Energy….“Local Solutions With Global Benefits”

Emerging Natural Gas Technologies:

Latest Advancements

Presentation by:Rich BiljetinaEnergy Solutions Center202-251-8902biljet@att.net

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Natural Gas Technologies:What’s in the News?

www.escenter.org

Time to ChangeOut that Boiler?

U.S. C&I Boiler Inventory

47% are 40 plus yrs old76% are 30 plus yrs old

Advancements in Boiler

Technologies

• Modular Boilers• High Efficiency Boilers• Linkage-Less Controls

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Several steam or hot water modular boilers replace one large boiler that operates much of the time at low efficiencies

High fuel-to-steam/hot water efficiencies are maintainedover wide variations of load

Added benefits:

Low space and weight requirements

Rapid start-up

Rapid response to changes in steam demand

High steam quality

Reduced emissions

Reduced blow-down

Modular BoilersSave $$ by Improving

Your In-Service Efficiency

Compact Boilers SaveSpace & Provide Flexibility

200 BHPFiretube

Boiler

200 BHPMiuraBoiler

Compact Boiler Save Space and Provide Flexibility

High Efficiency Boilers: One Example

• Hinged Premix Burner

with Metal Fiber Head

• Full Modulation (5:1 Turndown)

• Efficiencies up to 98%

• Single Pass - Down Fired Design

• Fully Condensing Design

• No minimum flow requirements.

• No minimum return

water temperatures

ClearFire Hot Water Boiler by Cleaver-Brooks

ClearFire Steam Boilers: 10 – 60 HP

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Boiler MFGs working with ESCto Promote Energy Efficiency

Clayton Industrieswww.ClaytonIndustries.com

Cleaver Brookswww.Cleaver-Brooks.com

Miurawww.MiuraBoiler.com

Hurst Boilerswww.HurstBoiler.com

Linkage Less Boiler Controls:

Why Migrate Toward Linkage-Less Controls?

The ProblemJackshaft/Linkages

Slop/wear

Hysteresis losses

Linkage-Less Boiler Controls

Linkage-Less Boiler Controls

• Safe and reliable operation

• Repeatability and less

maintenance

• Emissions reduction

• Increased boiler efficiency

• Energy savings $$$

The Benefits

Introduction

Objectives

Analyzer’s

Savings Fuel/Air ratio control

Burner safety control

UV or IR flame safeguard

Gas Valve Proving

FGR Management

Precise target setpoint control

(PID)

Lead lag control for both

steam and hot water (I.B.S.)

3 Parameter Trim,

O2, CO2 & CO

The Solution

Case Study – Courtesy Autoflame

Case Study Five Boilers

Annual Reductions

592 lbs NOX (30%)

5,731 lbs CO (93%)

Electricity Saved:$35,000

Maint. Savings$40,000

NG Savings:$170,000

INTEL (New Mexico)

Before After Before After

Lever

Position

NOx

ppm

NOx

ppm

CO

ppm

CO

ppm

Low Fire 23.0 27.2 263.0 2.8

2 23.0 20.3 71.0 0.7

3 24.0 20.2 55.0 0.0

4 26.0 22.0 10.0 0.0

5 26.0 21.9 1.0 0.0

6 25.0 24.2 0.0 0.1

7 27.0 21.6 0.0 0.0

8 27.0 24.7 0.0 0.7

9 28.0 24.8 1.0 1.6

High Fire 29.0 21.8 1.0 0.6

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Resources for Linkage-Less Controls –

presented at June 2010 ESC Panel Session

Autoflamewww.autoflame.com

Fireyewww.fireye.com

Honeywell

- Industrial/Process Control Group http:hpsweb.honeywell.com/cultures/en-us/default.htm

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Boiler House Improvements!

Boilers

Burners

Controls

www.CleanBoiler.orgor contact me:Rich Biljetina, 202-251-8902biljet@att.net

Additional Steam System Resources:

Armstronghttps://www.armstronginternational.com/steam-system

Spirax Sarcohttp://www.spiraxsarco.com/

Yarwayhttp://www.yarway.com/steam_traps.asp

• Energy analysis software tools

• Case studies/tip sheets/manuals

• Energy efficiency training

for plant staff

• Qualified software specialists

• DOE-supported energy

assessments

• Plant information package & CD

Website:

877-337-3463

www.eere.energy.gov/industry/saveenergynow

DOE Resources for Energy Savings

Info Center:

TanklessWater Heaters

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Tankless Water Heaters

Have no storage tank

Heat water on demand

Higher first cost but theylast three times longer

No standby-losses from the tankprovide energy savings

High efficiency: 97+%

Customers like both the ‘look’ and thespace-saving features!

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What Makes Tankless Water Heaters Green?*

They reduce energy consumption by up to 40% because you heat water only on demand.

They can save water by heating water quicker and because they can be placed close to fixtures, reducing time for hot water to arrive.

They can reduce your carbon footprint with better energy efficiency and lower gas emissions.

They reduce waste and material usage by being much smaller than traditional hot water tanks and they last 3 times longer.

They have many recyclable parts, including copper and steel core components.

*http://tanklesswaterheating.net

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Tankless Water Heaters: Lots of Choices!

AO Smith

American WaterHeater Co.

Bosh

Navien America

Noritz

• Rheem

• Rinnai

• RUUD

• State Water Heaters

• Takagi

HVACHumidification

DehumidificationImproving Indoor Air Quality &

Customer Comfort

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Optimum Humidity Levels

40% to 50%

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Advantages of Humidifiers Inhibits respiratory infections and allergy-related

illnesses

Contributes to health and comfort of building occupants and eliminates static electricity

Reduces employee absenteeism; increases productivity

Protects expensive computers, equipment, furnishings and supplies

Precise humidity control for manufacturing and preservation of artifacts

Reduce Influenza!

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Dehumidification

Proper humidity levels help control grow of bacteria and mold and can reduce the spread of viruses

Winter dryness causes cracked lips, dry skin, and bloody noses

People feel more comfortable at proper humidity levels

Save energy required for cooling

Helps reduce/eliminate the need for sub-cooling and re-heating

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…and Specifically for Restaurants

Dehumidification

• Reduces growth of disease-causing microbes

• Controls odors, mold and mildew

• Eliminates condensation and prevents damage

to furnishings, carpeting, tiles, and other

building materials

• Increases diner, employee, and chef comfort

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Engine DrivenCooling

http://www.gasairconditioning.org

AbsorptionCooling

Some AdditionalTechnologies

of Interest

InfraredThermography

For Your Energy Audits

Process Heater –scale build-up on wall

Sp2

Sp1

850.4

1102.1 °F

900

950

1000

1050

1100

FL IR Sy s te m s

Courtesy FLIRwww.flir.com

http://us.fluke.com/fluke/usen/products/categoryti

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Unit heaters / Infrared

High Efficiency Unit Heaters‒Hot air

Infra Red Heating Systems‒Standard

‒Tube

OnsitePower GenerationIs Now the Time?

Gas supply projections reach all time high -~40% increase providing over 100 yrs in potential resources!

0

500

1000

1500

2000 2001 2002 2003 2004 2005 2006 2007 2008

Bil

lio

n C

ub

ic F

eet

Barnett Shale Production ofUnconventional Gas

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Engine-Based CHP in a Package !

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Natural Gas Engine CHP System Capacity, kW

400 500 600 1,500900 1,000700 800

Waukesha

200 300

Tecogen

2G-Cenergy

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Freewatt

Marathon Engines

I-Power Energy

MTU

1.2

2 to 4.7

2

60 to 100

100 to 3,510

40 to 400

1,000

23 to 365

From 1 kW to 1 MW plus

Now available from the factory in sizes from 1 kW to 1 MW +

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Waukesha – APG1000 Combined Heat and Power

The 1.0 MW Enginator CHP package allows for optimized efficiency by

maximizing heat recovery.

3 Circuit Plate & Frame

Heat Exchanger

Dungs® Gas Train

CHP Control Panel

Achieve up to 88.8%

total efficiency with the

APG1000 CHP Package

Factory built and tested CHP system

Minimizing time and

packaging cost, all CHP

components are factory

mounted

More Information from ESC

Boilers and Steam Systemswww. CleanBoiler.org

Cogeneration & Distributed Generation

www.PowerOnsite.org

Commercial & Industrial Efficiencywww. NaturalGasEfficiency.org

Natural Gas Cooling Equipmentwww.GasAirConditioning.org

Brought to you by

Energy Solution Center Consortia www.escenter.org

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Thank you!