BI THERMAL CORE™

Industrial process heat. Stabilized. Scalable. Controlled.

BI THERMAL CORE™ is not a boiler and not a power plant.
It is a thermal interface between energy inputs and industrial heat demand.

By combining high-temperature thermal storage, intelligent control, and standardized steam outputs, the Thermal Core™ converts volatile energy inputs into a stable, SLA-secured heat supply — independent of individual fuels or electricity price fluctuations.

The result: lower operational risk, improved utilization of existing assets, and full control over the cost, performance, and availability of process heat.

Operational Intelligence for Industrial Heat

1. Overall System Description

The BI THERMAL CORE™ is a modular, container-based thermal energy system designed to supply industrial process heat and steam with high availability, predictable performance, and reduced exposure to energy price volatility.

The system acts as a thermal interface between multiple energy sources and one or more industrial heat consumers. It decouples energy generation from heat demand by using high-temperature thermal storage, enabling stable steam delivery independent of real-time energy availability.

The Thermal Core is designed for:

continuous industrial operation (24/7)
scalable capacity growth
integration into existing steam and heat infrastructure
compliance with industrial safety and pressure equipment standards

2. Functional Flow & System Operation

2.1 Energy Input Phase

Energy enters the system through a multi-source input manifold. Depending on site configuration, typical sources include:

electric power-to-heat units (grid, PPA, surplus power)
waste heat recovery loops
solar thermal loops
auxiliary fuel-fired backup modules

Each input is hydraulically and thermally decoupled via heat exchangers or controlled injection points to protect the core system from source-side disturbances.

2.2 Thermal Storage Phase

The absorbed energy is transferred into the thermal storage unit, which acts as an enthalpy reservoir.
Depending on application and temperature level, the storage medium may be:

pressurized water
thermal oil (HTF)
molten salt (for high-temperature and superheated steam applications)

The storage smooths load fluctuations, absorbs excess energy during low-cost periods, and ensures continuous availability during peak demand or source outages.

2.3 Steam Generation & Heat Delivery

Heat is extracted from the storage via a heat exchanger train, typically consisting of:

economizer (feedwater preheating)
evaporator (saturated steam generation)
optional superheater (for dry or superheated steam)

Steam is delivered to the consumer at defined pressure, temperature, and quality, independent of which energy source is currently feeding the core.

2.4 Continuous Operation Logic

The system continuously balances:

storage state of charge
real-time heat demand
source availability
cost and efficiency parameters

This allows the Thermal Core to operate as a thermal flywheel, stabilizing downstream steam systems and reducing mechanical stress on boilers and auxiliary equipment.

Control Room / System Management

1.1 Centralized System Control

The BI THERMAL CORE™ is operated through a centralized industrial control environment based on PLC and SCADA architecture. All thermal, hydraulic, and electrical subsystems are supervised from a single control layer, providing a unified operational view of the entire installation.

1.2 Real-Time Process Visibility

Operators have continuous real-time access to key parameters such as temperatures, pressures, mass flows, storage charge levels, and steam output conditions. All data is visualized via industrial HMIs designed for 24/7 operation and clear decision-making.

1.3 Operational Optimization Logic

The control system dynamically manages charging and discharging of the thermal storage based on predefined rules and constraints. Energy source prioritization follows availability, operational limits, and economic parameters, ensuring stable heat delivery while minimizing operating costs.

1.4 Asset-Level Operation

From an operational perspective, the Thermal Core is treated as a single controllable asset rather than a collection of independent components. This simplifies plant operation, reduces operator workload, and enables performance-based operation and service contracts.

Modular System Architecture

1.1 Modular Design Principle

The BI THERMAL CORE™ is based on a fully modular architecture. All major system functions are separated into standardized modules, allowing flexible configuration, fast deployment, and controlled system growth.

1.2 Standardized Modules

Typical modules include:

thermal storage containers
heat exchanger skids
energy input skids
control and electrical containers

Each module is factory-assembled, tested, and delivered as a pre-engineered unit.

1.3 Scalable Capacity Expansion

The modular concept allows capacity expansion without major system redesign. Additional storage or heat exchanger modules can be integrated in parallel to increase thermal output or storage duration as demand grows.

1.4 Reduced Project Risk

By avoiding monolithic plant construction, the modular approach reduces upfront CAPEX, shortens installation time, and lowers technical and financial risk during project execution.

Steam System & General Piping

1.1 Steam Generation Interface

Steam is generated through a dedicated heat exchanger train connected to the thermal storage system. The configuration supports saturated and superheated steam at defined pressure and temperature levels according to process requirements.

1.2 Steam Distribution System

The generated steam is routed through a centralized steam header designed for continuous industrial operation. The piping system ensures stable pressure, low pressure drop, and proper condensate handling.

1.3 Piping Design Standards

All piping systems are designed according to recognized industrial standards and include:

pressure-rated steel piping
welded and flanged connections
full thermal insulation
expansion compensation
condensate drainage and steam traps

1.4 Integration with Existing Infrastructure

The Thermal Core can be integrated into existing plants as a parallel heat source, a preheating stage, or a primary steam supplier with existing boilers operating in backup or standby mode.

Monitoring & Safety

1.1 Comprehensive Instrumentation

The system is equipped with extensive instrumentation, including:

pressure sensors
temperature sensors
flow meters
energy meters (MWhₜₕ)
valve position and actuator feedback

All relevant data is continuously logged for operational analysis and compliance.

1.2 Safety Systems & Interlocks

Multiple safety layers are implemented, including:

pressure relief systems
redundant sensors
automated interlocks
controlled shutdown procedures
emergency venting and bypass lines

1.3 Reduced Risk Through System Design

Where applicable, thermal storage loops operate at low or no pressure, significantly reducing the overall risk profile compared to conventional high-pressure water-based systems.

1.4 Standards & Compliance

The BI THERMAL CORE™ is designed in compliance with:

Pressure Equipment Directive (PED)
applicable EN or ASME codes
functional safety requirements (project-specific SIL/LOPA)