hovalwerk ag 01.09.2002 1 gas condensing technology h2oh2o director - marketing und development...
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Hovalwerk AG 01.09.2002 1
Gas Condensing Technology
H2O
Director - Marketing und DevelopmentHeating Technology Division
Markus Telian
Hovalwerk AG 01.09.2002 2
Gas Condensing Technology
Physical basics
Combustion
Efficiency
State of the art in boiler technology
Content
Hovalwerk AG 01.09.2002 3
Gas Condensing Technology
HHC C C C C C C C C CHH
HH HH HH HH HH HH HH HH HH HH
HH HH HH HH HH HH HH HH HH HH
HH
HH
C
C
C
C
C
C
C
C
HH
HH
C
C
C
C
C
C
C
C
C
C
C
C
C C
C C
HH
HH HH
HH
HH HH
HH HH
CHH
HH
HH
HH
C C C
HH HH HH
HHHH
HH HH HH
HHC C C C
HH HH HH HH
HH
HH HH HH HH
coalCoronen H:C = 0.5 : 1
oilDecan H:C = 2 : 1 Natural gas
Methan H:C = 4 : 1
Propane C3H6
Butane C4H8
Energy sources and their carbon / hydrogen ratio
Hovalwerk AG 01.09.2002 4
Gas Condensing Technology
natural gas
oil
coalwood
lignite
0.40 0.36 0.33 0.26 0.20
in kg in kg COCO2 2 / kWh / kWh fuel inputfuel input
COCO22-formation of different energy sources-formation of different energy sources
Hovalwerk AG 01.09.2002 5
Gas Condensing Technology
COCO22- production by comparison old or new- production by comparison old or new
0,40
0,31 0,29
0,220,18
100%old
combustion engineering
48% optimized
combustion engineering
oldOil
ges = 0.65
oldN.Gas
ges = 0.65
newN.Gas
ges = 0.90
newGas
Condensingges = 1.09
newOil
ges = 0.90
... in kg CO2 / kWh useful energy
0,25
newOil
Condensingges = 1.04
Hovalwerk AG 01.09.2002 6
Gas Condensing Technology
FuelsPhysical basics for condensation firing fuel oil or gas
Gross calorific value(Ho)
net calorific value (Hu)
theoretical condensingppower generationower generation (Ho-Hu)
theoreticalaccrual condensing wateraccrual condensing water
steam dew pointsteam dew pointat Lambda 1.2
acidity - pH-value
12.56 kWh/kg
11.80 kWh/kg
0.76 kWh/kg
1,3 kg HEL
47°C
~ 2 - 4
11.14 kWh/m3
10.06 kWh/m3
1.08 kWh/m3
1.6 m3/ Erdgas H
56°C
~3 - 5
FuelOil
NaturalGas
Hovalwerk AG 01.09.2002 7
Gas Condensing Technology
Schematic representation
Chemical reactions:
COO OO = CO2 (carbon dioxid)
H HOO = H2O (water vapour)
gasCH4 C H
H
H
H
OO OOS = SO2 (sulphur dioxid)
CO2+ 2H2OAfter the combustion
Combustion of 1m3 natural gas
Hovalwerk AG 01.09.2002 8
Gas Condensing Technology
Wherein lie the most important savings of energy?
a) Lowering the flue gas temperature Conventional boiler: flue gas temperature 140 °C up to 190 °C
Condensing boiler: flue gas temperature 5 K up to 20 K above return temp.
approxmimate value:
Reduction of the flue gas temperature by 20K gives an increase of the
efficiency of 1%.
b) Condensation fo the water steam in the flue gas (latent heat: 0.66 kWh/kg condensate)
Hovalwerk AG 01.09.2002 9
Gas Condensing Technology
(Hu)
HH22OO
""vaporousvaporous""
(Ho)
HH22OO
„fluid"„fluid"
Gai
ned
qu
antit
y of
he
at a
t ful
lco
mbu
stio
n
2.)
1.)
net & gross calorific valuenet & gross calorific value
1.111.091.081.061.06
10.06 kWh/m3
25.88 kWh/m3
34.32 kWh/m3
11.80 kWh/kg10.08 kWh/l
11.14 kWh/m3
28.11 kWh/m3
37.17 kWh/m3
12.56 kWh/kg10.68 kWh/l
Natural Gas H*PROPANE BUTANE HEIZÖL EL**HEIZÖL EL
gross (Ho) net (Hu) relation Ho / Hu
fuels
2) Referred efficiency determination on Hu (100 %)
* russian natural gas** Specifikation ÖMV "Futura"
1) the larger the difference between gross and net calorific value the larger the energy gain!
Influence and characteristicsggross calorific valueross calorific value
netnet calorific value calorific value
Hovalwerk AG 01.09.2002 10
Gas Condensing Technology
Return
Flow
Condensate Drain
Flue Gas
Fuel and Combustion Air
1200 - 1600 °C
First part of the heat exchanger
Second part of the heat exchanger
120 - 180 °C
~ 40 °C
< 35 °C
Burner Design:
Atmospheric Burner, Premix Burner, Pressure Jet Burner
Schematic picture of a condensing boiler
Temperatures are examples!
Hovalwerk AG 01.09.2002 11
Gas Condensing Technology
Bo
iler
Sh
ellDew point
Flue Gas 52 - 57 °C
Boiler WaterFlue Gas
Combustion
COCO22Fuel Dew Point specific amount
of condensationTheor. max.CO2-Content *)
Natural Gas ~ 56°C
~ 52°C
~ 51°C
~ 47°C
0.16 kg/kWh
0.12 kg/kWh
0.12 kg/kWh
0.09 kg/kWh
11.8 %
13.7 %
14.1 %
15.3 %
PROPANE
BUTANE
Fuel Oil EL*) ÖNORM M7510,T2
Hovalwerk AG 01.09.2002 12
Gas Condensing Technology
60
50
40
30
20
10
4
6
8
10
12
14
16
Dew
po
int
°C
CO
2-C
on
ten
t V
ol.
-%
05 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Water Contnet (Vol.-%)
Natural GasNet CV = 10,04 kWh/m3
CO2max = 12,0 %
ColeNet CV = 7,91 kWh/kgCO2max = 20,6 %
FuelOil ELNet CV = 11,86 kWh/kgCO2max = 15,3 %
Dew pointin dependenceof thefuel and theCO2-content
Hovalwerk AG 01.09.2002 13
Gas Condensing TechnologyE
ffic
ien
cy %
Amount of Condesateg/kWh
20 30 5040 600
30
60
90
120
1020
4050
7080
100110
Return Temperature °C
air ratio 1.1
natural gas H
95
110
105
100
90
1
Efficiency
Condensate
3
.... Depends on the temperature
difference in the boiler shell
2
Amount of condensate and efficiency in dependence of the return temperature
Condensate in real (Theory = 100%): ~70-75 %
~60-65 %
~45-50 %
naturalgas
Hovalwerk AG 01.09.2002 14
Gas Condensing Technology
UltraGas® efficiency -comparison ( )
Available heat
90 % gross
100 % net
93 % net87 % gross
91 %net85 % gross
Radiation losses
Not usedcondensationheat
Fluegas losses
100 % gross
111 % net
109 % net98 % gross
108 % net97 % gross
Low temperature-boiler Condensing boiler-gasCondensing boiler-oil
100 %gross
106 % net
104 % net98 % gross
103 % net 97 % gross
gross (GCV)
net (LCV)
Radiation losses Radiation losses
Fluegas losses Fluegas losses
Not usedcondensationheat
Not usedcondensationheat
gross (GCV) gross (GCV)
net (LCV)net (LCV)
Available heat Available heat
Hovalwerk AG 01.09.2002 15
Gas Condensing Technology
UltraGas® efficiency comparison ( ) acc. to DIN 4702 - 8
75 / 60 °C75 / 60 °C
40 / 30 °C
LT-boiler Condensing boiler
86 % (gross)95 % (net)
95 % (gross)105 %(net)
98 % (gross)109 % (net)
The efficiency calculated according to DIN 4702 - 8 is an objective and comparable figure for boilers (heating mode)
Hovalwerk AG 01.09.2002 16
Gas Condensing Technology
A single pass, natural gas down fired, firetube boiler.
Fully condensing capable, hot water boiler.
boiler sizes with capacity range of 50kW through 650kW single and from 250kW to 1300kW as double unit available.
UltraGas®
State of the art in boiler technology
Hovalwerk AG 01.09.2002 17
Gas Condensing Technology
General plan of types modulating ratio power range at 40/30°C
UltraGas® (50) 13 - 52 kWUltraGas® (60) 13 - 62 kWUltraGas® (80) 21 - 82 kWUltraGas® (100) 21 - 101 kW UltraGas® (125) 25 - 125 kWUltraGas® (150) 32 - 150 kWUltraGas® (200) 44 - 202 kWUltraGas® (250) 49 - 250 kWUltraGas® (300) 55 - 300 kWUltraGas® (350) 55 - 350 kWUltraGas® (400) 99 - 400 kWUltraGas® (450) 99 - 450 kWUltraGas® (500) 99 - 500 kWUltraGas® (650) 94 - 650 kW
Hovalwerk AG 01.09.2002 18
Gas Condensing Technology
General plan of types modulating ratiopower range at 40/30°C
UltraGas® (250D) 25 - 246 kW UltraGas® (300D) 32 - 300 kWUltraGas® (400D) 44 - 404 kWUltraGas® (500D) 49 - 500 kWUltraGas® (600D) 55 - 600 kWUltraGas® (700D) 55 - 700 kW UltraGas® (800D) 99 - 800 kWUltraGas® (900D) 99 - 900 kWUltraGas® (1000D) 99 - 1000 kWUltraGas® (1300D) 94 - 1300 kW
Hovalwerk AG 01.09.2002 19
Gas Condensing Technology
Optimised stratification, a counter flow heat exchanger design to provide optimal heat transfer Heavy Polymer flue gas collection box prevents acidic corrosion.
Design
Hovalwerk AG 01.09.2002 20
Gas Condensing Technology
The extended heating surface design provides the ideal solution for the demands of a condensing boiler and helps to recover virtually all the latent heat of the flue gas.
The tube consists of an outer stainless steel 1.4571 (316 Ti) tube (waterside) and an aluminium profile on the flue gas side.
The Clearfire is also qualified for the use of inhibitors. I.e. used in heating systems with oxygen diffusion.
aluFer®
Hovalwerk AG 01.09.2002 21
Gas Condensing Technology
Aluminium has a ten times higher heat conductivity compared to stainless steel.
The complex aluminium profile with fins and micro structures produce a huge heat transfer surface.
The micro structure causes a complex turbulent flow pattern and intensities the heat transfer.
The vertical position of the tubes enables a self-cleaning effect. A reduction in efficiency due to deposits on the surface is avoided.
each aluFer® tube is divided into eight flow channels.
As a result, turbulent flue gas flow is created and a hot core stream is avoided
aluFer®
Hovalwerk AG 01.09.2002 22
Gas Condensing Technology
extremely clean combustion
turn down ratio 1 : 6.5
low noise
minimum electrical power consumption
Ultraclean®- burner system
Hovalwerk AG 01.09.2002 23
Gas Condensing Technology
schematic diagram
Gas valve
Air
Gas
Fan
Burner
Venturi
p Ignition
Ultraclean®
Hovalwerk AG 01.09.2002 24
Gas Condensing Technology
The Clearfire®-premix burner is made of a high temperature resistant Fecralloy metal fibre
almost flameless combustion of thehomogeneous gas / air mixture.
The solid body radiation of the burner surface cools the flame and enables extremely low emissions.
The flexible metal fabric prevents thermal stresses, resulting in a long lifetime of the
Ultraclean®-premix burner. Ultra Low NOx Performance
Ultraclean®
Hovalwerk AG 01.09.2002 25
Gas Condensing Technology
UltraGas® (300,350,600D,700D) emissions
NOX and CO in relation to the burner load (dry, 3 % O2)
01020304050607080
0 10 20 30 40 50 60 70 80 90 100
burner load [%]
NO
x / C
O in
[m
g/m
]3
NO(x) UltraGas® (300,350,600D,700D) CO UltraGas® (300,350,600D,700D)
Hovalwerk AG 01.09.2002 26
Gas Condensing Technology
Summary
Condensation
Maximum efficiency
Saves money
Less primary energy used
Less CO2 (approx 42%)
Protects the Environment