Thermal supply for buildings with renewable energy

Heating, Cooling, Hot Water, Ventilation

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WATERKOTTE The story of WATERKOTTE goes back to a pioneering step taken by its founder Klemens WATERKOTTE. In 1969, he buried a flat collector made of plastic pipes in his garden. He was able to obtain renewable energy with it. Using this energy in combination with heat pump system technology, he was able to heat his house using the underfloor heating he installed - right up to the present day. In 1972, WATERKOTTE established an engineer’s office and started producing and developing heat pumps. In 1976, he established the present-day company. The aim was the same then as it is now: to efficiently obtain and use renewable energy for supplying buildings with thermal energy.

Use in private residential projects The depleting reserves of gas and oil mean that the aforementioned system will soon cost less in total than any other solution. It was therefore possible to unite ecology and economy.

Use in commercial projects Even in the early days of the company, WATERKOTTE recognized the opportunities for the use of renewable energy in commercial projects; these can hardly be run without air-conditioning these days (labour laws). The crucial factor is that the heat pump installed for heating purposes can be used simultaneously as an air-conditioning cooling system - that means without further investment. In connection with geothermal energy probes, even under the building and an appropriate system with optimized automation, it has become possible to sink the total costs of the thermal supply to an insignificant amount. A project completed in this way has the highest return on investment for the investor, the advantage increases as the cost of other types of energy rise. Competitiveness is guaranteed in the rental market.

Copyright 2009 by WATERKOTTE GmbH Gewerkenstr. 15 D-44628 Herne Nachdruck und Vervielfältigung, auch auszugsweise, sind nicht gestattet und dürfen nur nach einer schriftlichen Genehmigung erfolgen. Trotz sorgfältiger Erstellung übernehmen wir keine Gewährleistung (weder ausdrücklich noch stillschweigend) bezüglich Richtigkeit, Vollständigkeit, Aktualität und Druckfehler. Inhalte & Bildmaterial © WATERKOTTE GmbH

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THERMAL SUPPLY

This brochure shows a few examples of our systems in Germany and abroad.

WATERKOTTE philosophie

WATERKOTTE has been involved with research, development and engineering for energy saving technology using ground coupled sustainable energy from a renewable source, using heat pump technology, for over 40 years.

To maximise the available geoenergy for any site using durable, sustainable ground coupled energy sources i.e.

WATERKOTTE are the leading manufacturer of heat pump units and components providing complete system solutions to a growing number of countries throughout Europe.   WATERKOTTE systems can provide: ++heating ++cooling ++domestic hot water ++ventilation WATERKOTTE complete solutions: planning, design, installation, commissioning, start up and service. WATERKOTTE complete service: regional system partners, consulting engineers and installer network across Europe.   WATERKOTTE solutions include: ++WATERKOTTE complete automation technology ++WATERKOTTE remote technology ++Geoenergy technology

++Heat source: ground water ++Heat source: ground coupled horizontal collectors ++Heat source: ground coupled vertical probes   WATERKOTTE unique solutions provide excellent economic and environmental results. Geoenergy solutions versus conventional heating: ++compared with oil:

saving 73 %

++compared with Gas:

saving 61 %

++compared with wood pellets: saving 58 %  

(source of results: Energie AG, Linz a. D.)

  Other advantages include: ++Reduction of total costs (rate of interest for the investment plus energy costs) ++Reduction of pollution and CO2 emission ++Reduced dependence on fossil fuels Outstanding results - our best recommendation!

++COMMON CONSULT GmbH system engineering

We would like to thank our customer referees for their kind permission to print these articles

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WATERKOTTE Group

WATERKOTTE GmbH Herne Development and production of heat pumps and system components right up into the megawatt capacity performance range Back office support for planners Automation and development Completion and supervision of automated solutions, visualization and telemonitoring (even in the waste water technology field)

TERAMEX GmbH Herne, Berlin, Austria

Completion of geothermal probes, probe fields, completion of response tests

WATERKOTTE Partners WATERKOTTE Partners

WATERKOTTE-Austria GmbH WATERKOTTE EuroTherm, Courtaman CH nutherm, Donegal, Ireland Energie Recoursses, Ancona, Italy

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2 Substainable Solutions in Structural Engineering Our definition of a sustainable solution is a solution that saves energy and lowers costs. These include: long life expectancy, low servicing costs and an additional investment, whose annuity is more than compensated for through its energy consumption and the expected energy price development. If these requirements are fulfilled, then environmental compatibility is a self-occurring side effect. Structural engineering is capable of providing the highest level of saving. That is true for all areas such as: ++Private residential construction ++Rental apartment construction ++Administrative buildings ++Buildings with special requirements e.g. hospitals, hotels, supermarkets, shopping centers, indoor swimming pools, sports facilities, etc. Renewable energies Structural engineering generally offers the best conditions for both the collection and use of renewable and recuperative energy. With very little effort, it is possible to lower the required temperature level of the energy supply far enough that it is possible to introduce a highly efficient, sustainable energy supply. To be able to use this possibility, various projects must be included at the beginning of a project development. Carrying out the planning ++Choosing the technical equipment ++Choosing the heat source ++Planning of the automation The result leads to the universal use of heat pump technology: ++For the extraction of renewable energy from soil, water and air. Extraction of geo-thermal energy close to the surface with vertical collectors and probe lengths between 70 and 140 m is the most abundant source. ++For the extraction of energy from waste air and waste water ++For the use of energy management ++For the preparation of cooling facilities Recuperative energy for increasing efficiency Soil, air and water are regarded as primary energy sources. In addition, secondary recuperative energy, whose use increases the efficiency of the heat pump considerably, occurs in technical building equipment: ++Energy recovery via recuperative technology – heat exchange between outgoing and outside air ++Recovery and use of recoverable heat sources with heat pump technology, for example, from outgoing air (air circulation in indoor swimming pools) and waste water ++Recovery and use of renewable energy as well as the redirection and use of surplus energy from the building (cooling) with help of heat pump technology.

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Active cooling, passive cooling In the field of heat pump technology, one defines the expression “passive cooling” as the possibility to lower high room temperatures with geothermal cooling at high outside temperatures. At, for example, 14° C soil geothermal temperature, the fluid in the collector is maybe about 16° C. A circulation pump pushes it via a bypass past the heat pump into the sun heated floor or concrete core or into the ceiling mounted radiant panels. These components cool down by a few degrees. Due to the artificially increased temperature difference, heat now flows from the room air into the screed or concrete or into the panels. It transfers to the fluid there. Its temperature is now considerably below the soil temperature now. With this the direction of heat circulation reverses: the collector stores the room heat in the ground or in the ground water, instead of extracting energy from these sources. The consumption level of electrical energy is minimal. Only the circulation or delivery pump is running, using 80 Watts or so. Due to the natural conditions, passive cooling is limited. In contrast, if one feeds the fluid into the heat pump and one switches the pump to cooling mode, the supply temperatures to the rooms can be lowered even further. This operation, which lowers the room temperature with the support of the compressor of the heat pump, is active cooling. The capacity is around 75% of the heating capacity of a heat pump. A room ceiling is used as a cooling surface. No cold air accumulates below the ceiling, so that new cold air can be constantly produced. If, in contrast, one cools via the underfloor heating, one should make sure there is some convection in the room; this prevents a build-up of cold air on the floor which would slow the thermodynamic process. The cooling capacity via the floor is around 60% of that from the ceiling. On the other hand, the relationship is the opposite when heating. Due to the rising hot air, the floor is the considerably more effective heat exchanger in comparison to the ceiling.

Legionella-free Hot Water In a number of WATERKOTTE objects the planners were able provide germ-free warm water preparation. Legionella and other bacteria are able to breed ferociously at temperatures between 30 and 40°C; that means around the floor of water tanks. There is a health risk for people with weakened immune systems, ill or older inhabitants, if water of this kind runs directly from the boiler to the extraction points in the bathroom or kitchen. The idea of having a heat exchanger flow through heater in each apartment is seen as being safe and conforms to DVGW guidelines. The schema is like this: the heat pump or the hot water condensing boiler feeds the water directly into the heating circuits in the floor for heating purposes. For the purpose of providing hot water, the heat pump supplies a separate condensing boiler. It does not supply the sanitary installations directly. The warm water circulates through one decentralized heat exchanger per apartment and heats fresh cold water here. These heaters function like normal flow-through heaters. Therefore the heating water in the tank does not come into contact with the drinking water. It flows back to the condensing boiler. This configuration has another economic advantage: each apartment only requires one singular cold water meter to measure warm and cold water consumption.

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COMPANY PANALPINA

Panalpina: Optimisation through responce test Objekt: Builder: Planning: Year of construction: Heat source: Heat pump: Collector: Operation:

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Logistikzentrum Panalpina, Stuttgart Panalpina Welttransport GmbH Ingenieurbüro Gedinia, Korb 2005 Screed 2 x DS 6271.3, 220 kW 11 probes à 150 m Heating: 7000 m² Cooling: RLT-System

The Panalpina Welttransport GmbH, Stuttgart, is a subsidiary of the Panalpina group. During the winter, the 8400 m² hall has to be heated from a temperature of 10° C. In addition, there are 4500 m² of office space to be heated or climatised. There are 40 geothermic probes on the property; they are each 150 m deep. The drilling work was preceded by a response test. This provides information about the extraction capacity of the ground. Of course, the results of the test provide information as to the number of probes required. An estimate is normally sufficient for smaller sites. When dealing with systems above 50 kW, the expense of a response test is normally recuperated through the savings made by knowing the precise number of metres to bore. 40 was the exact number of bore holes recommended by the onsite analysis. Heating panel for room heating

The logistic centre required a heating capacity of approximately 380 kW. It must be heated to at least 11° C. This task is completed by a surface heating system in the floor panels. In this case, it is actually a surface heating system: there is no heating provision cooling in the hall.

A second heat pump supports this installation, in that it is only responsible for providing hot pumped air at temperatures between 20 and 22° C in winter. A heat exchanger, which transfers the low ground temperature to the supply air, is integrated into the switching system of the cooling system in summer.

On the other hand, there is cooling for the office building. The engineering office Gedinia from Korb did not incorporate any concrete core activation. The reason for this was that a second, faster reacting, heat distribution system had to be installed. The planner Gedina: chose a larger cooling panel and therefore did not install any thermal active measures. “The metal panels below the ceiling heat and cool. They are connected to the first of the two heat pumps. The cooling load for cooling in summer is dealt with by a separate heat exchanger; this bypasses the heat pump at a ground temperature of 14 or 15° C. 9

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VOLKSBANK MÜNSTERLAND e.G.

Volksbank Rheine: Energy Efficieny as a duty to the customer Object: Builder: Planning: Year of construction:

Bank building Volksbank Rheine Volksbank Nordmünsterland e.G., Rheine Ingenieurbüro Temmen VDI, Rheine 2005

Heat source: Heat pump: Kollektor: Operation:

Soil 3 x DS 6388.4, total capacity 600 kW 50 Vertical probes à 130 Metres Heating/Cooling

A scenario where the managing director of a company has to explain an internal company decision to his or her customers is not normal, unless of course the company is an incorporated association. The reason for this is that the savers themselves take part in the highest decision making event, the general meeting. They own the shares. It was therefore an unwritten clause in the specification data of the planning and building of the Volksbank Nordmünsterland e.G. in Rheine that one should be particularly careful with the savers’ money. This rule was of course observed. The careful consideration of all the alternatives for heating and cooling the building all came to the same conclusion: the geo-thermal heat pump was the answer. Comfort and cost-effectiveness spoke – and speaks – for this sustainable solution.

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The responsible economic thinking of the bank management is not only proven by the choice of a heat pump. But by the fact that even in the difficult banking year of 2008 the bank managed to steer a successful course. Whilst many renowned national and international financial institutions had to deal with sometimes existence threatening losses, the bank managed to make a profit. The balance sheet total of the Volksbank Nordmünsterland e.G. rose 7.9 % compared to 2007 to 1.15 (2007: 1.06) billion Euros.

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LVM-INSURANCE

LVM Münster: Architecture- and Energy Prize Object: New building Landwirtschaftliche Versicherungsverein Münster LVM Builder: Landwirtschaftlicher Versicherungsverein Münster Architect: Duk-Kyu Ryang/ HPP Architects and Engineers, Düsseldorf Planning: Ingenieurbüro Nordhorn, Münster/ TEB, Vaihingen/Enz, Erdsondenfeld TERAMEX, Herne Year of construction: 2008 Heat source: Soil Collector: 92 Vertical probes, 70-100 Metres Function: Heating/Cooling

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Pro heat pump: One of the largest soil probe fields in Germany heats the new building of the Landwirtschaftlichen Versicherungsverein Münster LVM. 92 to 100 metre deep probes temper the concrete core. The architecture and energy concept are so harmoniously coordinated that the object has won the award, “energieeffizientes Bauen für die Zukunft” (energy efficient construction for the future) from the NRW ministries for construction and roads and economics and energy. NRW minister Christa Thoben presented the prize at a ceremony at the 16th of February.

Special feature: The insurance company’s building (3 million customers, 9 million contracts, 2.3 billion turnover) requires only 44 kWh/m²a in primary energy. The total office area is 8800 m² the area to be tempered (heating and cooling) is 6025 m². Concrete core tempering provides comfortable room temperatures. Annex 48 analyzes and documents consumption data and temperatures in the buildings of the insurance concern over many years. The aim is to observe the effectiveness of energy concepts of this kind in practical situations and to discover possible optimizing potential.

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Residential Complex

Sonnenstraße Residential Complex: 16 probes heat 50 apartments Object: Residential Complex Sonnenstraße 99 105, Düsseldorf Builder: Boss Bau GmbH & Co KG, Düsseldorf Architect: Architekturbüro Schwingen, Düsseldorf Planning: PBS & Partner, Erkrath Year of construction: 2005 - 2006 Heat source: Soil Heat pump: Type DS 5194.3, 150 kW Collector: 18 Vertical probes à 100 m Operation: Heating with heat recovery

Pro heat pump: When the first inhabitants moved into Dusseldorf’s Sonnenstraße 99-105 in 2006, this complex was considered the largest geothermallyheated residential complex in North-Rhine Westphalia. A total of 1800 metres of geothermal probes heat the 55 private residential units, split into two to four room apartments. Heat requirement: EnEV standard (German Energy Saving Ordinance). As well as the exchanger field, heat pumps and waste heat recovery from six hot water tanks each containing 950 litres, the heat is provided by an additional separating tank and high-capacity heat exchangers for each apartment. These peripheral 54 kW plate heat exchangers satisfy the hot water demand for kitchens and bathrooms. Special feature: The six hot water tanks take priority over the heating system when it comes to supplying heat. Depending on the time of day and the season, the closed loop control can remove the underfloor lines

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from the network for half an hour or even a whole hour, under certain circumstances. The large circulating water quantity might bridge a certain time span without any noticeable effects on the room temperatures. However, the planners saw a certain residual risk in terms of the heating technology in the priority circuit of the water heating system. Therefore, they integrated a 980 litre separating tank and assigned it two fundamental tasks: to benefit from longer operating times for the heat pump due to the now-enlarged heatable water volume, and, as mentioned, to benefit from sufficient heat supply.

Ralf Mnich, managing director of PBS says, “The hydraulic adjustment of an exchanger field is decisive for the function and for the heat loss performance. The modern probe distributor by WATERKOTTE with the adjustable valves makes this precise litre adjustment possible. Each probe must actually have the fluid amount allocated to it, irrespective of the distance, meaning irrespective of the resistances. We preset the water amounts using the level indicators on the distributor bars and finely adjust them using ultrasound measuring equipment.”

Of course, the PBS planning office did not break any new geothermal ground with the “Sonnenstraße” complex. Anyone venturing onto the 400 m² heat pumpheated living space can rely on its extensive wealth of experience. An iron rule has emerged from this experience for PBS: there is no approval of the installation if the individual vertical lances in the exchanger field are not exactly adjusted down to the last litre for the hydraulics.

Now, of course, surprises can still lurk in the form of temperature deviations due to local geological inhomogeneities in the ground. However, this event of fault is kept within limits. In his radius of activity, Ralf Mnich has not yet registered any major deviation from the forecast loss performances or from the information in the geothermal maps supplied by the geological surveys of Germany. 15

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IKEA

IKEA Cologne: Heat pump creates shopping environment Object: Builder: Architect: Planning: Year of construction: Heat source: Heat pump: Well: Operation: 16

Newbuild IKEA, Butzweiler Hof, Cologne IKEA Deutschland GmbH & Co. KG Schindler Ingenieurgesellschaft, Dietzenbach Schindler Ingenieurgesellschaft, Dietzenbach 2009 Groundwater (Geothermal energy) 2 x DS 6500, (380 and 480 kW) 4 wells (suction/injection wells) 70 m deep Heating/Cooling

Pro heat pump: In March 2009, IKEA started work on their second branch in Cologne, at the time this was Germany’s largest IKEA store. In “Am Butzweiler Hof”, the location and name of the store, IKEA implemented its company sustainability strategy of using renewable energy. The furniture store spent 2 million Euros for the use of geothermal heating via ground water and heat pumps, for solar collectors and the roof rainwater system with two underground tanks as reservoirs for water for flushing the toilets and extinguishing water. Large scale underfloor heating, ceiling mounted radiant panels and ventilation devices with heat recuperation transfer heat in the sales areas. The entire investment in the building (without) land was 65 million Euros. Two different systems, a high temperature circuit and a low temperature circuit, heat and cool the building. The high temperature circuit produces heat with two gasfired boilers. The central is located on the 2nd floor. The boilers supply, among other things, the room ventilation

technology, the door curtain systems and the warm water preparation in winter. In summer, this work is done by the solar system. Special feature: The low temperature circuit consists of two heat pumps (Type DS, 380 and 480 kW, controlled power output 75-100 %). The heat is extracted from the groundwater with wellheads. The central is located on the first floor below ground. The heat pumps supply the following groups: - Ceiling mounted radiant panels in the market place and furniture exhibitions - Underfloor heating - Greenhouse (low temperature circuit)

mum of 3 K. The engineers set the circulation volume, the heat exchangers and the heat transfer in the salesrooms (ceiling mounted radiant panels, underfloor heating) according to this spread. The same jump of 3 K is also valid for the cooling scenario: the increase in temperature is allowed to be a maximum of 3 K. In regards to the average well temperature of 14° C, the limits for the building technology are 11 and 17° C The planning predicts the following system temperatures: Heating - Supply/ return heat pumps 38/33° C - Supply/ return ceiling mounted radiant panels 38/34° C - Supply/ return underfloor heating 35/30° C

When heating, according to the regulations set down by the Cologne water authorities, the well water returned to the ground may only have been cooled by a maxi17

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IKEA

Cooling - Supply/ return heat pumps 12/17° C, after the heat exchanger 14/19° C - Supply/ return ceiling mounted radiant panels 15/19° C - Supply/ return underfloor heating 16/19° C The pipes in the floor can supply the basic load for heating. The residual heat is supplied by the boilers; the residual cooling is supplied by the ventilation systems. The current supply temperature of the two control circuits (underfloor heating, ceiling mounted radiant panels) adjusts itself according to the inside dew point and preserves a safety margin of 1 K above the dew point. To prevent a constant chopping, of the heat pump, which would have a negative effect on longevity and efficiency, the planners included water tanks as buffers. When starting up, the control unit guides the supply past the containers via a bypass; this means that heat or cold is available at the distributor more quickly. In addition, the electronics appoint the heat pump with the 18

lowest running time to the leading machine, this takes place on a weekly basis; in the case of malfunction the second machine takes its place. The switch to heating takes place at an outside temperature of below 16° C, delayed by 16 hours, the switch to cooling takes place at an outside temperature of above 16° C, now the delay is 6 hours. A comfortable climate in the salesrooms increases the propensity to buy. At outside temperatures of up to 24° C the ideal temperature in the (Ikea) salesrooms is 22° C. If the temperature rises, then it can be a few degrees warmer. In the case of cooling, socio-psychological and physiological factors of this kind play a very important role in summer as far as buyer behaviour is concerned. The control electronics take these influences into account. In normal conditions, they stabilize the room temperature at 22° C, but track the temperature when

the sun has reached its highest point. At a temperature of 35° C, they allow an inside temperature of 28 or 29° C. The microprocessors initially control the nominal value with the free cooling; they do this by transporting relatively cold water through the ceiling panels, although through an intermediate heat exchanger. If this is not sufficient, then the heat pump switches on as a cooling machine. If it becomes apparent that the groundwater temperature is too high or the load is too heavy to keep to the 3K limit or to 17° C, then the cooling tower must be used.

changer. That is the reason for the alternating system. The supply and return temperatures, the temperature differences and the water volumes of the wells are all stored by the IT systems; the system documents the water volumes uses the trend curves as proof that the limits which have to be observed are not breached. The plans stipulate a maximum annual capacity of 210 000 m³ for cooling and 370 000 m³ for heating. The network is designed to have a peak capacity of 190 m³/h for cooling and 280 m³/h for heating.

The planners have thought of this as well: the total of 4 wells work in pairs and alternately as wellheads or injection wells. Firstly, the constant injection of cold water would cool the ground down, secondly, when cooling; one wants the coldest possible water in the heat ex19

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Bergische Achsen

Bergische Achsen: Practice confirms simulation Object: Test centre Bergische Achsen, Wiehl Builder: BWP Bergische Achsen KG, Wiehl Planning: CommonConsult/Metternich Haustechnik/Integral Ingenieure Year of construction: 2008 Heat source: Soil Heat pump: DS 5072.3, 52 kW heating capacity, 39 kW cooling capacity Collector: 10 Vertical probes à 99 Metre Heat requirement: Low energy house Operation: Heating/passive and active cooling

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Pro heat pump: Since autumn 2008, the heat pump system has heated the upper office floor as well as the QS test centre on the ground floor at the automobile industry supplier Bergische Achsen KG. QS stands for quality and safety. The tests are carried under the most stringent conditions. To prevent the test results on the gigantic marble tables from being compromised, the room temperature, for example, is not allowed to deviate from the intended temperature of 20° C +/- 1° C. Despite their inertia, the planners CommonConsult as well as Metternich Haustechnik, Windeck, suggested concrete core cooling, supplemented by solarstores as shadowing elements and a ventilation system as a dynamic component. CommonConsult had previously had the feasibility of the project investigated by Integral Ingineure, Aachen. Assignment: examine the thermal behaviour of

the object with the performance data of the DS-heat pump – heating capacity 52 kW, cooling capacity with activated cooling 39 kW; these values already incorporate a reserve. The switching system included and includes provisions, among other things, to cool the QS testing centre passively in summer, with only the deficit being actively balanced. The simulation included the key data about the building, the topological height, the temperatures in the region etc. The virtual test run did not discover any weak points in the precise planning. It confirmed the accuracy of the design. Special feature: As a result, the customer gave the schema the go ahead. This was due to the fact that the cost-effectiveness of the schema overwhelmed the alternative - a gas heating system plus air-conditioning. The investment costs of both solutions were on a similar level, the running costs were seen to be on a ratio of 1:4. The heat pump system only has ¼ of the running

costs of the gas heating system. The balance after the real winter test 2008/2009: the guaranteed temperatures were maintained. BPW Bergische Achsen Kommanditgesellschaft (limited partnership) is Europe’s leading manufacturer of axles and chasses for lorry trailers and semi trailers. The company in Wiel near Cologne manufactures mainly heavy axles (axle load 5.5 t).Their output in 2008 was approximately 550 000 pieces. The family owned and run company has 12 production plants in Hungary, Italy, South Africa and China to name but four –and twenty distribution companies. The company group employs around 5000 employees. In 2008, the company had a turnover of about 1 billion Euros.

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SANDVIK Holding

Sandvik Düsseldorf: Heat pumps also as cost-effective cooling systems Object: Builder: Architect: Planning: Year of construction: Heat source: Heat pump: Collector: Operation:

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Administration building Sandvik Holding GmbH, Düsseldorf Kai 18, Düsseldorf Architekturbüro Schwingen, Düsseldorf CommonConsult, Herne 2005 Soil 3 Type DS, configured as cascade, total capacity 270 kW 30 Vertical probes, total 4000 m Heating, passive cooling, active cooling, ventilation with heat recovery

The Sandvik Group is an internationally active, Swedish company with its focus on tools for machining, mining products and metal processing (stainless steel). In 2008, the Group employed 50,000 employees in 130 countries. The turnover was 93 billion Swedish Kroner (approx. 10 billion Euro). Germany-based Sandvik Holding GmbH is based in Düsseldorf, has offices and branches in Tübingen, Renningen, Fellbach, MörfeldenWalldorf, Frankfurt and Essen among other places. With about 3900 employees, Germany contributed 7 percent (700 million Euro) to the Group’s transactions in 2008. The Holding in Düsseldorf moved into a new building on Heerdter Landstraße in 2005. A canteen area and larger kitchen are attached to the four-storey management building. Heating, cooling and hot water provision for both the offices and supply equipment is carried out monovalently by the three heat pumps. They operate the concrete core cooling system, various water reservoirs and the ventilation system.

Pro heat pump: The installation was connected to a geothermal response test with building simulation (EED simulation). It had to provide information on whether the soil on the land had sufficient energy. The test was positive. On the basis of the simulation assuming the statistical local temperatures, the annual energy costs for the entire building amount to 29,500 Euro for the geothermal system. With a natural gas boiler plus cooling system, the annual gas and electricity bill would amount to 55,100 Euro. Therefore, the saving is 25,600 Euro. In addition, CO2 emissions are reduced to just 40 percent in comparison to the boiler system with cooling system. Two of the heat pumps are responsible for heating and cooling. The third provides the very hot water for the kitchen. They travel with different coolants, depending on the different target temperatures.

Special features: The entire plant is designed for several operating conditions. Firstly, “heating” with the participants: exchanger field (geothermal energy) plus heat pump system plus concrete core cooling. Secondly “natural cooling” with the participants: exchanger field (geothermal cooling, fluid temperature about 15 – 18 °C) plus concrete core cooling, i.e. without heat pump. Thirdly “active cooling” with the participants: exchanger field (geothermal cooling) plus heat pump as cooling system plus concrete core cooling. Furthermore, the plant manufacturers realised a fourth circuit for ventilation and de-aeration with waste heat recovery (in heating operation) or for passive cooling in the summer. In the second case, the air register flushes the fresh night air, which is some degrees below the room air, through the offices bringing down the entire thermal temperature mass after the office has shut down for the night. 23

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Terraced Housing, Düsseldorf

Terraced Housing in Düsseldorf: Waste heat Increases Brine temperature Object: Two houses with 15 apartments, Cloppenburger Weg, Düsseldorf. Builder: Boss Bau GmbH & Co. KG, Düsseldorf Architect: Architekturbüro Schwingen, Düsseldorf Planning: PBS & Partner, Erkrath Year of construction: 2005 Heat source: Soil Heat pump: DS 5072.3; 71.8 kW, tandem configuration (2 compressors) Collector: 9 Vertical probes à 70 m Operation: Heating with heat recovery

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Pro Heat Pumps: Heat pumps and underfloor heating in 15 dwellings at Cloppenburger Weg in Düsseldorf cover an average living area of 85 sq. metres. Both buildings were constructed in 2005 in accordance with their structural-physical specific values for the standard EnEV house. Since consumer behaviour has a significant impact on heat consumption, the building contractor, Bossbau, did not invest in insulation measures exceeding the EnEV standard, since if windows were opened, the potential gains would be lost. The improved effectiveness of efficient heating technology, on the other hand, essentially leads to more cost-effective heating. Due to the two compressors, the tandem heat pump permits staged energy regulation dependent on heating needs. In accordance with the regulation governing heating costs, the costs incurred for use of a heat pump are to be calculated not in terms of the actual energy used in the individual apartments, but on a collective basis according to the total living area. The landlord

fixed a tariff of 1.0 euro per sq. metre and was adequate an adequate sum for the first two heating periods. Special feature: The heat pump works on two condensing boilers – one for heating and one for drinking water. The planners projected 1,900 litres of drinking water at a temperature level of 55° C. When fixing this volume, simultaneous usage of all 15 dwellings was taken into account, primarily with respect to water consumption for early morning showers. During a time period of about 1.5 hours, the boiler must have the capacity to cover for a specific maximum simultaneous usage. However, it does not directly supply the tapping points in the kitchen and bathroom. Instead, each apartment has a heat exchanger similar to a flow through heater with 54 kW. In circulation, hot storage water tempers the inflow of cold water. This ensures that bacteria (legionella), which may potentially form on the tank floor, cannot enter the drinking water. Since tap water preparation has priority, during the early morning, in particular, the screed tem-

perature may not be sufficient to cover heating needs for the dwelling. Therefore, the building technicians also set up a boiler for hot water in the heating room at Cloppenburger Weg. The dimensions are such that it can cover requirements during the shower phase. It is charge up to 45° C. When heating the operating factor of the heat pump is between 4.5 and 4.8. Controlled ventilation in the living areas prevents damage in the apartments due to damp and mould formation, and is installed as a central unit. Users cannot change the setting. Due to the airing composite (door slits) in the apartments, disc valves are sufficient for extraction both in the bathroom and kitchen. A collector duct extracts the waste air to the ventilation unit with heat recovery in the conical bottom of one of the two buildings. The exhaust air emits about 50 per cent of its heat content to a water circuit that uses this recovered energy via another heat exchanger to raise the fluid temperature to the heat pump and therefore increase efficiency. 25

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Residential estate

Niehler WohnArt: “Start of the regenerative Era” Object: Builder/ Architect: Planning: Year of construction: Heat source: Heat pump: Well: Operation:

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Residential estate “Niehler Wohnart”, ca. 400 apartments/detached houses GAG Immobilien AG, Köln CommonConsult, Herne 2007 – 2009/2010 Groundwater 10 x Type DS, total capacity 1.7 MW 21 suction and injection wells Heating

GAG Immobilien AG, Cologne’s dominating housing association with about 42,000 apartments and about 100,000 tenants, began to construct several hundred apartments and houses on the former Siemens site on Amsterdamer Straße in Köln-Niehl in March 2007. Specifically, Niehler WohnArt is made up as follows: 50 KfW-60 standard privately owned homes, 89 privately owned apartments and 265 state-aided apartments. The 1.7 MW needed for heating adds up to ten systems with capacities of 160 kW (Type DS 5162) and 190 kW (Type DS 5193). The machines permit a capacity control of between 70 and 100 %. Pro heat pump: GAG managing director Günter Ott says, “This geothermal energy project is not a pilot project. Rather, it is the beginning of an implementation of state-of-the-art regenerative energy into the building practice – in major dimensions. We crossed the threshold of experiment a long time ago. “The GAG has already implemented regenerative energy projects in another site together with sustainable construction and lots of projects are “in the pipeline” (Ott).

Boiler

Buffer

suction well (temperature 13.7 °C)

Drilling 25 m

For example, the solar settlement of Westend in Ossendorf is worth mentioning. This measure has 144 apartments in its portfolio. The use of further heat pumps is also planned for new-build settlements in Köln-Müngersdorf and in Koln-Zollstock. In Köln-Vingst, GAG avoids about 7000 tonnes of CO2 each year after the energetic modernisation of 2,082 apartments. In the old building state, 9,000 t/a of CO2 were accrued. This pollution is now only 2000 t/a for the renovated properties. Undersecretary Werner Lechner from the Ministerium für Wirtschaft, Mittelstand und Energie NRW also spoke in favour of the heat pump, “The trend to use environmental heat is continuing. The fact that the conditions for using geothermal energy including groundwater, one of the effective energy sources for heat pumps, are particularly good in North-Rhine Westphalia also contributes to this. About 70 percent of the state’s area is fantastically suited to this, according to investigations by the geological surveys of NRW.”

Heat exchanger injection well (temperature 11.2 °C)

Special feature: Groundwater as heat source. The total of 21 suction wells and injection wells allows heat extraction of 1.7 MW. This underground architecture with borings no deeper than 30 metres has been given approval by the Untere Wasserbehörde. In Köln-Niehl, a giant earth exchanger field would have been required for the 400 apartments if geothermal energy were to be used instead of groundwater. This did not come into question for both reasons of cost and technology. Due to its strength in the immediate Rhine proximity, the groundwater flow offered itself as an alternative. The additional costs in comparison to condensing boiler technology should be amortised in seven to ten years. Managing director Ott says, “The heat insulating package and modern utilities management systems keep the auxiliary costs low. Rent has increased by about 8 percent in the last 8 years, auxiliary costs by about 73 percent. This makes investment in alternative energy forms all the more important. “The entire investment by GAG for the construction of 404 apartments and houses in “Veedel mit Hätz” amounts to about 70 million €. 27

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Semi-Detached House

Renovation of Ruppichteroth Semi-Detached House: Geothermal Energy instead of Fuel Object: Residential and commercial property Ruppichteroth/Bergisches Land Owner: Keßler family, Ruppichteroth Renovation planning: Metternich Haustechnik, Windeck Year of construction: ca. 1900, renovation 2000-2008 Heat source: Soil Heat pump: DS 5062.4, tandem configuration, 34 kW Collector: 10 vertical probes, total 700 m probe length Operation: Heating

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Pro heat pump: Mr and Mrs Keßler, who own the property, are moving from oil to geothermal energy in their historically-significant property made of Bergisch quarrystone. The over 100-year-old building accommodates five families over 700 square metres of living space and is also used commercially. Major renovation works began in 2000 – new roof, insulating glazing, 12 cm insulation on the external walls – and ended in 2008 with the installation of the heat pump system. The high and climbing heating oil costs of the previous oil heating system clinched the decision to change to cost-effective environmental energy. The Keßlers took advice on a tandem system with two compressors because they must work with relatively high supply temperatures in the frosty periods as their house has no underfloor heating. The owner left the – already oversized as a result of the additional insulating measures - radiators. However, in some parts, the renovations made new radiators necessary. The heating installer designed these to a maximum supply temperature of 50 oC. Radiator heating tends to mean that the heat pump must cover a broad range of different capacities in times of heating.

Special feature: A tandem system with its two levels (2 compressors) fulfils this task particularly economically. If the building tends only to place a small load on it, it then it only works with one compressor. This enables a longer lifespan. This, in turn, has a positive effect on the internal refrigeration circuit which increases the annual coefficient of performance: as a result, the intelligent control in the WATERKOTTE heat pumps has enough time to optimise operation and ensure that the heat generator runs for 15 or 20 minutes with ideal values. With single compressor systems, the compressor, which is oversized for partial load, would only start up temporarily in order to immediately turn back off. This damages the lifespan and efficiency. For this reason, tandem systems are recommended specifically for properties with heavily deviating performance requirements. The control strategy can be adjusted in parallel for three different consumers: for the water heating system with condensing boilers, for the underfloor heating and for a swimming pool, if there is one, for example, in hotels, commercial properties, apartment blocks, etc. As a

general rule, the return temperature is taken to be the reference variable for the underfloor heating, for condensing boilers it is the water temperature in the boiler and for swimming pools it is the pool water temperature. Individual target values and circuit times can be programmed for all three consumers. For a renovated old building without underfloor heating, the stated annual coefficient of performance of 3.5 including hot water provision is a good value in the relatively cold heating period of 2008/2009. It complied with the specification. In concrete terms, the property needed 15,130 kilowatt hours of electricity according to the heat pump meter in 2008/2009. Converted to the 700 square metre residential area, this means 22 kilowatt hours of ultimate energy per square metre and year. As a result, the Ruppichteroth renovation corresponds to a better level than the new building standard in accordance with Energieeinsparverordnung (Energy Saving Ordinance) of 2007 which was valid at the point of renovation.

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„Brügger Mühle“

„Brügger Mühle“: Rainwater heats and cools in the Neandertal Valley Object: Cultural and service complex “Brügger Mühle”, Erkrath Builder/ Investor: Hasso von Blücher, Blücher Gruppe Planning: CommonConsult/PBS & Partner, Erkrath Year of construction: 2005-2008 Heat source: rainwater/Groundwater Heat pump: 2 Type DS 5136.3 Collector: 10 vertical probes, total 700 m probe length Operation: Heating, passive cooling, active cooling

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Near to Düsseldorf, in the romantic Neandertal Valley, through whose gentle slopes the River Düssel meanders, Italian quarrymen dug up 16 bone fragments and a skull in 1856. Bonn-based scientists added to these findings with further anatomical excavations of Homo neanderthalensis. The Neanderthal made the Auen landscape world-famous. However, in the past, something disturbed the idyll, an industrial wasteland in the valley with a crumbling old paper factory in the centre. However, over the past years, this has been transformed structurally, technically and scenically into a modern cultural, art, residential and service centre while carefully integrating the historical substance. Today, the total floor area is 5500 m2. Patron: Hasso von Blücher, descendant of the legendary field marshal of the Napoleonic Wars. Pro heat pump: Neandertal Valley – environmental technology meets nature. In the redesign, ecological aspects had to play a major role. This obligation is complied with by the heat pump energy cascade. Its energy source: the reservoirs of the former paper factory. In which, the intermediate product wood pulp was stored

in the past until it softened into mush. Now, in the “Brügger Mühle” project, the builders are now assigning the task of an energy store to the reservoir. They operate the heat pump energy cascade, consisting of two Type DS machines, with the rainwater collected from the roofs and car parks. It goes without saying that the supply engineering also allows for a longer dry period. As a substitute, the reservoir is filled by groundwater pumps from 32-metre deep wells. A hollow floor for heating, cooling and ventilating is installed in the rooms (‘ClimaLevel’ brand, Cologne). This type accommodates the heating and cooling pipes as well as the cables. In addition, it guides the supply air that is preheated in the floor through the circuits to the rooms. Using slotted outlets beneath the window, it expands into offices and apartments. This ventilation architecture promises the highest levels of thermal comfort in connection with underfloor heating, according to experiments at the Universities of Copenhagen and Dresden. Special feature: The entire management and control system was realised by the Computer Process Control department of WATERKOTTE GmbH. They networked

the reservoirs, the well pumps, the change-over valves and the heating, air conditioning and ventilation control system of the entire building. The well and reservoir pumps also provide the flood control measures on the site. The engineers set up a server in the PBS + Partner offices for remote control and parameterising. This server communicates with sensors and actuators in the system using modems, regularly records the operational conditions and provides the technicians with decisive data on how to optimise operations. In this way, the data processing analyses the current situation of the control strategy from the measurements of external and internal temperatures, incoming and outgoing air, the reservoir water and ground water. A look at the amortisation times. In comparison with a conventional heating system with, for example, a fuel value gas boiler and air-conditioning technology with classic cooling system, the heat pump technology is amortised after seven years based on energy savings according to the cost calculation using the decisive VDI guidelines. 31

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SolarWorld

Concern Headquarters Bonn: Heat Pumps in SolarWorld Object: Restructuring of water works for company headquarters Builder: Frank Asbeck, SolarWorld Holding AG Architect: Architekturbüro Ralph Schweitzer, Bonn Planning: PBS & Partner, Erkrath Year of construction: Restructuring 2008/2009 Heat source: Groundwater Heat pump: 4 x DS 5109, total 240 kW Well: Historical well on premises, return via an artificial lake into the Rhine Operation: Heating/Cooling

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Concern director Frank Asbeck has relocated the company headquarters of his SolarWorld AG to a listed disused waterworks site in Bonn. The rise of the city to the Federal capital is reflected in the architectural style of the building complex of the former “waterworks”: the ornamental industrial culture of the Gründerzeit period with rugged whitewashed brickwork connects with the very geometrical glass brick architecture of the 1960s, when the Prussian portfolio had to be expanded with a high-performance new building. The Federal Republic’s capital’s thirst for water wanted to be quenched. Then, 50 years ago, technical history met technical present in the area. Today, on Martin-Luther-King-Straße in Plittersdorf , technical past, technical present and technical future all collide: in the form of the requirement to integrate the existing infrastructure of installations and pipes of the old waterworks into the use of the property and into the heating system with an energy and resource-saving groundwater heat pump energy cascade. This condition was a challenge for all parties concerned.

Example of use: The workplaces are scattered in the open spaces between the retired water processing plant or are located in the shut-down active carbon filters with 4 m diameters. Example of heating: as well as the powerful, former well water pipes with 700 mm diameter, the installers fed in a new groundwater pipe system with 200 mm diameter. It had to be regenerated because a full 700 mm cast iron pipe of umpteen metres in length needs a considerable reservoir volume when disconnecting the heat pump, which would lose several temperature degrees in the winter meaning the heat pump efficiency would be reduced. Optically successful integrations run through the entire property. The SolarWorld AG concern is among the global leaders of high-quality solar energy technology suppliers. Turnover in 2008 was about 900 million Euro, generated by 2500 employees. The company is active on all value added levels from the raw material silicon through to turnkey solar energy plants and solar energy power stations including recycling and is present on all the solar growth markets of the world. The largest production sites are in the Saxon town of Freiberg and in Hillsboro/ USA.

Pro heat pump: The corporate management feels committed to sustainable, economical, ecological and socially justifiable growth. Not just in Germany. Under the name Solar2World, the concern also carries its ethical fair development commitment into emerging markets and developing countries. This sustainability is visibly and noticeably reflected by the renovation of the waterworks in the Auen landscape on the banks of the Rhine into the management headquarters. Visible and noticeable in a positive sense: The builders are not imposing a reflective silicon tent over the listed building. Instead, a reminiscent architecture was designed, which deals extremely carefully with the past and future. Nevertheless, with its 600 square metres of photovoltaic in balustrades and on roof areas, the title “Solar House” may prevail. The architects added on the younger building specifically, those from the 1960s, with an open-plan office as the third floor. They demolished the neighbouring atomisation tower, which enriched the drinking water with oxygen during its active period, through to the first floor in order to reconstruct it as a management tower.

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SolarWorld

Concern Headquarters Bonn: Heat Pumps in SolarWorld Historical building cores, the maintained nature on the company’s land, pot-bellied pigs and fallow deer in the bushes near the main building, the clean chalky-white of the old facades intensify the tangible peacefulness of the corporate philosophy, business and product – no place for gas and oil, of course not. Frank Asbeck wanted heat pumps and approved the Type DS because he also maintains the temperature of his private house satisfactorily with the WATERKOTTE brand. Special features: The heat pump energy cascade consists of two lots of two machines. They are connected alternately as a component in order to run two different temperature levels. This is because the preservation order has forbidden heat-insulating measures being added to the old building. Therefore, the cast iron radiators are staying in the building, supplemented, in part, with panel heaters and ceiling heating elements. This also compelled the planners to design two temperature circuits, a high temperature circuit up to 65° C for rooms with a high specific heat requirement and one for lower temperature heat. The second operates the underfloor heating, panel heaters and concrete core cooling and ceiling heating elements respectively. 34

To store the heating water, the plant manufacturer set up three condensing boilers, each with 1500 litres of content. Two containers supply the lower temperature consumers – which are also connected to the passive cooling system – and the third tank stores supply temperatures above 50 °C. The two heat pump components start the two levels on an alternate basis. As the heating medium is taken from the groundwater flow and fed into the Rhine flow, several authorities are involved in the water authorisation. For example, the Landesamt für Natur, Umwelt und Verbraucherschutz NRW in Recklinghausen for the groundwater, the Untere Umweltbehörde for the city of Bonn for malfunction reports for the wells. Various obligations result from this. For example, removal of the groundwater is limited to the following quantities: 11.6 l/s, 42 m³/h and 30,000 m³/a. The inlet temperature into the Rhine must not exceed 25° C.

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