Rexroth wins with a combinationof heat and power

www.bosch-industrial.co.uk

When Bosch Rexroth introduced a new worldwideenvironmental policy targeting a substantial reduction inCO2 emissions across all its sites, the companysGlenrothes facility took the opportunity to implement, aspart of a package of actions, an innovative heating andpower solution. Working closely with the organisation, wewere able to design and install a bespoke system toguarantee the effective provision of heating and electricity.

The Bosch Rexroth site in Glenrothes, located in Fife,Scotland manufactures hydraulic motors for fork lift trucks,mini excavators and other mobile plant for householdnames such as JCB and Caterpillar.

The Glenrothes site was a significant consumer of both gasand electricity with a large number of machines and testrigs in both the main manufacturing area and the R&Dfacility.

Additionally, the shop floor was heated by a number oflarge gas-fired radiant heaters, which were over 20 yearsold, whilst the office space was heated by multiple gasboilers, some of which were in excess of 25 years old.

The immediate catalyst for change was Bosch putting inplace a new environmental policy for all sites to reduceemissions by a minimum of 15 per cent before 2012 (setagainst a 2007 baseline) and by a minimum of 25 per centahead of 2020.

Project: Bosch Rexroth, Glenrothes

Product: 4 x GB162 100kW3 x CHP CE140

"... we have the double benefit ofsubstantially reducing our energy billsand significantly driving down our CO2emissions by over 30 per cent, meaningthat our corporate environmentaltargets for 2020 are already realised.

Derek Donnelly, Health,Safety & Environmental Managerat Bosch Glenrothes

The benefits of the new system arealready evident with planned energyreductions already being realised. The CHPsolution as implemented not only meets inexcess of one third of our electrical needs,it also provides 100 per cent of our officeand shop floor heating and process needs

Derek Donnelly,Health, Safety & Environmental Managerat Bosch Glenrothes

www.bosch-industrial.co.uk

CHP: The complete system solutionIt was quickly realised that a site-wide strategy wasrequired and, following detailed analysis, it was determinedthat a combined heat and power (CHP) technology offeredthe best plan. The theory behind CHP is that a gas-fuelledpiston engine drives a generator to produce three-phaseelectrical power, which feeds into the mains distributionsystem where it can be used locally or exported to theNational Grid.

Heat, which is produced as a by-product of the electricitygenerating process, is used to generate hot water for spaceheating of offices or during an industrial process such asthe large number of process wash machines at Glenrothes.

With a view to securing the efficient provision of heatingand electrical output, Bosch Rexroth contacted BoschCommercial & Industrial Heating. After an extensiveanalysis, it was concluded that the Glenrothes site had thepotential to produce one third of its total electricityrequirement with the installation of three 140kW(electrical) CHP units. The units work 24 hours a day,seven days per week, with four GB162 100kW boilers asheating back up during planned maintenance cycles.

In addition, hot water is stored in three 10,000 litre buffertanks which can hold hot water at 90oC. The entire systemis controlled by a full building management system, whichcontrols and measures all inputs and outputs from the CHPunits and can be adjusted on PCs located around the site.

Plug and play solutionCrucially, the installation of the new CHP system wasachieved with no disruption to the Glenrothes sitesmanufacturing capability. In fact, the entire plantroom, including CHP units, pipework, back-up boilersand controls at the Glenrothes site was manufacturedoff-site and then shipped to Scotland as a completedplant room, ready for connection and commissioning.The plant room is effectively a plug and play solutionwith everything manufactured and put together off-site with no welding or construction on site.

Derek Donnelly, health, safety and environmentalmanager at the Glenrothes facility and also BoschRexroth UK energy manager comments: The benefitsof the new system are already evident with plannedenergy reductions already being realised. The CHPsolution as implemented not only meets in excess ofone third of our electrical needs, it also provides 100per cent of our office and shop floor heating andprocess needs. Our environmental targets for 2020have already been achieved.

As a consequence, we have the double benefit ofsubstantially reducing our energy bills andsignificantly driving down our CO2 emissions by over30 per cent, meaning that our corporateenvironmental targets for 2020 are already realised.

For more information on Bosch Commercialand Industrial Heating and our CHP range,visit www.bosch-industrial.co.uk