Friday 27th March 2015

Energy Supply Company – Stadtwerke Meiningen (SM) Visit

This day, we head to Stadtwerke Meiningen GmbH - a municipal company that located in Meiningen, in the southern part of the state of Thuringia for our first destination.

Stadtwerke Meiningen GmbH operates in a wide range of business areas, offering to its customer gas, heating, electricity and water treatment. This is the chance to see different technologies system applied in combination which deliver around 70% of the energy requirement to the town from renewable technologies. The synergy effects of this cross system are to minimize emission and operating costs. Moreover, this company is owned by the municipality and income is reinvesting into the community. Their aim is to supply 100% to the town with renewable energy that has been set back by locals when a geothermal installation was blocked because of the concern of over hills rolling down. This can related to the same issue of fracking we have in the UK.

Figure 33-34: Left picture shows the engine cooling system and the right picture shows the district heating generation system

We are first directed to see the district and local heating system. A district heating scheme comprises a network of insulated pipes used to deliver heat, in the form of hot water or steam, from the point of generation to the end user. The district heating system uses three engines, which can be used individually when needed; the heat produces can supplies over 3500 flats and 40 companies. The heat generated by the system is sufficient to carry heat across the town of Meiningen and there is an interesting fact that with the engine cooling system represented with the green tubing on the picture, the company is able to heat their offices at no cost. That is what we call efficiency! (Salvatore) Furthermore, district heating networks provide direct benefit such as enabling the efficient transportation and the use of heat for a wide variety of users and provide a means of securing significant reduction in CO2 emissions.

Figure 35: Part of the heating district scheme system

Afterwards, we are going to visit their solar panel installation, which they install for environmental reason only on the rooftops of building as policy. Located on their car park they have a solar PV installation which produces 640 Kw/h. Each of the PVs system has a microchip which helps them to trace back if stolen. The car park was constructed for the solar array and has an electric car charger which is free to use for anyone with an electric car. Here we are shown the two type of plug system they use and we are given the chance to test drive electric car, the new Renault Zoe which cost around 25,000 euro and the Renault van.

Figure 35-37: The overview of the Renault Van

Figure 38-39: PV Panel (left) & a conceptual picture for PV solar system

Figure 40-41: A device which focus solar energy cooking method

In addition, we saw a device which concentrates the solar energy to provide cooking power. Made with lightweight aluminum, cost around 300 euros easy to use and assemble ideal for sunny countries.

Finally, we have realied that Stadtwerke Meiningen GmbH is operating in cooperation with the Agricultural Society Herpf mbH, which tend to supply the gas to city using a combination of animal and vegetable waste products. Through targeted mixing and fermentation of manure and crops such as maize and grass, they produce biogas. The power generation is approximately 7 million kW/h of district heating and 10 million kW/h of electricity can be provided solely by the biogas plant.

Figure 42: The overview of the site and the farming area (taken from the official website)

Back to BCS College for feedback & say goodbye

As our time comes to the end in Germany, we go back to BCS College to have lunch and meet with the head manager for our final programme. After we all finish our lunch, we are being invited to discuss what we have learnt during the whole trip. Each of our team has their chance to say what they feel the trip has meant to them. For me (Gary), I very satisfied for the whole timing for this trip as it is not very rushes and the programmes are very rich and cover a lot. I am impressive about the local people that we have met are very respected to the regional’s environment. The growing of German’s renewable technologies is very fast, with efficiency and clean. One concern for me is about the houses in UK built are heated by using the cheap energy, even the ventilation system in some of the UK building like the library in my University is very bad (too hot and can’t breathe). After seeing the technique of Passive House, I would like to see a continuing European programme that can be developed, so that they can help and solve the problem of UK houses insulation in future.

Rest of the team clarified that they are all very satisfied with the whole journey for the programme as it is in good time management, cover a lot, deep and all facilities are good to learn, especially the hydro visit, solar world visit and the waste plant visit. Jose said that it will be good if the internet speed in guest house can be highly improved in future. Millie suggested that it will be good for the entire leaflets websites and presentation are in English version, so that everyone can save their time for translation and it is easier for everyone to read in their homes.

Figure 43: Group picture in BCS College dining hall, everyone is holding their great, successful and meaningful certificate with smiles

Figure 44: Everyone is picking up the souvenirs for theirselves in BSC College 

Figure 45: Nicola found something impressive on the table

Figure 46-47: Two mini handmade houses, good for decoration. 

Great Experience for Everyone!

Thursday 26th March 2015

The Technical University of llmenau visit

As usual, we have our breakfast at 7:30 am and we leave the guesthouse at around 8:30 in the morning, Mr. Mullier is going to drive us to the first destination of the day –‘The Technical University of llmenau’. As soon as we know, this is a new destination that even the staffs from BCS have never been to there before. It is amazing that we are all given a nice presentation by a senior electrical engineer and his fellows to start our day.

Ilmenau University of Technology was founded in 1894. They have 6 faculties and approximately 7000 students right now. They are all focusing on engineering – Institution of Electric Power and Control Technologies (IEPC). They have carious department such as the department of power systems, power electronics, electrical machines, lighting and overvoltage protection. It is good to know that they are doing the project of Smart Grid production in Turingia. As we know, they have a very strong lab which is including the key component of small SCADA Applications for lab purpose, energy managing systems, power system simulation, remote protocol simulation, automated management metering system and so on. They are going to improve the real world applications of CHP, wind power generation, different PV panels and especially the charging system for Electronic Vehicles (EVs).

Figure 25 & 26: Introductory presentation by a senior electrical engineer, the Technical University of llmenau. Also, the picture on the right hand side shows the remote charging system management for EVs.

There are other projects have also been introduced during this section. For example, they were doing a project with 50 Mini-EVs in Berlin (2009-2011). The objectives of this project is to define the correlation between EVs power generation and it charging power, proof the concept of automated demand control in a real world application and the consideration of grid constraints.

Similar project – Gesteuertes Laden V3.0, have also been discussed during this presentation. The objectives of this project is to improve and provide ancillary services through the fleet of EVs, consideration of LV-gird security constraints and develop a Business Model. They are thinking about how to balance the system of power generation and consumption in EVs (BMW), also the profitable issue between the manufactures company (BMW) and consumers.

Finally, the last project that has been introduced is called ‘Mobil mot Stom. In English –‘Mobile with current, 2012-2013). The objective of this project is to improve the ratio of the regulation of charging energy for EVs and analysis local market forecast. For now, ‘User Activity’ is the limiting factor for developing EVs. It is also interesting to note that the fundamental vehicle system is trying to use renewable energy of any given time in Germany now. 16% of EVs can prevent the shutdown of renewable energy production and they are making good sense of using grid.

Figure 27-30: Nice BMW i3 Series Electronic Vehicle, with 16 separate batteries (8 year life time), free renewable, 4 hours charging time (can charge it at home), 120 km walkable distance, smart

Figure 31: Group picture in front of the BMW i3 series Electronic Vehicle.

Solar World (Solar Panel Production) Visit

Our second destination for today is the most impressive global company –‘Solar World’. Once we arrive at there, we meet Mrs Christina, the head of Corporate Communication Arnstadt and her fellows. Mrs Christina is going to deliver us a nice presentation. As soon as we know, Solar World was established in 1998, they commit to build the solar world of tomorrow and today. They believe energy should be supplied not only for people requirements, but also with those of the environment. To achieve this goal, they produce solar modules with premium quality and solar system solutions in Germany.

After the presentation, we are all very lucky to be invited and able to see the production lines of solar modules in their factory. We find that quality is the determining factor in their manufacturing processes. Their actions are designed to achieve the highest levels of quality for their solar modules and this is their corporate policy and the pillar of their success.

Solar quality means their solar modules are reliable, which seems to be a major selling point for customers who know to only invest the best solar power plant globally. A solar power plant is just like another investment that people can invest in quality if they want guaranteed returns.

Although taking photo is forbidden in this area, we are all happy to see the whole manufacturing processes for making solar modules –‘from the source of element Silicon (Si), to the production of wafers and solar cells, to solar modules and custom-made system kits.’ They seems coverall stages of the value chain in Germany, this should be one of the secrets behind their integrated quality assurance.

Figure 31: Lots of Solar Modules are installed in the main building, Solar World

Finally, they rely on German quality standards and a coherent quality system: through quality tests such as Climate Chamber Test, Electrical Test, Hotspot Test, UV Light Aging Test, and Hemisphere Lighting Test and so on, are all conducted after every single manufacturing step and at all levels of their production, very professional. They always take the decisive step forward and they combine expertise and passion to produce the high level quality in Germany.

Wednesday 25th March 2015

Professional Training and Technology Centre, BTZ Rohr-Kloster Visit

Day three, what a lovely sunny day! We leave about 8:30 in the morning from guest house and heading to the Rohr professional training and technology centre. Firstly, we meet Michael Mickel, the head of training officer or this centre today. Then, we are all being invited to have an introduction section in a lecture room.

Figure 16 & 17: We are in the lecture room, photo credited by Gary

BTZ Rohr-Kloster Centre was being established on 1st July 1990, as an inter-company vocational training centre. It costs investment of 60 million Euro in construction project with the total area of 12.8 hectares. There have approximately 100 employees including trainers, teachers, social, technical, and sales personal and so on. Business areas are including Inter-company training centre, consulting services centre, metal and manufacturing technology centre etc. They also have various departments such as Building and construction department, electrical department and Butchery department etc.

During the introduction section, we are being described about the topics of energy revolution or building energy efficiency in Germany. It is interesting to note that, the old house for residential used and commercial used in Germany do have an energy efficiency problem. Infrastructure issue such as no high speed internet indoor, heating is not adapted and energy used for each company calculation difficulties both are being discussed.

After that, we are all being introduced by Mr. Michael about the concept and the need of ‘Passive House’. He said, no matter the climate or region, passive house stay at a comfortable temperature all year around with minimal energy inputs. It is good to know that this building is heated passively: they make efficient use of sun, internal heat sources, heat recovery, and rendering conventional heating systems are unnecessary throughout the winter. During warmer period passive house makes use of passive cooling technique strategic shading to keep comfortably cool. Either way, superior components combined with care planning ensure that temperatures remain constant and comfortable in all year around. So it is Sustainable, affordable and comfortable for everyone.

After lunch, we are going to look deeper in the techniques of ‘Passive House’. A passive house building acts more like an insulated flask, which passively keeps its contents at the right temperature without the need for active heating or cooling.

Figure 18 & 19: Two demonstration of Passive House in the main building

1. Insulation: A well-insulated building is going to keep warm in winter and heat out in summer.
2. Passive House Windows: Have to be strategically positioned, and highly insulated in order to make good use of sun’s energy.
3. Ventilation with heat recovery: Passive House ventilation systems provide plentiful fresh and dust-free air with maximal energy efficiency through heat recovery.
4. Airtightness: Passive House are all designed to avoid leakage in the building envelope thus boosting the energy efficiency while preventing draughts and moisture damage




Figure 14 & 15: Lovely Sunny pictures are taken in the centre and we are heading to the main building

5. Thermal bridge free design: Avoidance of thermal bridges, weak points in the building envelope, it has to be contributes to pleasant, even temperature while eliminating moisture damage and improved the overall energy efficiency.

Figure 20 & 21: We are all given a talk by the head training officer Mr. Michael, and we are discussing about the principles of Passive House Buildings, photo credited by Gary 

It is good to know that for now the versatility of passive house standard is increasing in Germany. It is going to be used in retrofits the standard of EnerPHit and as for non-residential buildings such as schools, administrative buildings, manufacturing plants and hotels. As passive house is based on physical principles, each building can and should be adapted to its particular climate.

In addition to vast, long term energy savings make passive house an excellent investment globally, especially in the face of decreasing energy resources and rising energy costs in Germany. The passive house standard exemplifies sustainable affordability. Financial support for passive house have already available in a number of countries, not just in Germany, further reduce its cost. Even without such financial support, passive house are cost-effective over its life-cycle then their other conventional counterparts.

Figure 22 & 23: More pictures about the Passive House and the materials they used for the insulation 

Figure 24: Group picture in front of the BTZ Rohr Educational & Technology Centre, the main building

Tuesday 24th March 2015

Vattenfall (Waterfall)– Water pump storage

On our second day, the sun is shining and we leave early for the drive. After one hour driving we find ourselves in a tranquil area, pine forest and birds chirping and here we are told about a man made water reservoir on top of the mountain which feed the hydroelectric water pump station to generate electricity. The Goldistahl hydropower plant has been commissioned between 2003/2004. It is located in the eastern part of the Thurinigian forest. The top basin has a volume of 12 million cubic meters and the artificial lake created has a volume of 3,370 cubic meters alongside with a height that varies between 10 to 40 meters depending on the shape of terrain. This amount of water can be cleared in eight hours, operating the four turbines at full capacity which will generate 1,060MW. The four turbines are constructed by two large steel cased tubes with a diameter that diminish from 4.35 meters to 6.20 meters. The turbine can be started up in 19 seconds and it can also reach a nominal speed of 333 rotations per minute.

Figure 8: A conceptual picture for the whole hydropower system that has been owned by Vattenfall and it is one of the biggest energy companies in Europe

Moreover, a small scale water plant is situated in downstream, we are told the turbine can generate so much electric power that an emergency service of the pumped storage power plant can be maintained, even if all auxiliary power supply units breaks down. The water pump station is used only for peak time energy that are requesting from the national grid and this happens early in the morning, lunchtime and evening. Moreover, the supplying constant electricity would not be sustainable as extra energy would be required to pump water up to the reservoir and this is because it takes 12 hours to fill the top basin.

Figure 9: Left is our driver P. Mullier and the right is Gary,

photo is taken in the site  

Figure 10: Left is Gary and the right is Salvatore, this photo is taken outside of the site 

It is also good to note that this hydropower station is under controlled headquarter in Hamburg. If the HQ in Hamburg state that there is too much energy in the German’s gird, this site will start do the revering processing – use the cheap power in the night, use the turbines as a motor and pump the water back to the top basin, then generate electricity again in peak times if it is needed and sell the power back to the grid. It is about 30% of the power is offset to power the process so it is 70% for the energy efficiency.

In overall, Vattenfall is owned by Swedish Government. For Germany, Vattenfall has totally 11 pump storage facilities. Vattenfall is Swedish for Waterfall and it is the state of the art engineering feat the biggest of its kind in Europe. It is operated as a hydro-electric station free from emissions and a study on environmental compatibility has been set up for Goldisthal.

Figure 11: We are having a group picture in the tunnel during our great visit in this hydropower plant, Vattenfall, photo credited by Gary 

VDE.8.1 ICE (Traffic project of Germany- Fast Train and New Railway development)

After we did the hydro visit, we are going to see the information point of traffic project in Germany. It is good to know that German are constructing a new railway work –‘ Long Tunnels for High Speed Train Project’, servicing from Munchen/Verona to Hamburg/Rostock. They will finish the whole construction in 2018 and start scheduling how’s the high speed train is going to run in those rail and tunnels.

Actually, it is a great infrastructure as we seen today, we have taken our own gear such as helmet and a little save box that the train museum are provided. Then, we are going to visit the two famous tunnels – Tunnel Blebberg & Tunnel Goldberg. It is interesting to note that the German’s train company do have their own gird, and they are not just using renewable energy to run their own works, they are also buying non-renewable energy such as fossil fuel and coal burning for the electricity required for the whole train’s system.

Figure 12: Group picture in front of the Tunnel Blebberg, photo credited by Gary

Figure 13: Left is Salavatore and right is Gary, we are in the outside of the train museum

Monday 23rd March 2015

BSC College Visit

Figure 1 : Good Morning in Guest house

It is 7 a.m. in the morning, looking from the window of the guest house, the panorama is delightful, winter still keep stronghold and won’t make way to spring. The grass still shining with frozen droplets on the left hand side and I can see a long chimney and wondering what is for. Still tired from the journey I make my way to get breakfast and rekindle with my fellow travelers: Nicola Hayes, Todorka Petrova, Jose Alberto, Millie Darling, Simon Gordon and Gary Suen.

Time flew and it was time to start the green adventure, P. Muller came to pick us up from the guest house and 5 minute drive later we were sitting and being introduced to the BCS program by Chief executive, H. Gerlach and his team.

The CEO of the company gave a brief description of BCS history and how it became the learning center from a small industrial and training company of East Germany. At the moment BSC offers a diverse training system that can last up to 42 month on a large spectrum, ranging from professional retraining, modular training and consultancy. Their courses can said to be ‘all in one’ because all hands on practice are comprehensive with the theory, covering home economics, textile, industrial and much more. BCS focus on improving employability shown that they do not only think about energy sustainability but also concerning about the social care for residential people. It is also good to know that if people have already employed by a company and they need to be retrained in here because of the technological system they use were being updated, they actually don’t have to pay for their course because Job Centre in Germany will pay for them. We believe that is a good policy for employees.

During our discussion time, it is interesting for us to know as shown in following:

1. Now there are some existing debates between nuclear energy and renewable energy because German thinks that nuclear energy can make a high profit for them.
2. Complicate political issues are still not fully approved for renewable energy until it is worth.
3. In 2009, people can start producing their own energy, use it and sell it to the others but the price for the electricity (Kw/h) has been currently decreased as people think that they might save enough money to survive.
4. Technical system such as heating pumps in Germany has been improved. The old heating pumps need to consume 82 Kw/h but now it just only need around 8 to 10 kw/h, so it is more energy have been saved.

Figure 2: From left: Jose, Simon, Millie, D.Herβ, Mark, Nicola, Muller, Salvatore and Todorka, photo credited by Gary Suen

Solar PV System Installation Visit

After talking about the current German situation and why there was a boom in energy produced from photovoltaic which was made mainly profitable and how now lobby from fossil fuel producer and policy changes slowed down this thriving success which could not be supported economically, we head to see their PV installation in Haus ΙΙ.

Here we are shown two working PV systems, one is located on the central section of the building installed in year 2007 before, with a capacity of 10 KWh. The second one on two sides of the building installed in 2011 with 29 KWh capacities. This self-installed PV has a 15 degree inclination and is exposed south to maximize solar energy intake.

This installation cost BCS around € 80.000 and this capital cost will be annuitized in 8 years, with an expected lifetime of around 30 years. We believe that is a good investment and it is also very efficient because they produce enough energy per year to cover 36% of the energy they needed in Haus ΙΙ which is around 100,000 KW a year from their various departments, including metal and plastic engineering departments with high tech control systems.

Figure 3: Solar PV Installation in Central Section of the building 

Figure 4: It shows different readings such as the power of Solar PV generating and the carbon dioxide generating at the moment

Combined Heat and Power (CHP) Visit

After lunch, we were being invited to visit the combined heat and power plant (CHP), called Dachs Arbitsprinzip, next to the dining room. CHP is the simultaneous utilisation of heat and power from a single fuel or energy supplies. During the process of power generation, heat is produced. Thereby part of this heat, the usable one is then captured and distributed. This system enables the power plant to achieve a high overall thermal efficiency by recycling heat that would be wasted into the surrounding environment. Dachs Arbitsprinzip was produced by the company Senertic in Schweinfurt, it is 50km distance from BSC and it works since 2008. The electrical energy that generated from CHP is tend to be used up completely by BCS itself and the heat of the system is used for heating up the water now. The system has an efficiency of 90% and it used gas as its fuel. The electrical power is 5.5kw, and the thermal power is 12.5kw. In overall, Haus I produced 40,000kwh electrical energy per year. The total electrical energy for Haus I is 120,000kwh per year. Therefore, BCS has generated around 30% of the energy needed theirselves. The cost for the whole system is 40,000 euro and its amortisation time is from 10 years.

Waste Plant (ZAST) Visit

After that, we are going to visit the residual waste plant (ZAST) that is only two minutes away from the BSC College.

Figure 5: I’m surprise to see a huge plant with few operators and I’m explained that is mostly a mechanized facility by Salavatore

As soon as we get in, we are welcomed by the ZAST manager and he had given us a brief which about the plant with a bird eye view picture and a section showing how this plant is going to be operated. As soon as we get in, we are welcomed by the ZAST manager and he had given us a brief which about the plant with a bird eye view picture and a section showing how this plant is going to be operated.

Figure 6: The front view of the waste plant, ZAST  

Figure 7: the front view of waste collecting point

After that, we are being described by how the waste is loaded and burnt at a minimum of 800 ⁰C, which is required by law in Germany. This site can be taken up to 160,000 tons of waste per year, nearly half of a million German’s waste collecting in here. The waste is then divided into industrial and residential from an area of around 500,000. We are being told that waste is highly selected in Germany with recycling reaching around 50% compared to UK which struggle to reach 20%! It is good also good to know that ZAFT also buy some industrial waste to burn and sell it to the energy exchange system

Before we are going to visit the waste collection point, we see a fully-waste carried truck which is going to be weighted and have a radio nucleus waste check. Once we arrive at the waste collecting point. It is hardly we can smell anything because the high pressurized system prevents odours escaping from the concrete chamber. At this point, waste has been dumped into the tank from the truck. From the chamber, a mechanized hand picks and drops the waste into the burner and the heat will be extracted by heating up the purified water and finally electricity has been generated. For the residual ash, it will be collected in a second concrete chamber. This is all the heavy staff that will fall directly due to gravity. Before releasing the smoke into the air, smoke cleaning is very important because it is a step to restore dangerous materials before they get emitted. These can be treated in four stages:

• Ammonia is injected into the smoke and then convert the nitrogen oxides into nitrogen and water
• Reaction with calcium carbonate to reduce Sulphur dioxide, neutrlisation process.
• To reduce NOx emissions, they will ensure the complete combustion of the fuel is operating.
• As for fly ash or particulate matter, there are bag filters are used to separate heavier particles.

Finally, ZAST need to cost 100 million euro to build with a 20 year repayment plan. It starts planning in 2003 and built in 2005. The main purpose of this plant is to reduce to almost zero the amount of waste that goes to landfill, which is around 2% now in Germany. It also has a complier system with the aims of balancing the output of heat and electricity in different season, such as we might need more electricity in summer and need more heating in winter. Therefore, ZAFT can change its energy system planning in order to fit with our daily life. At the end, it is good to know that EU had passed a law that makes illegal for sending untreated wastes to landfill. Therefore, we all believe that ZAST is a self-sufficient plant with an energy reservoir that serves also the fire trucks of Suhl.

Introduction

 Community Energy Exchange Trip to Germany

Giving the power back to the people UK  

carbon saving targets 30% by 2020 80% by 2050

 

A group of six community energy practioners join a Professional Good Practice Exchange trip organised by My Embrace to the Green Heart of Germany. They visit national renewable sites of significant importance and are inspired by large scale city wide heat networks. During their visit they witness first hand just how Germany has gone about powering and heating their communities locally. 

 Through the eye of a Francis turbine (right to left) – Jason Hannah, Worthing Energy Shop; James Wing, Sustainables 4U; Nick Cheyne-Brow, Graduate; Nick Rouse, OVESCo; Callum Steveley, My Embrace; Ollie Pendered, OVESCo/Barcombe Energy Group; Richard Watson, Energise Sussex Coast. 

  

As we fly into Munich I overhear a child in the row behind us remarking at the sparkles on the ground – like stars on the ground, the solar panels shine from the roof tops. We come lower to the ground and see solar farm PV arrays running adjacent to railway lines, on the outskirts of villages, on large barn roofs, homes and industrial buildings.

 

We are guests of a training College, BCS Bildungs-Center Sudthuringen located at Suhl in Central Germany in the region of Thuringen. Suhl is in the Thuringen Forest known as the green heart of Germany and is a UNESCO Biosphere.