Smart Energy Plant: 20–40% More Efficiency via Heat Recovery

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Expansion of the Hilzingen heating network – biomass used with maximum efficiency

District Heating Hilzingen, Solarcomplex AG, Singen, Germany

The Hilzingen heating network is growing, and with it the responsibility for a sustainable energy supply. Solarcomplex is taking on this responsibility. For 25 years, the company has been planning, building, and operating plants for the supply of electricity and heat from renewable energies.  

Wood, a valuable commodity

When expanding Hilzingen, the approach was clear from the outset: renewable energies and wood form the backbone of the heat generator, in the knowledge that natural resources are a valuable commodity that must be treated with respect and used in the best possible way.

 Expansion of the heating plant with innovative spirit

With active flue gas condensation and maximum efficiency gains, the municipality of Hilzingen and Solarcomplex are going one step further. For the expansion of the heating network, this means that an absorption heat pump will be used in addition to a flue gas condensation system.

In order to achieve optimal results in flue gas condensation, a network return temperature of less than 50°C is required. This value is often exceeded in existing networks. In the new heating plant in Hilzingen, the return temperature is now lowered with an intermediate absorption heat pump and forwarded to the flue gas condensation system.

The absorption heat pump has the advantage that it is powered by warm water from the wood chip boiler and thus consumes only a fraction of the electricity.

Intelligentge Energiezentrale - multimodal, hocheffizient und CO2-neutral
Intelligentge Energiezentrale - multimodal, hocheffizient und CO2-neutral

Technology from a single source – a reliable partnership

Schmid has long been a trusted partner for us – we have already successfully completed numerous projects together. The reliability of the systems plays a particularly important role for us. Schmid provided us with a complete solution from a single source: from the wood chip boiler to the flue gas condensation system with absorption heat pump – everything seamlessly integrated and tailored to our requirements.

Thanks to this integrated solution, we not only benefit from maximum efficiency, but also from a well-designed system that is tailored to our needs. The combination of modern technology and sustainable energy generation sets new standards in terms of environmental friendliness and cost-effectiveness.

This powerful combination takes the efficiency of our plant to a new level.

Edgar Kunz, Chief Technology Officer, Solarkomplex AG

Key data of the network

Consumers: 278 house transfer stations / network length approx. 17 km
heat requirement: 11 046 MWh/a Commercial and residential development,
Capacity (without GF): 8.047 MW
Capacity (with GF 0.5 WG/0.7 GEW): 4.812 MW
Capacity (with GF 0.5 all): 4.024 MW
Total EE generators: 4 100 kW
CO2savings / fossil energy:approx. 2 350 t CO2 / a or approx. 1.3 million liters of oil
buffer tank: 75 (existing) and 150 (new) m³ (water)

Brief information

Plant type: Boiler 1: UTSR-2400 visio moving grate boiler, Boiler 2: UTSR-900 visio moving grate boiler
Control system: PersonalTouch visio, Revolution adaptive
Operating medium: warm water max. 110°C
fuel: forest woodchips/forest maintenance wood (P63)
Capacity and use: 2 400 kW and 900 kW / 3 300 kW for district heating

Efficiency-enhancing measures:

  • Revolution adaptive
  • flue gas condensation HEG-EC-0330 (Heger)
  • Absorption heat pump K3 (StepsAhead)

Silo: 449 m³
Discharge: Drop chute with moving floor
Flue gas dedusting: Multi-cyclone/APF filter
Furnace ash removal system: undergrate ash removal, auger discharge system, BigBag ash removal system 1 000 l
Commissioning: November 2025
Building contractor: Solarcomplex AG, Singen, Germany
Plant site: district heating Hilzingen, Hilzingen, Germany
Project planning: Pro-Energie GmbH, Eschlikon, Switzerland