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Bio-Energy-Expo 2012
Nanjing, China
May 2012
BIOFLEX® Digester Heating
Efficient – Safe – Easy to Install
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Bio-Energy-Expo 2012
Nanjing, China
May 2012
BIOFLEX® Digester Heating
Efficient – Safe – Easy to Install
Content
 The BRUGG Group
• BRUGG Pipesystems
 Digester heating system
• Why digester heating?
• Different types of digester heating systems
• What makes an efficient digester heating system?
• The BRUGG solution
 District Heating
• What to do with the waste heat of the gensets?
• Flexible pre-insulated pipe CALPEX
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Bio-Energy-Expo 2012
Nanjing, China
May 2012
Brugg Pipesystems
Presents to you the BRUGG group
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Bio-Energy-Expo 2012
Nanjing, China
May 2012
The Brugg group
Headquartered in Brugg, Switzerland
Headquarter in the town of Brugg, 30 km west of Zurich.
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Bio-Energy-Expo 2012
Nanjing, China
May 2012
Keydata
Shareholders
Privately owned; controlled by Suhner, Merker, Wartman families
No stock exchange quotation
Founded by Gottlieb Suhner in 1896
Sales turnover 2010: 702 Mio. CHF (584 Mio. €)
Employees: ca. 2’000
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Bio-Energy-Expo 2012
Nanjing, China
May 2012
World wide network
More than 44 companies in 17 countries
Switzerland
Europe
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Bio-Energy-Expo 2012
Nanjing, China
May 2012
North America / Asia
Divisions
Cable systems
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Wire rope technology
Bio-Energy-Expo 2012
Nanjing, China
May 2012
Piping systems
Process control
systems
Brugg Pipesystems
BRUGG Rohrsysteme GmbH, Wunstorf
German Pipe GmbH, Nordhausen
Brugg Rohrsystem AG, Kleindöttingen
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Bio-Energy-Expo 2012
Nanjing, China
May 2012
Four strategic business fields
Heating systems
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Industry
Bio-Energy-Expo 2012
Nanjing, China
Petrol stations
May 2012
Systems packages
Heating systems
• district heating
• district cooling
• local heating
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Bio-Energy-Expo 2012
Nanjing, China
• cooling pipes
• custom manufacturing
• delivery in 24h, special prefabricated parts 72h
May 2012
Petrol stations
• suck pipe
• pressure pipe
• liquid gas reinforced
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Bio-Energy-Expo 2012
Nanjing, China
• single walled
• double walled
• monitored
May 2012
Industry
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Bio-Energy-Expo 2012
Nanjing, China
May 2012
System packages
• Biogas
• Heat and cold exchanger
• AdBlue
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Bio-Energy-Expo 2012
Nanjing, China
• Geothermal
May 2012
BIOFLEX® Digester Heating
Efficient – Safe – Easy to Install
Content
 The BRUGG Group
• BRUGG Pipesystems
 Digester heating system
• Why digester heating?
• Different types of digester heating systems
• What makes an efficient digester heating system?
• The BRUGG solution
 District Heating
• What to do with the waste heat of the gensets?
• Flexible pre-insulated pipe CALPEX
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Bio-Energy-Expo 2012
Nanjing, China
May 2012
Biogas in General
agriculture
Biogas!
life stock
digester
heating system
Genset
Heat
electricity
power to the grid
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Bio-Energy-Expo 2012
Nanjing, China
May 2012
~
~
~
district
heating
Why Digester Heating ?
For optimal biogas generation you have to:
1. maintain certain temperatures
0
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Bio-Energy-Expo 2012
Nanjing, China
May 2012
10
20
30
40
50
60
70
80
90
Why Digester Heating ?
For optimal biogas generation you have to:
1. maintain certain temperatures
2. take care of envelope
heat losses
0
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Bio-Energy-Expo 2012
Nanjing, China
May 2012
10
20
30
40
50
60
70
80
90
Why Digester Heating ?
For optimal biogas generation you have to:
1. maintain certain temperatures
2. take care of envelope
heat losses
3. heat up input material
process temperature
e.g. 38°C
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Bio-Energy-Expo 2012
Nanjing, China
May 2012
Digester Heating Systems
smooth bore pipe
e.g. 2“ / DN50
(stainless) steel
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Bio-Energy-Expo 2012
Nanjing, China
May 2012
Digester Heating Systems
smooth bore pipe
e.g. 2“ / DN50
(stainless) steel
plastic pipe
e.g. 1“ / DN25
polyethylene
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Bio-Energy-Expo 2012
Nanjing, China
May 2012
Digester Heating Systems
smooth bore pipe
e.g. 2“ / DN50
(stainless) steel
plastic pipe
e.g. 1“ / DN25
polyethylene
corrugated pipe
2“ / DN50
Stainless steel SS 316 L
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Bio-Energy-Expo 2012
Nanjing, China
May 2012
Digester Heating
efficient
digester heating system
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Bio-Energy-Expo 2012
Nanjing, China
May 2012
Digester Heating
efficient
digester heating system
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Bio-Energy-Expo 2012
Nanjing, China
May 2012
Efficiency
BIOFLEX ®
Rigid stainless steel
PE-pipe
Stainless Steel has good heat
transfer properties…
Polyethylene is more or less a
heat insulation…
High grade stainless steel
corrugated pipe…
… but wall thickness of approx.
2mm…
…and not a heat transfer
material.
…has got a very good heat
transfer compared to smooth
bore pipes.
low efficiency
= big amount of pipe
needed
just semi efficient
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Bio-Energy-Expo 2012
Nanjing, China
May 2012
Good efficiency
= small length of pipe
needed
Efficiency
heat transfer from hot water to substrate
depending on:
• heat conductivity, property of material
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Bio-Energy-Expo 2012
Nanjing, China
May 2012
Efficiency
Optimal choice of Material
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May 2012
Efficiency
heat transfer from hot water to substrate
depending on:
• heat conductivity, property of material
• “inner“ heat transfer
 from hot water to the pipe wall
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Bio-Energy-Expo 2012
Nanjing, China
May 2012
stainless steel
316 L
Efficiency
turbulent
flow condition
inside
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Bio-Energy-Expo 2012
Nanjing, China
optimal
heat transfer
inside of
the pipe
May 2012
ideal
heat transfer
from
heating medium
to pipe wall
Efficiency
heat transfer from hot water to substrate
depending on:
• heat conductivity, property of material
• “inner“ heat transfer
 from hot water to the pipe wall
• “outer” heat transfer
 from pipe wall to substrate
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Bio-Energy-Expo 2012
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May 2012
Efficiency
turbulent
flow outside
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Bio-Energy-Expo 2012
Nanjing, China
optimal
heat transfer
to the
substrate
May 2012
ideal
heat transfer
from
heating medium
to substrate
Efficiency
heat transfer from hot water to substrate
depending on:
• heat conductivity, property of material
• “inner“ heat transfer
 from hot water to the pipe wall
• “outer” heat transfer
 from pipe wall to substrate
• effective heat exchange surface
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Bio-Energy-Expo 2012
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May 2012
Efficiency
more surface
+ 40%
corrugated pipe DN 50
less pipe
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Bio-Energy-Expo 2012
Nanjing, China
May 2012
Efficiency
EXAMPLE: Biogas plant „Schnega“ (Lower Saxony)
Replacement of plastic pipes with NIROFLEX
heating
loops
circuits
length
Q
[m]
[ kW ]
PE – pipes
13
13
936
100
BIOFLEX®
1
2
145
100
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Bio-Energy-Expo 2012
Nanjing, China
May 2012
Efficiency
ca. 200%
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Bio-Energy-Expo 2012
Nanjing, China
May 2012
Digester Heating
efficient
digester heating system
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Bio-Energy-Expo 2012
Nanjing, China
May 2012
Fast Installation
BIOFLEX ®
Rigid stainless steel
PE-pipe
Pipes need to be bended before
installation…
Plastic pipes are endless
and flexible…
High grade stainless steel
flexible pipe…
… and welded together at each
joint!
…but multiple loops inside
needed.
…no junctions inside
the fermenter
specified personnel
required
= additional costs
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Easy installation
Bio-Energy-Expo 2012
Nanjing, China
May 2012
Easy and fast
installation
Fast Installation
1. Installation of pipe supports
2. Unrolling of the pipe
5. The ready-made
fermenter heater
3. Fixing the pipe
• „endless“ pipe
• fast installation
• reduction of installationtime
• reduction of installationcosts
4. Installation of end connectors
Installation of the fermenter heater within a few hours
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Bio-Energy-Expo 2012
Nanjing, China
May 2012
Digester Heating
efficient
digester heating system
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Bio-Energy-Expo 2012
Nanjing, China
May 2012
long lasting
BIOFLEX ®
Rigid stainless steel
PE-pipe
Preparation and post-processing
of skilful weld seams on site
is difficult („expensive“) …
Plastic, PE
high grade stainless steel
„endless“ pipe
… and so the risk of
Microbiological influenced
Corrosion (MIC) at
weld seams exists!
Diffusion and
reduction of flexibiliser
no junctions inside
the Fermenter
Reduction
of durability
= additional costs
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Reduction
of durability
= additional costs
Bio-Energy-Expo 2012
Nanjing, China
May 2012
Optimal
durability!
Flexible Installation
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Bio-Energy-Expo 2012
Nanjing, China
May 2012
2 Heating Circuits
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Bio-Energy-Expo 2012
Nanjing, China
May 2012
2 Heating Circuits – 3 Loops
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Bio-Energy-Expo 2012
Nanjing, China
May 2012
BIOFLEX® Digester Heating
Efficient – Safe – Easy to Install
Content
 The BRUGG Group
• BRUGG Pipesystems
 Digester heating system
• Why digester heating?
• Different types of digester heating systems
• What makes an efficient digester heating system?
• The BRUGG solution
 District Heating
• What to do with the waste heat of the gensets?
• Flexible pre-insulated pipe CALPEX
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Bio-Energy-Expo 2012
Nanjing, China
May 2012
System Package
Digester heating system
Local Heating Grid
Casaflex CFX
Bioflex BFX
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Bio-Energy-Expo 2012
Nanjing, China
May 2012
Calpex CPX
Calpex ®
Temperature 95°C
Pressure PN 6/10
• For district heating
• Best ratio between insulation/handling/range
Dimension DN 20-125
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Bio-Energy-Expo 2012
Nanjing, China
May 2012
Calpex ®
•
•
•
infinite length possible
easy handling
perfect insulation
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Bio-Energy-Expo 2012
Nanjing, China
May 2012
Calpex ®
System package for the biogas plant Bad Meinberg (northern Germany)
Digester Heater
182 m BIOFLEX
District Heating
600 m Calpex
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Bio-Energy-Expo 2012
Nanjing, China
May 2012
Thank you for your attention
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Bio-Energy-Expo 2012
Nanjing, China
May 2012
Thank you for your attention
布鲁格管道系统有限公司
BRUGG Rohrsysteme GmbH
Adolf-Oesterheld-Straße 31
D-31515 Wunstorf
迈克 舒伯特
Meik Schubert
产品经理 硕士工程师
Product Manager, Dipl-Ing, M.Sc.
电话：0049 (0)5031 170 127
手机：0049 (0)171 3 87 51 52
电邮：meik.schubert@brugg.de
公司主页：www.brugg.de
telephone：0049 (0)5031 170 127
mobile：
0049 (0)171 3 87 51 52
email：meik.schubert@brugg.de
www.brugg.de
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Bio-Energy-Expo 2012
Nanjing, China
May 2012