Solutions for generating energy in industry and commerce

Heating systems

Industrial systems

Refrigeration systems

Contents

High pressure steam boilers

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All part of the serviceIndustrial systems for steam, power, heating and cooling are developed from a single source for each individual customer, and extended with a comprehensive range of services.

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Energy generators and system modulesSteam boilers up to 120 t/h, power stations for generating power up to 50 MW, hot water boilers up to 120 MW and heat pumps for heating and cooling up to 2 MW.

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The Viessmann range of services: Everything from a single sourceFrom consultation and the design concept right through to maintenance, the focus is on the complex lifecycle of the energy system.

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Systematic approach: Sample applications for hospitals and the paper industryBy renewing or replacing an energy centre, savings of up to 30 % can be achieved.

Always nearbyWith sales companies and agents in 74 countries, it is quick and easy to get in touch with Viessmann anywhere in the world.

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International referencesInternational references provide evidence of Viessmann's expertise. The six systems presented here include ones that use both mono and multi mode operation.

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Contents

Steamup to 120t/h

Electricityup to 50 MWel

Heatup to 120 MWth

Coolingup to 2 MWth

Industrial energy systems

Consultation/design concept

Implementation Maintenance/service

Steam up to 120 t/h

Power up to 50 MWel

Heating up to 120 MWth

Cooling up to 2 MWth

In the four energy areas of steam,

power, heating and cooling,

Viessmann offers a comprehensive

range of products and services for

industry and commerce

Heat pump

Combined heat and power unit

Biomass boiler

Flame tube boiler

Double flame tube boiler

Special boiler

Water tube boiler

PYRO

VENT

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Industrial systems for steam, power, heating and cooling

Efficient and clean provision of energy, as well as high operational safety and reliability, are essential requirements for energy generating systems employed by industry and commerce.

Viessmann is the technological trailblazer for efficient energy systems. Matching components and systems are developed from a single source for each individual customer, and extended with a comprehensive range of services.

Waste heat boiler Biomass plant

Overview of the product range The following outputs refer to the largest type of boiler or energy generator. Higher outputs can be achieved by linking individual boilers into cascades.

Industrial boiler systems for: Steam up to 120 t/h Power up to 50 MW Heating up to 120 MW

Biomass plants for: Steam up to 50 t/h Power up to 15 MW Heating up to 50 MW

CHP units for: Power up to 530 kW Heat up to 660 kW

Heat pump systems for: Heating and cooling up to 2 MW

Steam up to 120 t/h

Steam generation up to 120 t/h with renewables, fossil fuels and waste heat utilisation

Thanks to their excellent equipment level, Viessmann steam boilers meet the criteria for a variety of application areas. The boilers are robust and require only a low level of maintenance. They form part of a tailor made boiler house concept designed as a system solution for industrial steam generation.

Steam boiler systems Steam output up to 120 t/h per boiler Operating pressure up to 130 bar Hot steam temperatures up to 540 °C Systems with shell boilers or water tube

boilers Broad range of fuel types Waste heat boilers to utilise process heat;

they can be combined with gas turbines and CHP units

Modular design

Waste heat boiler for

steam generation

Steam boiler with

biomass combustion

Double flame tube boiler for steam generation

System modulesAll of the components Viessmann supplies are matched to the relevant steam boiler system.

Boilers and superheaters Flue gas heat exchanger Thermal and chemical treatment plants for

feedwater Combustion equipment, fuel storage and

charging Regulating and control systems Flue gas scrubbing Steam storage Boiler platforms

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Power generation for on-site requirements and for exporting to the public grid up to 50 MW

Viessmann offers four types of system for industrial power generation which cover a broad output range. They are designed for environmentally responsible CHP operation. The user benefits from reduced costs for power and heat.

Combined heat and power units (CHP) Output range up to 530 kWel

CO2 neutral operation with bio natural gas Equipped as standard for mains

substitution mode in the case of power failure (island mode)

Stringent connection conditions (AR-N 4105) issued by the power supply utility are met

ORC system for power generation

Combined heat and power units

Power up to 50 MWel

Steam turbine power stations Output range up to 30 MWel

Industrial steam turbines for use with continuous steam processes

Suitable for efficient power generation

Gas and steam turbine power stations Output range up to 50 MWel

High electrical efficiency in excess of 50 percent

Flexible operation due to rapid load changes

ORC systems Output range up to 2 MWel

Power generation in a thermal oil-based process

Use in industrial waste heat processes Utilisation of waste heat from ORC process

up to 90 °C

Heat generation up to 120 MWth

Hot water boiler with gas burners

Heat generation up to 120 MW with biomass, oil, gas and natural heat

Viessmann offers the right solution for industry and commerce with its energy systems. Users have a choice of high efficiency hot water boilers, CHP units and heat pump systems.

Heat generators Hot water boilers with an operating

pressure of up to 50 bar – Fired with oil or gas up to 120 MW – Fired with biomass up to 50 MW – Waste heat boilers up to 120 MW to

utilise process heat; can be combined with gas turbines and CHP units

CHP units up to 660 kWth

Heat pumps up to 2 MW per unit (cascades possible)

Biomass boiler

System modules Boiler Combustion equipment, fuel storage

and charging Flue gas heat exchanger Intermediate flow piece with safety equipment Regulating and control systems Return temperature raising facility Boiler platform

Quick commissioning through pre-assembled containerised systemsTime is money – particularly for industrial and commercial enterprises, where new heating centres often have to be operational in the shortest possible time, so that heat for production can be supplied on time. For time saving installation and commissioning, Viessmann now offers pre-assembled containerised solutions that are compact and easy to transport.

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Large heat pump for heating and cooling

Economical cooling with heat pumps up to 2 MW

Customer-specific large heat pumps are available for industry, large residential premises, office buildings and hotels. For industrial and commercial applications, the cooling function of the heat pump is just as important as its heating function – for example, for cooling food storage rooms or providing air conditioning in production rooms.

This energy system has the particular advantage of being able to heat and cool at the same time.

Ice store system with 1800 m3

storage capacity

Cooling up to 2 MWth

Large and special heat pumps Individually designed heat pumps

with outputs up to 2 MW per unit (cascades possible)

Able to be installed even in the most awkward spaces

Implementation of dual mode heating systems in combination with an oil or gas condensing boiler to cover peak loads

System modules Vitofriocal ice store system Dry cooler Collectors

Services

3-D boiler house design

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Large number of matching components are pre-assembled

Professional project design concept

Professional maintenance and service concepts

The Viessmann comprehensive range stands for innovative and efficient technology at its best. From consultation and design concept right through to maintenance, attention remains focused on the complete lifecycle of the energy system.

Consultation/design conceptViessmann treats all projects individually, with each and every aspect of the design concept being geared towards high efficiency: Impartial consultation on technology and fuel type

Best solution recommended from an ecological and economical standpoint

Information about national and international legislation and regulations

Plant analysis Viability studies

ImplementationCoordination with all technical departments while the system is under construction to ensure timely delivery and installation:

Design, basic and detailed engineering, site planning

Manufactured with a high level of pre-assembly to minimise time on site

Delivery and installation Trouble-free commissioning Comprehensive output tests As-built documentation

Maintenance/service/trainingReliable operation is ensured through customer-specific service concepts with guaranteed spare part supply, regular maintenance and boiler checks:

24/7 customer service Remote monitoring and diagnosis Conversion and modernisation Service, maintenance and repairs Performance of inspections and

examinations Delivery and installation of spare parts Boiler hire Training at the Viessmann Academy

The Viessmann range of services: Everything from a single source

System solutions

High cost pressure forces many companies to seriously examine their energy expenditure and take steps to realise potential energy savings. By renewing or completely replacing an energy centre, savings of up to 30 % can be achieved.

This means that new technology pays for itself quickly and eases the burden of current expenditure.

Systematic approach: Sample applications for hospitals and the paper industry

Expertise in multi mode heating systemsViessmann's comprehensive range offers innovative and powerful technology that can be tailored to the system user's own aspirations and requirements.

Multi mode systems are increasingly being used for commercial applications, combining renewables and fossil fuels. For this, Viessmann offers the necessary system expertise. For covering the base load, biomass boilers, heat pumps or CHP units are deployed; peak loads are covered by oil or gas boilers.

Combined heating system with a high output and a high level of supply security The graphic on the left shows a sample system solution: In a hospital, two Vitobloc 200 combined heat and power units (4) generate some of the required power. For heating water and domestic hot water there is also a Pyrotec biomass boiler (2) and two Vitomax 200-LW with Vitotrans 300 (7). Pure steam for clinical applications, e.g. for sterilisation, is produced by the Vitomax  200-HS high pressure steam boiler (8).

For perfect interaction and therefore the highest level of efficiency, Viessmann combines all of the system components in accordance with individual requirements.

1 Woodchip store2 Pyrotec biomass boiler3 Heating water buffer

cylinder4 Vitobloc twin CHP system5 DHW cylinder 6 Distributor

Power grid

1 4 5 6 7 82 3

7 Cascade with two Vitomax 200-LW with Vitotrans 300 flue gas/water heat exchanger

8 Vitomax 200-HS high pressure steam boiler with thermal and chemical water treatment systems and a pure steam generator

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1 Generator2 Gas turbine3 Waste heat boiler with

water tube design4 High pressure steam

boiler with water tube design

5 Economiser6 Feedwater pumps7 Feedwater tank with

integral deaerator8 Paper mill

21 3 4 5 6 7 8Natural gas

High pressure steam

Feedwater

Electrical power

Efficient solutions for steam and power generation Typical applications for steam generation in large volumes can be found in paper mills (above). Here, the associated power station generates steam and electricity. A generator (1) driven by a gas turbine (2) supplies the mill with power. The heat from the combustion gas is used in a waste heat boiler (3) to generate hot steam. A separate high pressure steam boiler (4) supplies the redundancy required for the production process and covers possible peak loads. The output of the power station is equivalent to the energy required for a town of around 50,000 inhabitants.

The greater the energy demand, the more positive the impact of the savings achieved by Viessmann's highly efficient energy systems.

International references provide evidence of Viessmann's systems expertise. Six systems are presented on the following pages, including ones that use both mono and multi mode operation.

References

Sembcorp Utilities, Wilton (United Kingdom)

SpecificationDouble flame tube boilers 4 x Vitomax D HSFuel type Natural gasSteam output/boiler 30 t/hHot steam temperature 300 °COperating pressure 17 barFeedwater temperature 105 °CBoiler efficiency 91 % (without

economiser)Commissioned 2009

Standard delivery High pressure steam boilers Burner Superheater Feedwater system Main pipelines, steel structure and platforms Chimney stack Control unit

Sembcorp Utilities, Wilton (United Kingdom)The international energy group, Sembcorp, provides up to 60 t/h steam for several chemical companies on an industrial site.

HKB, one of the Viessmann Group companies, was the general contractor responsible for the construction of the steam boiler system for this project in 2009, based on an individual design. Due to industrial requirements, four Vitomax D HS double flame tube boilers were installed, each with a steam output of 30 t/h. Two of these are kept for redundant backup to ensure high operational reliability. Pre-assembled system modules helped to reduce the installation time.

Steam production for the chemical industry

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Lotte World Tower, Seoul

(scheduled for completion in 2015)

Lotte World Tower, Seoul (Korea)The "Lotte World II" skyscraper complex will be 555 m tall. Energy for the building is to be supplied by environmentally responsible technology. Twelve KWT heat pumps will provide the renewable part of the building's heating and air conditioning supply.

Six brine/water heat pumps, each with 1.7 MW heating output and 1.9 MW cooling capacity, will be supplied by 720 geothermal probes sunk 200 m into the ground. In addition, six water/water heat pumps will be installed, each with 2 MW heating output and 1.7 MW cooling capacity. The latter use water from the river that runs past the tower. All twelve heat pumps will be operated in a cascade, which is controlled by a higher ranking control centre.

SpecificationHeat pump type 12 x special

heat pumpsTotal cooling capacity 20.4 MWTotal heating output 22.2 MWFlow temperature Up to 55 °CCold water temperature Up to 7 °CCommissioned 2015

Standard delivery Brine/water heat pumps Water/water heat pumps

KWT heat pump

Natural heat for modern architectural concepts

References

Bioheating centre at E-Werke Frastanz, Austria

E-Werke Frastanz (Austria)E-Werke Frastanz chose to invest in a bioheating plant to supply the Vorarlberg region in Austria with energy from renewable resources. The plant supplies private, public and commercial buildings with natural heat from woodchips all year round.

The chippings are automatically transported from the silo to the combustion chamber using a pushrod discharge system. A flat moving grate (FSB) with variable speed ensures optimum combustion of fuels that have a high water and ash content.

Bioheat for regional energy supply

SpecificationBiomass boiler 2 x Vitoflex 300-FSB

(1100, 550 kW)Fuel type BiomassWater temperature 95 °CBoiler efficiency 85 %Commissioned 2009

Standard delivery Wood combustion system Push floor Trough chain conveyor Hydraulic feed Multi cyclone separator Electrostatic filter Bunker cover Control unit

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Heating plant in Gräfelfing with biomass boiler (right) and hot water boiler for peak loads

Bio-Wärme, Gräfelfing (Germany)The heating centre at Bio-Wärme Gräfelfing GmbH meets all the demands for quality, efficiency and optimum interaction between component modules. The particular focus is on a long service life and ease of maintenance. Both of these factors make a significant contribution to the continuous yet economical operation of the plant, which stands at more than 8000 hours per year.

The Vitoflex boiler used is notable for its low fuel requirements. Wood with a water content of up to w60 can be combusted reliably and cleanly. The boiler's modulating operating mode matches the system output to the actual heat demand. If required, a Vitomax 200 peak load boiler can be started up as well.

Multi mode heating centre for local heating supply

SpecificationBiomass boiler Vitoflex 300-SRTFlame tube boiler Vitomax 200-LWTotal output 3650 kWFuel type Biomass, gasCommissioned 2012

Standard delivery Wood combustion system Hydraulic direct feed (fuel transport) Pushrod discharge (fuel discharge) Flue gas dust extraction using multi

cyclone separator Hot water boiler Control unit

Model view of the heating plant

References

Tropical atmosphere at the

Badeparadies Schwarzwald leisure

complex

Badeparadies Schwarzwald leisure complex, Titisee (Germany)A Vitobloc 200 CHP unit was installed in the Badeparadies Schwarzwald leisure complex to provide low cost power and heat. The system is operational for around 8000 hours per year and primarily produces power for use by in-house consumers.

The simultaneously generated heat is used for central heating and DHW, resulting in an energy utilisation level in excess of 90 percent for this CHP system. The Vitobloc 200 provides the base heat load that is required all year round.

In the warm summer months, the CHP unit takes over sole provision of power and heat.

Tailored system solutions for swimming pools

CHP unit (left) in the leisure

complex. Two Vitoplex boilers cover

peak loads when required.

During the winter, a Vitoflex woodchip system covers the additional heat demand. For redundant backup and possible peak loads, two Vitoplex 200 low temperature boilers were installed.

SpecificationCHP unit Vitobloc 200 EM

(401 kWel/ 549 kWth)

Low temperature boilers 2 x Vitoplex 300 (3200 kW)

Wood combustion system Vitoflex 300-FSR (2100 kW)

Fuel type Natural gas, oil, biomass

Commissioned 2010

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DGUV, St. Augustin (Germany)At the head office of the German Social Accident Insurance Institution (DGUV) in St. Augustin near Bonn, five Vitobloc 200 CHP units generate the power that is used in the building itself. If there is a public grid power failure, the system can provide emergency power in island mode and safeguard the necessary power demand. The mains substitution management this requires is provided by the Viessmann multi module management system 300.

The heat generated by the CHP plant is mainly used for operating absorption refrigeration machines and for heating the building. If required, a Vitoplex 300 low temperature boiler supplies additional heat.

CHP units for power supply and air conditioning in office complexes

DGUV administration building

The DGUV energy centre with five

CHP units in St. Augustin

SpecificationCHP units 5 x Vitobloc 200 EM

(238 kWel/363 kWth)Low temperature boiler Vitoplex 300

(1250 kW)Fuel type Natural gas, oilCommissioned 2012

Standard delivery Combined heat and power units MMM 300 multi module management

system for mains substitution management, including active load distribution

Low temperature boiler

Industrial energy

systems

Product and engineering brochures

Further information can be found

in the engineering and product

brochures.

Easy to order from

www.viessmann.de/Industrie

20/21

All of the information you need is just a click away: online at www.viessmann.de/Industrie

With just a few clicks of the mouse, trade partners, design engineers and operators can go online to discover Viessmann's entire range of products and services for industry, commerce and local heating networks.

Viessmann referencesAdvanced and efficient energy systems from Viessmann are in use in many large buildings, making an important contribution to the sustainable exploitation of energy reserves.

Detailed information on international reference systems can be found in the database on the Viessmann website.

The website for industrial energy

systems provides information about

all of our products.

Viessmann international

Viessmann is represented by sales

offices and agents in 74 countries.

www.viessmann.comAll members of the Viessmann Group are represented here, along with a short summary of each company, to provide insight into the wide variety of powerful energy systems that are on offer.

Proximity to customers and rapid availability are important criteria for the professional design and implementation of energy systems for industry and commerce. Viessmann is represented in major industrial countries with its own sales offices and experienced experts. They ensure that every energy system, whether it is for steam, power, heating or cooling, is individually tailored to the required application. This includes ongoing support after successful commissioning.

Always nearby

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