ENERGY SAVINGS, WASTE HEAT UTILIZATION & SMART …...Preheating of boiler feedwater and combustion...
Transcript of ENERGY SAVINGS, WASTE HEAT UTILIZATION & SMART …...Preheating of boiler feedwater and combustion...
ENERGY SAVINGS, WASTE HEAT UTILIZATION & SMART GRID MANAGEMENTENERGY EFFICIENCY PORTFOLIO
BILFINGER | SNS2020
BILFINGER at a glance
page 2
Making sure our clients can concentrate
on what they do best: their core business.
Employees
Revenue 2019
About 34,000
€ 4,327 million
Bilfinger is a leading international industrial service provider for the process
industry. The group covers the entire value chain of projects and industrial
plants from consulting, engineering, manufacturing, assembly and plant
expansion to turnarounds and also includes environmental technologies and
digital applications.
Bilfinger SE | Energy Efficiency Portfolio
BILFINGER Energy Transition Portfolio
page 3Bilfinger SE | Energy Efficiency Portfolio
⦿ Bilfinger has a comprehensive portfolio
of products and services to support its
industrial customers to reach their
sustainability goals and meet climate
change targets.
⦿ From mature activities like Hydro power,
District Heating or Flue Gas Cleaning to
new areas such as Green Hydrogen,
Carbon Capture Utilization & Storage
(CCUS), Power/Waste-to-X or Energy
Efficiency, Bilfinger is constantly
developing its capabilities to better serve
its customers throughout the entire value
chain and move from hard to abate
emissions.
BILFINGER in Energy Efficiency
Your needs & constrains VS our solutions
Bilfinger SE | Energy Efficiency Portfolio page 4
Industrial Customers
Regulatory Pressure(Global, EU & National)
OPEX Cost
Pressure
Energy Prices
Pressure
Reputational
Pressure
Energy Efficiency
GHG Emissions
Renewable energy share
Electrification
BILFINGER is providing you with solutions
that tackles all these issues:
Increase Energy Efficiency
Reduce GHG Emissions
Reduce Energy Consumption & Cost
Optimize process, operation & plants’
balance sheet
Provide extra flexibility
Contribute to positive brand image
Reduce local risks with all stakeholders
BILFINGER in Energy Efficiency
Your needs & constrains VS our solutions
Bilfinger SE | Energy Efficiency Portfolio page 5
Quick Measures i.e. Avoid Heat Losses, Identify High Consumption areas1
Reuse Waste Heat2
Optimize plants’ processes, equipment & operations3
Energy Monitoring/
TIPCHECK®e.g. Insulation
We perform a TipCheck® Analysis to
identify heat losses and provide the
immediate recovery measures trough our
insulation teams
=
Average Pay Back Time
1 to 3 years
We design and deliver modular solutions
to capture and utilize your available waste
heat for re-use within your processes or
export to external users (neighbor
industries, district heating networks, etc.)
Based on a Pinch Analysis we develop a
model and the associated business case
for a thermally optimized plant with
complementary use of best available
technology and can even support you up to
the modelling and optimization of energy
generation and trading.
Consultancy
CO2 Master Planning
We provide step by step approach to
create a master plan for your road to
CO2 reduction. By looking at the
processes, the ambitions of your
company, and the environment in which
your company operates,
BILFINGER in Energy EfficiencySupporting customers throughout projects and assets’ life cycle
Bilfinger offers integrated solutions for project execution covering the
entire life cycle from engineering and technology to fabrication,
construction and maintenance.
LIFE CYCLE VIEW
Bilfinger SE | Energy Efficiency Portfolio
EARLY BUSINESS CASE PLANNINGOur Pitstop approach
“The pitstop approach decreases throughput time and increases project
quality by gathering decision makers, stakeholders and specialists to
brainstorm options, collect available information, key project requirements
and make decisions in a creative process.”
Cost estimate on maturity level end conceptual
Engineering documents minimum level end feasibility
Early go/no goPossibility to scale down to other stage gates
Bilfinger SE | Energy Efficiency Portfolio
CO2 MASTER PLANNING
APPROACH & REFERENCES
CO2-REDUCTION MASTER PLANNINGApproach
Bilfinger provides a step by step approach to
create a master plan for your road to CO2
reduction. By looking at the processes, the
ambitions of your company, and the environment
in which your company operates, Bilfinger
analyses the potential, risks, and costs to create
a route map towards a carbon neutral company.
⦿ Complete overview of the necessary steps
leading towards a masterplan for CO2-
reduction with a corresponding roadmap.
⦿ Different studies and methodologies to obtain
the desires level of information for each step.
⦿ The selection of topics is client specific and is
therefore decided in accordance with the
client. This decision is based on the
information/data available, certain steps can
be discarded or shortened.
Bilfinger SE | Energy Efficiency Portfolio page 9
• New plant extension has to fit within theemission limits and the sustainablestrategy
• Uncertainties about the possibilities andlimitations regarding technology andbudget.
10
• Sustainability not as a separate project withreturn on investment, but as an utility toenable production
• Creation of an overview with the options, totalcost of ownership, and impact on emissionsand strategy.
Emissions
Cost Reduction
CO2-REDUCTION MASTER PLANNINGReference – example heating upgrade
1. QUICK MEASURESEnergy Monitoring & Scan, TIPCHECK® & simple remediation solutions
APPROACH & REFERENCES
1.1 Energy MonitoringApproach
Bilfinger SE | Energy Efficiency Portfolio page 12
Energy Optimization & CO2 reductionSynergies of Technology & Advanced Analytics
1.1 Energy MonitoringReference – ISO 50001 Dashboard
Bilfinger SE | Energy Efficiency Portfolio page 13
• Energy Management System ismostly not connected to otherrelevant data sources
• Combine data from energycounters with other data sourcessuch as productions plans,operational hours, processparameters
• Bad-actor analysis highlightunusual energy consumption
Asset Integrity
Increased asset integrity
by standardized
information for e.g. audits
(ISO50001)
1.1 Energy MonitoringReference – Virtual Sensors
Bilfinger SE | Energy Efficiency Portfolio page 14
• Moisture level is key toquality & energy consumption
• Large moisture measurementintervals (3h) lead to significantquality changes and higher energycosts
• Predictive moisture level in 1-minintervals with the Virtual Sensorwithout additional installations
• Process stabilization throughautomatic recommendationsfor process improvement
OEE
Improvement
Energy
1.2 Energy Scans / TIPCHECK®Approach
Service
▪ Inspection of existing insulation for damage
▪ Identification of possible "hot spots" and thus an increase in
security
▪ Identification of energy saving potentials & opportunities for
process improvement and increased efficiency
▪ Amortization calculation
▪ Average payback period < 1 year
Project approach
4 Energy savings report
TIPCHECK report & energy savings measures with payback
period + Identification of opportunities for process improvement
and increased efficiency
3 Energy savings potential
Indication on energy savings potential in utilities and process,
Optimization suggestions, amortization calculations
2 Energy analysis and evaluation
Thermographic analysis, load duration curves, and weekly and
yearly profiles, report for each examined component of the plant,
listing of the determined total heat losses
1 Site visit
Data gathering through thermal imaging cameras and
thermography sensors (surface and humidity sensors).
Bilfinger SE | Energy Efficiency Portfolio page 15
• DSM has an energy savings target toachieve 15% final energy savings in theperiode 2015-2025.
• Bilfinger performed 3 quick scan energyaudits
• We developed site specific road maps toimprove energy efficiency.
• Focus areas were steam, cooling,compressed air systems, heat integrationand waste heat recuperation, energymanagement
Energy
Cost Reduction
1.2 Energy Scans / TIPCHECK®Reference - Energy Scans
16Bilfinger SE | Energy Efficiency Portfolio
• Identification and development of energy
saving measures and waste heat
recuperation
• Part of framework of Encore program for
14 Friesland Campina dairy plants
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• Example Beilen: 3 quick scan saving measureshave been identified, specified and implemented
• 1: avoiding 72 kton/yr of CO2 emissions
• 2: avoiding 270 kton/yr of CO2 emissions
• 3: saving 110 000 kWh/yr of electricity.
• Example Aalter
• avoiding 100 kton/yr of CO2 emissions
Energy
Cost Reduction
1.2 Energy Scans / TIPCHECK®Reference - Energy Scans
Bilfinger SE | Energy Efficiency Portfolio
1.3 Simple Remediation MeasuresApproach – e.g. Insulation works
page 18
Cold Insulation
Hot Insulation
Specialised Insulation
Average payback period < 1 year
Bilfinger SE | Energy Efficiency Portfolio
Bilfinger SE | Energy Efficiency Portfolio page 19
Effective annual energy savings
~90 %Effective annual cost savings
~90 %Effective annual CO2 savings
~5t/year
1.3 Simple Remediation MeasuresReference – e.g. Insulation works
Steamcollectors
Feed watertank
Valvestations
Steamcollectors
Feed watertank
Valvestations
Steamcollectors
Feed watertank
Valvestations
Energy Savings
94%
95%
95%
94%96%
96%
Cost Savings
CO2 Savings
2.1 WASTE HEAT UTILIZATION
APPROACH & REFERENCES
2.1 WASTE HEAT UTILIZATION
Approach
page 21
The Principle (to be developed to skid mounted solutions):
Examples implemented and under developments:
Intercooler steam boiler plant CO2 reduction 0.7 kton/yr + Payback 2 yr
Industrial heat pump distillation column CO2 reduction 9.4 kton/yr + Payback 6.5 yr
Process cooling water for industrial building heating CO2 reduction 3.6 kton/yr + Payback 5-7 yr
Waste vapor heat recovery for district heating CO2 reduction 20 kton/yr + Payback 7-10 yr
Bilfinger SE | Energy Efficiency Portfolio
2.1 WASTE HEAT UTILIZATION
Reference - Intercooler steam boiler plant, preheating water with flue gas waste heat
Total annual operational
cost savings90 k€/year
Total natural gas savings plant circa 4%
1 - 2 years
Business case summary
Pay-back time
105 °C 1.2 bara
80 °C
DEAERATOR
Steam
Make
-up
Make
up
INTERCOOLER
ECONOMIZER
BOILER
15 °C
ca. 65 °C
BFW
Intercooler to preheat make-up water to deaerator while
cooling down boiler feed water to economizer (105° ->80°C)
Boiler feed water is reheated in the economizer while cooling
down further the flue gases, hence increasing boiler
efficiency.
Duty heat exchanger: ca. 400 kW, 8400 h/yr
gas savings 400 000 Nm3/yr
CO2 reduction 0.7 kton/yr
saving gas costs: € 96 000/yr
STACK
condensate
50%
Bilfinger SE | Energy Efficiency Portfolio page 22
2.1 WASTE HEAT UTILIZATION Reference - Industrial heat pump distillation column
Usefull heat @high temperature
Low temp. waste heatfeed
bottom
QH
QL
W
Evaporation valve
Company X Financial feasibility
Operational hours 8700 h/yr
Gas saving costs € 1 266 000/yr
Add. electr. costs - € 428 000
Saving energy costs on bill € 839 000/yr
Pay-back time ca. 6.5 years (13.5% Subsidy)
50% gas savings >5,300,000 Nm³/yr (9.4 kton CO2/yr)
• Conscious choice: no Mechanical Vapor Recompression
(open heat pump) unit for distillation column in zoning area (Ex)
• Closed Heat pump package outside zoning area of distillation unit
• Heat pump producing low pressure steam (1.3 bara), low pressure
steam tie – in on existing steam piping, no need for additional reboiler.
Refrigerant: environmental friendly, not flammable, not toxic
• Robust design (hydraulically, controllability), easily to start up / stop;
when heat pump unavailable => normal operation boiler steam for
reboiler column
Bilfinger SE | Energy Efficiency Portfolio page 23
2.1 WASTE HEAT UTILIZATION
Reference - Process cooling water for industrial building heating
Closed cooling water system with 80°C waste heat from several
process units
Idea: Extension of existing system, use waste heat for:
Heating of large industrial building (1.7 MW)
Preheating of boiler feedwater and combustion air (1.5 MW)
Project:
New additional heat exchanger to extract waste heat.
New underground warm water distribution network plus local heat
delivery station.
Start realisation: Q1 2019
Gas Savings: ca. 2,000,000 Nm³/yr (3.6 kton CO2 /yr)
Financial saving ca. 500 k€/yr; Pay-back ca. 5-7 years
Bilfinger SE | Energy Efficiency Portfolio page 24
Waste vapor (steam) from process, currently being condensed by
cooling water (approx 15 MWth).
Waste heat could be available at ca. 95°C
Idea: Deliver waste heat as baseload to nearby DH system
Project:
New condensers to extract waste heat at higher temperature.
Aboveground distribution network ca. 1500 m
Expected start realisation: 2020
Saving of approx 20 kton CO2
Pay-back ca. 6-7 years
2.1 WASTE HEAT UTILIZATION
Reference - Waste vapor heat recovery for district heating
Bilfinger SE | Energy Efficiency Portfolio page 25
2.1 WASTE HEAT UTILIZATION
Reference - Heat pump plant + buffer
Bilfinger SE | Energy Efficiency Portfolio page 26
Customer: Heineken
Project: 9 MW warm water Heat Pump Plant + 400 m3 pressurized warm water buffer
Scope:
Technical & economic feasibility study
Pattern analysis modelling study: waste heat supply versus heat demand (see next sheet)
Conceptual design
Basic design incl. specification + supplier evaluation (role as utility specialist)
2.2 ENERGY EFFICIENCY SOLUTIONS
TECHNOLOGY PORTFOLIO
2.2. ENERGY EFFICIENCY – SOLUTION 1
Pump Drives - Main Features of Bilfinger´s PumpCheckApp
Bilfinger SE | Energy Efficiency Portfolio page 28
Input main pump data (operating design) Visual inspection Input vibration data Pump analysis :
o Mechanical (vibrations)o Energy Efficiency (OP vs. BEP)
The concept is to make a quick analysis of customers’ centrifugal pumps. Several parameters to be checked. Output will give clients a priority list to
o Increase pump availibility, o Decrease energy consumption, ando Decrease maintenance costs for the future
.2. ENERGY EFFICIENCY – SOLUTION 2
HoCoSto/Enpuls, Sun City
To enable the heat transition in the build
environment Bilfinger developed a conceptual
design for a smart thermal grid.
This design constituted of solar thermal
collectors and a thermal heat storage tank, to
supply the heat demand of 10 residential
houses. The thermal buffer was designed in
collaboration with HoCoSto.
Scope of work
• Conceptual design
• CAPEX 40% and OPEX
• PFP incl heat and mass balance
• Dynamic system modeling
• Structural stability check
• Basic routing of heat network
• Design of pump station
Storage of hot and cold
Bilfinger SE | Energy Efficiency Portfolio Seite 29
2.2. ENERGY EFFICIENCY – SOLUTION 3
Energy Nest
Steam Storage
Bilfinger SE | Energy Efficiency Portfolio Seite 30
2.2. ENERGY EFFICIENCY – SOLUTION 4
Sound Energy
Turn heat into cooling
Bilfinger SE | Energy Efficiency Portfolio Seite 31
2.2. ENERGY EFFICIENCY – SOLUTION 5
Qpinch
Industrial Heat Pump
Bilfinger SE | Energy Efficiency Portfolio Seite 32
2.2. ENERGY EFFICIENCY – SOLUTION 6
Orcan Solutions
Heat to power
Bilfinger SE | Energy Efficiency Portfolio Seite 33
2.2. ENERGY EFFICIENCY – SOLUTION 7
Heat Matrix
Heat recovery from corrosive media – polymer heat exchangers
Bilfinger SE | Energy Efficiency Portfolio Seite 34
3. SMART GRIDS
APPROACH & REFERENCES
3. SMART GRID MANAGEMENT
Approach (1/3)
page 36
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IMMEDIATE MEASURES (QUICK WINS)
No potential detected that can be developed economically.
Analysis report incl. recommendations
Decision-oriented approach
Transparent
Documented
Scalable and flexible
Ongoing stakeholder
involvement
Active management of
complexity
Continuous business-case
orientation
SUBSIDIES SUPPORT
Bilfinger SE | Energy Efficiency Portfolio
3. SMART GRID MANAGEMENT
Approach (2/3)
The Pinch Analysis
page 37
Analysis of thermal process streams (cold and hot streams) & Heat exchanger networks
Data capture and analysis
Temperature
Mass flow or volume flow rate
Contamination
Heat capacity
Operating time
Energy demand profile
Utilities-Costs
Restriction
Pinch-Analysis
Pinch-Point Pinch-Rules
Max. Thermal integration
Composite-Curve
Heat exchanger networks : Mathematical programming
Minimization of capital costs
Minimization of operating costs
Bilfinger SE | Energy Efficiency Portfolio
3. SMART GRID MANAGEMENT
Approach (3/3)
Plants and systems optimization
page 38
Thermally optimized
plants
Data collection from
existing plants
Pinch-Analysis
Integrating …
… Alternate technologies
High temperature heat pumps up
to 150°C
Absorption chiller
Organic Rankine Cycle (ORC)
Heat storage units
Etc.
….Renewable energysources
Solar thermal energy
Geo thermal energy
Biomass
Bilfinger SE | Energy Efficiency Portfolio
3. SMART GRID MANAGEMENT
Results
Benefits for industrials
Cost reduction based on reduced energy consumption
CO2-emissions reduction further reducing operational costs
Reduced local and sites risks
o Reduced environmental impact
o Legal compliance
o Local stakeholder engagement
Positive employer branding
(sustainable, innovative, forward-looking)
Improved operations and assets optimization
Maximization of power generation
Model-based calculation of heat tariffs (feed & offtake) through a
dedicated software analyzing, modelling and optimizing energy
generation and trade
page 39
Our solution in a nutshell:
1. Compact and comprehensive
analysis, delivering a realistic potential
assessment right at the start
2. Leading experts in all disciplines
3. Well-established interfaces
4. Decision oriented approach
5. Single point of contact for the whole
process
6. End-to-end responsibility
Bilfinger SE | Energy Efficiency Portfolio
3. SMART GRID MANAGEMENT
Reference – 050 Buurtwarmte: Circular District Heating System
page 40Bilfinger SE | Energy Efficiency Portfolio
Bilfinger has been working with several
stakeholders in a community power-to-
heat initiative.
When implemented, the Paddepoel
project will reduce the neighborhood’s
CO2 footprint considerably utilizing high-
temperature heat pumps.
Scope of work
• Conceptual design based on energy, pipelines and architectural engineering
• CAPEX 25%
• Consultancy on safety, soil, noise, air and necessary permitting
3. SMART GRID MANAGEMENT
Reference – Meppel Energy: Energy Efficiency Analysis Heating District
page 41Bilfinger SE | Energy Efficiency Portfolio
Heat analysis / expert review of the heating district
Scope of work
• Energy balance
• Energy savings report
3. SMART GRID MANAGEMENT
Reference – Heat Accumulator
42
▪ Wien Energie: Hot Water Heat Accumulator 165°C 850MW
▪ Scope of work:
▪ Conceptual process design
Charge and discharge systems for different pressure levels
▪ Expansion system
▪ Mass and energy balance
▪ P&ID process layout by COMOS
▪ 3D layout plan by PDMS
▪ Instrumentation and measurement by COMOS
▪ Electrical engineering and control plan
▪ Function plan by COMOS
▪ Start-up procedure
▪ Test run
©W
ien
Energ
ie G
mbH
Bilfinger SE | Energy Efficiency Portfolio
3. SMART GRID MANAGEMENT
Reference – Pinch-Analysis & Heat Exchanger Network Optimization
▪ Lenzing AG: Pinch-Analysis and optimization of heat exchanger network
▪ Scope of work:
▪ Pinch Analysis through TVTHENS
▪ Optimization of heat exchanger network by Rethen
▪ Mass and energy balance by IPSEpro
▪ Publication:
▪ Chemie Technik (2011)
Bilfinger SE | Energy Efficiency Portfolio
▪ Location : Lenzing (Austria)
43
3. SMART GRID MANAGEMENT
Reference – Pinch-Analysis & Energy Optimization
Lenzing Fibers: Pinch-Analysis and energy optimization (new technologies & renewable energy sources)
▪ Scope of work:
▪ HX network optimization by TVTHENS
▪ Mass and energy balance by IPSEpro
▪ Dynamic simulation by TRNSYS
▪ Presentation:
▪ Achema (2012)
▪ Energy Masters (2011)
▪ ProcessNet (2010 & 2012)
▪ Publication:
▪ PROCESS (2013)
▪ ATE (2011)
▪ Chemie Ingenieur Technik (2010 & 2012)
Bilfinger SE | Energy Efficiency Portfolio 44
3. SMART GRID MANAGEMENT
Reference – Combined Heat & Power
▪ Zapad: combined heat and power unit for the production of electrical energy and heat
▪ Scope of work:
▪ 3D layout plan by PDMS
▪ Piping and instrumentation diagram
(P&ID) by COMOS
▪ Mass and energy balance
▪ Conceptual process design
▪ Ventilation system
▪ Lubrication system
▪ Expansion system
Electrical power [kW] 3 x 3328
Thermal power [kW] 3 x 3384
Electrical efficiency [%] 44
Gas motor manufacturer GE Jenbacher
District heating supply and return temperature [°C] 85/65
Energy source Natural gas
Bilfinger SE | Energy Efficiency Portfolio
▪ Location: Serbia
▪ Customer: NoviSad
45
3. SMART GRID MANAGEMENT
Reference – Combined Heat & Power
▪ EOS: combined heat and power unit for production of electrical energy and heat
▪ Scope of work:
▪ 3D layout plan by PDMS
▪ Piping and instrumentation diagram (P&ID)
by COMOS
▪ Mass and energy balance
▪ Conceptual process design
▪ Ventilation system
▪ Lubrication system
▪ Expansion system
Electrical power [kW] 5 X 3047
Thermal power [kW] 3 X 3108
Electrical efficiency [%] 44,1
Gas motor manufacturer GE Jenbacher
District heating supply and return temperature [°C] 90/70
Energy source biogas
Bilfinger SE | Energy Efficiency Portfolio
▪ Location: Vienna (Austria)
46
3. SMART GRID MANAGEMENT
Reference – Low Temperature Heat Recovery
▪ TIGAS: low temperature – heat recovery through absorption heat pump
▪ Scope of work:
▪ Mass and energy balance
▪ Conceptual process design
▪ Soot blower
▪ Heat pump
▪ Expansion system
Electrical power (waste heat) [kW] (40/30°C) 2500
Thermal power (driving heat) [kW] (160/140°C) 3500
Thermic capacity (district heating) [kW] (60/90°C) 6000
Heat pump manufacturer Thermax
COP thermal (district heat/driving heat) 1,71
Soot blower manufacturer Parmo Desarrollos
Bilfinger SE | Energy Efficiency Portfolio
▪ Location: Tyrol (Austria)
47
3. SMART GRID MANAGEMENT
Reference – Waste Heat Recovery
▪ Marienhütte: waste heat recovery (high temperature heat pump)
▪ Scope of work:
▪ 3D layout plan by PDMS
▪ Piping and instrumentation diagram
(P&ID) in COMOS
▪ Mass and energy balance
▪ Conceptual process design
▪ Ventilation system
▪ Heat pump
▪ Expansion system
Electrical power [kW] 2 x 2380
Thermal power [kW] 2 x 3300
COP thermic (district heat/electrical power) 3,4
Heat pump manufacturer Friotherm
District heating flow and return flow temperature [°C] 90/63
Waste heat flow and return flow temperature [°C] 33,8/29
Bilfinger SE | Energy Efficiency Portfolio
▪ Location: Graz (Austria)
48
3. SMART GRID MANAGEMENT
Reference – Waste Heat Recovery
▪ RHI Norwegen: heat recovery from rotary kiln waste gas
▪ Scope of work:
▪ 3D layout plan by PDMS
▪ Piping and instrumentation diagram
(P&ID) in COMOS
▪ Mass and energy balance by IPSEpro
▪ Conceptual process design
▪ Heating surface cleaning system
(soot blower)
Water supply and return temperature [°C] 60/45
Thermal power [kW] 2000
Flue gas volume flow rate [Nm³/h] 70.000
Flue gas heat exchanger manufacturer Bilfinger Rosink
Soot blower manufacturer Bilfinger Rosink
Flue gas In- & Output temperature [°C] 200/130
Bilfinger SE | Energy Efficiency Portfolio
▪ Location: Porsgrunn (Nowray)
49
3. SMART GRID MANAGEMENT
Reference – Power to Heat
Power to heat: up to 50 MWelectrical
Technologies
Electrode boiler
Electric water heater
Scope of work:
3D layout plan by PDMS
Piping and instrumentation diagram (P&ID)
by COMOS
Mass and energy balance
Mechanical and process design
Construction
Bilfinger SE | Energy Efficiency Portfolio 50