technical modifications I Printed in Ger-many 03/2014 Dreyer & Bosse Kraftwerke GmbH Streßelfeld Gorleben Telefon +49 (0) Telefax + 49 (0) info@dreyer-bosse.de Stand 03/2014