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Dreyer & Bosse Profitable Power and Heat

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Page 1: Dreyer & Bosse · Dreyer & Bosse: Profitable Power and Heat wide product range Dreyer & Bosse is a technological leader among system suppliers for decentralised heat and power ge-

Dreyer & Bosse Profitable Power and Heat

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Page 2: Dreyer & Bosse · Dreyer & Bosse: Profitable Power and Heat wide product range Dreyer & Bosse is a technological leader among system suppliers for decentralised heat and power ge-

Dreyer & Bosse:Profitable Power and Heatwide product rangeDreyer & Bosse is a technological leader among system suppliers for decentralised heat and power ge-neration. Our range includes tailor- made combined heat and power units (CHP) for biogas and natural gas, as well as plants for gas scrub-bing and upgrading.

highest availabilityAs 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.

Dreyer & Bosse• Gorleben, Lower Saxony• founded 1997• around 100 employees• certified to DIN ISO 9001• Member of the Biogas e.V. trade association and ADBA UK• Partner in the Academy for Renewables

Contents4-5 6-7 8-9

Applications and function: viable solutions for every demand

Construction and control:top performance from an ideal combination

Components:High efficiency through sophisticated technology

Page 3: Dreyer & Bosse · Dreyer & Bosse: Profitable Power and Heat wide product range Dreyer & Bosse is a technological leader among system suppliers for decentralised heat and power ge-

„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

everything from a single sourceDreyer & Bosse provide not only re-liable, 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 require-ment. 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 efficiencyDreyer & Bosse pay particular at-tention to the optimum sizing of its plants, aligned to your requirements and local conditions. This is the only way to fully utilise the technical po-tential of the individual CHP compo-nents and to achieve a high system efficiency. Excellent efficiency me-ans faster payback for your plant.

10-11 12-13 14-15

Gas scrubbing:more economical with the Vita-Mundus system

Gas upgrading:highest biomethane flexibility

Service:maximum yield through maximum availability

Overview

Page 4: Dreyer & Bosse · Dreyer & Bosse: Profitable Power and Heat wide product range Dreyer & Bosse is a technological leader among system suppliers for decentralised heat and power ge-

viable solutions for every demandapplicationsCHP units from Dreyer & Bosse are suitable for operators of biogas plants, sewage treatment plants and waste disposal sites who want to turn their gas into power in an en-vironmentally responsible way with the potential for economical use of the waste heat they generate.

combined heat and power gene-rationIn our CHP units, a special gas engi-ne drives a generator. The power ge-nerated by this can be used on site by the plant operator or exported to the grid for appropriate remunera-tion. The waste heat generated by the process, from the engine coolant and exhaust gas, can be extracted by heat exchangers, making it avai-lable for heating purposes, for hea-ting DHW or as process heat.

good for the climateThe combined generation of heat and power (CHP) makes the best use of the energy contained in bio-gas. High overall efficiency levels are achieved. This not only reduces the plant operator‘s energy costs; it also protects our environment. This preserves fossil fuels and sustainab-le raw materials. Noxious emissions are reduced, as less fuel is required. There is a significant reduction of cli-mate-damaging CO2 emissions.

Abattoir in Cyprus with eight Dreyer & Bosse CHP units, delivering a total output of 2.1 MW. The biogas plant utilises the waste products from production for producing gas. The majority of the power generated by CHP units is used on site. Even frequent mains failures are bridged by using the plant in standalone mode, supplying the entire site with power. The generated waste heat provides water heating for cleaning purposes and pro-cesses.

engine

engine cooling

heat exchanger

exhaustheat exchanger

generator

exhaust

gas

electricity for own use or feed into

national grid

absorptionrefridgeration

cooling or airconditioning

integration in existing heating

system

scheme cogeneration

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Page 5: Dreyer & Bosse · Dreyer & Bosse: Profitable Power and Heat wide product range Dreyer & Bosse is a technological leader among system suppliers for decentralised heat and power ge-

utilising energy efficientlyThe experience gathered over many years in the development and construction of CHP units, Dreyer & Bosse to handle the most diverse range of applications with utmost professionalism. We are highly conversant with the use of waste heat utilisation modules and would be delighted to extend your existing plant on request with the following:

• an absorption-type refrigeration system• a steam generator• a thermal oil heat exchanger for high temperatures• an ORC plant for turning the waste heat into power and ex- porting this into the national grid

The high efficiency of our systems offers you not only reliable energy provision, but also financial bene-fits.

More than 700 CHP units worldwide bear our logo.The majority of Dreyer & Bosse CHP units have been installed in Germa-ny. 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, Po-land, Sweden, Slovakia, Czech Repub-lic, Hungary, Uruguay, USA and Cyprus.

Benefits of combining heat and power generation in summary:

u reduced energy costs through the combined generation of energy (heat + power) u careful handling of valuable raw materials and reduction of pollutants (carbon dioxide, nitrogen oxide)u greater independence from the energy marketu in many countries, public subsidies for the energy generated by com bined heat and power units (feed-in tariffs, tax credits)

Applications and functions

Page 6: Dreyer & Bosse · Dreyer & Bosse: Profitable Power and Heat wide product range Dreyer & Bosse is a technological leader among system suppliers for decentralised heat and power ge-

top performance from an ideal combinationreliabilityThe efficiently operating CHP unit is the result of reliable and matching technology. Consequently, Dreyer & Bosse only uses system compo-nents that have proven themselves in practical applications, developing some technologies inhouse and op-timising their interaction. In doing so, we ensure that your plant func-tions perfectly and can achieve plant availability levels of up to 99 %. You, as plant operator, can enjoy high ef-ficiency and rapid payback.

easy to serviceCHP 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 frequen-cy servicing, and associated costs. A minimum transfer of engine vibra-

tions reduces structure-borne noise and the use of costly sound attenua-tion.

flexible installationThe open design of our CHP units also offers you many individual op-portunities for linking your system into the wider plant. Whether instal-ling in a new power station or in an exist-ing building complex, the lay-out of components can be adapted and designed according to prefe-rence and purpose. Alternatively, all relevant system components can be fitted inside a container and deliver-ed as one unit ready for installation. We will manage any space challenge you may face.

Dreyer & Bosse Biogas CHP-series Vita

Type/ Vita-Pico CHP Vita-Grandis CHP unit 75 104 125 150 190 210 255 366 400 500 600 800 1.200 1.560 2.000

Electrical output kW 75 104 125 150 190 210 255 366 400 500 600 800 1.200 1.560 2.000Thermal output max. kW 91 108 153 171 202 207 290 408 370 510 570 760 1.126 1.492 1.874Electrical efficiency % 36,2 38,2 36,4 37,4 38,5 40,3 38,7 39,3 42,8 40,7 42,7 42,8 42,0 41,7 42,0Thermal efficiency % 44,0 39,7 44,6 42,7 41,0 39,7 44,0 43,8 39,6 41,5 40,6 40,6 39,4 39,8 39,4Biogas needed at 6kWh/Nm3 Nm3/h 35 45 58 68 84 88 112 158 158 208 238 317 484 624 476 Cylinders R6 R6 R6 R6 R6 R6 V8 V12 V8 V12 V12 V16 V12 V16 V20Energy input kW 207 272 343 400 493 521 659 932 935 1.230 1.405 1.871 2.858 3.745 2.858Built up L/B/H m 6/2,45/2,6 9/3/2,9 12/3/2,9 15/3,2/3,2

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.

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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 me-ans of commercial fieldbus systems.

our head-startThe Dreyer & Bosse PLC (Program-mable 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 operationOur most advanced LICA control sys-tem comes with display and control elements. You can make adjustments directly and easily via a touchscreen that provides you with all relevant pa-rameters.

You have complete control of your power station from anywhere

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 email despatch for information exchange (fault and warning messages

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Designand control

Page 8: Dreyer & Bosse · Dreyer & Bosse: Profitable Power and Heat wide product range Dreyer & Bosse is a technological leader among system suppliers for decentralised heat and power ge-

high efficiency through sophisticated technologypowerAt the core of our plants lies an ex-tremely robust and powerful spe-cial 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 requirementsOur oil management system is a further inhouse 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 engi-ne oil. As a result, the engine only requires an oil change every 3000 hours run (max.).

environmentally responsibleOur specifically sized oxidation cata-lytic converters (OxiKat) are used to treat the exhaust gas prior to emis-sion. The OxiKat reduces formal-dehyde and carbon monoxide emis-sions: Country-specific limits are complied with.

noise reductionSound packs tailor-made to your needs reduce noise emissions to the minimum necessary. We design cooler, container wall and exhaust silencer to individual requirements. Where required, we even meet emis-sions of 40 dB(A) at 10 m distance.

exhaust

exhaust

water / thermal oil

water / thermal oil

• Smoke exhaust

• cross counterflow principle

Typical heat exchange function

Economical deploymentIn 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.

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Page 9: Dreyer & Bosse · Dreyer & Bosse: Profitable Power and Heat wide product range Dreyer & Bosse is a technological leader among system suppliers for decentralised heat and power ge-

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 Expansion with additional control elements is all it takes to make integration into a virtual power station possible

In agricultural enterprises, sewage treatment plants or on waste disposal sites, our open design and modular control allows our engineers to match your CHP unit perfectly to your com-pany‘s demands and requirements.

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Components

Page 10: Dreyer & Bosse · Dreyer & Bosse: Profitable Power and Heat wide product range Dreyer & Bosse is a technological leader among system suppliers for decentralised heat and power ge-

economical with the Vita-Mundus systemefficiency and durabilityBiogas contains pollutants such as siloxane, hydrogen sulphide and ammonia. If these are combusted in-side the engine without prior scrub-bing, the engine will suffer greater wear, as will downstream plant com-ponents such as the catalytic con-verter and heat exchangers. In other words, the efficiency and service life of your CHP unit depend largely on the fuel quality and consistency.

Vita-Mundus systemThe Vita-Mundus system from Dreyer & Bosse offers a solution at the very highest technical level. It scrubs your gas in two stages and comprises of a gas cooler and an activated carbon filter. The deploy-

ment of these two components re-duces your maintenance and ser-vice costs by up to 75 %.

higher efficiencyEveryone can provide cooling, but not necessarily separation. Our coo-lers offer a crucial advantage thanks to their integrated hygro filter. Our gas cooler reduces the gas tempe-rature from 38 °C to 4 °C. This col-lects suspended matter in the con-densate trap, together with water separated out by filtration. Extrac-ting water effectively improves the engine efficiency as well. The ener-gy that would have been required to heat the water vapour content inside the combustion engine is now avai-lable as additional power.

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Benefits of Vita-Mundus system in summary:

u Improvement of the gross calorific value of gas

uProtection of engine and downstream components, such as heat exchanger and catalytic converter, from corrosion and wear

ulonger operating times for engine oil and spark plugs

u high plant availability

u long service intervals, maintenance and service bills are reduced by up to 75 %

u enables the use of an exhaust gas oxidation catalytic converter for the reduction of formaldehyde and carbon monoxide

u Prevention of falling below the dew point in longer gas pipelines

Scrubbing the gas with the Vita-Mundus system improves the reliabi-lity, service life and effectiveness of your CHP unit. Your investment: only around 1 % of the overall plant outlay. An investment that pays handsome dividends.

Activated carbon filter for the best possible cleaning effectIn the second stage the gas is rou-ted through the activated carbon, which binds large amounts of sul-phur and siloxane. The two stage activated carbon filter comprising of an active and a monitoring filter is also an inhouse development of Dreyer & Bosse. The working filter can charge the activated carbon with up to 100 % of its weight in sulphur. If the activated carbon in-side the working filter is not repla-ced in time, the monitoring filter will prevent hydrogen sulphide from entering the engine.

Rüpke Biogas GmbH & Co. KG counts on a Dreyer & Bosse CHP unit with an electrical output of 366 kW with upstream gas scrubber. The Vita-Mundus system daily separates out up to 240 litres of water from biogas. Rüpke Biogas GmbH & Co. KG benefits from fuel savings, a longer service life of the plant, plus plant availability of up to 98.7 %.

With our two-stage activated carbon filters, carbon can even be replaced whilst the CHP unit is operational. This reduces downtime and improves the plant availability.

Scrubbing and dehumidifying the gas with the gas cooler improves the gross calorific value and prevents engine damage.

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Gas cleaning

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highest biomethane flexibilitybiogas into biomethaneAre you operating a biogas plant in an area where economically viable utilisation of heat from a CHP unit is not feasible? In that case a biomet-hane plant from Dreyer & Bosse may well be the most viable solution for you.

clean and rich in energyRaw biogas is essentially a compo-sition of methane and carbon dioxi-de as well as gas admixtures, such as hydrogen sulphide and water. If this gas is desulphurised, dried and enriched with methane through se-parating out carbon dioxide, the re-sult will be high grade biomethane rich in energy.

innovative and highly efficientWith our amine gas treatment (Amin-Select), proven over many years in operation, plus a new innovative

diaphragm technology, we offer you two gas upgrading processes that stand out through an extremely low methane loss and high methane pu-rity. Subject to project conditions and the demands of your gas mains operator, we select the optimum upgrading system for you.

economically attractive utilisation optionsCurrently, the following are on offer:• Sell into national grid• Turning the gas into electricity by means of a combined heat and power unit at a location that can better utilise the heat generated• Use as fuel in vehicles that run on natural gas

on top: Clean and pioneering: Biometha-ne as fuel for cars, lorries and buses.

above: Direct injection into public natural gas grids is becoming economically, more and more attractive.

on the right: Schematic illustration of gas scrubbing with an amine treatment from Dreyer & Bosse

Methan to 99,9 %0 - 3,5 bar (ü)

Raw biogasca. 55 % CHca. 45 % CO

dehydration

1. step0 - 200 mbar (ü)

2. step1,5 - 4 bar (ü)

heat-introduction

110 °C to 130 °Cheat-extraction70 °C to 40 °C

regenerationphase

carbon dioxideMethanloss < 0,1 %

CO fineregulation

42

Biogas / Biomethan detergent CO -low2 detergent CO - saturated 2

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Page 13: Dreyer & Bosse · Dreyer & Bosse: Profitable Power and Heat wide product range Dreyer & Bosse is a technological leader among system suppliers for decentralised heat and power ge-

Benefits of the Dreyer & Bosse biomethane plants:

u the carbon dioxide content of biomethane can be reduced to 0.1 %u high gas purity enables injection into natural gas grids and mini- mises costs for gas conditioning u CO2 content in biomethane can be selected from 0.05 % to 6 %u no economical disadvantages through high methane losses (Methane leakage < 0.1 %)u flexible, may be used to generate power, heat or biofueluProduction and use are independent of time and placeu Delivery pressure from the plant up to 3.5 bar (positive) - no further compression required in low or medium pressure mains* (*details applicable only for amine gas treatment)

AminSelect upgrading from Dreyer & Bosse has been in operation at Kraft und Stoff GmbH in Dannenberg (Elbe) since December 2010. Up to 400 Nm³ raw biogas is upgraded per hour into high grade biomethane. The majority of this is injected into the local distribution system of the E.ON Avacon. The injection pres-sure of 1.5 (positive) is generated directly by the AminSelect plant, making any separate compressor station super-fluous. Additionally, several biomethane filling stations in Lower Saxony are supplied with biomethane.

„I decided in favour of gas upgrading from Dreyer & Bosse, as this company can draw on many years of experience in handling complex biogas projects. The plant operates efficiently. “

Horst Seide, operator of the Dannenberg biogas plant and President of the Biogas Trade Associationbandes Biogas

Gas upgrading

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maximum yield through the highest availabilityregular service & maintenanceOn-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 ser-vicing and maintenance.

individual supportWe prevent unscheduled downtimes and repairs with maintenance and service contracts that are individu-ally tailored to the requirements of your plant. In this, we go beyond the recommendations of engine sup-pliers. Instead, we also apply our own experiences. Your benefits are predictable costs and successful plant operation.

immediate helpIf, nevertheless, your plant should suffer a fault our service team, which you can contact via our hotline, is available to you 24/7. Most prob-lems can be determined and sol-ved quickly by our team of experts through remote dial-up.

rapid on-site serviceOur 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 sta-tus as quickly as possible.

„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 custo-mers. 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.“

Roman Brillowski, Dreyer & Bosse employee

You can reach our service team any time. We answer your questions and assist you quickly.

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Benefits of maintenance and service in summary:

u24/7 emergency service and troubleshooting

u Technical hotline: Remote dial- up and diagnostics, telephone consultation on technical questions

u individual maintenance and ser- vice contracts, designed to meet your needs precisely

u well sorted spare parts stock at Gorleben guarantees a quick de- livery 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!

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Dreyer & Bosse Kraftwerke GmbHStreßelfeld 1 • 29475 GorlebenTelefon +49 (0)5882 9872-0 Telefax + 49 (0)5882 [email protected] Stand 03/2014

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!

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