An Advanced Heat Recovery System for Commercial and Industrial Steam Boilers

Transcription

1 An Advanced Heat Recovery System for Commercial and Industrial Steam Boilers Place your chosen image here. The four corners must just cover the arrow tips. For covers, the three pictures should be the same size and in a straight line. Christopher A. Cavanagh, PE Principal Project Manager Davis Gaudet, CEM Senior Energy Engineer

2 National Grid Overview Customers US 8 Million UK 11 Million Pipes & Wires US 125,000 miles UK 215,000 miles 2 nd Largest US Utility Largest UK Utility UK Electric UK Gas Service Areas: Electric Gas Both Electric and Gas National Grid Gas and LIPA Electric System

3 Agenda Introduction Technology Description The Transport Membrane Condenser Demonstration Results Richardson Brands Candy Energy Efficiency Program Evaluation National Grid Energy Efficiency Programs Evaluation of a Hypothetical Ultramizer Installation Best Applications Other Uses for the TMC Q & A

4 Agenda Introduction Technology Description The Transport Membrane Condenser Demonstration Results Richardson Brands Candy Energy Efficiency Program Evaluation National Grid Energy Efficiency Programs Evaluation of a Hypothetical Ultramizer Installation Other Uses for the TMC Q & A

5 Introduction A new Advanced Heat Recovery System for commercial and industrial fire-tube boilers New installations Retrofit Recovers heat and water from boiler flue gasses Reduces overall emissions production Criteria pollutants (NO x ) Greenhouse gases

7 Technology Description The Transport Membrane Condenser Conventional economizers first cools boiler flue gas to within about 20 to 50 F of its dew point Flue Gases from natural gas combustion passes over membrane outer surface with boiler make-up on the inside. (not dual-fuel). The TMC recovers about 15-40% of the available moisture in flue gas. Water condenses in the micropores of the ceramic membrane at a temperature above the normal condensation point (dew point) because of the phenomenon of capillary condensation. Avoids corrosive condensate and contaminants (O 2 & CO 2 )

8 Technology Development The Transport Membrane Condenser Initial Partners History 2000 Concept Development at GTI Cleaver Brooks Participation Initial Site Demonstrations (4 CA,UT, AL) 2010 National Grid Demonstration at Richardson Brands Commercialization Licensed Nationally to Cannon Boiler Works of PA by GTI Ultramizer see NYSERDA Program Support

10 Demonstration Richardson Brands Candy New Cleaver Brooks 238 HP Fire-tube boiler at 140 psig Replaces steam supply from neighboring Beechnut plant Commissioned January 2011

11 Demonstration Richardson Brands Candy Canajoharie, NY Steam Production High and low pressure economizers Low NO x burner (9 ppm) Limited headroom

12 Demonstration Richardson Brands Candy

13 Demonstration Richardson Brands Candy 7-8 inches Hg vacuum

14 Demonstration Results System monitored Jan 2011 to April 2011 RBC Measured Fuel-Steam Efficiency : 92.3% May % improvement attributable to the TMC 0.65 gpm water recovered at 100% firing rate Flue Gas temperature reduced from 5151 o F overall to 119 o F Good reliability Minor control issues resolved Vacuum leak in one module, replaced.

15 Demonstration Results

16 300 Boiler HP AHRS Energy Savings Simple Payback* * Typical unsubsidized simple payback assuming a large firm gas customer paying a total of $10.70 per DTH not including water savings.

17 300 Boiler HP AHRS Water Savings * Typical water costs are range from $3.45 to $10.30 per 1,000 gallons Water recovery is about 4.5 gallons water per 1,000 scf gas input

19 Reducing Reliance on Traditional Energy Sources National Grid operates gas and electric programs approved by public utility commissions in all states served Massachusetts New York Rhode Island ENERGY STAR Partner of the Year Energy Efficient Program Delivery Since inception of energy efficiency programs: More than 4.7 million National Grid customer efficiency projects completed in New England, saving more than $3.6 billion in energy costs Programs save customers over $300 million annually Over $1.5 billion invested in efficiency Savings targets double between 2010 and 2012 Least cost procurement legislation approved in MA and RI within last two years

20 Energy Efficiency Programs & Technologies (Typical) Residential Weatherization High Efficiency Heating / Water Heating ENERGY STAR Lighting and Products ENERGY STAR HVAC New Concepts (Hot roofs, Automation, heat pump water heaters) New Concepts (Hot roofs, Automation, heat pump water heaters) Commercial & Industrial Lighting (Outdoor and Indoor) High Efficiency HVAC High Efficiency Motor Variable Frequency Drives (VFD) Air Compressors Custom Measures For unique situations Projects must pass Benefit/Cost test to be eligibility (examples: Controls, Solar HW, Combined Heat & Power etc.)

21 MA Approved Plans The energy efficiency measures installed in the electric and gas programs, combined, are estimated to provide $6 billion in benefits and almost $3.9 billion in net economic benefits Savings Target Electricity (MWh) National Grid 289, , ,107 1,211,340 Statewide 624, ,069 1,103,423 2,624,919 Annual energy savings of 2.4 percent of retail electricity sales in 2012* Natural Gas (Therms) National Grid 7,241,878 11,539,070 14,572,864 33,353,813 Statewide 13,593,912 19,087,301 24,687,219 57,368,432 Annual energy savings of 1.15 percent of retail natural gas sales in * Total projected savings in Massachusetts approximately 30% of 2020 electricity

22 Energy Efficiency Program Evaluation - MASSACHUSETTS Customer Name Project Description Existing or Base Case Condition Description Proposed Description State Fuel Type Program Measure Description Massachusetts Customer in Boston Super Boiler Conventional Steam Boiler at 80% Efficiency Super Boiler 300 HP Steam with Ultramizer Heat Recovery Utility Contact Dave Gaudet MA Phone Gas Application ID Retrofit Funding Type Heating Other Measure Code HTGO Default Life 15 Life 20 overrides default measure life Electric PA Gas PA NSTAR Elec National Grid Gas

23 Energy Efficiency Program Evaluation - MASSACHUSETTS COST DATA INPUTS Total Equipment Cost $ 193,000 Total Labor Cost $ 150,000 Total Cost $ 343,000 Installed kw (CHP ONLY) CHP Measure? No This project is eligible for gas and/or electric incentives. Please contact your PA for more information

24 Energy Efficiency Program Evaluation - MASSACHUSETTS ANNUAL NON ELECTRIC NON GAS BENEFITS (COSTS) INPUTS Annual Oil Savings (mmbtu) Annual Propane Savings (mmbtu) Annual Water Savings Annual Sewer Savings Other Annual Benefits ($) Other One-Time Benefits ($) 400,000 (gallons) (gallons)

25 Energy Efficiency Program Evaluation - MASSACHUSETTS ANNUAL GAS SAVINGS (INCREASES) INPUTS Gas - Seasonal Heating Gas - Year Round Load Gas - All (Both of the above) Total (therms) 52,566.0 (therms) (therms) 52,566.0 (therms)

26 Energy Efficiency Program Evaluation - MASSACHUSETTS TRC BCR: 2.31 ELECTRIC INDICES LIFETIME MWH LIFETIME kw-years ELECTRIC UNITS CALCULATED VALUES ELECTRIC INCENTIVE $ AUTHORIZED VALUES $/ ANNUAL kwh: N/A $/UNIT: N/A GAS INDICES LIFETIME THERMS 1,051,320 GAS INCENTIVE $ 78,849 $/ANNUAL THERM $ 1.50 PAYBACKS WITHOUT INCENTIVE ELECTRIC GAS TOTAL N/A CALCULATED AUTHORIZED TOTAL INCENTIVE: $ 78,849 $ - ELEC PAYBACK N/A N/A GAS PAYBACK PAYBACK W/INCENTIVE N/A N/A DUAL FUEL COST ALLOCATION ELECTRIC INCENTIVE N/A $ - ELECTRIC BENEFITS GAS INCENTIVE N/A N/A $ - GAS BENEFITS 100%

28 Best Applications High Operating Hours Target 6,000 hrs per year at 80% firing rate Matched to boiler make-up rate. Make-up (% of feedwater): Hospital 10-20% Multi-family 3-15% Industrial varies 4% to 100% (RBC > 50%) Maximum Benefits above approx. 15% make-up before TMC. Minimum efficiency benefits approximately 85% of maximum benefits down to 1.2% make-up water

30 Other Potential Uses for the TMC Water-tube boilers (e.g. Nebraska Boiler) High pressure superheated steam Fuel flexible Energy and Water Recovery from Flue Gasses and Waste Streams (non-boiler) Open-air dryers employed in food processing (e.g. tortilla manufacturing) Commercial cleaners Sludge processing High Efficiency Cogeneration (60- to 5,000-kW) Stream Driven Gas Turbines with Heat Recovery Steam Generators Residential Humidifier

31 Agenda Introduction Technology Description The Transport Membrane Condenser Demonstration Results Richardson Brands Candy Energy Efficiency Program Evaluation National Grid Energy Efficiency Programs Evaluation of a Hypothetical Ultramizer Installation Other Uses for the TMC Q & A

32 Going Forward With your help we can lead the way in creating the climate for change nationalgrid