INDUSTRIAL BOILERS - HYDROGEN

INDUSTRIAL BOILERS -HYDROGENSTEAM · HEAT · POWER

FELIPE GUERRERODANIEL GOSSE MATTHIAS RAISCH

Thermotechnology | TT-CH/MKT | April 2020

© Bosch Industriekessel GmbH 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.

Agenda

1. Introduction

2. Bosch

3. Thermotechnology

4. Product Portfolio

5. Decarbonisation

1. Actual situation

2. Hydrogen

3. Other fuels

6. Future

7. Questions and answers



Key figures 2019*Bosch – four business sectors

3

Share

of sales

Leading in drive and control technology, packaging,

and process technology

Industrial

Technology

One of the world’s leading providers of mobility solutionsMobility Solutions

Leading supplier of power tools and accessories

Leading supplier of household appliancesConsumer Goods

One of the leading manufacturers of security and communication technology

Leading manufacturer of energy-efficient heating products

and hot-water solutions

Energy and Building

Technology

Bosch Group402,800

associates

77.9 billion euros

in sales

*As of 12.19

Preliminary, rounded figures based on internal accounting

60%

40%



Market and figures for 2019*

Bosch

77.9 billion euros

in sales

243

manufacturing sitesBosch Group

402,800

associates

Europe

129

245,900

52%

Asia Pacific1

75

112,200

29%

Americas

39

44,700

19%

Manufacturing sitesAssociatesShare of sales* As of 12.19

1 Including other countries

Preliminary, rounded figures based on internal accounting

4


© Bosch Industriekessel GmbH 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.5

OUR MANUFACTURING PLANTS

Sao Paulo

Fort Lauderdale Shanghai

Engels*

Wettringen

EibelshausenLollar

Gunzenhausen

Bischofs-

hofen

Krnov*

Industrial boilers

Heating boilers

CHP units

Cooling / AC

Solar thermal systems

Heat storage tanks

*exclusively for local markets



JUST A FEW OF OUR CUSTOMERS…



SYSTEMS AND SOLUTIONS

Steam boilers

CHP*

Industrial

heating boilers

Waste heat boilers

Commercial

heating boilers*

Heat storage tanks*

Solar thermal systems

Commercial

heating boilers*Multivalent systems*

Remote access System control

Boiler controls

*Some products not available worldwide.

CHP*

Digital efficiency assistant

Process heat and

heatingDomestic hot water Power

Controls and

connectivity



Components

Hydraulics

e.g. Pump

module

Boilers

Hea

tin

g / h

ot

an

d w

arm

wa

ter

Ste

am

/ p

rocess e

nerg

y

Modules for:Water

Condensate

Steam

Efficiency

Waste heatRecovery & usage

Waste heat

steam boilers

Waste heat boilers Steam/hot water

4-pass

boiler with

burner

3-pass boiler

without burner

Boiler and system controls

Fuel

e.g. Gas regulation

module

Intelligent control technology:

- Boiler controls

- Boiler system controls

- Remote access

- Efficiency assistant

Uni Condens UT-L UT-M UT-H UT-HZ

U-MB CSB UL-S(X) ZFR(-X)

T max

Output

p max.

T max

Output

p max.

~1MW <1-25 MW <1-19 MW <1-18 MW 13-38 MW

110 °C 120 °C 190 °C 240 °C

6 bar 16 bar 30 bar

0.2-2 t/h 0.3-4.8 t/h 0.3-5.2 t/h 1.2-28 t/h 18-55 t/h

204 °C 110 °C 204 °C 300 °C

6 bar 0,5 bar 16 bar 30 bar

DECARBONISATIONOF HEATING ANDPROCESS HEAT

Thermotechnology | TT-CH/MKT | 2020.02.10


It’s our responsibility to act.

Now.

…global acting companies

likely to be first movers

introducing CO2 neutral

standards also to 2nd/3rd

world sites and supplier

specifications…

Globally increasing

demand for industrially

manufactured food,

goods, materials…

…first world countries

expected to motivate

shift to carbon-neutral

technology like H2,

biofuel, biogas, ethanol,

synthetic fuels and

electric solutions…

…increase global

demand for

process heat

systems…



Increasing global energy demand in the next decadesFossile energy use continues to increase until >2040

12



Bosch pioneers to become truly CO2 neutralOur path to climate neutrality

13

When it comes to the climate, words

are not enough. Companies need to

aim for carbon neutrality, here and now.

DR. VOLKMAR DENNER,

CHAIRMAN OF THE BOARD OF MANAGEMENT

“”

As early as 2020, Bosch will be carbon neutral at its

400 locations worldwide.



The path to climate neutrality – what it will takeDecarbonisation of process and thermal heat

14

CO₂ emissions from

direct combustion

(e.g. natural gas, oil, fuel)

at our locations

CO₂ emissions from

indirect combustion

(e.g. electricity, district heat)



Decarbonisation of heating and process heatEnergy consumption, example Germany

38,9

25,622,6

57,9

Mechanical energy

Heating Process heat

Hot water Other

Energy consumption in Germany 2018 by application in %

53,2 %

30,1

25,815

29,5

Energy consumption in Germany 2018 by sector in %

Traffic

Residential homes

Trade, commerce,services

Industries

15

AGEB – BMWi Energy data,

Table 7, Oct. 2019. statista.de

AGEB – Evaluation data energy

statistics for Germany 1990-2018,

Page 21 ff. Oct. 2019. statista.de

Thermal energy use responsible for more than half of the CO2 emissions



TODAYMainly direct use of fossil fuels…

Typical heating applications up to 110 °CDecarbonisation of heating and process heat

16

IN THE

FUTURE

…such as natural

gas and oil.

…OR direct use of

alternative fuels such

as biofuels, biogas,

hydrogen or

synthetic fuels

.. power-2-heat

e.g. heat pumps,

electric boilers..



Decarbonisation of heating and process heatHigh-temperature processes, mostly between 110–300+ °C

Possibilities depend on

comprehensive availability of

alternative fuels and green power17

CHALLENGES Economical reaching of the required high temperatures by direct

combustion

CO2 neutral combustion with biofuels, green power or H2



Hybrid boilers

• Up to 5 MW heating coil

combined with burner

• Hybrid ready option for

partial electrical powering in

the future

CO2 neutral boilers• Up to 100% CO2 neutral

• Up to 100% hydrogen (H2)

• Up to 100% biogas

• Up to 100% biofuel/ethanol

Electrification CO2 neutral electrical steam

generation with regenerative

power supply

CO2 optimization of

existing boilers• Hydrogen upgrade

• Biofuel upgrade

• CO2 efficiency upgrade

HYDROGEN



Decarbonisation of heating and process heatGeneration/source of hydrogen

Lightest and smallest atom in the

universe

Several ways of hydrogen (examples)

„Blue“: Waste product of gas extraction

„Green“: Generated with green power

20

Only green

hydrogen is

CO2 neutral



Hydrogen sources (examples)Decarbonisation of heating and process heat

21

Truck Delivery or Pipeline

Truck delivery is available

today but often too expensive

Distribution networks are very

rare at the moment

Hydrogen Electrolysis

Renewable energy is used to

produce “green” hydrogen

This allows to store the

energy in the gas network or

in gas tanks

Chemical Processes

Today, by far the most of the

produced hydrogen comes

from processing fossil fuels

Electricity

+ Air & Water

Truck Delivery

Tank Processing

Natural Gas Oil Coal

H2 GasH2 Gas

Pipeline

or

Electrolysis



Decarbonisation of heating and process heatSpecifics of using hydrogen

The proportion of hydrogen in many of

today’s gas networks can be max. 10–15 %

Heating value comparison with natural gas

Hydrogen to natural gas 1:3

15 % of hydrogen share in the network are only

equivalent to 5 % of the heating value of natural

gas

At 100 % hydrogen combustion three times the

amount of gas volume is needed

22



Decarbonisation of heating and process heatCombustion of hydrogen

No CO2 at the combustion of hydrogen

(2H2 + O2 = 2H2O)

Flame temperature of hydrogen roughly 2000 °C,

flame is not visible, thermal NOx generation

Careful handling of hydrogen is required to

prevent explosions

Hydrogen diffuses through metal

using certified materials only

Hydrogen can create hydrogen embrittlement

using certified materials onlyH2O instead of CO2

Measures vs. NOx necessary

„Soft Ignition“ measures

Special gas ramp materials



Hydrogen firingDecarbonisation of heating and process heat

24

Bosch Industrial can offer two solutions

Hydrogen Firing Hydrogen Ready

Boiler and Burner fully equipped to burn H2. The main criteria to have

100% hydrogen firing in a project, is the availability of H2.

Boiler ready to burn 100% hydrogen. Burner, gas supply, controls, etc. has to be

modified/replaced in the future to burn hydrogen.

- Oversize boiler body +10% - Oversize boiler body +10%

- Special gas supply components

Advantages:

- Boiler has not to be replaced when using H2

- Bosch supports a CO2 free future

- External recirculation installed

- Fully equipped H2 burner

(+100%)

H2

FiringH2

Ready

Main criteria for boiler selection and emissions is the current and future available fuel on site

If hydrogen becomes the “fuel of the future”, e.g. within the next 20 years, a burner replacement is pending anyway.



Hydrogen admixtures Decarbonisation of heating and process heat

25

Hydrogen admixture to the natural gas fuel in existing plants with marathon® burners:

The standard equipment of your marathon® gas / dual-fuel burners for natural gas requires a fluctuation in the

Wobbe number during operation no more than ± 2 %.

I. A hydrogen supply could fluctuate with a fluctuation range of 0 … 5 Vol-% in the regular equipment if the fluctuation

range of the Wobbe number is maintained. This H2 admixture would be compensated for by the existing / retrofitted O2

control in the case of regular maintenance and operation, without the burner setting normally having to be checked.

II. A feed of hydrogen up to a maximum of 10 Vol-% (with a fluctuation range in operation of maximum ± 5 Vol-%) could be

operated without changing the mixing device, but would mean readjusting the burner.

III. Hydrogen concentrations higher than 10 Vol-% can be achieved with additional technical and organizational measures

with a limited fluctuation range. Then it is necessary to consult an approved monitoring body (e.g. GWI Essen, TÜV Süd

etc.), because H2 concentrations higher than 10 Vol-% are not covered by the CE type examination of the burners.

Source: Dreizler company

BIOFUELS



Decarbonisation of heating and process heatGeneration/source and combustion of biofuels

Liquid biofuels occur in different forms

Bioethanol or biomethanol

Plant oil

Animal fat

Fish oil

Gaseous biofuels

Biogas

Sewer gas

27

An advantage of biofuels

is the shortly bound CO2

Burner technique with centrifugal tumbler

recommended

Boiler has to be adjusted for lower

emissions and in size

As some fuels tend to soot filters or air-

pressurized sootblowers should be installed

Lower heating value than natural gas

CO and O2 sensors should be used due to

unstable heating value



Decarbonisation of heating and process heatProject example with liquid biofuels

Bio oil creates covering of heat surfaces that require

daily (!) internal cleaning

Measure exhaust gas temperature increase related to

fuel consumption to detect necessary cleaning

Burner with rotary atomizer (because nozzles would

clog quickly)

Bosch special design with pressurized air valves

eliminates need for manual cleaning during the year

Constant efficiency up to 93% for bio oil (without

condensing technology)

28

2x 15 MW Bosch UT-L,

Denmark (Vattenfall)

ELECTRICAL SYSTEMS



Decarbonisation of heating and process heatHybrid boilers

Electrical heating supply

Steam and hot water boilers can be equipped with an additional heating device

Boiler can be operated with electricity, gas or both

Benefits

Using surplus electricity – Power to Heat

Participate in the balancing energy market

Keeping warm functionality provided by electrical heater

Fast availability and high efficiency (98%)

30

Electrical boilers are only CO2 neutral when the

power comes from CO2 neutral sources



Hybrid boilersDecarbonisation of heating and process heat

31

Very cheap electricity prices

Take advantage of the

phases of cheap electricity

Electricity as a back up

energy

Warm-keeping mode

Excess electricity

Avoid On/Off switch cycles

Create heat or steam out of

surplus electricity

Increasing the network

stability

Compensate load fluctuations

in the power grid

Consume the contractually

agreed purchase quantity

and/or

gas/oil electricity electricitygrid/ internal

consumptioncontrollerCHP grid/ internal

consumption

WASTE HEATRECOVERY



Waste heat utilisation for cost-efficient process heat generationDecarbonisation of heating and process heat

33

Our innovative heat recovery systems use existing waste heat sources

for efficient heat or process heat generation.



Decarbonisation of heating and process heat

34

Saving CO2by using waste heat

recovery efficiently

Typical applications for waste heat recovery

Engines

Gas turbines

Industrial waste heat:

Glassworks

Steel mills

Cement factories

MODERNISATION OF EXISTING BOILERSYSTEMS



Modernisation of existing boiler systemsDecarbonisation of heating and process heat

36

300 000 plants with

outputs between

100 kW and 36 000 kW

in Germany*

Only 17% of all

plants with state-of-

the-art technology**Source: BDH –Bundesindustrieverband

Deutschland Haus-, Energie-und

Umwelttechnik

Bosch boiler systems can be

retrofitted for use of alternative fuels

MEC Optimize

supports the operator

to save CO2 by

enhancing the mode

of operation.



Significant energy-saving potentials with system technology

Modulating firing

• up to 1% fuel saving

• wear reduction

Speed-controlled fan

• up to 75% electrical savings

O2 /CO burner control


Thermal degassing system

• up to 80% savings on chemicals

Expansion and heat

recovery module


• up to 1% make-up water saving

• up to 100% cooling water saving

• up to 70% waste water saving

Vapour heat exchanger

• up to 0.5% fuel saving

Condensate systems


• make-up/raw water saving

• waste water reduction

• up to 90% savings on chemicals

Economizer


Flue gas condenser


Air preheating


Feed water cooling


Water treatment

• increased water quality

• improved steam quality

• lower desalting rates

Settings and maintenance


• extended service life

• process reliability

• improved operation



Decarbonisation of heating and process heatSpecial solutions for binding CO2 in industrial processes

Cleaned CO2 from combustion

used for carbon dioxide in

beverages

No disadvantages compared to

coventional produced CO2

38

Heat is used for industrial

processes

Waste heat heats up

greenhouses

CO2 from combustion is brought

to the greenhouses

Increased CO2 value supports

faster growth of the plants

CO2 from combustion used to

preserve foods packed oxygen-

free and in protective atmosphere

longer

E.g. milk powder



Long term

Hydrogen/

synthetic fuels

Decarbonisation of heating and process heatTechnology forecast

39

NOW

Increase in efficiency

of existing systems

Next decade

Switch to biofuels and

electricity/hybrid boilers

20–30% of the

industrial energy use

can be reduced by

using the best

available technologies.

Factory of the

future



Decarbonisation of heating and process heatOur recommendation

Optimise existing systems

by efficiency increasing

measures regarding CO2

emissions

In certain countries there are

public subsidies for

modernisations and new

plants (short-term result

visible)

Prepare new plant for the

future (tenders with

subsequent retrofit to

alternative fuels

40

Check for alternative fuels

in the surroundings in the

medium-term (what is

available?)



Decarbonisation of heating and process heatOur recommendation for countries with H2 investment

Optimise existing systems

by efficiency increasing

measures regarding CO2

emissions

Take advantage of existing

customers with exceed of H2

for applying a pilot project.

Explore in mining sector pilot

projects for their industrials

boilers as benefit.

Transfer knowledge for

academic proffesional

careers

Generation of H2 should be

competitive in term of

selling price for processes.

41

Be part of organization for

developing H2 applications

in the industrial segments.

Concrete norms and

regulations for this fuel.



Decarbonisation of heating and process heatWhat is necessary for a H2 project supported by Bosch?

Bosch information need:

Scope of the project

Altitude

Location

Capacity or demand (steam

or tº)

Bar

Fuels: (e.g Hydrogen 10% +

90% Natural gas)

Fuel pressures

% Efficiency required

Estimated time of delivery

Transfer knowledge for

academyc profesional

carrers.

Generation of H2 should be

competitive in term of

selling price for processes.

42

Be part of organization for

developing H2 applications

in the industrial segments.

Concrete norm and

regulation for this fuel.

Bosch configurates with

plant:

Look for the best burner

alternative

Pressure

Fuels: (e.g. Hydrogen 10% +

90% Natural gas)

% Efficiency required

Best delivery lead time

Bosch Chile delivers its

offer:

Efficiency guaranteed

Technical offer

Price

Commissioning

Warranty



Latin American contacts Decarbonisation of heating and process heat

43

[email protected]/ [email protected]

[email protected]/ [email protected]

[email protected]

[email protected]

[email protected]

mailto:[email protected]/

mailto:[email protected]







News! Decarbonisation of heating and process heat

44

Bosch reveals a new hydrogen

wall hung boilers as prototype in

order to produce for next years.

QUESTIONS AND ANSWERS

45



Junkers Bosch en Chile

THANK YOU

47

INDUSTRIAL BOILERS - HYDROGEN

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