C B il W kCannon Boiler WorksBoiler Heat Recovery

Hi t d R t AdHistory and Recent Advances

Serving the steam and process industries for more than 35 years.

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Increased Energy Demand due to increasing standards of livingdue to increasing standards of living

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Increased Energy Demandgy

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Why is heat recovery becoming a necessity?Why is heat recovery becoming a necessity?•Increased restrictions on emissions such as California air quality initiatives being approvedquality initiatives being approved

•Top down corporate sustainability initiatives are looking for innovative equipmentinnovative equipment

High efficiency equipment allows all customers to do the same amount of work with their steam system, at a lower y ,energy cost and will less emissions of green house gasses.

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Cannon Traditional Welded Economizers

•Heat recovery for dirty fuel burning boilers systems, (oil, wood, coal)

•Heavy duty design for long service life in difficult in environments

•Reduces fuel consumption 2-6%

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Welded Economizers

Pros• Best used for heavy or dirty fuels• Best used for heavy or dirty fuels• High corrosion allowance built-in

Cons• Costly to build, weight = $

Hea to install time $• Heavy to install, time = $• Difficult to repair, custom parts required• Long downtime expected during repairsg p g p• No cold feedwater applications

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Feedwater HeatersHistory• Designed by Cannon in the 1980’s to resolve problems

with traditional economizers

Design Attributes• Lightweight design• Easy to Install, Operate & Repair• Low Pressure Drop Design• Control of Corrosion• Control of Corrosion• Indoor or Outdoor Installation• Vertical or Horizontal InstallationVertical or Horizontal Installation• All parts available for individual sale

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MEET OUR MODELSFeedwater Heaters

Model Model Model Model FB

“Baby”FS

“Standard”FJ

“Jumbo”FG

“Giant”

Standardized Modular Construction

Many more models and variations available

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Cannon Feedwater Heaters

•Reduces fuel consumption 3-10%

•Feature all bolted construction for ease of install and maintenance

•Unit is designed for use in both Non-Condensing and gFully-Condensing applications

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Scenario #1Scenario #1DA Water

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Make up water

System Layouts

Economizer

Make-up water

DADATank

B ilTo process

Boiler

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Materials Selection for DA waterwhy it’s so important?why it s so important?

• Carbon steel tubes and fins are used, as an industry standard, for deaerated.

• Stainless steel material upgrades are available

• Carbon steel is preferred because of the superior heat transfer coefficients and low cost.

• If all equipment is working properly we expect a minimum of corrosion potential.minimum of corrosion potential.

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Real Numbers forDA Water economizersDA Water economizers

125 hp 600hp 1200hp

227 227 227Water Inlet

p p p

262 263 262

400 400 400

Water Outlet

Gas Inlet

284 282 286

$1.93 $9.45 $18.17

Gas Outlet

Saving/hr $ 93 $9 5 $ 8

$9,240.00 $45,108.00 $87,528.00

0 98 years 0 63 years 0 52 years

Saving/year*

Equipment

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0.98 years 0.63 years 0.52 years

*Annual saving per year calculated using 8,400 hrs/year at 50% firing rate with $1/therm gas prices.

q ppayback

Scenario #2Scenario #2Feedwater Tanks

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System LayoutsMake-up water

Economizer

Make up water

F d t T k

Boiler

Feedwater Tank

BoilerTo process

*Use this system layout with Modulating feed pumps

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System LayoutsMake-up water

Economizer

Make up water

F d t T k

Boiler

Feedwater Tank

Boiler

To process

*Use this system layout with constant circulating pumps

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Materials SelectionWhy is it so important?Why is it so important?

• Stainless steel tubes and carbon steel fins are used in our baseline offer.

• Stainless steel material upgrades are available or suggested by Cannonsuggested by Cannon

• Carbon steel fins are preferred because of the superior h t t f ffi i t d l theat transfer coefficients and low cost.

• If all equipment is working properly we expect aIf all equipment is working properly we expect a minimum of corrosion potential.

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Real Numbers forHot well tank economizersHot well tank economizers

125 hp 600hp 1200hp

150 150 150Water Inlet

p p p

201 202 200

400 400 400

Water Outlet

Gas Inlet

235 231 238

$2 74 $13 48 $25 89

Gas Outlet

Saving/hr $2.74 $13.48 $25.89

$13,104 $64,428 $124,992

1 12 0 51 Y 0 42

Saving/year*

Equipment

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1.12 years 0.51 Years 0.42 yearsq ppayback

*Annual saving per year calculated using 8,400 hrs/year at 50% firing rate with $1/therm gas prices.

Scenario #3Scenario #3Cold Water < 100F

Used only with natural gas or similarly clean fuels

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What is a Condensing Economizer

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Used only with natural gas or similarly clean fuels

What is a Condensing Economizer

Economizer are designed for relatively equal mass flow on both sides of the finned tube, but this does not always lend it lf t d i f th flitself to condensing of the flue gas

Cold = 80F and under – condensing of flue gas is likely

Preheated = 80-130F – condensing of flue gas is not consistent

Hot water = 130F and over – condensing of flue gas is nearly impossible

Used only with natural gas or similarly clean fuels

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System LayoutsMake up water

Economizer

Make-up water

B il

Tank

Boiler

To process

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Materials SelectionWhy is it so important?Why is it so important?

• Stainless steel tubes fins are used in our baseline offer.

• All stainless steel material upgrades are suggested by Cannon

• If all equipment is working properly we expect a minimum of corrosion potential.minimum of corrosion potential.

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Real numbers forCity water economizersCity water economizers

125 hp 600hp 1200hp

60 60 60Water Inlet

p p p

124 126 123

400 400 400

Water Outlet

Gas Inlet

194 186 196

$3.43 $17.08 $32.56

Gas Outlet

Saving/hr $3 3 $ 08 $3 56

$16,716 $83,496 $161,280

1 36 years 0 57 Years 0 46 years

Saving/year*

Equipment

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1.36 years 0.57 Years 0.46 years

*Annual saving per year calculated using 8,400 hrs/year at 50% firing rate with $1/therm gas prices.

q ppayback

Overcoming the issuesProblem: Pressure drop or Space limitationsProblem: Pressure drop or Space limitations

Solution: Unit that is skid mounted with induced draft fan. Can be installed away from boiler and does not induce and backpressure on boiler exhaust.

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Cannon On-Demand Economizers

Can be installed indoors or outdoors

Completely invisible to your boiler system

Two or three stages of heat recovery are also possible with On-Demand units

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GTI•Not-for-profit research, with 65+ year history

•Facilities 18 acre campus18 acre campus near Chicago200,000 ft2, 28 specialized labs

Energy & Environmental Technology Center

Other sites in Oklahoma and Alabama

Flex-Fuel Test

Facility Offices

•Staff of 250

•Experiencing substantial

y Offices & Labs

•Experiencing substantial growth

•1000 patents; 500

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products

TMC Heat RecoveryTMC Heat Recovery•Natural gas combustion produces about 18% water

•Water vapor up the stack accounts for 10% of fuel energyaccounts for 10% of fuel energy input, or energy in water is 65% of stack loss

•Key to higher energy efficiency is to recover both sensible andlatent heat

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Heat Recovery – General Approach1 R ibl1. Remove sensible

heat with two economizers (HTE + Steam Out

Deaerator/ Make-Up

Tank

LTE)

2 Remove latent

Fuel inBoiler

LPEHPE

2. Remove latent heat and water with Transport M b

Ambient airFlue gas out

TMC

BFW

Membrane Condenser (TMC)

Make-up water

Suitable for end users with make-up water over 35% and

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water over 35% and under 80F

Heat Recovery – TMC Concept– Nanoporous ceramic

membrane tubes– Water vapor permeation

via capillary condensation, which occurs more readilywhich occurs more readily than condensation in typical condensing economizerseconomizers

– Partial vacuum on tube side

– Counter-flow configuration

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TMC Installation ResultsSpecification Rubber 300 HP •93-94% efficiency•19% reduction in fuel cost•19% reduction in GHG emissions•5% reduction in boiler feed water•40% smaller footprint15 000 h f ti•15,000 hours of operation

•Early prototype design

Clement Pappas 300 HPClement Pappas 300 HP•92-93% efficiency•40% smaller footprint•Two-stage burner <5 ppmTwo stage burner, <5 ppm•Nox10,000 hours of operation

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TMC Installation ResultsBaxter Healthcare, Thousand Oaks, CA, 300 HP retrofit•93% efficiency•15% reduction in fuel cost•15% reduction in GHG emissions•5% reduction in boiler feed water4000 h f ti•4000 hours of operation

ORNL 300 HP Standard Boiler•Commissioned May 2010•Commissioned May 2010•Initially 95% efficiency•200 psig design•Integrated control panelIntegrated control panel

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TMC Installation ResultsRBC N 300 HP St d d B ilRBC New 300 HP Standard Boiler•Startup June 2010•Expect 94% efficiency•Expect 15% reduction in fuel cost•Expect 15% reduction in fuel cost•Expect 15% reduction in GHG emissions•Expect 5% reduction in boiler feed water

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Specific Results at Thousand OaksOriginal Boiler System = 81 9% efficientOriginal Boiler System = 81.9% efficientAHRS Retrofit = 93% efficient

Components:1. High pressure economizer (HPE)2. Low pressure economizer (LPE)3. Transport membrane condenser (TMC)4. Air heater (AH)

F l i•Fuel savings$36,655/yr

•Greenhouse gas emission reduction2595 tons CO2/yeary

•Water recovery~40% of total vapor in exhaust

Funding partners•Funding partnersUS DOESouthern CA GasBaxter Healthcare

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Commercialization

Cannon Boiler Works has been supplying heat recovery products to the industrial boiler industry for over 35recovery products to the industrial boiler industry for over 35 years

A full range of customized products available, including:g p , g•Traditional Welded Economizers•Feedwater Heater Economizers•Condensing Feedwater Heater Economizers•Skid Mounted On-Demand Heat Recovery Systems•The Ultramizer System

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Development of the GTI – CBW Relationship•GTI contacted Cannon in January of 2009 with an offer to begin due diligence for licensing one portion, the TMC system, from the overall superboiler project.

•After 8 months of negotiation CBW accepted the challenge and began our commercialization program.

•We are on schedule for late 2010 commercial sales in the 200 to 400 BHPWe are on schedule for late 2010 commercial sales in the 200 to 400 BHP range.

•The DOE and GTI are very interested to see the commercialization of the technologytechnology.

•We have seen great interest from trade groups, and some major corporations who have already made commitments to reduce energy intensity in the next few years.intensity in the next few years.

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Cannon Ultramizer System•Combines Cannon’s HTE and LTE Feedwater Heaters with TMC Technology to provide the ultimate in heat and water recovery

•TMC Technology recovers Sensible and Latent Heat from flue gas stream

•Recovers clean water from natural gas burning combustion systems

•Boiler efficiencies of 95% are possible

•Reduction in emissions is equal to the reduction in fuel consumption

•Three year simple paybacks are possible

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Cannon Ultramizer SystemCannon offers alternate methods of installation.

The HTE can be in the stack

The LTE Feedwater Heaters withThe LTE Feedwater Heaters with TMC Technology can be skid mounted in a convenient location

This provides the ultimate in heat and water recovery that fits difficult sites.

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Current Status of Commercialization•Software is being developed to enhance and add to CBW’s capabilities for one, two, or three stages of heat recovery.

•Production facility upgrades are ongoing. A clean room has been built for construction and testing of the ceramic tube bundles.

•Additional personnel are required. Product Manager, AutoCAD dd o a pe so e a e equ ed oduc a age , u oCdesigner have been hired, and additional sales personnel are being interviewed.

•Establishing relationships with vendors for ceramic tubes and fiber g preinforced tubesheets, along with quality control standards.

•Gather operating data from existing sites

•Optimizing operating range of TMC•Optimizing operating range of TMC

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Current Status of Commercialization

•Establishing performance warranty through testing over several site conditions and load conditions.

•Establish pricing for in stack applications as well as On-Demand applications, with an emphasis on short ROI

•Addition of the combustion air heater is possible for lower makeup rates.

•Dirty fuels testing is being done by GTI for future applicationsDirty fuels testing is being done by GTI for future applications

•Evaluate non-boiler flue gas or hot moist air streams

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Current Status of Commercialization• Future size range of 400 to 800 BHP, and finally 800 to 3000 BHP

•Evaluate process water applications – where flow, temperature,Evaluate process water applications where flow, temperature, and availability of the water are all independent of the boiler operation

•Notifications of major advancements made to DOE, state regulatory agencies, and trade organizations

•Establish the Ultramizer as best available commercial technology gyin fuel, emissions, or water conscious areas

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Current Status of CommercializationM di C i i t d j l ith i d d l t i•Media Campaign in trade journals with magazine ads and electronic

banner ads online

•New website landing pageg p g

•Representative on-line training tools

•Representative on line rating tools•Representative on-line rating tools

•Live webinars

•Targeted customer lists in cooperation with area representatives

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TMC Units in OperationTMC Units in OperationPrevious installations:

Specification Rubber Alabaster ALSpecification Rubber – Alabaster, AL

Clement Pappas – Ontario, CA

Baxter Healthcare – Thousand Oaks, CA

Oak Ridge National Laboratories – Oak Ridge, TN

Coming soon:

Richardson Brand Candies – Canajoharie, NY

China Lake National Labs – China Lake, CAChina Lake National Labs China Lake, CA

City Brewing – Latrobe, PA

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CBW warrants the performance of the equipment,

Performance Warrantyp q p ,

operating in a clean condition both water side and gas side, to the operating conditions presented to CBW at the time of sale Should CBW equipment fail to meetthe time of sale. Should CBW equipment fail to meet the predicted performance, CBW reserves the right CBW reserves the right toto repair, modify, replace the unit, to produce

fguaranteed performance, or remove the unit at no additional cost to the owner. All performance testing to guarantee performance will be the responsibility of the g p p yowner and will be conducted in accordance with ASME test procedures.

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Cannon Boiler WorksServing the process steam industry since 1972Serving the process steam industry since 1972

510 Constitution BlvdNew Kensington, PA 15068New Kensington, PA 15068

www.cannonboilerworks.comwww.cbwservices.com

Ph 724 335 8541Fx 724 335 6511

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Other Products Manufactured by C B il W kCannon Boiler Works

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Cannon –Manufactured Products•Steam Accumulators

•Custom Heat ExchangersCusto eat c a ge s

•Feedwater/Softener Systems

•Pressure Vessels

•Turn-key EquipmentTurn key Equipment Installations

•Patented Fluidized Bed Boilers for waste coal or biomass

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Custom Heat Exchanger ProductsT i l A li tiTypical Applications:

•Hot oil coolers•Dryer air heaters•Column condensersP d t l•Product coolers

•Water/Glycol coolers•Gas heating/ cooling•Steam condensers•Quench oil coolers•Inter & after coolers•Heat recovery

Industries Served:Ch i l•Chemical

•Pharmaceutical•Food processing•Pulp and paper•Hospital and institutionp•Refining and petrochemical•Primary metals•Plastics•Coating & ResinsUtilities

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•Utilities

Custom Heat Exchanger ProductsCapabilities:

•Custom Designed units

•Thermal Design

•Finned tube heat exchangers•Finned tube heat exchangers

•Shell and tube heat exchangers

•Thermal Design Software•HTRI•B-JAC Software

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Vent CondensersVSt d d F t Vent

Cold Water

Standard Features:•No moving parts.•Easily installed.•Corrosion resistant materials•Safety protected.•Extended surface.•Computerized selection.•One year guarantee.Quality construction

Condensate(Backside, not shown) Hot Water

•Quality construction.

Benefits:•Energy recovery from latent heat process•Water recovery from plume condensate

Hot Steam

y p•Stop moisture damage to the roofing structure•Prevent ice/snow build up on the roof in winter months•Aesthetic reasons: removal of the steam plume

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Vent CondensersVent Condensers

Information required for a quotation

•Vented Steam Flow•Water temp inlet•Water flow available

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