expert engineering and manufacture heat and steam generation
TRANSCRIPT
Off site manufacturing Complete, modular energy centres
prefabricated and fully tested off site
Training and safety services BOAS accredited training courses Steam boiler log books
Expert engineering and manufacture
Heat and steam generation
Wide range of applications Building services CHP Systems District heating energy centres Wastewater treatment Waste to energy processes Industrial production Brewing and distilling Drying processes
2
H i g h e f f i c i e n c y h e a t a n d s t e a m g e n e r a t i o n
Product Overview
• up to 10:1 turndown on gas
• suitable for pre-heated combustion air temperatures of up to 300°C whilst maintaining a body temperature below 50°C
• ultra low NOx emissions
Simultaneous co-firing solutions
• multi fuel burners safely and simultaneously fire natural gas and biogas and have the capability to burn gas, gasoil and recovered waste gases
• dedicated channel of control for each individual fuel
• oil pre-heat function
Boiler sequencing systems
• each boiler is assigned its own modulation settings
• automatic lead boiler selection ensures even operating hours across all burners
• feed forward function anticipates step changes in operating demand
• fast, effective retrofit to existing plant
Ultra low NOx axial air flow burners
• 160kW to 14MW output
• 10:1 turndown on gas
• 4:1 turndown on oil
• 8:1 turndown on oil fired steam/air atomisation
• ultra low NOx emissions: 35mg. per kWh on gas and biogas 105mg. per kWh on oil
3
• maximum pressure lift of 170mbars
• cast iron construction
Touchscreen controls and bespoke software
• fingertip screen control and command
• full boilerhouse management
• unique fail-safe design
• data accessed in situ or via remote access
• accurate boiler efficiency data based on site specific variables
Product design, testing and building information
modelling data
• collaborative BIM software for Product Data Sheets; 3D modelling and comprehensive data files
Offsite manufacture of complete, modular
boiler houses
• pre-fabricated, multi fuel energy centres delivered fully tested and assembled
• all FDS reports, DSEAR analyses, SIL calculations and risk assessments completed
• units designed for biogas, liquid biofuels, recovered organic fuels, biodiesel, natural gas and oils
• fully ATEX compliant
4
H i g h e f f i c i e n c y h e a t a n d s t e a m g e n e r a t i o n
Axial air flow combustion
Dunphy’s patented axial air flow combustion process provides virtually perfect air distribution to the burner head at ALL levels of firing (including, in particular, low fire operation.) The process also assures:
• lower fuel consumption
• inherently low NOx
Variable speed drives and energy savings
Unlike other burner designs, the air distribution in our axial air flow burners is not adversely affected by the installation of variable speed drives (inverters). Significant efficiency benefits can be gained therefore by using inverters to control the speed of burners to the levels optimally required to match air or fuel flows (essential for maximising efficiency on steam generating plant.)
Energy savings are twofold:
• only the absorbed power of the motor is used
• in conjunction with an axial air flow burner, inverters will increase turndown on gas fired plant to a ratio of 10:1
Dunphy ‘T’ series axial air flow burners typically achieve turndown ratios of:
• 10:1 on gas
• 4:1 on oil
Boiler specification
Dunphy will specify correctly dimensioned and designed boiler shells so that maximum efficiency and lowest emissions are achieved from the integrated plant.
We are not tied to any boiler maker and are therefore free to specify the appropriate shell design, geometry, water flow and heat transfer required for low NOx, high efficiency hot water or steam generation.
5
1
‘T’ series gas burners
For use with all gaseous fuels with a CV value ranging from 3 to 30kWh/m3. Burner components can be made from stainless steel for use with corrosive gases.
‘T’ series gasoil burners
For use with liquid fuels up to a maximum viscosity of 5.5cSt at 40°C.
‘T’ series dual fuel burners
For use with combinations of oils and gases.
‘T’ series axial air flow burners Our ‘T’ series of monobloc, axial air flow burners are designed for single or multi fuel use with all liquid and gaseous fuels and are suitable for applications between 80kW and 14MW including:
• heat and steam systems in buildings
• industrial, manufacturing, drying, brewing, distilling and dairy processes
• waste to energy processes
• incineration
Output options ‘T’ series gas, light oil and multifuel burners ‘T
’ s er
ie s
bu rn
er s
‘T’ series axial air flow duel fuel burner.
Fuel changeover can be carried out automatically or remotely via our burner control systems.
Safe simultaneous firing is available controlled by Ratiotronic™ combustion control software.
Output in Megawatts
2
3
6
10
14
6
H i g h e f f i c i e n c y h e a t a n d s t e a m g e n e r a t i o n
‘B’ series burners
Our heavy oil burner range is suitable for fuel oils up to a maximum viscosity of 40 cST at 100°C.
The range is suitable for use on most types of boilers and process applications operating in the range of 160kW to 14MW (dependent on appliance resistance).
Air atomisation is available on all Dunphy liquid fuel burners.
Air atomisation gives the added advantage of higher turndown ratios and the ability to burn higher viscosity fuels on heavy oil burners.
The core features of this range of burners are:
low NOx combustion head
• high precision digital servo motor control
• low leakage, fully digital modulating damper control
Bu rn
er ty
‘T’ series axial air flow heavy oil burners
‘B’ series bespoke burners The Dunphy ‘B’ series of bespoke design burners is designed for a wide range of high output applications.
Applications include incineration, auxiliary firing for biomass boilers and special fuels.
This type of burner is also ideal for air preheat applications and ATEX and SIL approved options.
B1
B2
B3
B4
B5
B6
B7
B8
B9
1
2
3
6
10
14
20
30
40
7
Dunphy has wide experience in manufacturing, assembling, commissioning and maintaining high efficiency, low NOx industrial energy centres.
Whether specified for internal or external sites, Zone 1 or Zone 2 compliance, CHP or waste treatment processes, our engineering solutions deliver consistently high fuel performance and low emissions.
Advantages of retrofitting air pre-heat systems to boilers
Our air pre-heat burners are designed to enhance efficiencies and save fuel and can easily be retrofitted to most types of boiler.
As an example, a low temperature, hot water boiler fitted with a Dunphy gas burner, economisers and an air pre-heat system will condense around 1,150 litres of water per hour.
Some of this water can then be sprayed back into the burner air stream. This, in turn, improves the heat transfer rate of the boiler.
‘HB’ series bespoke burners These bespoke design burners are designed for pre-heated combustion air temperatures of up to 300°C whilst maintaining a body temperature of below 50°C.
Burner design features include:
• up to 10% increase in system efficiency compared with ambient air burners
• double skin construction with thermal suppression barriers
• components manufactured from materials able to withstand high temperatures
Externally sited 38 tonne twin furnace, superheated steam plant approved for Zone 2 application.
8
H i g h e f f i c i e n c y h e a t a n d s t e a m g e n e r a t i o n
Burners for ultra low NOx waste to energy processes Gasification, pyrolysis, plasma arc treatment, incineration,
anaerobic digestion, fermentation, mechanical biological processes, wastewater treatment
Our in-house designed multi fuel combustion plant can achieve NOx emissions as low as
35mg. per kWh on gas, biogas and waste recovered gases
and
105mg. per kWh on oil
Bespoke sluice, start-up and auxiliary burners • high heat output for fast furnace heating
• automatic sluice gate sealing system for water tube applications
• vertical and horizontal designs to ensure efficient operation with all types of fluidised bed and other waste recovery processes
• retractable burner heads
• spark ignition options
Dunphy has extensive experience in manufacturing and fitting high efficiency burners for CHP and district heating plant.
Burners are designed with axial air flows, internal flue gas recirculation and CFD optimised combustion heads to deliver high reliability, high efficiency and ultra low NOx emissions.
Olympic Park district heating centre
Dunphy burners fitted to 20MW twin furnace boilers with adjacent free standing Ratiotronic™ control panel.
Glasgow University CHP Energy Centre
Dunphy gas burners fitted to five boilers providing 42MW capacity for the university’s local district heating scheme.
CHP Energy Centres
Many hospitals, universities, hotels and other large buildings are able to benefit from the significant energy cost savings that can be gained from combined heat and power systems.
Dunphy burners are a preferred combustion source for leading CHP specifiers.
10
H i g h e f f i c i e n c y h e a t a n d s t e a m g e n e r a t i o n
NOx reduction techniques
Provided that the geometry of the boiler is appropriate to site operational demands (and Dunphy can advise and assist with this specification and procurement) then our burners will recirculate flue gases and develop the eddying currents essential for achieving low NOx emissions.
Low temperature hot water boilers
When fitted to correctly dimensioned boilers with a given fuel type and operating temperature and pressure, Dunphy burners can achieve reduced NOx emissions as low as 35mg. per kWh on gas and biogas and 105mg. per kWh on gasoil at 3% oxygen. Our high levels of competence in this area have enabled us to install many of our burners in Switzerland and other countries with exceptionally stringent NOx standards.
Dunphy low NOx gas burners fitted to three x 24MW high pressure hot water boilers in Copenhagen’s district heating system achieving NOx emissions of
65mg/m3 at 3% oxygen.
When used with a correctly dimensioned boiler, Dunphy burners are inherently low NOx emitters due to their design characteristics which include:
• staged combustion mitigating the formation of thermal NOx
• CFD optimised combustion head
Dunphy burners are key components for compliance with all Local Authority, national and international
permitted NOx emissions levels.
11
Co-firing fossil and bio fuels Simultaneous firing of fuels can be a cost effective option for low NOx heat and steam generation.
Each fuel selected will, however, show significant differences in volatility, reactivity, emissions and ash characteristics. Boiler/burner design and controls must be carefully specified to ensure the safe firing of each particular mix of fuels.
Dunphy has developed a range of Ratiotronic™ control systems and software for managing the safe and efficient co-firing and switching of fuels derived from fossil, bio and recovered organic waste sources – including a dedicated channel of control for each individual fuel.
Dunphy multifuel burners simultaneously fire natural gas and biogas and have the capability to burn gas and gasoil.
Pre-heating liquid biofuels
Accurate temperature control of liquid biofuels is essential to avoid swings in viscosity which result in combustion variation.
Oil pre-heating is therefore a key functionality and is one of the most valuable design features in Dunphy burners. This ensures that our low carbon burners operate with consistent combustion efficiency, high turndown ratios and low NOx emissions.
Non ferrous materials are used for all components which come in contact with biofuels.
Dunphy multifuel systems deliver significant cost benefits of co-firing fuels of varying volumes and calorific volumes as well as full compliance with Directive 2000/76/EC.
12
H i g h e f f i c i e n c y h e a t a n d s t e a m g e n e r a t i o n
Retrofitting Dunphy sequencing systems to existing plant can typically generate between 5% and 10% fuel cost savings.
Boiler Sequencing Systems
The order in which the lag boilers are called on line is pre-determined and linked to the operation of the nominated lead boiler.
Each boiler within the system can be assigned its own modulation settings to ensure that boilers of different sizes are efficiently incorporated into the sequencing programme.
Automatic lead boiler selection ensures even operating hours across all burners.
The ‘feed forward’ function anticipates step changes in operating demand.
Our sequencing system can be successfully fitted to all types of boiler or furnace fired by Dunphy or other makes of burner.
Our engineers will quickly and efficiently retrofit sequencing systems to existing plant.
The purpose of sequencing boilers is to ensure that the desired operating load can be met at all times in the most economical way.
During periods of low load a single boiler can be programmed to modulate to meet demand effectively. During peak load operations it is more efficient to automatically bring on line a defined sequence of boilers, at scheduled intervals, to deliver consistent heat or steam matching the variations in load.
13
Control systems product range
Dunphy software engineers continually develop and test new products to improve energy management processes which, in turn, contribute significantly to enhanced safety, reduced emissions and valuable cost savings.
In addition to our digitally modulated burners and our suites of Ratiotronic™ and DunphyDelta control systems, we offer a wide range of other optional control units which can be tailored to individual site operating requirements. For example:
• boiler control panels incorporating water level and TDS/blow down control
• remote (gatehouse) alarm panels
• control solutions utilising PLCs from leading manufacturers such as Allan Bradley and Siemens
• web based remote monitors and controls
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H i g h e f f i c i e n c y h e a t a n d s t e a m g e n e r a t i o n
Touch screen control systems Dunphy’s innovative combustion control software is developed in-house and can be configured for all types of single and multifuel burners, boiler houses and energy centres. Information can be collated from single or twin furnace steam/ hot water boilers, CHP systems, feed water pumps, metering equipment, water level and other combustion equipment and controls.
In addition to single source management of the full range of information required for data sheets, control documentation and the display of technical manuals, the system also provides a unique boiler test system which allows bespoke and site specific test reports to be created, scheduled and exported for later analysis.
Ratiotronic System 5000 touchscreen
Panel mounted Ratiotronic control unit
Boiler house information at your fingertips
• simple, intuitive design
• password protected control of common burner and boiler functions including on/off, set-point, fuel profile, modulation rate, fill/drain, water level tests and more
• auto change setpoints based on day/hour settings enabling efficient use of steam and hot water
• metering information recorded and accurate boiler efficiency measures displayed based on input variables versus steam output
• automatic recording of all faults and lockouts with detailed descriptions
• historical data can be configured to suit site management requirements
• data can be easily passed to a remote system for monitoring and control
• the system will monitor and control the safe firing of up to 4 fuels and fuel changeover is performed safely and quickly
• fully PM5/BG01 compliant
Unique fail-safe feature
Engineering designed redundancy ensures plant continues to run fully and safely if touchscreens are not operational
15
DunphyDelta is exceptionally easy to set up - and delivers real business benefits:
• immediate operational command of plant from remote management sites
• significant reductions in downtime and associated costs by reducing avoidable shutdowns, missed maintenance or malfunctions
• near instantaneous access to real time operational data via visualised reports and graphs
• secure end to end encryption of data in transit and in storage
• scaleable application for multiple plant rooms wherever sited
• multiple devices can be given simultaneous access to data via password protected screens
• easy to use ‘drag and drop’ analyses of real time and historical data based on actual site utility costs
• very quickly deployed using standard Modbus devices in plant rooms and central offices
• reduced IT costs through elimination of software downloads, external hard drives, LANs, cabling, extra data servers and the need for PCs to be linked to plant control systems
DunphyDelta – remote monitoring and control systems Designed in-house, our remote monitoring and operational control systems manage one or more boiler houses from any connected tablet, smartphone, laptop or PC.
DunphyDelta eliminates the need for new software, cabling, extra onsite servers and USBs.
The system provides site specific reports tailored to site operational needs - for example:
• consumption and costs of water, electricity and of each fuel in use
• quantified steam outputs
16
H i g h e f f i c i e n c y h e a t a n d s t e a m g e n e r a t i o n
Benefits of fitting Dunphy burners Compared with a new boiler shell, a burner can be less than half the capital cost.
Yet it’s the burner not the boiler that has the major impact on energy efficiency, fuel consumption and levels of emissions.
For example, fuel savings of up to 10% may be achieved by improving the turndown ratio from 4:1 to 10:1 on axial air flow gas burners, by reducing excess oxygen levels across the turndown range (2% to 3.5% on gas) and by fitting effective digital combustion controls to maintain these key ratios across all loads.
Our single and multi fuel burners safely combust gas, oils, B5 to B100 biodiesel, biomass, liquid biofuels and biogas derived from a wide range of recovered organic wastes.
Dunphy burners are used worldwide in an extensive range of applications:
• hospitals, universities, colleges, schools, large residential properties
• CHP and District Heating Energy Centres
• waste to energy AD, gasification, other conversion technologies
• incineration
• steelworks and foundries
Minimal retrofit downtime
Dunphy’s extensive range of burners fit all makes and types of boiler and furnace shells.
All our burners are designed for fast and safe fitting and commissioning by our teams of field based engineers.
Site disruption and downtime are minimal.
17
Off-site manufacture of modular boiler houses Dunphy prefabricated, containerised boiler houses are manufactured and tested off-site in our factory complex in Rochdale.
We have extensive experience in designing, building and commissioning complete plant rooms using fossil fuels, biogas, liquid biofuels, biodiesel and recovered organic wastes in single or multi fuel firing combinations.
Our plant is ATEX compliant and we prepare all FDS reports, DSEAR analyses, SIL calculations and risk assessments.
The containerised plant room shown above is a double storey unit (7m x 9m x7m) supplying heat and steam to a Cambi thermal hydrolysis process which uses a twin stream combination waste heat boiler.
The biogas fired section provides 2500kg/hr of steam and is supplemented by 586kg/hr of steam generated by the waste heat section.
Consider a prefabricated boiler house when
• space is at a premium
• on-site construction would be expensive or disruptive
• a biofuel system is being installed to supplement an existing traditional boiler house
• a high spec energy centre is needed for a new development
18
H i g h e f f i c i e n c y h e a t a n d s t e a m g e n e r a t i o n
Gas boosters Our range of simplex, duplex and triplex gas boosters is available in horizontal or vertical side mounted orientations.
Pressure lift up to 170mbars can be specified.
Features include cast iron construction for a high level of safety, low noise and a flat curve characteristic which makes our boosters ideal for multiple burner applications.
Variable speed drives and ATEX options are also available.
Spare parts Dunphy operates a highly efficient global spare parts delivery service with around 20,000 items held in our central stores and most being delivered to site next day.
Our field based service team also carry stocks of the most frequently needed spares.
Steam boiler log books • 52 sets of 7 Daily Log Sheets and one Weekly/Monthly Log sheet
• four typical boiler control layouts with recommended tests for each
• NOx emissions levels test guidance
19
Boiler Operation Accreditation Scheme (BOAS) The BOAS accreditation programme is designed for operators and managers of industrial steam and hot water boilers and is recommended by the Health & Safety Executive.
Dunphy is a licensed and approved BOAS training provider delivering four day modular programmes of instruction and hands-on learning followed by written examinations and assessments by external Kiwa GASTEC assessors. Plant operators successfully passing the course examinations and assessments may use the designation Cert. IBO, or for plant managers, Dip.BOM.
Training and assessments are carried out on client sites or in our purpose built Technology Training Centre adjacent to our main factory complex in Rochdale.
Steam and energy audits The cost of generating and managing steam is a major component of manufacturing and process energy budgets. Our specialist engineers will assess and audit the efficiency of all types of plant room equipment and processes. Our Steam Audit Reports detail the parameters which must be routinely measured and managed to ensure the efficient generation and distribution of quality steam at optimum quantities and pressures along the steam pathway - across all demand loads.
Similar detailed audits are carried out for other heat generation processes with our engineers delivering recommendations for improving energy efficiency.
We design, manufacture, install, commission and service high efficiency, low emissions combustion plant
We also provide dedicated technical support and service throughout the UK
Field based services are managed from our manufacturing centre with wireless communication between service and factory engineers ensuring fast, high quality maintenance and parts replacement –
minimising costs and plant downtime.
Dunphy Combustion Ltd Queensway Rochdale England
OL11 2SL
Edinburgh Scotland EH20 9LZ
For further information, contact [email protected]
www.dunphy.co.uk 01706 649217
Training and safety services BOAS accredited training courses Steam boiler log books
Expert engineering and manufacture
Heat and steam generation
Wide range of applications Building services CHP Systems District heating energy centres Wastewater treatment Waste to energy processes Industrial production Brewing and distilling Drying processes
2
H i g h e f f i c i e n c y h e a t a n d s t e a m g e n e r a t i o n
Product Overview
• up to 10:1 turndown on gas
• suitable for pre-heated combustion air temperatures of up to 300°C whilst maintaining a body temperature below 50°C
• ultra low NOx emissions
Simultaneous co-firing solutions
• multi fuel burners safely and simultaneously fire natural gas and biogas and have the capability to burn gas, gasoil and recovered waste gases
• dedicated channel of control for each individual fuel
• oil pre-heat function
Boiler sequencing systems
• each boiler is assigned its own modulation settings
• automatic lead boiler selection ensures even operating hours across all burners
• feed forward function anticipates step changes in operating demand
• fast, effective retrofit to existing plant
Ultra low NOx axial air flow burners
• 160kW to 14MW output
• 10:1 turndown on gas
• 4:1 turndown on oil
• 8:1 turndown on oil fired steam/air atomisation
• ultra low NOx emissions: 35mg. per kWh on gas and biogas 105mg. per kWh on oil
3
• maximum pressure lift of 170mbars
• cast iron construction
Touchscreen controls and bespoke software
• fingertip screen control and command
• full boilerhouse management
• unique fail-safe design
• data accessed in situ or via remote access
• accurate boiler efficiency data based on site specific variables
Product design, testing and building information
modelling data
• collaborative BIM software for Product Data Sheets; 3D modelling and comprehensive data files
Offsite manufacture of complete, modular
boiler houses
• pre-fabricated, multi fuel energy centres delivered fully tested and assembled
• all FDS reports, DSEAR analyses, SIL calculations and risk assessments completed
• units designed for biogas, liquid biofuels, recovered organic fuels, biodiesel, natural gas and oils
• fully ATEX compliant
4
H i g h e f f i c i e n c y h e a t a n d s t e a m g e n e r a t i o n
Axial air flow combustion
Dunphy’s patented axial air flow combustion process provides virtually perfect air distribution to the burner head at ALL levels of firing (including, in particular, low fire operation.) The process also assures:
• lower fuel consumption
• inherently low NOx
Variable speed drives and energy savings
Unlike other burner designs, the air distribution in our axial air flow burners is not adversely affected by the installation of variable speed drives (inverters). Significant efficiency benefits can be gained therefore by using inverters to control the speed of burners to the levels optimally required to match air or fuel flows (essential for maximising efficiency on steam generating plant.)
Energy savings are twofold:
• only the absorbed power of the motor is used
• in conjunction with an axial air flow burner, inverters will increase turndown on gas fired plant to a ratio of 10:1
Dunphy ‘T’ series axial air flow burners typically achieve turndown ratios of:
• 10:1 on gas
• 4:1 on oil
Boiler specification
Dunphy will specify correctly dimensioned and designed boiler shells so that maximum efficiency and lowest emissions are achieved from the integrated plant.
We are not tied to any boiler maker and are therefore free to specify the appropriate shell design, geometry, water flow and heat transfer required for low NOx, high efficiency hot water or steam generation.
5
1
‘T’ series gas burners
For use with all gaseous fuels with a CV value ranging from 3 to 30kWh/m3. Burner components can be made from stainless steel for use with corrosive gases.
‘T’ series gasoil burners
For use with liquid fuels up to a maximum viscosity of 5.5cSt at 40°C.
‘T’ series dual fuel burners
For use with combinations of oils and gases.
‘T’ series axial air flow burners Our ‘T’ series of monobloc, axial air flow burners are designed for single or multi fuel use with all liquid and gaseous fuels and are suitable for applications between 80kW and 14MW including:
• heat and steam systems in buildings
• industrial, manufacturing, drying, brewing, distilling and dairy processes
• waste to energy processes
• incineration
Output options ‘T’ series gas, light oil and multifuel burners ‘T
’ s er
ie s
bu rn
er s
‘T’ series axial air flow duel fuel burner.
Fuel changeover can be carried out automatically or remotely via our burner control systems.
Safe simultaneous firing is available controlled by Ratiotronic™ combustion control software.
Output in Megawatts
2
3
6
10
14
6
H i g h e f f i c i e n c y h e a t a n d s t e a m g e n e r a t i o n
‘B’ series burners
Our heavy oil burner range is suitable for fuel oils up to a maximum viscosity of 40 cST at 100°C.
The range is suitable for use on most types of boilers and process applications operating in the range of 160kW to 14MW (dependent on appliance resistance).
Air atomisation is available on all Dunphy liquid fuel burners.
Air atomisation gives the added advantage of higher turndown ratios and the ability to burn higher viscosity fuels on heavy oil burners.
The core features of this range of burners are:
low NOx combustion head
• high precision digital servo motor control
• low leakage, fully digital modulating damper control
Bu rn
er ty
‘T’ series axial air flow heavy oil burners
‘B’ series bespoke burners The Dunphy ‘B’ series of bespoke design burners is designed for a wide range of high output applications.
Applications include incineration, auxiliary firing for biomass boilers and special fuels.
This type of burner is also ideal for air preheat applications and ATEX and SIL approved options.
B1
B2
B3
B4
B5
B6
B7
B8
B9
1
2
3
6
10
14
20
30
40
7
Dunphy has wide experience in manufacturing, assembling, commissioning and maintaining high efficiency, low NOx industrial energy centres.
Whether specified for internal or external sites, Zone 1 or Zone 2 compliance, CHP or waste treatment processes, our engineering solutions deliver consistently high fuel performance and low emissions.
Advantages of retrofitting air pre-heat systems to boilers
Our air pre-heat burners are designed to enhance efficiencies and save fuel and can easily be retrofitted to most types of boiler.
As an example, a low temperature, hot water boiler fitted with a Dunphy gas burner, economisers and an air pre-heat system will condense around 1,150 litres of water per hour.
Some of this water can then be sprayed back into the burner air stream. This, in turn, improves the heat transfer rate of the boiler.
‘HB’ series bespoke burners These bespoke design burners are designed for pre-heated combustion air temperatures of up to 300°C whilst maintaining a body temperature of below 50°C.
Burner design features include:
• up to 10% increase in system efficiency compared with ambient air burners
• double skin construction with thermal suppression barriers
• components manufactured from materials able to withstand high temperatures
Externally sited 38 tonne twin furnace, superheated steam plant approved for Zone 2 application.
8
H i g h e f f i c i e n c y h e a t a n d s t e a m g e n e r a t i o n
Burners for ultra low NOx waste to energy processes Gasification, pyrolysis, plasma arc treatment, incineration,
anaerobic digestion, fermentation, mechanical biological processes, wastewater treatment
Our in-house designed multi fuel combustion plant can achieve NOx emissions as low as
35mg. per kWh on gas, biogas and waste recovered gases
and
105mg. per kWh on oil
Bespoke sluice, start-up and auxiliary burners • high heat output for fast furnace heating
• automatic sluice gate sealing system for water tube applications
• vertical and horizontal designs to ensure efficient operation with all types of fluidised bed and other waste recovery processes
• retractable burner heads
• spark ignition options
Dunphy has extensive experience in manufacturing and fitting high efficiency burners for CHP and district heating plant.
Burners are designed with axial air flows, internal flue gas recirculation and CFD optimised combustion heads to deliver high reliability, high efficiency and ultra low NOx emissions.
Olympic Park district heating centre
Dunphy burners fitted to 20MW twin furnace boilers with adjacent free standing Ratiotronic™ control panel.
Glasgow University CHP Energy Centre
Dunphy gas burners fitted to five boilers providing 42MW capacity for the university’s local district heating scheme.
CHP Energy Centres
Many hospitals, universities, hotels and other large buildings are able to benefit from the significant energy cost savings that can be gained from combined heat and power systems.
Dunphy burners are a preferred combustion source for leading CHP specifiers.
10
H i g h e f f i c i e n c y h e a t a n d s t e a m g e n e r a t i o n
NOx reduction techniques
Provided that the geometry of the boiler is appropriate to site operational demands (and Dunphy can advise and assist with this specification and procurement) then our burners will recirculate flue gases and develop the eddying currents essential for achieving low NOx emissions.
Low temperature hot water boilers
When fitted to correctly dimensioned boilers with a given fuel type and operating temperature and pressure, Dunphy burners can achieve reduced NOx emissions as low as 35mg. per kWh on gas and biogas and 105mg. per kWh on gasoil at 3% oxygen. Our high levels of competence in this area have enabled us to install many of our burners in Switzerland and other countries with exceptionally stringent NOx standards.
Dunphy low NOx gas burners fitted to three x 24MW high pressure hot water boilers in Copenhagen’s district heating system achieving NOx emissions of
65mg/m3 at 3% oxygen.
When used with a correctly dimensioned boiler, Dunphy burners are inherently low NOx emitters due to their design characteristics which include:
• staged combustion mitigating the formation of thermal NOx
• CFD optimised combustion head
Dunphy burners are key components for compliance with all Local Authority, national and international
permitted NOx emissions levels.
11
Co-firing fossil and bio fuels Simultaneous firing of fuels can be a cost effective option for low NOx heat and steam generation.
Each fuel selected will, however, show significant differences in volatility, reactivity, emissions and ash characteristics. Boiler/burner design and controls must be carefully specified to ensure the safe firing of each particular mix of fuels.
Dunphy has developed a range of Ratiotronic™ control systems and software for managing the safe and efficient co-firing and switching of fuels derived from fossil, bio and recovered organic waste sources – including a dedicated channel of control for each individual fuel.
Dunphy multifuel burners simultaneously fire natural gas and biogas and have the capability to burn gas and gasoil.
Pre-heating liquid biofuels
Accurate temperature control of liquid biofuels is essential to avoid swings in viscosity which result in combustion variation.
Oil pre-heating is therefore a key functionality and is one of the most valuable design features in Dunphy burners. This ensures that our low carbon burners operate with consistent combustion efficiency, high turndown ratios and low NOx emissions.
Non ferrous materials are used for all components which come in contact with biofuels.
Dunphy multifuel systems deliver significant cost benefits of co-firing fuels of varying volumes and calorific volumes as well as full compliance with Directive 2000/76/EC.
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H i g h e f f i c i e n c y h e a t a n d s t e a m g e n e r a t i o n
Retrofitting Dunphy sequencing systems to existing plant can typically generate between 5% and 10% fuel cost savings.
Boiler Sequencing Systems
The order in which the lag boilers are called on line is pre-determined and linked to the operation of the nominated lead boiler.
Each boiler within the system can be assigned its own modulation settings to ensure that boilers of different sizes are efficiently incorporated into the sequencing programme.
Automatic lead boiler selection ensures even operating hours across all burners.
The ‘feed forward’ function anticipates step changes in operating demand.
Our sequencing system can be successfully fitted to all types of boiler or furnace fired by Dunphy or other makes of burner.
Our engineers will quickly and efficiently retrofit sequencing systems to existing plant.
The purpose of sequencing boilers is to ensure that the desired operating load can be met at all times in the most economical way.
During periods of low load a single boiler can be programmed to modulate to meet demand effectively. During peak load operations it is more efficient to automatically bring on line a defined sequence of boilers, at scheduled intervals, to deliver consistent heat or steam matching the variations in load.
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Control systems product range
Dunphy software engineers continually develop and test new products to improve energy management processes which, in turn, contribute significantly to enhanced safety, reduced emissions and valuable cost savings.
In addition to our digitally modulated burners and our suites of Ratiotronic™ and DunphyDelta control systems, we offer a wide range of other optional control units which can be tailored to individual site operating requirements. For example:
• boiler control panels incorporating water level and TDS/blow down control
• remote (gatehouse) alarm panels
• control solutions utilising PLCs from leading manufacturers such as Allan Bradley and Siemens
• web based remote monitors and controls
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H i g h e f f i c i e n c y h e a t a n d s t e a m g e n e r a t i o n
Touch screen control systems Dunphy’s innovative combustion control software is developed in-house and can be configured for all types of single and multifuel burners, boiler houses and energy centres. Information can be collated from single or twin furnace steam/ hot water boilers, CHP systems, feed water pumps, metering equipment, water level and other combustion equipment and controls.
In addition to single source management of the full range of information required for data sheets, control documentation and the display of technical manuals, the system also provides a unique boiler test system which allows bespoke and site specific test reports to be created, scheduled and exported for later analysis.
Ratiotronic System 5000 touchscreen
Panel mounted Ratiotronic control unit
Boiler house information at your fingertips
• simple, intuitive design
• password protected control of common burner and boiler functions including on/off, set-point, fuel profile, modulation rate, fill/drain, water level tests and more
• auto change setpoints based on day/hour settings enabling efficient use of steam and hot water
• metering information recorded and accurate boiler efficiency measures displayed based on input variables versus steam output
• automatic recording of all faults and lockouts with detailed descriptions
• historical data can be configured to suit site management requirements
• data can be easily passed to a remote system for monitoring and control
• the system will monitor and control the safe firing of up to 4 fuels and fuel changeover is performed safely and quickly
• fully PM5/BG01 compliant
Unique fail-safe feature
Engineering designed redundancy ensures plant continues to run fully and safely if touchscreens are not operational
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DunphyDelta is exceptionally easy to set up - and delivers real business benefits:
• immediate operational command of plant from remote management sites
• significant reductions in downtime and associated costs by reducing avoidable shutdowns, missed maintenance or malfunctions
• near instantaneous access to real time operational data via visualised reports and graphs
• secure end to end encryption of data in transit and in storage
• scaleable application for multiple plant rooms wherever sited
• multiple devices can be given simultaneous access to data via password protected screens
• easy to use ‘drag and drop’ analyses of real time and historical data based on actual site utility costs
• very quickly deployed using standard Modbus devices in plant rooms and central offices
• reduced IT costs through elimination of software downloads, external hard drives, LANs, cabling, extra data servers and the need for PCs to be linked to plant control systems
DunphyDelta – remote monitoring and control systems Designed in-house, our remote monitoring and operational control systems manage one or more boiler houses from any connected tablet, smartphone, laptop or PC.
DunphyDelta eliminates the need for new software, cabling, extra onsite servers and USBs.
The system provides site specific reports tailored to site operational needs - for example:
• consumption and costs of water, electricity and of each fuel in use
• quantified steam outputs
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H i g h e f f i c i e n c y h e a t a n d s t e a m g e n e r a t i o n
Benefits of fitting Dunphy burners Compared with a new boiler shell, a burner can be less than half the capital cost.
Yet it’s the burner not the boiler that has the major impact on energy efficiency, fuel consumption and levels of emissions.
For example, fuel savings of up to 10% may be achieved by improving the turndown ratio from 4:1 to 10:1 on axial air flow gas burners, by reducing excess oxygen levels across the turndown range (2% to 3.5% on gas) and by fitting effective digital combustion controls to maintain these key ratios across all loads.
Our single and multi fuel burners safely combust gas, oils, B5 to B100 biodiesel, biomass, liquid biofuels and biogas derived from a wide range of recovered organic wastes.
Dunphy burners are used worldwide in an extensive range of applications:
• hospitals, universities, colleges, schools, large residential properties
• CHP and District Heating Energy Centres
• waste to energy AD, gasification, other conversion technologies
• incineration
• steelworks and foundries
Minimal retrofit downtime
Dunphy’s extensive range of burners fit all makes and types of boiler and furnace shells.
All our burners are designed for fast and safe fitting and commissioning by our teams of field based engineers.
Site disruption and downtime are minimal.
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Off-site manufacture of modular boiler houses Dunphy prefabricated, containerised boiler houses are manufactured and tested off-site in our factory complex in Rochdale.
We have extensive experience in designing, building and commissioning complete plant rooms using fossil fuels, biogas, liquid biofuels, biodiesel and recovered organic wastes in single or multi fuel firing combinations.
Our plant is ATEX compliant and we prepare all FDS reports, DSEAR analyses, SIL calculations and risk assessments.
The containerised plant room shown above is a double storey unit (7m x 9m x7m) supplying heat and steam to a Cambi thermal hydrolysis process which uses a twin stream combination waste heat boiler.
The biogas fired section provides 2500kg/hr of steam and is supplemented by 586kg/hr of steam generated by the waste heat section.
Consider a prefabricated boiler house when
• space is at a premium
• on-site construction would be expensive or disruptive
• a biofuel system is being installed to supplement an existing traditional boiler house
• a high spec energy centre is needed for a new development
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H i g h e f f i c i e n c y h e a t a n d s t e a m g e n e r a t i o n
Gas boosters Our range of simplex, duplex and triplex gas boosters is available in horizontal or vertical side mounted orientations.
Pressure lift up to 170mbars can be specified.
Features include cast iron construction for a high level of safety, low noise and a flat curve characteristic which makes our boosters ideal for multiple burner applications.
Variable speed drives and ATEX options are also available.
Spare parts Dunphy operates a highly efficient global spare parts delivery service with around 20,000 items held in our central stores and most being delivered to site next day.
Our field based service team also carry stocks of the most frequently needed spares.
Steam boiler log books • 52 sets of 7 Daily Log Sheets and one Weekly/Monthly Log sheet
• four typical boiler control layouts with recommended tests for each
• NOx emissions levels test guidance
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Boiler Operation Accreditation Scheme (BOAS) The BOAS accreditation programme is designed for operators and managers of industrial steam and hot water boilers and is recommended by the Health & Safety Executive.
Dunphy is a licensed and approved BOAS training provider delivering four day modular programmes of instruction and hands-on learning followed by written examinations and assessments by external Kiwa GASTEC assessors. Plant operators successfully passing the course examinations and assessments may use the designation Cert. IBO, or for plant managers, Dip.BOM.
Training and assessments are carried out on client sites or in our purpose built Technology Training Centre adjacent to our main factory complex in Rochdale.
Steam and energy audits The cost of generating and managing steam is a major component of manufacturing and process energy budgets. Our specialist engineers will assess and audit the efficiency of all types of plant room equipment and processes. Our Steam Audit Reports detail the parameters which must be routinely measured and managed to ensure the efficient generation and distribution of quality steam at optimum quantities and pressures along the steam pathway - across all demand loads.
Similar detailed audits are carried out for other heat generation processes with our engineers delivering recommendations for improving energy efficiency.
We design, manufacture, install, commission and service high efficiency, low emissions combustion plant
We also provide dedicated technical support and service throughout the UK
Field based services are managed from our manufacturing centre with wireless communication between service and factory engineers ensuring fast, high quality maintenance and parts replacement –
minimising costs and plant downtime.
Dunphy Combustion Ltd Queensway Rochdale England
OL11 2SL
Edinburgh Scotland EH20 9LZ
For further information, contact [email protected]
www.dunphy.co.uk 01706 649217