energy savings, waste heat utilization & smart …...preheating of boiler feedwater and...

ENERGY SAVINGS, WASTE HEAT UTILIZATION & SMART GRID MANAGEMENTENERGY EFFICIENCY PORTFOLIO

BILFINGER | SNS2020

BILFINGER at a glance

page 2

Making sure our clients can concentrate

on what they do best: their core business.

Employees

Revenue 2019

About 34,000

€ 4,327 million

Bilfinger is a leading international industrial service provider for the process

industry. The group covers the entire value chain of projects and industrial

plants from consulting, engineering, manufacturing, assembly and plant

expansion to turnarounds and also includes environmental technologies and

digital applications.

Bilfinger SE | Energy Efficiency Portfolio

BILFINGER Energy Transition Portfolio

page 3Bilfinger SE | Energy Efficiency Portfolio

⦿ Bilfinger has a comprehensive portfolio

of products and services to support its

industrial customers to reach their

sustainability goals and meet climate

change targets.

⦿ From mature activities like Hydro power,

District Heating or Flue Gas Cleaning to

new areas such as Green Hydrogen,

Carbon Capture Utilization & Storage

(CCUS), Power/Waste-to-X or Energy

Efficiency, Bilfinger is constantly

developing its capabilities to better serve

its customers throughout the entire value

chain and move from hard to abate

emissions.

BILFINGER in Energy Efficiency

Your needs & constrains VS our solutions

Bilfinger SE | Energy Efficiency Portfolio page 4

Industrial Customers

Regulatory Pressure(Global, EU & National)

OPEX Cost

Pressure

Energy Prices

Pressure

Reputational

Pressure

Energy Efficiency

GHG Emissions

Renewable energy share

Electrification

BILFINGER is providing you with solutions

that tackles all these issues:

Increase Energy Efficiency

Reduce GHG Emissions

Reduce Energy Consumption & Cost

Optimize process, operation & plants’

balance sheet

Provide extra flexibility

Contribute to positive brand image

Reduce local risks with all stakeholders

BILFINGER in Energy Efficiency

Your needs & constrains VS our solutions


Quick Measures i.e. Avoid Heat Losses, Identify High Consumption areas1

Reuse Waste Heat2

Optimize plants’ processes, equipment & operations3

Energy Monitoring/

TIPCHECK®e.g. Insulation

We perform a TipCheck® Analysis to

identify heat losses and provide the

immediate recovery measures trough our

insulation teams

=

Average Pay Back Time

1 to 3 years

We design and deliver modular solutions

to capture and utilize your available waste

heat for re-use within your processes or

export to external users (neighbor

industries, district heating networks, etc.)

Based on a Pinch Analysis we develop a

model and the associated business case

for a thermally optimized plant with

complementary use of best available

technology and can even support you up to

the modelling and optimization of energy

generation and trading.

Consultancy

CO2 Master Planning

We provide step by step approach to

create a master plan for your road to

CO2 reduction. By looking at the

processes, the ambitions of your

company, and the environment in which

your company operates,

BILFINGER in Energy EfficiencySupporting customers throughout projects and assets’ life cycle

Bilfinger offers integrated solutions for project execution covering the

entire life cycle from engineering and technology to fabrication,

construction and maintenance.

LIFE CYCLE VIEW


EARLY BUSINESS CASE PLANNINGOur Pitstop approach

“The pitstop approach decreases throughput time and increases project

quality by gathering decision makers, stakeholders and specialists to

brainstorm options, collect available information, key project requirements

and make decisions in a creative process.”

Cost estimate on maturity level end conceptual

Engineering documents minimum level end feasibility

Early go/no goPossibility to scale down to other stage gates


CO2 MASTER PLANNING

APPROACH & REFERENCES

CO2-REDUCTION MASTER PLANNINGApproach

Bilfinger provides a step by step approach to

create a master plan for your road to CO2

reduction. By looking at the processes, the

ambitions of your company, and the environment

in which your company operates, Bilfinger

analyses the potential, risks, and costs to create

a route map towards a carbon neutral company.

⦿ Complete overview of the necessary steps

leading towards a masterplan for CO2-

reduction with a corresponding roadmap.

⦿ Different studies and methodologies to obtain

the desires level of information for each step.

⦿ The selection of topics is client specific and is

therefore decided in accordance with the

client. This decision is based on the

information/data available, certain steps can

be discarded or shortened.


• New plant extension has to fit within theemission limits and the sustainablestrategy

• Uncertainties about the possibilities andlimitations regarding technology andbudget.

10

• Sustainability not as a separate project withreturn on investment, but as an utility toenable production

• Creation of an overview with the options, totalcost of ownership, and impact on emissionsand strategy.

Emissions

Cost Reduction

CO2-REDUCTION MASTER PLANNINGReference – example heating upgrade

1. QUICK MEASURESEnergy Monitoring & Scan, TIPCHECK® & simple remediation solutions


1.1 Energy MonitoringApproach


Energy Optimization & CO2 reductionSynergies of Technology & Advanced Analytics

1.1 Energy MonitoringReference – ISO 50001 Dashboard


• Energy Management System ismostly not connected to otherrelevant data sources

• Combine data from energycounters with other data sourcessuch as productions plans,operational hours, processparameters

• Bad-actor analysis highlightunusual energy consumption

Asset Integrity

Increased asset integrity

by standardized

information for e.g. audits

(ISO50001)

1.1 Energy MonitoringReference – Virtual Sensors


• Moisture level is key toquality & energy consumption

• Large moisture measurementintervals (3h) lead to significantquality changes and higher energycosts

• Predictive moisture level in 1-minintervals with the Virtual Sensorwithout additional installations

• Process stabilization throughautomatic recommendationsfor process improvement

OEE

Improvement

Energy

1.2 Energy Scans / TIPCHECK®Approach

Service

▪ Inspection of existing insulation for damage

▪ Identification of possible "hot spots" and thus an increase in

security

▪ Identification of energy saving potentials & opportunities for

process improvement and increased efficiency

▪ Amortization calculation

▪ Average payback period < 1 year

Project approach

4 Energy savings report

TIPCHECK report & energy savings measures with payback

period + Identification of opportunities for process improvement

and increased efficiency

3 Energy savings potential

Indication on energy savings potential in utilities and process,

Optimization suggestions, amortization calculations

2 Energy analysis and evaluation

Thermographic analysis, load duration curves, and weekly and

yearly profiles, report for each examined component of the plant,

listing of the determined total heat losses

1 Site visit

Data gathering through thermal imaging cameras and

thermography sensors (surface and humidity sensors).


• DSM has an energy savings target toachieve 15% final energy savings in theperiode 2015-2025.

• Bilfinger performed 3 quick scan energyaudits

• We developed site specific road maps toimprove energy efficiency.

• Focus areas were steam, cooling,compressed air systems, heat integrationand waste heat recuperation, energymanagement

Energy

Cost Reduction

1.2 Energy Scans / TIPCHECK®Reference - Energy Scans

16Bilfinger SE | Energy Efficiency Portfolio

• Identification and development of energy

saving measures and waste heat

recuperation

• Part of framework of Encore program for

14 Friesland Campina dairy plants

17

• Example Beilen: 3 quick scan saving measureshave been identified, specified and implemented

• 1: avoiding 72 kton/yr of CO2 emissions

• 2: avoiding 270 kton/yr of CO2 emissions

• 3: saving 110 000 kWh/yr of electricity.

• Example Aalter

• avoiding 100 kton/yr of CO2 emissions

Energy

Cost Reduction

1.2 Energy Scans / TIPCHECK®Reference - Energy Scans


1.3 Simple Remediation MeasuresApproach – e.g. Insulation works

page 18

Cold Insulation

Hot Insulation

Specialised Insulation

Average payback period < 1 year



Effective annual energy savings

~90 %Effective annual cost savings

~90 %Effective annual CO2 savings

~5t/year

1.3 Simple Remediation MeasuresReference – e.g. Insulation works

Steamcollectors

Feed watertank

Valvestations

Steamcollectors

Feed watertank

Valvestations

Steamcollectors

Feed watertank

Valvestations

Energy Savings

94%

95%

95%

94%96%

96%

Cost Savings

CO2 Savings

2.1 WASTE HEAT UTILIZATION



Approach

page 21

The Principle (to be developed to skid mounted solutions):

Examples implemented and under developments:

Intercooler steam boiler plant CO2 reduction 0.7 kton/yr + Payback 2 yr

Industrial heat pump distillation column CO2 reduction 9.4 kton/yr + Payback 6.5 yr

Process cooling water for industrial building heating CO2 reduction 3.6 kton/yr + Payback 5-7 yr

Waste vapor heat recovery for district heating CO2 reduction 20 kton/yr + Payback 7-10 yr



Reference - Intercooler steam boiler plant, preheating water with flue gas waste heat

Total annual operational

cost savings90 k€/year

Total natural gas savings plant circa 4%

1 - 2 years

Business case summary

Pay-back time

105 °C 1.2 bara

80 °C

DEAERATOR

Steam

Make

-up

Make

up

INTERCOOLER

ECONOMIZER

BOILER

15 °C

ca. 65 °C

BFW

Intercooler to preheat make-up water to deaerator while

cooling down boiler feed water to economizer (105° ->80°C)

Boiler feed water is reheated in the economizer while cooling

down further the flue gases, hence increasing boiler

efficiency.

Duty heat exchanger: ca. 400 kW, 8400 h/yr

gas savings 400 000 Nm3/yr

CO2 reduction 0.7 kton/yr

saving gas costs: € 96 000/yr

STACK

condensate

50%


2.1 WASTE HEAT UTILIZATION Reference - Industrial heat pump distillation column

Usefull heat @high temperature

Low temp. waste heatfeed

bottom

QH

QL

W

Evaporation valve

Company X Financial feasibility

Operational hours 8700 h/yr

Gas saving costs € 1 266 000/yr

Add. electr. costs - € 428 000

Saving energy costs on bill € 839 000/yr

Pay-back time ca. 6.5 years (13.5% Subsidy)

50% gas savings >5,300,000 Nm³/yr (9.4 kton CO2/yr)

• Conscious choice: no Mechanical Vapor Recompression

(open heat pump) unit for distillation column in zoning area (Ex)

• Closed Heat pump package outside zoning area of distillation unit

• Heat pump producing low pressure steam (1.3 bara), low pressure

steam tie – in on existing steam piping, no need for additional reboiler.

Refrigerant: environmental friendly, not flammable, not toxic

• Robust design (hydraulically, controllability), easily to start up / stop;

when heat pump unavailable => normal operation boiler steam for

reboiler column



Reference - Process cooling water for industrial building heating

Closed cooling water system with 80°C waste heat from several

process units

Idea: Extension of existing system, use waste heat for:

Heating of large industrial building (1.7 MW)

Preheating of boiler feedwater and combustion air (1.5 MW)

Project:

New additional heat exchanger to extract waste heat.

New underground warm water distribution network plus local heat

delivery station.

Start realisation: Q1 2019

Gas Savings: ca. 2,000,000 Nm³/yr (3.6 kton CO2 /yr)

Financial saving ca. 500 k€/yr; Pay-back ca. 5-7 years


Waste vapor (steam) from process, currently being condensed by

cooling water (approx 15 MWth).

Waste heat could be available at ca. 95°C

Idea: Deliver waste heat as baseload to nearby DH system

Project:

New condensers to extract waste heat at higher temperature.

Aboveground distribution network ca. 1500 m

Expected start realisation: 2020

Saving of approx 20 kton CO2

Pay-back ca. 6-7 years


Reference - Waste vapor heat recovery for district heating



Reference - Heat pump plant + buffer


Customer: Heineken

Project: 9 MW warm water Heat Pump Plant + 400 m3 pressurized warm water buffer

Scope:

Technical & economic feasibility study

Pattern analysis modelling study: waste heat supply versus heat demand (see next sheet)

Conceptual design

Basic design incl. specification + supplier evaluation (role as utility specialist)

2.2 ENERGY EFFICIENCY SOLUTIONS

TECHNOLOGY PORTFOLIO

2.2. ENERGY EFFICIENCY – SOLUTION 1

Pump Drives - Main Features of Bilfinger´s PumpCheckApp


Input main pump data (operating design) Visual inspection Input vibration data Pump analysis :

o Mechanical (vibrations)o Energy Efficiency (OP vs. BEP)

The concept is to make a quick analysis of customers’ centrifugal pumps. Several parameters to be checked. Output will give clients a priority list to

o Increase pump availibility, o Decrease energy consumption, ando Decrease maintenance costs for the future

.2. ENERGY EFFICIENCY – SOLUTION 2

HoCoSto/Enpuls, Sun City

To enable the heat transition in the build

environment Bilfinger developed a conceptual

design for a smart thermal grid.

This design constituted of solar thermal

collectors and a thermal heat storage tank, to

supply the heat demand of 10 residential

houses. The thermal buffer was designed in

collaboration with HoCoSto.

Scope of work

• Conceptual design

• CAPEX 40% and OPEX

• PFP incl heat and mass balance

• Dynamic system modeling

• Structural stability check

• Basic routing of heat network

• Design of pump station

Storage of hot and cold

Bilfinger SE | Energy Efficiency Portfolio Seite 29


Energy Nest

Steam Storage



Sound Energy

Turn heat into cooling



Qpinch

Industrial Heat Pump



Orcan Solutions

Heat to power



Heat Matrix

Heat recovery from corrosive media – polymer heat exchangers


3. SMART GRIDS


3. SMART GRID MANAGEMENT

Approach (1/3)

page 36

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ANALYSIS PROJECT DEVELOPMENT IMPLEMENTATION

PR

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INIT

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IMMEDIATE MEASURES (QUICK WINS)

No potential detected that can be developed economically.

Analysis report incl. recommendations

Decision-oriented approach

Transparent

Documented

Scalable and flexible

Ongoing stakeholder

involvement

Active management of

complexity

Continuous business-case

orientation

SUBSIDIES SUPPORT



Approach (2/3)

The Pinch Analysis

page 37

Analysis of thermal process streams (cold and hot streams) & Heat exchanger networks

Data capture and analysis

Temperature

Mass flow or volume flow rate

Contamination

Heat capacity

Operating time

Energy demand profile

Utilities-Costs

Restriction

Pinch-Analysis

Pinch-Point Pinch-Rules

Max. Thermal integration

Composite-Curve

Heat exchanger networks : Mathematical programming

Minimization of capital costs

Minimization of operating costs



Approach (3/3)

Plants and systems optimization

page 38

Thermally optimized

plants

Data collection from

existing plants

Pinch-Analysis

Integrating …

… Alternate technologies

High temperature heat pumps up

to 150°C

Absorption chiller

Organic Rankine Cycle (ORC)

Heat storage units

Etc.

….Renewable energysources

Solar thermal energy

Geo thermal energy

Biomass



Results

Benefits for industrials

Cost reduction based on reduced energy consumption

CO2-emissions reduction further reducing operational costs

Reduced local and sites risks

o Reduced environmental impact

o Legal compliance

o Local stakeholder engagement

Positive employer branding

(sustainable, innovative, forward-looking)

Improved operations and assets optimization

Maximization of power generation

Model-based calculation of heat tariffs (feed & offtake) through a

dedicated software analyzing, modelling and optimizing energy

generation and trade

page 39

Our solution in a nutshell:

1. Compact and comprehensive

analysis, delivering a realistic potential

assessment right at the start

2. Leading experts in all disciplines

3. Well-established interfaces

4. Decision oriented approach

5. Single point of contact for the whole

process

6. End-to-end responsibility



Reference – 050 Buurtwarmte: Circular District Heating System


Bilfinger has been working with several

stakeholders in a community power-to-

heat initiative.

When implemented, the Paddepoel

project will reduce the neighborhood’s

CO2 footprint considerably utilizing high-

temperature heat pumps.

Scope of work

• Conceptual design based on energy, pipelines and architectural engineering

• CAPEX 25%

• Consultancy on safety, soil, noise, air and necessary permitting


Reference – Meppel Energy: Energy Efficiency Analysis Heating District


Heat analysis / expert review of the heating district

Scope of work

• Energy balance

• Energy savings report


Reference – Heat Accumulator

42

▪ Wien Energie: Hot Water Heat Accumulator 165°C 850MW

▪ Scope of work:

▪ Conceptual process design

Charge and discharge systems for different pressure levels

▪ Expansion system

▪ Mass and energy balance

▪ P&ID process layout by COMOS

▪ 3D layout plan by PDMS

▪ Instrumentation and measurement by COMOS

▪ Electrical engineering and control plan

▪ Function plan by COMOS

▪ Start-up procedure

▪ Test run

©W

ien

Energ

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mbH



Reference – Pinch-Analysis & Heat Exchanger Network Optimization

▪ Lenzing AG: Pinch-Analysis and optimization of heat exchanger network

▪ Scope of work:

▪ Pinch Analysis through TVTHENS

▪ Optimization of heat exchanger network by Rethen

▪ Mass and energy balance by IPSEpro

▪ Publication:

▪ Chemie Technik (2011)


▪ Location : Lenzing (Austria)

43


Reference – Pinch-Analysis & Energy Optimization

Lenzing Fibers: Pinch-Analysis and energy optimization (new technologies & renewable energy sources)

▪ Scope of work:

▪ HX network optimization by TVTHENS


▪ Dynamic simulation by TRNSYS

▪ Presentation:

▪ Achema (2012)

▪ Energy Masters (2011)

▪ ProcessNet (2010 & 2012)

▪ Publication:

▪ PROCESS (2013)

▪ ATE (2011)

▪ Chemie Ingenieur Technik (2010 & 2012)

Bilfinger SE | Energy Efficiency Portfolio 44


Reference – Combined Heat & Power

▪ Zapad: combined heat and power unit for the production of electrical energy and heat

▪ Scope of work:


▪ Piping and instrumentation diagram

(P&ID) by COMOS



▪ Ventilation system

▪ Lubrication system


Electrical power [kW] 3 x 3328

Thermal power [kW] 3 x 3384

Electrical efficiency [%] 44

Gas motor manufacturer GE Jenbacher

District heating supply and return temperature [°C] 85/65

Energy source Natural gas


▪ Location: Serbia

▪ Customer: NoviSad

45


Reference – Combined Heat & Power

▪ EOS: combined heat and power unit for production of electrical energy and heat

▪ Scope of work:


▪ Piping and instrumentation diagram (P&ID)

by COMOS




▪ Lubrication system


Electrical power [kW] 5 X 3047

Thermal power [kW] 3 X 3108

Electrical efficiency [%] 44,1

Gas motor manufacturer GE Jenbacher

District heating supply and return temperature [°C] 90/70

Energy source biogas


▪ Location: Vienna (Austria)

46


Reference – Low Temperature Heat Recovery

▪ TIGAS: low temperature – heat recovery through absorption heat pump

▪ Scope of work:



▪ Soot blower

▪ Heat pump


Electrical power (waste heat) [kW] (40/30°C) 2500

Thermal power (driving heat) [kW] (160/140°C) 3500

Thermic capacity (district heating) [kW] (60/90°C) 6000

Heat pump manufacturer Thermax

COP thermal (district heat/driving heat) 1,71

Soot blower manufacturer Parmo Desarrollos


▪ Location: Tyrol (Austria)

47


Reference – Waste Heat Recovery

▪ Marienhütte: waste heat recovery (high temperature heat pump)

▪ Scope of work:



(P&ID) in COMOS




▪ Heat pump


Electrical power [kW] 2 x 2380

Thermal power [kW] 2 x 3300

COP thermic (district heat/electrical power) 3,4

Heat pump manufacturer Friotherm

District heating flow and return flow temperature [°C] 90/63

Waste heat flow and return flow temperature [°C] 33,8/29


▪ Location: Graz (Austria)

48


Reference – Waste Heat Recovery

▪ RHI Norwegen: heat recovery from rotary kiln waste gas

▪ Scope of work:



(P&ID) in COMOS



▪ Heating surface cleaning system

(soot blower)

Water supply and return temperature [°C] 60/45

Thermal power [kW] 2000

Flue gas volume flow rate [Nm³/h] 70.000

Flue gas heat exchanger manufacturer Bilfinger Rosink

Soot blower manufacturer Bilfinger Rosink

Flue gas In- & Output temperature [°C] 200/130


▪ Location: Porsgrunn (Nowray)

49


Reference – Power to Heat

Power to heat: up to 50 MWelectrical

Technologies

Electrode boiler

Electric water heater

Scope of work:

3D layout plan by PDMS

Piping and instrumentation diagram (P&ID)

by COMOS

Mass and energy balance

Mechanical and process design

Construction

Bilfinger SE | Energy Efficiency Portfolio 50

energy savings, waste heat utilization & smart …...preheating of boiler feedwater and...

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