Efficiency on a large scale: Steam boilers

Efficiency on a large scale: Steam boilers
Efficiency on a large scale
Steam boilers
2 | Efficiency on a large scale
Foreword
Bosch Industriekessel offers you shell boiler systems
middle of 2012 the systems were sold and distributed under
for all applications. Our boilers are not only used
the LOOS brand name, now we have consolidated our strengths
successfully in industrial companies, they also offer
and we sell our products under the Bosch brand name.
many advantages to smaller businesses and service
companies, as well as in office buildings and residential
This brochure gives you a detailed overview of our range of
blocks.
products and services for steam boilers. Above all however, the
following pages clarify what is particularly important to us at
Today we are part of the worldwide Bosch Group and
Bosch Industriekessel: the perfect fulfillment of your individual
the expertise centre of Bosch Thermotechnology for
wishes.
large-scale and industrial boiler systems. Up until the
Content
3 Expertise and trust
4
5
6
8
Environment and efficiency
Modular quality
Energy-saving system technology
UNIVERSAL steam boiler U-ND/U-HD
12 UNIVERSAL steam boiler U-MB
16 UNIVERSAL steam boiler UL-S/UL-SX
20 UNIVERSAL steam boiler ZFR/ZFR-X
24 Self-fired waste heat boiler
26 UNIVERSAL heat recovery steam boiler HRSB
27 Series UL-S and UT-H as waste heat boilers
28 Boiler control BCO
29 Service
30 References
Up to 1 500 large-scale and industrial boiler systems are
produced annually at our highly modern production sites in
Gunzenhausen in Germany and in Bischofshofen in Austria.
Efficiency on a large scale | 3
Expertise and trust
Bosch Industriekessel is a renowned specialist worldwide for boiler systems of all sizes and
performance categories. Since 150 years we have been providing innovation in industrial boiler
construction.
Technical pioneering spirit which sets standards
Benefit from experience and the power of
innovation: since our founding in 1865 we have
specialised in industrial boiler construction and
achieved extensive specialist know-how. Strength
of innovation, quality awareness and efficiency are
the benchmarks for our product range and services.
We have become a leader on the basis of this high
degree of specialisation.
Reliable energy for the whole world
More than 110 000 boiler systems supplied in
over 140 countries are clear evidence of the high
quality and reliability of our industrial boilers. You
will find our systems in practically every branch of
Industrial boilers with signature and seal
industry. We will be pleased to supply you on
Our highly modern production facilities ensure
request details of our numerous references.
that our systems have a quality advantage, which
is confirmed by the official quality seals of almost
all the approval bodies and certification institutes
in the world.
Industry and business
To the optimum solution through partnership
Trust and openness between partners are the
most important preconditions for mutual success.
Private and public facilities
As a leading manufacturer of innovative boiler
technology, we decided early on to distribute our
products through specialised companies. Thanks
to close cooperation with your particular specialist
Energy suppliers
company, you achieve the optimum solution for
your special requirement.
4 | Efficiency on a large scale
Environment and efficiency
As a responsible and innovative boiler manufacturer, we systematically focus on
environmental protection and saving of resources. Our sustainable and efficient
systems keep CO2 emissions low and contribute to climate protection.
Highest level of efficiency
Perfectly controlled, less consumption
We were one of the first manufacturers to equip
Intelligent control and regulating systems provide further
flame tube/smoke tube boilers of all sizes with
opportunities for energy saving. The incorporation of
integrated economizers in the factory. The heat
our innovative water analyzer not only protects the
contained in the flue gases is recovered and the
system from damage caused by insufficient water
efficiency increased. Additional energy potential can
parameters, but it also achieves additional energy
be used with our modular designed boiler house
savings in the consumption of fuel and fresh water.
components. Our condensate high-pressure plants
Speed-controlled burner fans reduce the electrical power
keep return-flow condensate up to pressure and
consumption enormously in the partial load range. The
temperature, so that it can be fed back to the boiler
modern burner systems, controlled by oxygen or carbon
circuit without loss of energy. Process-related heat
monoxide levels, provide for combustion of the highest
loss, which is contained for example in exhaust
possible efficiency thanks to minimal excess air levels.
vapour or desalting water, can be partially recovered
by means of suitable solutions such as our vapour
Investments which pay off
cooler or our expansion and heat recovery modules.
With our highly efficient boiler systems and the
appropriate boiler house components it is possible to
Lowest emissions
significantly reduce energy consumption and emissions.
Our boiler systems are suitable for liquid and
Through the reduction in running costs a new boiler
gaseous fuels. The modern burner systems comply
system is usually amortised in a very short period of
without any problems with the guidelines in all
time. You save money and the environment at the same
countries regarding the prevention and reduction of
time. Are you already thinking about modernising or
emissions. A completely neutral CO2 level can be
replacing your boiler system? We would be pleased to
achieved through the use of bio-oils or bio-gases.
Our boiler systems are perfectly
matched to your requirements.
This saves not only natural, but
also your financial resources.
advise you!
Efficiency on a large scale | 5
Modular quality
Reliability and long service life are particular characteristics of Bosch boiler systems.
The high quality of our systems is guaranteed by the most modern production machines,
strict quality controls and by continuous improvements and innovations.
Perfectly matched to each other
A boiler system tailored to your requirements is a
foundation stone on which you can sustainably
ensure the competitiveness of your company. We
offer you modular and universal solutions through
our complete boiler delivery programme. The
sizing and equipment level of the products are
designed to individual customer specification with
many different options and variants available. The
high manufacturing quality guarantees easy and
smooth acceptance.
High performance in a system alliance
Alongside innovative boiler system technology, the
ideal energy concept frequently includes additional
important components such as combined heat
and power, heat pumps or solarthermics. As a
company within the Bosch Group we have access
to an extensive range of additional system solutions
in thermal technology. This enables us to combine
different technologies and to implement these for
your benefit.
6 | Efficiency on a large scale
Energy-saving system technology
High-efficiency boiler plants with optimally-matched boiler house components ensure
low energy consumption and low emissions.
Economizer
 up to 7 % fuel saving
Flue gas condenser
 up to 7 % fuel saving
Air preheating
 up to 2 % fuel saving
Settings and maintenance
 up to 3 % fuel saving
 extended service life
 process reliability
 improved operation
Efficiency on a large scale | 7
Water treatment
Condensate systems
 higher water quality
 up to 12 % fuel saving
 improved steam quality
 make-up/raw water saving
 lower desalting rate
 waste water reduction
 up to 90 % savings on chemicals
Thermal degassing system
 up to 80 % savings on chemicals
Expansion and heat recovery
Modulating firing
module
 up to 1 % fuel saving
 up to 1 % fuel saving
 wear reduction
 up to 1 % make-up water saving
Speed-controlled fan
 up to 100 % cooling water saving
 up to 75 % electrical saving
 up to 70 % waste water saving
O2/CO burner control
Vapour heat exchanger
 up to 1 % fuel saving
 up to 0.5 % fuel saving
8 | Efficiency on a large scale
UNIVERSAL steam boiler U-ND/U-HD
This compact boiler combines the benefits of shell boiler technology with the effectiveness
of the flame tube/smoke tube system. This is a boiler on the reverse flame principle.
Efficiency on a large scale | 9
As a high-pressure or low-pressure steam boiler
The large volume flame tube and the smoke
Benefits at a glance:
tube bundle are perfectly matched to each
Intuitive boiler control based on PLC with very high
other. The boiler is characterised by a very
transparency of operating data
compact construction. We can offer you the
Effective thermal insulating materials with a high
UNIVERSAL steam boiler as well as high-
degree of efficiency
pressure or low-pressure steam boilers.
Automatic start-up, standby and shutdown
control SUC
Accessories which save energy
Suitable for many burner systems
For an energy-saving and efficient operating
Pollutant reduced combustion thanks to the use of
mode the compact boiler can be equipped
highly developed firing systems and careful matching
with an economizer, with continuous feed
of the best boiler and burner combination
water control and with many other heat
Easy for maintenance – simple to inspect on both
recovery devices. The investment in these
the flue gas side as well as the water side
energy-saving measures ensures a high degree
Robust, reliable and durable
of efficiency of your boiler system, it saves our
environment and reduces your running costs on
All high-pressure boiler systems are certified in
accordance with the European Pressure Equipment
a sustainable basis.
Directive – applied almost worldwide
Simple extension options thanks to integrated
module technology
Simple commissioning due to pre-parameterised
The UNIVERSAL steam boiler U-ND/U-HD is
boiler control
ideally suited to small to medium steam
Easy wiring on site thanks to plug-in connections
volume requirements – an ideal solution in
particular for smaller manufacturing
businesses and processing companies as well
as the service industry.
Technical data
Type
U-ND
U-HD
Heat transfer medium
Low-pressure saturated steam
High-pressure saturated steam
Design
Flame tube/smoke tube technology
Flame tube/smoke tube technology
Capacity in kg/h
175 to 3 200
175 to 3 200
Safety pressure in bar
up to 0.5
up to 16
Max. temparature in °C
110
204
Fuel
Oil, Gas
Oil, Gas
10 | Efficiency on a large scale
Construction
The cost-effective steam shell boiler impresses due to its
By means of the reverse flame principle the smoke
compact construction and technically efficient functionality.
gases in the flame tube are diverted to the front,
The large, centrally located flame tube ensures that there is
and then deflected in the front reversing chamber
excellent combustion of the fuels. The smoke tubes arranged
to the smoke tube sections. The pivoting boiler
concentrically around the flame tube provide for an optimum
front door (right/left) opens up convenient access
heat transfer.
for boiler and burner inspection. The high quality
mineral wool matting insulation over the entire
boiler body and the special heat insulation
material in the front door cut radiation losses to
an insignificant minimum.
Associated boiler house components:
Water treatment module WTM
Vapour cooler VC
Water service module WSM
Gas regulation module GRM
Condensate service module CSM
Oil circulation module OCM
Blow-down, expansion and cooling module BEM
Oil supply module OSM
Expansion and heat recovery module EHM
System control SCO
Expansion, heat recovery and blow-down module EHB
Pump module PM
Flue gas heat exchanger ECO 3, stand-alone
For further information see our brochure on 'Boiler house components'.
Efficiency on a large scale | 11
Equipment level
Our shell boilers are supplied inclusive of all
All the sensors and actuators of the boiler are already
equipment* and are therefore fully functional as a
wired into the integrated terminal box. Pre-assembled,
unit. The high quality basic equipment level includes
plug-in and coded cable bundles simplify the electrical
the boiler pressure vessel, the control and safety
wiring installation between the boiler control cabinet
technology, the burner unit, a pump module, a
and the terminal box. The free-standing or wall-
terminal box and the control switchgear cabinet
mounted switchgear cabinet can be adapted and set
including the easily operated boiler control BCO.
up to best suit the requirements on site.
1
2
3
18
22
17
4
21
5
6
20
7
8
14
9
27
10
26
24
13
25
12
15
19
16
23
1 Control switchgear cabinet with boiler control BCO
2 Blow-off tap
15 Feed water non-return valve
16 Feed water shut-off valve, maintenance-free
3 Reflective water level indicator
4 Manostat tube shut-off valve, maintenance-free
17 Sight hole
18 Burner
5 Pressure limiter
6 Pressure transducer (4-20 mA)
19 Insulation with protective shell
20 Base frame
7 Low-level limiter electrode
8 Pressure gauge
21 Gas regulation module
22 Terminal box
9 Level transducer (4-20 mA)
10 Pressure gauge shut-off valve with testing flange
23 Pump module
24 Drain shut-off valve, maintenance-free
12 Steam removal valve
13 Full-lift safety valve
25 Q
uick shut-off blow-down valve
26 Inspection opening, steam side
14 Fully automatic conductivity measurement and
27 Inspection opening, water side
28 Inspection opening, flue gas side
desalting
* the equipment level is variable and can be freely configured to customer requirements
28
12 | Efficiency on a large scale
UNIVERSAL steam boiler U-MB
The product designation U-MB stands for 'UNIVERSAL Modular Boiler'
(three-pass steam boiler in modular construction). The U-MB type consists of
several modules, which fulfil your individual requirements perfectly.
Flexibility from a modular system
The appropriate elements of the boiler are
configured with the focus on low emissions, high
Benefits at a glance:
steam quality and optimum energy efficiency.
Cost-effective despite shell boiler and three-pass
Thanks to modular construction with systematic
use of design elements and the same parts from
technology
High level of efficiency due to the integrated
other type series, you benefit from a particularly
attractive price-performance ratio.
economizer
Comprehensive series-wide basic equipment
Intuitive touchscreen operation and PLC control
Diversity with system
Small space requirement due to its compact base
The three-pass steam boiler can be used universally
for all applications. Naturally it can be combined
area
Simple commissioning due to pre-parameterised
with all the other available system components
boiler control
from our modular range for fuel and water supply,
Easy wiring on site thanks to plug-in connections
waste water disposal, water analysis and heat
Automatic start-up, standby and shutdown
recovery. The steam boiler's PLC control via
touchscreen, its teleservice capability and its
control SUC
Simple installation thanks to supply as a unit – the
other equipment are all identical with that of the
equipment, firing system and economizer have
large industrial boiler series.
already been fitted in the factory
The UNIVERSAL steam boiler U-MB is to be found
wherever small to medium steam volumes are
required. Classic areas of application are the food
and drinks industries, laundry and cleaning
companies, as well as smaller industrial
companies.
Technical data
Type
U-MB
Heat transfer medium
High-pressure saturated
steam
Design
Three-pass flame tube/
smoke tube technology
Capacity in kg/h
200 up to 2 000
Safety pressure
in bar
up to 16
Max. temperature in °C
204
Fuel
Oil, gas
Efficiency on a large scale | 13
14 | Efficiency on a large scale
Construction
The steam boiler U-MB is designed as a three-pass flame
Associated boiler house components:
tube/smoke tube boiler. It consists of several modules,
namely the heat generating section in three-pass
Water treatment module WTM
construction, the steam chamber on top of this, and an
Water service module WSM
integrated economizer. Since it is a genuine three-pass
Condensate service module CSM
boiler, there is no requirement for flow components in the
Blow-down, expansion and cooling
smoke tubes.
module BEM
Expansion and heat recovery
The heat generating section of the U-MB is based on the
module EHM
UNIMAT boiler design – proven for decades and many
Pump module PM
thousands of times in practice. The generously sized flame
Expansion, heat recovery and blow-down
tube geometry enables an efficient combustion process to
be carried out.
module EHB
Gas regulation module GRM
Oil circulation module OCM
The choice of the steam section has a critical influence
Oil supply module OSM
on the steam quality. A generous sizing has a very positive
System control SCO
impact on the residual steam moisture.
For further information see our
The integrated economizer has a direct influence on the
energy efficiency. The heat contained in the flue gases is
used for the preheating of the boiler feed water, and it is
therefore recovered to a large extent, meaning that fuel
consumption and emissions are reduced.
The steam generator is tested for type examination and
is manufactured to the strict guidelines of the Module D
Quality Assurance System of the Pressure Equipment
Directive.
brochure on 'Boiler house components'.
Efficiency on a large scale | 15
Equipment level
The UNIVERSAL steam boiler U-MB is supplied as
Pre-assembled, plug-in and coded cable bundles
a completely equipped unit. This includes the
make it easy to install the electrical wiring
insulated boiler with fitted equipment*, the boiler
between the boiler control cabinet and the
control cabinet and a low-emission firing unit. The
terminal box. The free-standing or wall-mounted
sensors and actuators are already wired into the
switchgear cabinet can be adapted and set up to
integrated terminal box.
best suit the requirements on site.
1
2
3
22
18
17
10
8
21
13
20
6
5
7
14
1
Control switchgear cabinet with boiler control BCO
2
Blow-off tap
3
Reflective water level indicator
5
Pressure limiter
6
Pressure transducer (4-20 mA)
7
Low-level limiter electrode
8
Pressure gauge
9
Level transducer (4-20 mA)
10 Pressure gauge shut-off valve with testing flange
12 Steam removal valve
13 Full-lift safety valve
14 F
ully automatic conductivity measurement and
desalting
15 Feed water non-return valve
16 Feed water shut-off valve, maintenance-free
12
9
19
26
15
16
27
34
24
33
32
14
28
25
23
17 Sight hole
18 Burner
19 Insulation with protective shell
20 Base frame
21 Gas regulation module
22 Terminal box
23 Pump module
24 Drain shut-off valve, maintenance-free
25 Quick shut-off blow-down valve
26 Inspection opening, steam side
27 Inspection opening, water side
28 Inspection opening, flue gas side
32 Flue gas heat exchanger ECO
33 Connection piping ECO/boiler
34 Vent shut-off valve ECO
* the equipment level is variable and can be freely configured to customer requirements
16 | Efficiency on a large scale
UNIVERSAL steam boiler UL-S/UL-SX
The UNIVERSAL steam boiler UL-S is a three-pass shell boiler, which fulfils
all the requirements in the medium to high output ranges.
Thought out to the final detail
Optimized efficiency
The flame tube, the internal wet-back rear smoke gas
The flue gas flow from the steam boiler contains
reversing chamber, as well as the first smoke tube and
significant heat potential. For an increased
second smoke tube, are all arranged for optimum flow
boiler efficiency this series of boiler is also
within the horizontal cylindrical pressure vessel. Radiant
available with an integrated economizer for
and convection heat surfaces generate in tandem a rapid
flue gas heat recovery.
water circulation, which accelerates the steam bubble
transport to the steam chamber. The transferred fuel heat
In addition the optional modules for
is converted into steam quickly and without material stress
continuous feed water control, speed-
through an even heat transfer. The large water chamber
controlled burner fan and O2 or CO control
offers sufficient storage volume to be able to cover off even
sudden peaks in consumption.
should also be used to give an even more
efficient and environmentally friendly
operation.
Benefits at a glance:
Intuitive boiler control based on PLC with very high
transparency of operating data
High level of efficiency due to three-pass technology, an
integrated economizer and effective heat insulation
materials
High level of pressure consistency and steam quality
even with widely fluctuating steam demand
The boiler can be equipped with a separate fourth pass
for waste heat use
The boiler body can also be used as a pure waste heat
boiler behind combined heat and power plants or gas
turbines
Automatic start-up, standby and shutdown control SUC
Suitable for all burner systems
Pollutant reduced combustion thanks to the use of
highly developed firing systems and careful matching of
the best boiler and burner combination
Simple commissioning due to pre-parameterised boiler
control
Easy wiring on site thanks to plug-in connections
The UNIVERSAL steam boiler UL -S can be used
wherever steam or heat is required in a
medium to high output range, such as for
example in processing industries, in the
commercial sector or in communal blocks.
Efficiency on a large scale | 17
Technical data
Type
UL -S
UL -SX
Heat transfer medium
High-pressure saturated steam
High-pressure superheated steam
Design
Three-pass single-flame tube/smoke
tube technology
Three-pass single-flame tube/smoke
tube technology
Capacity in kg/h
1 250 up to 28 000
2 600 up to 28 000
Safety pressure in bar
up to 30
up to 30
Max. temperature in °C
235
300
Fuel
Oil, gas
Oil, gas
18 | Efficiency on a large scale
Construction
Our three-pass patent dating from 1952 forms the
basis for the outstanding and ongoing success of this
series. The flame tube (first pass) and two smoke
tube bundles (second and third pass) are integrated
with the wet-back rear reversing chamber in the
pressure vessel in an ideal way. The laterally
positioned flame tube, and the horizontal rear and
vertical front heating gas reversal produce a large
radiant and convection heating surface with a large
steam chamber, and all of this within the smallest
dimensions. The floors are anchored stably by the
large continuous flame tube and they are connected
with the boiler shell by means of the cleverly devised
If superheated steam is required instead of
use of corner anchors for even load distribution.
saturated steam, a superheater module can be
placed on the front reversing chamber. A bypass
flap constantly controls the temperature of the
superheated steam over a large load range.
The smoke tube areas remain easily accessible
thanks to the pivoting door of the reversing
chamber.
▶ Modular system, controlled on the flue gas
side - no injection water required for
temperature control of the superheated steam
▶ Easy maintenance and installation - simple
cleaning possible for the second and third
boiler pass
▶ High service life thanks to low thermal loading
of the heat exchanger bundle of the superheater
For further information see our technical
report on 'Superheater module'.
Equipment level
You can obtain all our shell boilers inclusive of all
equipment* as fully functioning units. The basic
equipment level includes the boiler pressure vessel,
the control and safety technology, the burner unit,
a pump module, a terminal box and the control
switchgear cabinet including our easily operated
boiler control BCO. The integrated terminal box is
already wired. Pre-assembled, plug-in and coded
cable bundles simplify the electrical wiring
installation between the boiler control cabinet and
the terminal box.
*the equipment level is variable and can be freely configured to customer requirements
Efficiency on a large scale | 19
15 Feed water non-return valve
16 Feed water shut-off valve, maintenance-free
17 Sight hole
1
Control switchgear cabinet with boiler
2
Blow-off tap
3
Reflective water level indicator
4
Manostat tube shut-off valve, maintenance-free
5
Pressure limiter
6
Pressure transducer (4-20 mA)
7
Low-level limiter electrode
8
Pressure gauge
9
Level transducer (4-20 mA)
control BCO
21 Gas regulation module
22 Terminal box
10 Pressure gauge shut-off valve with testing flange
11 Steam dryer
12 Steam removal valve
13 Full-lift safety valve
and desalting
2
3
4
18
5
21
6
20
7
8
9
10
26
23 Pump module
24 Drain shut-off valve, maintenance-free
25 Quick shut-off blow-down valve
26 Inspection opening, steam side
27 Inspection opening, water side
28 Inspection opening, flue gas side
29 Flue gas collection chamber
32 Flue gas heat exchanger ECO
33 Connection piping ECO/boiler
14 Fully automatic conductivity measurement
1
18 Burner
19 Insulation with protective shell
20 Base frame
11 12
22
Associated boiler house components:
Water treatment module WTM
13
14
24
25
33
19
17
27
15
16
32
28 30 23
Expansion and heat recovery module
EHM
Water service module WSM
Pump module PM
Condensate service module CSM
Expansion, heat recovery and blow-
Blow-down, expansion and cooling
module BEM
down module EHB
Vapour cooler VC
Water analyzer WA
Gas regulation module GRM
Flue gas heat exchanger ECO 1,
Oil circulation module OCM
stand-alone
Flue gas heat exchanger ECO 6 for
condensing use
Oil supply module OSM
Oil preheater module OPM
System control SCO
For further information see our brochure on 'Boiler house components'.
20 | Efficiency on a large scale
UNIVERSAL steam boiler ZFR/ZFR-X
The UNIVERSAL steam boiler ZFR is a shell boiler in three-pass technology with two flame
tubes and completely separate smoke gas passages. It is to be found wherever
a reliable steam and heat supply with high output is required.
Efficiency on a large scale | 21
Proven for decades and still pioneering
The double-flame smoke tube boiler with separate
smoke gas passages is also suitable for operation
Benefits at a glance:
with only single firing. The three-pass principle
Intuitive boiler control based on PLC with very high
with a rear smoke gas reversing chamber lying in
the water chamber was patented in 1952. The
transparency of operating data
High level of efficiency due to three-pass technology,
economizer and superheater can be upgraded in
an integrated economizer and effective heat insulation
simple modular construction. The dimensions of
materials
the flame tubes, smoke tube bundles, water
chamber and steam chamber have optimum
thermodynamics. Radiant and convection heating
surfaces generate a special dynamic in conjunction
High level of pressure consistency and steam quality
even with widely fluctuating steam demand
Automatic start-up, standby and shutdown
control SUC
with the possibility of single-flame tube operation.
Suitable for all burner systems
The fed fuel heat is transferred evenly by means
Pollutant reduced combustion thanks to the use of
of flow components mounted on the water side,
highly developed firing systems and careful matching
and it is then converted into steam without
of the best boiler and burner combination
material stress.
Easy for maintenance – simple to inspect on both the
flue gas side as well as the water side
Modules which help you save
Robust, reliable and unsurpassed in its durability
The modulating output regulator for 'unrestricted'
Acceptance in accordance with the European Pressure
single-flame or double-flame tube operation and
for continuous feed water control is mandatory
with the UNIVERSAL steam boiler ZFR. In order to
achieve additional savings potential, we can offer
you, subject to the system conditions, the
following optional modules for increased
Equipment Directive – applied worldwide
Extremely high control range thanks to single-flame
tube operation
Simple extension options thanks to integrated module
technology
Simple commissioning due to pre-parameterised boiler
efficiency:
control
Speed-controlled burner fan
Easy wiring on site thanks to plug-in connections
O2 controls
CO controls
The UNIVERSAL steam boiler ZFR series is also very
well suited to the dynamic pooled output of several
boilers. Important areas of use are those of commercial
operations in all sectors of the economy, of processing
industries and supply industries, as well as of
communal buildings.
Technical data
Type
ZFR
ZFR-X
Heat transfer medium
High-pressure saturated steam
High-pressure superheated steam
Design
Three-pass double-flame tube/smoke
tube technology
Three-pass double-flame tube/smoke
tube technology
Capacity in kg/h
18 000 to 55 000
18 000 to 55 000
Safety pressure in bar
up to 30
up to 30
Max. temperature in °C
235
300
Fuel
Oil, Gas
Oil, Gas
22 | Efficiency on a large scale
Construction
Its suitability for the unrestricted parallel or single
operation of its firing units is not only due to the
stable separation on the flue gas side. The special
design measures for neutralising the tension forces in
single-flame operation are critical for permanent
stability. The flame tubes are pushed through in the
front and rear floors and welded tightly all around.
The wet-back rear smoke gas reversing chamber is
separated with a stabilising tube wall, which has
water flowing through, and it is fastened to the rear
floor. Water circulation and heat transport are given
dynamic effect by means of guide profiles on the
boiler base, and they are additionally accelerated by
If superheated steam is required instead of
flow paths between the flame tubes and the smoke
saturated steam, a superheater module can be
tube areas lying next to each other.
placed on the front reversing chamber. A bypass
flap constantly controls the temperature of the
A fully automatic operation with one or both burners
superheated steam over a large load range.
is possible without restriction due to the approved
The smoke tube areas remain easily accessible
single-flame operation. Even different fuels in both
thanks to the pivoting door of the reversing
firing units do not present any barriers. The control
chamber.
range is doubled and each low load phase is run with
Modular system, controlled on the flue gas
one burner and with consequent gain in efficiency
side – no injection water required for
level.
temperature control of the superheated
steam
For further information see our technical report on
'Double-flame tube boilers'.
Easy maintenance and installation – simple
cleaning possible for the second and third
boiler pass
High service life thanks to low thermal
loading of the heat exchanger bundle of the
superheater
For further information see our technical
report on 'Superheater module'.
Equipment level
You can obtain all our shell boilers inclusive of all
equipment* as fully functioning units. The basic
equipment level includes the boiler pressure vessel,
the control and safety technology, the burner unit,
a pump module, a terminal box and the control
switchgear cabinet including our easily operated
boiler control BCO. The integrated terminal box is
already wired. Pre-assembled, plug-in and coded cable
bundles simplify the electrical wiring installation between the boiler control cabinet and the terminal box.
* the equipment level is variable and can be freely configured to customer requirements
Efficiency on a large scale | 23
1
16 Feed water shut-off valve, maintenance-
Control switchgear cabinet with boiler
control BCO
free
2
Blow-off tap
17 Sight hole
18 Burner
3
Reflective water level indicator
4
Manostat tube shut-off valve, maintenance-free
5
Pressure limiter
6
Pressure transducer (4-20 mA)
7
Low-level limiter electrode
8
Pressure gauge
9
Level transducer (4-20 mA)
19 Insulation with protective shell
20 Base frame
21 Gas regulation module
22 Terminal box
23 Pump module
24 Drain shut-off valve, maintenance-free
25 Quick shut-off blow-down valve
10 Pressure gauge shut-off valve with testing
26 Inspection opening, steam side
27 Inspection opening, water side
28 Inspection opening, flue gas side
flange
11 Steam dryer
12 Steam removal valve
13 Full-lift safety valve
30 Flue gas collection chamber
31 Water circulation guide profiles
14 Fully automatic conductivity measurement and
32 Flue gas heat exchanger ECO
33 Connection piping ECO/boiler
desalting
15 Feed water non-return valve
1
2
3
4
18
5
6
21
20
7
8
19
9
10 26
22
31
11
12
13
14
33
24
15 16 17
25
27
32
30
23
Associated boiler house components:
Water analyzer WA
Water treatment module WTM
Expansion and heat recovery module EHM
Water service module WSM
Gas regulation module GRM
Condensate service module CSM
Oil circulation module OCM
Blow-down, expansion and cooling
Oil supply module OSM
module BEM
Oil preheater module OPM
Pump module PM
System control SCO
Expansion, heat recovery and blow-down
Flue gas heat exchanger ECO 1, stand-alone
module EHB
28
Flue gas heat exchanger ECO 6 for condensing use
Vapour cooler VC
For further information see our brochure on 'Boiler house components'.
24 | Efficiency on a large scale
Self-fired waste heat boiler
The conventional fired boiler generates thermal heat or process heat while simultaneously utilising the
heat potential from waste heat sources.
These hot water and steam boilers are conventionally-
Construction
fired boilers based on a 3-pass design, with an addition-
The design of our self-fired waste heat boilers corre-
al separate integrated smoke tube pass for waste heat
sponds to the basic design of the UL-S or UT-H series.
utilisation. They are primarily used in combination with
The boilers are fitted with an additional integrated
CHP units or gas turbines. The waste heat system uses
smoke tube (4th pass) for waste heat utilisation.
hot flue gases from upstream combustion processes to
assist in the generation of thermal or process heat.
Equipment level
The equipment available is identical to that available
Additional peak load boilers are normally required if
for the UNIVERSAL steam boiler UL-S and UNIMAT hot
waste heat boilers without an auxiliary burner are used.
water boiler UT-H series.
It is often superfluous due to the self-firing functionality.
This allows huge amounts of money, space and
equipment to be saved.
Technical data
Type
UL-S
Heat transfer medium
High-pressure saturated
steam
Design
Three-pass flame tube/
smoke tube boiler with
integrated fourth smoke
tube pass
Capacity in kg/h
700 to 28 000
Safety pressure in bar
up to 30
Benefits at a glance:
▶ Improved efficiency and environmental friendliness through the use of waste heat sources
▶ High supply reliability thanks to self-firing function
▶ Matched, modular system for easy planning and fast installation
▶ Complete system including CHP unit on request
▶ Intuitive boiler control based on PLC
with very high transparency of operating data
Max. flue gas temperature of
the waste heat source in °C
550
Min. flue gas volumes of the
waste heat source in kg/h
500
Max. flue gas volumes of the
waste heat source in kg/h
23 500
▶ Robust, reliable and durable
Waste heat source fuel
Natural gas (other flue
gas types on request)
Output range of combinable
CHP units in MWel
approx. 0.2 to 4
▶ Simple commissioning due to pre
parameterised boiler control
▶ Easy wiring on site thanks to plug-in
connections
▶ Reduced component diversity with regard to availability of spare parts
▶ Service from a single source
Efficiency on a large scale | 25
Extremely simplified diagram
1
Water service module WSM-V
2
Flue
gas heat exchanger
3
Economizer
4
4-pass steam boiler
5
CHP
6
Distributer
7
Consumer
8
Chimney
26 | Efficiency on a large scale
UNIVERSAL heat recovery steam boiler HRSB
The heat recovery boiler uses accumulated flue gas heat to generate process steam.
Used in conjunction with a combined heat and power unit,
efficiency of the heat exchanger even further. A flue
the heat recovery steam boiler HRSB can play a significant
gas bypass can be added if required. If no steam is
part in strategies for using primary energy efficiently. The
extracted, the boiler will use this for diversion on the
hot flows of flue gas from the upstream combustion pro-
flue gas side. This means that the CHP unit or other
cesses are conducted into the heat recovery boiler and
waste heat sources can continue operating without
used for steam generation purposes. Thanks to its modular
interruption.
design and compact dimensions, it is the ideal choice for
both new plants and modernisation projects alike.
Equipment level
The heat recovery steam boiler is insulated and features
Construction
state-of-the-art safety equipment. The flue gas bypass
The heat recovery steam boiler, which is certified in
is supplied separately to facilitate transportation and is
accordance with the PED (Pressure Equipment Directive),
fitted and insulated on site. The boiler control BCO,
is available in eight standardised versions. It consists of
based on PLC, can be controlled via touchscreen and
a highly efficient tubular heat exchanger. An economizer
is housed in a separate floor standing or wall mounted
can be integrated as an option, which increases the
control switchgear cabinet.
Benefits at a glance:
▶ Increase in efficiency and environmental respon-
Technical data
Type
HRSB
Heat transfer medium
High-pressure saturated
steam
▶ Complete system including CHP unit on request
Design
Heat recovery shell boiler
▶ High efficiency through efficient tubular heat
Capacity in kg/h
400 to 4 100
Safety pressure in bar
10 and 16
Max. flue gas temperature of
the waste heat source in °C
550
Min. flue gas volumes of the
waste heat source in kg/h
500
Max. flue gas volumes of the
waste heat source in kg/h
23 500
Waste heat source fuel
Natural gas (other flue
gas types on request)
Output range of combinable
CHP units in MWel
approx. 0.5 to 4
sibility through use of waste heat sources
▶ Matched, modular system for easy planning and
fast installation
exchanger and good thermal insulation
▶ Additional efficiency gain thanks to optional
integrated economizer
▶ Intuitive boiler control based on PLC with very
high transparency of operating data
▶ Simple commissioning due to pre-parameterised
boiler control
▶ Easy wiring on site thanks to plug-in connections
▶ Robust, reliable and durable
▶ Reduced component diversity with regard to
availability of spare parts
▶ Service from a single source
Efficiency on a large scale | 27
5
2
5
3
4
6
4
1
7
10
8
11
9
Extremely simplified diagram
Series UL-S and UT-H as waste heat boilers
▶the UL-S and UT-H boiler series can also be used
purely as waste heat boilers
▶ for use in high flue gas temperatures
▶for use in combination with combined heat and
power units or gas turbines
▶utilization of waste heat for generating steam or
hot water
1
Heat recovery boiler
2
Bypass
dampers
3
Flue gas bypass
4
Economizer
5
Chimney
6
Peak load steam boiler
7
Consumer
8
Distributor
9
Water service module WSM-V
10 Make-up water
11 CHP unit
28 | Efficiency on a large scale
Boiler control BCO
The intuitive boiler control based on PLC offers very high transparency of operating data for optimum
boiler operation.
The boiler control BCO comes with all necessary functions for
operating steam and hot water boilers according to specialised
requirements. Extensive information regarding operating states,
operating data and measured values can be viewed on its touchscreen display. Diverse system data are analysed, evaluated and
transparently displayed via a traffic light model using the "Condition
Monitoring basic" integrated software. Operating characteristics
that could lead to a drop in efficiency, increased wear or unplanned
stoppages can be determined at an early stage and thereby avoided.
A consistently high efficiency and availability of the boiler systems is
achieved. The diagnostics function, which is included as standard,
supports the boiler operating company or the service technician in
quickly localising and rectifying irregularities in operation. This
results in a further increase in transparency and operating safety.
The automatic start-up, standby and shutdown control SUC is
optionally available for high-pressure steam boilers via the boiler
control BCO. When SUC is used, start-up and shutdown processes
are performed fully automatically at the press of a button, or in
Benefits at a glance:
response to an external request signal. The automatic functions
▶ Intuitive operation with graphical
protect the system against unnecessary strain during cold starts,
symbols and state-of-the-art touchscreen
in heat maintenance mode, and in normal operation.
displays
▶ Simple optimisation of all measuring and
control functions
▶ Maximum supply and operating reliability
Basic functions:
▶ Performance regulation
thanks to integrated monitoring and
▶
Level control
protection functions
▶
Low-load control
▶ Easy connection to higher-level visualisation and control systems
▶ Ready for use with Teleservice: Opera-
▶
"Condition Monitoring basic" - predictive condition and
efficiency monitoring
▶ Boiler hours run meter
ting parameters and messages can be
▶
Diagnostics function
accessed via an optional modem
▶
Burner hours run meter
▶ "Condition Monitoring basic" for con-
▶
Recording of number of burner starts
sistently high system efficiency and
▶
Plain text display of operating signals and fault messages
availability of steam, hot water and
▶
Message history
heating boiler systems
▶
Intuitive, menu-driven operation via touch-sensitive graphic
▶ Diagnostics function for rapid localisation of irregularities in operation
▶ Start-up, standby and shutdown
Equipment level
display
▶
Display and intermediate storage of all relevant measured
values and states
control SUC allows fully automatic high-
In addition to the basic functions, further options and functions
pressure steam boiler operation
can be added to the BCO control.
Efficiency on a large scale | 29
Service competence:
fast, professional and customer orientated
With us you can benefit from a comprehensive portfolio of products and services from a single supplier.
In addition to perfectly tailored system solutions, we also offer our customers a wide range of services.
Always there for you: first class service
Our customer service is there for you around the
clock every day of the year. Thanks to our closely knit
network of service areas we can ensure the shortest
possible reaction times.
Beside maintenance services, fault tracing and
repairs, we also offer you support with the regular
inspection of your system. Not sure whether your
system is still state of the art and working
efficiently? Here too we will be pleased to assist you,
we will analyse your system and modernise it if
required.
During normal working hours contact your local
customer service engineer direct, the contact details
can be found on the switchgear cabinet of your boiler
system. We place great value on personal service,
direct contact also saves valuable time.
Customers from abroad should please contact our 24
hour Service Hotline. That also applies if a fault
occurs outside normal working hours. If you call via
Reliable supply of spare parts
a fixed network, you will be connected to the
Spare parts are available immediately ex ware-house,
customer advisor responsible depending on the
even those parts which have been in service for many
country/region. Your problem will be located in the
years. Our Spare Parts Hotline is also manned outside
course of professional advice over the phone, or
business hours and on Sundays and public holidays.
alternatively the deployment of a customer service
engineer will be coordinated.
Spare Parts Hotline Germany/International:
+49 180 5010540*
Service Hotline Germany/International:
For further information see our brochure on 'Services'
+49 180 5667468*
and under www.bosch-industrial.com
Service Hotline Austria:
+43 810 810300**
*EUR 0.14/min from German landline
**max. EUR 0.10/min from Austrian landline
Charges for phone calls from mobile networks
and for international calls may vary.
30 | Efficiency on a large scale
Reference: Valenzi in Suderburg
Heat recovery equipment and heat storage tank ensure optimised efficiency.
Since 2012, two modern Bosch steam boilers with a steam
Result:
output of 5 000 kg/h each have been in use at the forest fruit
Through the new boiler system alone, Valenzi is expec-
preserve producer Valenzi GmbH & Co.KG based in Suder-
ting energy cost savings of some 40 000 Euro and CO2
burg in Lower Saxony. Components for heat recovery, water
savings of approximately 300 tonnes per annum. Addi-
treatment and condensate return permit energy-efficient,
tional measures, such as utilising the waste heat from
optimised boiler operation. The speed-controlled fans of the
the compressors and cold stores, further improve the
natural gas burners also ensure low current consumption.
energy balance.
fresh water
fresh water
1 Water treatment module WTM
6 Steam distributor
11 Heat storage tank
2 Water service module WSM-V
7 Production
12 Heat exchanger
3 Economizer ECO
8 Condensate service module CSM
13 Process water for washing
4 Steam boiler UL-S
9 Heat exchanger cold stores
5 Expansion, heat recovery and
Extremely simplified diagram
blow-down module EHB
10 Heat exchanger compressors
and cleaning purposes
Efficiency on a large scale | 31
Reference: Fixkraft in Enns
Steam boiler plant cleverly combined with solar heat.
At Fixkraft Futtermittel GmbH in Enns, Austria, a Bosch
steam boiler with a steam output of 2 500 kg/h, com-
Result:
Besides reducing CO2 emissions by 85 tonnes per
bined with a solar thermal system, provides the process
annum, an energy saving of 15 % on the old system
heat required for animal feed production. The additional
is achieved.
water is drawn from the company's own well, treated
and pre-heated with solar energy. Heat recovery units
supply additional energy and high-pressure saturated
steam is generated in the boiler.
fresh water
1 Osmosis plant
7 Water service module WSM-V
2 Heat storage tank
8 Economizer ECO
3 Solar thermal system
Extremely simplified diagram
9 Chimney
4 Heat exchanger
10 Steam boiler UL-S
5 Condensing heat exchanger ECO
11 Production
6 Vapour cooler VC
Production facilities:
Factory 1 Gunzenhausen
Bosch Industriekessel GmbH
Nürnberger Straße 73
91710 Gunzenhausen
Germany
Factory 2 Schlungenhof
Bosch Industriekessel GmbH
Ansbacher Straße 44
91710 Gunzenhausen
Germany
Factory 3 Bischofshofen
Bosch Industriekessel Austria GmbH
Haldenweg 7
5500 Bischofshofen
Austria
www.bosch-industrial.com
© Bosch Industriekessel GmbH | Pictures
only examples | Subject to modifications |
10/2014 | TT/SLI_en_P-Dampf_02
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