Three companies – one local heating network

LEW Innovationspreis (Lechwerke Innovation Award)

By presenting the Innovationspreis (innovation award), Lechwerke AG (LEW), a hydroelectric power company, boosts the spirit of invention and actual ideas in the area of sustainable climate protection and energy efficiency.
The competition showcases the skill and expertise of the geographical area and of the Bavarian district of Swabia as a business location.

Project description

e-con AG developed an integrated energy concept for three medium-sized companies (Goldhofer AG, PFEIFER, Dachser). The companies are now using one shared infrastructure for heating and generating electricity. The centrepiece is the heating plant built between the companies’ three adjacent campuses. There, a 3.3 MW wood chip boiler generates the majority of the heat distributed through the underground local heating network. Consumption peaks are covered by a redundant gas and oil-fired boiler system with an output of 5 MW. In addition, a combined heat and power plant safeguards the base load supply with heat and electricity. In conjunction with a photovoltaic output of 2.9 MW to the corporate headquarters buildings, 90 percent of the electricity required by the three companies is generated on site.
The regenerative energies replace approximately 1,200,000 litres of heating oil and conserve approx. 5,500 to 6,000 tonnes of CO2. In addition, refrigeration for cooling at the three companies is generated by a decentralised geothermal system with an efficiency of 90 percent. The investment costs are approximately 10,500,000 euros.

The project’s innovative approach 

The use of outstandingly energy-efficient technology by having a shared supply for multiple companies; 25% higher energy efficiency through intelligent open-loop and closed-loop control technology.

Integrative energy concept that links a variety of regenerative energy systems with each other – Contribution of the project to climate protection and energy efficiency
50% decrease in immissions compared to standalone systems thanks to powerful filter technology
80% decrease in the use of fossil fuels – Use of wood energy from the region: short transport distances and up to 90% regional value creation – Coverage of 90% of the electricity requirement through in-house generation – Reduction of CO2 emissions by 70%.

Shapers of the energy transformation

Innovative energy concepts

“Sustainable energy supply and storage are central tasks and the greatest challenges of our time. Thanks to its innovative energy concepts, e-con AG has awakened an enthusiasm for the energy transformation among people in its immediate environment. What an impressive way to demonstrate how this challenge can be mastered,” explains Franz Josef Pschierer, Bavarian State Minister of Economic Affairs, Energy and Technology. He awarded the plaque to e-con AG’s Sascha Fuchs and Andreas Müller, honouring them as “Shapers of the energy transformation.” The Free State of Bavaria’s Ministry of Economic Affairs grants this distinction to citizens, companies and organisations that advance the energy transformation agenda in the state.

e-con AG is taking on the energy transformation

“We are pleased to receive this tremendous distinction. We have been facing the great challenge of the energy transformation for years now, helping to bring this mammoth project forward with dedication and purpose – whether it is in the form of smaller standalone solutions or complex energy systems for our customers. Even within our own company, however, we are making use of environmentally friendly energy concepts and sustainability,” says Andreas Müller, Member of the Board of Directors of e-con AG. He states that the focal point of the energy projects is on heating and cooling with regenerative energies.
Energy projects have economic potential

“e-con AG’s projects are impressive proof that the energy transformation is, above all, an opportunity for our country and for each of us as individuals. The transformation offers tremendous economic potential, saves money and creates jobs, in addition to sparking a vast number of technical innovations,” said Pschierer in praise of the company. e-con AG’s energy concepts conserve about 18,320 tonnes of CO2 annually.

WWK Arena Augsburg

KUMAS  – Kompetenzzentrum Umwelt e.V.

The heating of the newly erected stadium is implemented using two identically designed heat pumps in conjunction with a gas-fired condensing boiler. The heat source for operating the heat pumps is multiple extraction and absorption wells from which groundwater is drawn and to which it is returned.
Individual solution

The well system is made up of special structures due to the energy outputs required. For this purpose, separate and extensive expert reports and simulations had to be created. The heating system has been divided according to the temperature requirements of the consumer groups into a high-temperature system (max. 75/55°C) and a low-temperature system (50/30°C).

The concept

The heating concept ensures that the heat supply, wherever possible, is implemented solely using the heat pumps. Only if high feed temperatures (> 50°C) are required by the high temperature consumer groups does the condensing gas boiler come online, supplying these consumers as needed. The low-temperature consumption groups are supplied by the two heat pumps. The gas condensing boiler also acts as a redundant heat generator if the heat pumps fail.
The cooling concept ensures that the cooling processes take place by means of natural cooling. In this design, the low temperature level of the groundwater is used to supply cool water (12/18°C) to the consumers. In addition, on hot days, the temperature of the SGL arena’s turf can be controlled. The new stadium of the FC Augsburg is unmatched anywhere in the world in terms of the
energy-related design of the heating, cooling and ventilation systems.
The majority of the energy required is supplied using groundwater from the two deep wells. The use of CO2-free electricity to power the heat pumps and fire the gas boiler with biogas provides the finishing touch to the concept.

One stadium on the vanguard of the world

The FCA WWK Arena is thus the world’s first arena to have a CO2-neutral energy balance in operation. In 2010, the stadium was honoured by Kompetenzzentrum Umwelt e.V. (KUMAS) for an innovative project that reduced environmental impact.

Compared to the original performance put up for tender, the following benefits result:

  • Optimised energy efficiency
  • Minimum environmental impact
  • Minimum Life Cycle Costs

Thoma Metallveredelung

Twice the honours for lighthouse project

Twice the honours for the project.

First off, the hard chrome plating plant has been recommended and suggested by the IPA Fraunhofer Institute in Stuttgart. The facility was awarded the KUMAS environmental prize in 2009. The planning and project engineering were carried out by e-con along with Thoma Metallveredelung and the Fraunhofer IPA. This made it possible to triple the degree of energy utilisation. The project was a model project of the DBU. The outstanding results make it a flagship building with a style and character that has been copied around the world. In addition, Thoma was represented at the “Woche der Umwelt” fair at the KUMAS stand at the Kompetenzzentrum Umwelt in Augsburg, along with three other exhibitors.
Award-winning concept for efficiency and sustainability

Measurements of the energy flows have shown that the plant reaches an overall COP of over six, despite the fact that it provides unusually high heating temperatures of up to 80°C. The heat pump is used to generate both heating and cooling. This synergy effect increases the effectiveness of the heat pump and thus also boosts the economical and ecological efficiency. The clever linking of natural heating and cooling resources with production-related excess heat enables 100 percent heat recovery.
This is an unbeatable concept when using state-of-the-art heat pumps in industry, process heat recovery and environmental protection. Compared to a conventional cooling and heating system (oil or gas-fired boiler and refrigerator), the concept makes it possible to conserve about 77 percent of the energy costs and approximately 264 tonnes of CO2.