M o d u l a r O n - D e m a n d S t e a m S y s t e m s. GVA Northwest LLC / Miura Boiler. John Hilton

Transcription

1 M o d u l a r O n - D e m a n d S t e a m S y s t e m s GVA Northwest LLC / Miura Boiler. John Hilton

2 Accounting for the Environment: The global environment & economies are on a crash course with each other that will in the end leave them inseparable CO 2 is the new currency of the green economy Energy efficiency is the first fuel for addressing environmental challenges =

3 Sustainable Business Principles: Triple Bottom Line : Social Responsibility Extended Product Stewardship Online Maintenance System Safe & Easy Operation Environmental Stewardship Reduced Fossil Fuels Consumption Reduced GHG Emissions Reduced Water Consupmtion Economic Prosperity Reduced Fuel Costs Reduced Operation Costs Increased Operational Efficiency

4 Boiler Fuel Consumption (TBtu / yr) U. S. Boiler Market Survey: Energy Consumption U.S. Industrial Boilers Energy Consumption (2005): ~ 6.5 Qbtu / yr or up to 40% of all energy at industrial facilities 2,500 2,000 1,500 1, Food Paper Chemicals Refining Primary Metals Other Mfg

5 Boiler Units Boiler Capacity (MMBtu / hr) U.S. Boiler Inventory: Distribution by Region U.S. Industrial Boilers Breakdown by Region (2005): West Coast: Total Capacity ~ 130 Billion Btu / hr 25, ,000 20, ,000 15, ,000 10, ,000 5, ,000 ENC ESC MA MTN NE PAC SA WNC WSC

6 Boiler Capacity (MMBtu / hr) U. S. Boiler Market Survey: Age Distribution U.S. Boilers Age Distribution of Boilers > 10 MMBtu/hr (2005): C/I Boiler Inventory 163,000 units w/ capacity of 2.7 Trillion Btu/hr 1,200,000 1,000,000 47% of existing inventory 40+ yrs. old 76% of existing inventory 30+ yrs. Old 800, , , ,000 Pre

7 Unlocking U.S. Energy Efficiency Bang for Buck Industrial Sector 2009 McKinsey EE Report for DOE / EPA: Steam Systems Waste Heat Recovery Energy Mgmt for E/I Processes ~ 13 Quadrillion Btu s at an avg. capital investment of ~ $7 / MMBtu

8 FEMP Guidelines: Boiler Selection Criteria FEMP = Energy Star for larger energy-using equipment Minimum boiler efficiency guidelines Boiler system selection & sizing guidelines If building loads are highly variable, as is common in commercial buildings, designers should consider installing multiple small (modular) boilers. Modular systems are more efficient because they allow each boiler to operate at or close to full rated load most of the time, with reduced standby losses.

9 U.S. GHG Emissions: U.S. CO2 Emissions (Gigatons CO 2 e) : 29% of GHG s Traced to Site Emissions in the Commercial / Industrial Sectors

10 U. S. Boiler Market Survey: What are the roots of the boiler technology currently operating in the U.S.? Miura is focused on energy efficiency technology transfer to bring the U.S. boiler inventory into the 21 st century

11 Reducing Boiler Footprint Physical Footprint: Reduced space requirements Reduced energy plant construction costs Reduced boiler hardware Energy Footprint: Reduced energy consumption / wasted energy Reduced explosive energy Reduced embodied energy Environmental Footprint Reduced consumption of natural resources Reduced harmful emissions Reduced carbon footprint 60% 20% 20% - 70%

12 Innovative Design Summary: Key Benefits Modularity Highly efficient load management with back-up capability & flexibility for changing steam demands Size New Construction - Cut boiler room size up to 50% Existing Applications - Double your steam capacity in the same space or free up space for other uses Efficiency Startup-to-steam in 5 minutes Average 20% in annual fuel savings via improved system efficiency Reduced Environmental Impact Reduced harmful emissions (NOx & CO 2 ) Safety Reduced water volume = reduced explosive energy in the boiler Low Maintenance / Durable Design Floating Header design eliminates damage caused by thermal stress

13 Managing Energy Load Variability: Conventional Systems Conventional boiler systems expend large amounts of energy to meet variable load conditions Design limitations of conventional boilers prevent them from efficiently responding to every-changing load demands Result: Significant wasted energy & emissions at load swings Single 1000 BHP Boiler

14 Managing Energy Load Variability: Modular On-Demand Systems Modular on-demand boiler systems reduce energy consumption required to meet variable loads by dividing the output capacity among multiple small units (like gears in a transmission) Modular systems are designed specifically to meet varying load demands Result: Significantly reduced energy & emissions at load swings BHP Modular Boilers

15 Optimized Energy Management via Modularity Modular design concept: 200HP TDR=1:3 Step(H,L) 200HP TDR=1:3 Step(H,L) 200HP TDR=1:3 Step(H,L) 200HP TDR=1:3 Step(H,L) 200HP TDR=1:3 Step(H,L)

16 Optimized Energy Management via Modularity Modular design concept: Each boiler unit acts like a single piston in the overall boiler system 1000HP boiler system TDR=1:15 (15 steps of modulation)

17 Understanding Boiler Efficiency: In-Service Efficiency Boiler Efficiency = Steam / Hot Water Output Energy Input Energy Gas

18 Understanding Boiler Efficiency: Combustion Efficiency (E c ) The effectiveness of the burner to ignite the fuel Per ANSI Z21.13 test protocol Thermal Efficiency (E t ) The effectiveness of heat transfer from the flame to the water Per the Hydronics Institute BTS-2000 test protocol Recognized by ASHRAE 90.1 standard Boiler Efficiency Often substituted for combustion or thermal efficiency Fuel-to-Steam Efficiency (A.K.A. Catalog Efficiency) The effectiveness of a boiler operating at maximum capacity and a steady state, with flue losses and radiation losses taken into account.

19 Understanding Boiler Efficiency: Fuel-to-Steam vs. In-Service Efficiency Understanding operating efficiency = tracking energy losses Radiation Loss FUEL IN Exhaust Loss Fuel-to-Steam Efficiency Start-up Losses Pre- & Post-purge Losses Blow-down Losses High Turndown Changing Loads Radiation Idle / Stand-by IN-SERVICE EFFICIENCY

20 Increasing Efficiency = Reducing Losses: Radiant Losses With energy efficiency, size matters Increase efficiency via reduced boiler thermal footprint FUEL IN Fuel-to-Steam Efficiency IN-SERVICE EFFICIENCY 200 BHP Firetube Boiler 1,000+ Gallons VS 200 BHP Modular Boiler 65+ Gallons Smaller Boiler Surface Area = Significant Reduction in Radiant Losses

21 Increasing Efficiency = Reducing Losses: Radiant Losses Radiant Losses: 12 MMBtu/hr input at 100% output Option A Conventional System: Single 12 MMBtu/hr unit input Rated at 2% radiant loss 240,000 Btu/hr energy loss Option B Modular System: 3 x 4 MMBtu/hr unit input Rated at 0.5% radiant loss 3 x 20,000 Btu/hr losses = 60,000 Btu/hr energy loss 0.5% 2% 0.5% FUEL IN 0.5% Fuel-to-Steam Efficiency IN-SERVICE EFFICIENCY

22 Increasing Efficiency = Reducing Losses: Radiant Losses Radiant Losses: 12 MMBtu/hr input at 33% output Option A Conventional System: Single 12 MMBtu/hr unit at 33% = 4 MMBtu/hr input FUEL IN Fuel-to-Steam Efficiency IN-SERVICE EFFICIENCY 240,000 Btu/hr energy loss Results in 6% total radiant loss 6% Option B Modular System: 3 x 4 MMBtu/hr units (only 1 operating) 1 x 20,000 Btu/hr losses = 20,000 Btu/hr energy loss Only 0.5% total radiant loss 0.5% 0% 0%

23 Space Savings Addition by Subtraction: Small boiler footprint (good for point-of-use applications) No tube-pull space required Double the boiler output of a typical boiler room (existing facilities) Reduce required boiler room area by over 50% (new construction) Without Tube-Pull & Door- Swing Space Modular Systems Offer Substantial Space Savings

24 Space Savings Addition by Subtraction: The 21 st century boiler plant Take advantage of freed-up space to: Increase capacity Incorporate other systems (CHP, etc.) Incorporate other functions (in lieu of costly new construction)

25 Increasing Efficiency = Reducing Losses: Exhaust Losses Utilize feed-water economizer for built-in waste heat recovery Feed-water economizers increase efficiency by capturing waste exhaust gases to preheat feedwater entering the boiler FUEL IN Fuel-to-Steam Efficiency IN-SERVICE EFFICIENCY Boiler efficiency can be increased by 1% for every 40 o F decrease in stack gas temperature

26 Increasing Efficiency = Reducing Losses: Start-up Losses Thermal shock/stress is the #1 cause of fire-tube boiler damage & repair Conventional boiler performance is limited by thermal stress resulting in inefficiency by requiring slow boiler start-up & perpetually idling operation FUEL IN Fuel-to-Steam Efficiency IN-SERVICE EFFICIENCY Firetube boilers typically require as much as 90 minutes for cold start-up & must remain idling when in stand-by mode resulting in significant wasted energy & emissions

27 Increasing Efficiency = Reducing Losses: Start-up Losses Utilize Floating Header pressure vessel design to eliminate thermal shock Direct contact furnace-less design Upper Header Fuel / Air Intake FUEL IN Fuel-to-Steam Efficiency IN-SERVICE EFFICIENCY Steam Out Strategic placement / density of fin tubes create uniform thermal expansion / contraction from burner to exhaust outlet Single-pass design for even temperature distribution Burner Allows for steam production in 5 minutes from cold start Water In Lower Header

28 Increasing Efficiency = Reducing Losses: Blow-down Losses U.S. DOE steam systems BEST PRACTICES recommendation: Improve boiler efficiency and reduce water consumption by utilizing automatic surface blow-down in lieu of continuous and/or manual blow-down. Utilize a boiler control system that includes automatic blow-down for optimization of blowdown for highest efficiency operation Automatic blow-down is managed via a proportional flow system and/or back-up conductivity probe that monitor TDS to maximize boiler performance and efficiency FUEL IN Fuel-to-Steam Efficiency IN-SERVICE EFFICIENCY

29 Increasing Efficiency = Reducing Losses: Pre- & Post-Purge Losses Utilize a control system that includes an intelligent purge system to optimize boiler performance FUEL IN Fuel-to-Steam Efficiency Purge Cancel function interrupts post purge when fast restart is required, eliminating heat loss and improving response time IN-SERVICE EFFICIENCY Optimized response time (w/in 10 seconds) = increased efficiency + reduced emissions Boiler stop Restart signal Typical controller Post-purge Pre-purge Boiler start sequences Smart controller Post-purge = Pre-purge Boiler start sequences

30 Increasing Efficiency = Reducing Losses: Losses at High Turn-down Modular boiler system: FUEL IN Fuel-to-Steam Efficiency MT1 Twisted pair cable MP1 IN-SERVICE EFFICIENCY

31 Boiler Scale Detection & Prevention: Heat Transfer Losses - Scale An eggshell thickness of scale can reduce boiler efficiency as much as 10%* (25% for 1/8 thickness, 40% for 1/4 thickness) FUEL IN Fuel-to-Steam Efficiency IN-SERVICE EFFICIENCY *Just 1/32 of scale thickness multiplied times each industrial boiler in the U.S. inventory ~ Over $7 billion in wasted energy / yr (@ $1.00/therm) Over 50 million metric tons of CO 2 emissions / yr

32 Boiler Scale Detection & Prevention: Integrated Water Softener System Smart water softener system Enhanced performance / reduced salt usage via split-flow regeneration Automatically alternates between primary / regeneration tanks for optimized performance Monitors brine tank level & alarms thru BL Controller Interfaces with Colormetry, BL Controller & Online Monitoring System NEW Miura Boilers ML2 Panel MW CMU-H

33 Miura Online Maintenance: M.O.M. System Utilize online maintenance system that interfaces with boiler control system as thermal energy management dashboard Speeds maintenance by diagnosing fault conditions Alerts maintenance staff to warnings before they become problems Provides monthly reports Standard with every boiler shipped 6 months monitoring with monthly reports free with boiler system purchase

34 Benchmarking to Save Energy: First Steps Why benchmark?... You are not managing what you do not measure Benchmarking thermal energy systems first and foremost confirms that existing systems are sized appropriately for current load demands Benchmarking assesses energy performance of existing systems in comparison with the current state of the shelf in available technology Benchmarking allows facilities to better evaluate the carbon intensity of their operations Benchmarking data can be used to identify opportunities for energy savings & reduced emissions via systems upgrades Benchmarking data can be used as the basis of capital planning and/or award for energy efficiency rebates / grants

35 In-Service Efficiency Analysis: Benchmarking Tools Miura s Data Logger records metered usage to benchmark existing efficiency: Tank Radiant Losses Steam Steam Demand Water Water Meter Gas Meter Gas Existing Boiler Blow-down Miura Data Logger

36 In-Service Efficiency (%) Understanding Boiler Efficiency: In-Service Efficiency In-Service Efficiency by Boiler Type: Miura s modular systems provide increased energy efficiency at around 85% consistently from low to high load factors Load (%)

37 Power-Plant-in-a-Box Concept: Modular Micro-Cogen System Complete Packaged On-Demand Heating, Cooling & Power Generation Carrier A United Technologies Com A United Technologi high pressure (B) Chilled water in / out (G) low pressure (A) Gas (E) Cooling water in / out (C) (F) Miura Boiler (D) Condensate Carrier Micro-Steam (back-pressure turbine) Carrier Absorption Chiller Condensate