Liebherr-Werk Ehingen – Retrofit of the paint shops with a focus on energy and sustainability
Liebherr-Werk Ehingen GmbH is one of the world’s leading manufacturers of mobile cranes. The product range includes state-of-the-art telescopic and lattice boom cranes on mobile and crawler chassis. From development to service, the needs of the customer are the top priority. The aim is to set standards in terms of quality, functionality and safety and to ensure high availability of the equipment in use. The plant in Ehingen (Donau) in southern Germany offers the approximately 5,000 employees attractive jobs with a wide range of tasks.
World market leader for mobile and crawler cranes
Liebherr-Werk Ehingen GmbH was founded in 1969. Thanks to its high-quality and market-oriented products, the company has developed into the world market leader for mobile and crawler cranes. Since its foundation, the production facility and its capacities have been continuously expanded. Today, six mobile cranes are delivered from Ehingen to customers all over the world every day.
SEHON modernizes its paint shops | Focus on energy and sustainability
At the Liebherr plant in Ehingen, SEHON carried out a retrofit of the Liebherr painting systems and modernized them with a focus on energy and sustainability. The focus was on the intelligent use of a combination of photovoltaics and combined heat and power units. The CHP units run on biogas fuel. Heat storage and peak load boilers are crucial for ensuring that the renewable energy generated is secured without losses. An energy management system is used to monitor and control the energy flows. The Liebherr plant in Ehingen now has a new, CO₂-reduced paint shop. An additional challenge was that the modernization took place during ongoing business operations. The entire plant technology, including the components and pipework, required 25 truckloads. This illustrates the dimensions of this modern paint shop.
Documentation of the Liebherr project
The CO₂-reduced paint shop
Liebherr works in accordance with the EU guidelines for CO₂ neutrality. The company relies on energy-efficient equipment, resource-conserving procurement and renewable energies to minimize its ecological footprint. Liebherr continuously optimizes its processes. The protection of people and the environment is of particular importance in all business activities. For Liebherr products and their manufacture, this means that they must be safe, efficient and environmentally compatible. In its long history, the Liebherr Group has grown successfully through responsible, future-oriented action. Thinking about tomorrow today will therefore continue to be one of the company’s principles.
Photovoltaic system on Liebherr building
Combined heat and power units (CHP) at Liebherr in Ehingen
Functional description: Energy center of the Liebherr paint shop
Liebherr has a multivalent energy center for needs-based power and heat generation. The main energy generators are
- 3 combined heat and power plants (CHP) for the generation of electrical energy and heat.
- 1 gas condensing peak load boiler to generate heat.
- 1 electric boiler to generate process heat from surplus PV electricity generation.
- 1 photovoltaic system for generating electricity from sunlight
Energy cockpit and energy management system (EMS) for heat and power generation:
The coordination of the generation of electrical and thermal power and its adjustment to the property’s requirements is carried out taking economic and ecological aspects into account. This is done by an energy management system (electronic system control) in conjunction with energy meters. System monitoring ensures efficiency.
Process heat generation using CHP units:
The CHP units generate energy for the painting and drying production processes.
Energy management system (system monitoring)
Heat storage for renewable energies
Process heat generation using electric boilers (power-to-heat):
The electric boiler generates process heat from surplus photovoltaic electricity. Further reduction in energy costs through:
– 100% renewable energy for CO₂ reduction
– Full integration into the energy management system
Energy storage:
A heating water buffer tank balances out the different times and quantities of heat generation and consumption. Peak load boilers are used to ensure the required process temperatures and to cover peak demand. They also provide redundancy in the event that the CHP unit is shut down for maintenance work.
Purchase and supply of electrical energy:
If the electrical power generated by the CHP unit and the PV system is not sufficient to cover the property’s electrical power requirements, the shortfall is purchased from the energy supply company (EVU). Conversely, any surplus electrical energy generated is fed into the public grid.
State-of-the-art aggregate technology
The result – a future-proof energy system
- Demand-oriented energy generation
- Production of blue, CO₂-reduced electricity through the use of CHPs
- Flexible adaptation to changing energy markets
- Maximum photovoltaic self-consumption
- Monitoring the energy flows
Liebherr-Werk Ehingen GmbH
Dr.-Hans-Liebherr-Straße 1
89584 Ehingen
Phone: +49 7391 502-0
Fax: +49 7391 502-3399
E-mail: info.lho@liebherr.com
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