Steam Boiler House, Bavaria
Our engineering firm planned a modern steam boiler house with a capacity of 48 tons of steam per hour, designed for 1.3 MPa and 195°C. The facility includes three boilers, each generating 16 tons of steam per hour. The project involves replacing the existing boiler economizers with new ones equipped with additional flue gas condensers, which cool the flue gas to 35–40°C. These measures significantly improve energy efficiency. In addition, more powerful feed pumps were installed, and a separate flue gas condensation circuit was developed to heat cold process water and reduce energy consumption. The entire gas pipeline system was redesigned to meet the new requirements. At the beginning of the project, we conducted an assessment of the existing infrastructure, created a digital model, and performed the necessary calculations and planning.
Challenges
Integrating the new steam boiler house into the existing infrastructure was a central challenge. The heavy boiler systems and high temperature requirements demanded precise structural calculations. Furthermore, the limited space on site required the development of compact workshop and construction plans. The reconstruction of the gas pipeline system and the implementation of the separate flue gas condensation circuit required careful coordination between trades and precise technical planning to ensure the efficiency of the facility.
01.02.2020 - 01.03.2020
| Tonnage | 29.9 | tons |
| Planning hours | 1450 | hours |
| Total area | 1100 | m² |
| Length | 60.6 | m |
| Width | 18.4 | m |
| Height | 10.3 | m |
Adress:
Bavaria, Germany
Project phases
Requirements Analysis
In this initial phase, we conducted a thorough requirements analysis to define the technical and operational needs for the new steam boiler house. This included the capacity target of 48 t/h of steam, the desired steam parameters (1.3 MPa at 195°C), and the replacement of the existing economizers with a new section including flue gas condensers, as well as the replacement of the feed pumps. This analysis formed the foundation for energy and efficiency improvements across the entire system.
Surveying with 3D Laser Scanning
The existing boiler systems and site were precisely surveyed using 3D laser scanning to obtain accurate data on the geometry and placement of all relevant building components. The collected data served as the basis for modeling and integrating new systems such as the new economizers, boilers, and the separate flue gas condensation circuit.
As-Built Modeling
Using the laser scan data, we created a digital model of the existing structure that represented the conditions and positions of all relevant components such as existing boilers, pipelines, and the gas piping system. This modeling allowed us to optimally position all new components and systems and to ensure that the new gas pipeline system was properly designed to align with the expanded economizer and boiler system.
Design Phase LPH 3 and Concept
In the design phase, we developed a detailed concept including the installation of three boilers (each with a capacity of 16 t/h) and the additional flue gas condensation system to cool down to 35–40°C. During this phase, the separate flue gas condensation circuit was designed to heat cold process water for the company's needs. In addition, the entire gas pipeline system was recalculated to meet the requirements of the expanded facility.
Approval Planning LPH 4
During approval planning, all relevant plans, calculations, and technical documentation were prepared for approval by the client and the responsible authorities. This phase included documentation for the new boiler and economizer sections, the requirements for the new gas pipeline system, and the integration of the flue gas condensers.
Implementation Planning LPH 5
In the implementation planning phase, detailed workshop and construction drawings were created. These plans included all technical details necessary for the precise fabrication and installation of the new boilers and economizers with flue gas condensers, the replacement of feed pumps, and the adjustment of the gas pipeline system. All construction documents were designed to ensure a smooth installation and commissioning process while meeting the high efficiency standards of the new steam boiler house.
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