Natural Gas Energy Efficiency Opportunities for Commercial & Industrial Customers. Michael Pace Lead Engineer C & I Efficiency Programs

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1 Natural Gas Energy Efficiency Opportunities for Commercial & Industrial Customers Michael Pace Lead Engineer C & I Efficiency Programs

2 Agenda Energy Efficiency Opportunities for Small/Mid Commercial Facilities Energy Efficiency Opportunities for Large Commercial and Industrial What s new & upcoming for energy efficient gas technologies Leveraging Utility Incentives for Efficiency Improvements

3 Boiler Reset Controls On/Off or Modulating Control for one or more Boilers As Outdoor Air Temp changes, so does Hot Water Supply Temp 3

4 Heating Equipment Infared Heaters Low intensity tubular heaters generate radiant heat like the sun and is absorbed by objects, such as floors and equipment, this heat then is re-radiated back out to the surrounding area Efficiencies to 90% Extremely comfortable heat for warehouses, manufacturing space, garages etc 4

5 Heating Equipment Condensing Boilers How does a condensing boiler work? Very similar to a hydronic boiler except it is designed capture even more heat from the flue gases. The flue gases give up their latent heat, forming condensate. Flue Gas temperature of Condensing boiler is degrees Flue Gas temperature of standard hydronic boiler is 250 to 400 degrees High efficiency condensing boilers are 90 % or higher 5

6 6 Condensing Boilers

7 7 Condensing boiler efficiency

8 Water Heaters On Demand Indirect Condensing Energy Star 8

9 Kitchen Equipment Fryers Ovens Steamers Spray Valve Griddles 9

10 Energy Efficiency Opportunities for Large Commercial and Industrial Steam Boiler Efficiencies Popular Energy Efficiency Measures 10

11 Pipe Leaks Increases Boiler Capacity Reduces Fuel Usage Reduces City Water Make-Up Increases Personnel Safety 11

12 Pipe Insulation Increases Boiler Capacity Reduces Fuel Usage Improves Heat Distribution Increases Personnel Safety 12

13 13 Pipe Insulation

14 14 Pipe Insulation

15 15 Pipe Insulation

16 Steam Traps Increase Boiler Capacity Reduce Fuel Usage Prevent Condensate Pressurization Reduce City Water Make-Up Reduce Chemical Treatment 16

17 Steam Traps Inverted Bucket Float & Thermostatic Disc Thermostatic 17

18 Steam Traps DOE research has found in steam systems that have not been maintained for 3 to 5 years, between 15% to 30% of the installed steam traps may have failed These failures allows live steam to escape into the condensate return system. Steam in condensate loops causes overheating in adjacent rooms. In a recent steam trap audit of a RI school, we found that 54% of the facilities steam traps were leaking or blowing by. The payback to install all the measures was under a year. 18

19 Steam Traps Steam Trap Maintenance Results in Savings of More Than $100,000! A steam trap assessment of three VA hospitals located in Providence, RI, Brockton, MA, and West Roxbury, MA was conducted with help of FEMP & the SAVEnergy Program. The facilities are served by 15, 40, and 80 psig steam lines. The Providence system alone includes approximately 1,100 steam traps. The assessment targeted steam trap performance and the value of steam losses from malfunctioning traps. The malfunctioning traps were designated for either repair or replacement. Included in this assessment was a training program on steam trap testing. The cost of the initial steam trap audit was $25,000 for the three facilities. Estimated energy savings totaled $104,000. The cost of repair and replacement traps was about $10,000. Thus, the cost savings of $104,000 would pay for the implementation costs of $35,000 in about 4 months. 19

20 Combustion Controls Optimizes Fuel-to-Air Ratio Increases Combustion Efficiency Maximum Efficiency at all Loads Minimizes Short-Cycling 20

21 Combustion Controls Linkage Controls are common on modulating burners. One motor usually positions the fuel valves and combustion air damper via fixed position cams and rods. Burners typically set-up for stable Light- Off ratio and efficient HI-Fire position, but lack a LO- Fire position and efficient part-load positions. Parallel Positioning Controls use Direct-Coupled Actuators (DCA) on the fuel valve(s) and air damper individually receiving directions from a Programmable Logic Controller (PLC) to position them at most efficient points to maximize efficiency at up to 24 points on the burner s combustion curve. O 2 Trim Controls use Parallel Positioning Controls with a continuous feedback signal from an oxygen sensor in the exhaust gas to continually and automatically minimize excess oxygen. 21

22 22 Combustion Controls

23 23 Combustion Controls

24 Combustion Controls Fire Tube Boiler with linkage controls 24

25 Combustion Controls Fire Tube boiler with linkage less controls 25

26 Combustion Controls Modulating Burners Only Payback usually 1-3 Years 26

27 Blowdown Heat Recovery Minimize City Make-Up Water Increase Steam System Efficiency Reduce Fuel Usage 27

28 Blowdown Heat Recovery Continuous Steam Boiler Surface-Level Blowdown System 28

29 Blowdown Heat Recovery Blowdown rates are typically 4%-8% of total steam generated, but can be as high as 10% where incoming water has high solids content. If a 150 psig steam boiler generates 10,000 PPH of steam at a blowdown rate of 10%, the heat recovery potential is ~220,000 Btu/H. At $12/MMBtu and 80% combustion efficiency, the potential savings is ~$25,200/Y. 29

30 30 Blowdown Heat Recovery

31 Boiler Stack Economizer Increase Steam System Efficiency Reduce Fuel Usage 31

32 Boiler Stack Economizer Non-Condensing Stack Economizer Condensing Stack Economizer 32

33 Boiler Stack Economizer Economizers Pre-Heat Feedwater & Combustion Air Dependent on Exhaust Gas Temperature, Feedwater Flowrate & Boiler Operating Hours Exhaust Gases typically exit from 450 o F-650 o F Rule-of-Thumb 1% Increase for each 40 o F Decrease Fuel Usage Reduction of 4%-10% Common Paybacks of ~0.5-3 Years on Economizers 33

34 34 Boiler Stack Economizer

35 Flash Steam Heat Recovery Increase Steam System Efficiency Reduce Fuel Usage 35

36 Flash Steam Heat Recovery Condensate & Deaerator Boiler Surface & Mud-Drum Blowdown Tank Vents 36

37 37 Flash Steam Heat Recovery

38 What s New & Exciting in the Natural Gas Energy Efficiency world Advanced High Efficiency Boiler Maximizing steam generation efficiency for commercial and industrial boilers Up to 95% fuel to steam efficiency with novel heat and water recovery device 15% carbon emission reduction Ultra low NO x (sub 9 ppmv) Target: < 2 year payback Multiple field tests underway 38

39 Transport Membrane Condenser (TMC) Tubes with nanoporous membrane that selectively removes water through low-pressure-drop capillary condensation Simultaneously captures waste heat and pure water (from combustion products) Applicable to wide range of applications Industrial and commercial boilers Steam power plants, engines and turbines Industrial drying and dewatering processes 39

40 Ultra-High Efficiency Boiler Advanced Heat Recovery System at RBC Over 15% savings in steam production costs Up to 20% less make-up water consumed Lower NO x and CO 2 emissions 40

41 Ultra-High Efficiency Boiler Advanced Heat Recovery System at Baxter Healthcare 13-15% energy and carbon savings Total efficiency of 93-95% Over $35,000 annual savings at Baxter Over $80,000 at higher hours & firing rates Over 250,000 gallons annual water savings Cannon Boiler Works 41

42 Commercial Food Service Equipment Saving energy First Boilerless Gas- Fired Steamer Improving product quality Increasing foodservice productivity High-Efficiency Wok Burner High Efficiency Pizza Ovens & Combi-Ovens High-Efficiency Low Oil Volume Fryers 42

43 Energy Efficiency Incentives Available from your Program Administrator Prescriptive incentives are designed to cover approximately 75% of incremental cost Retrofit incentives have increased, now up to 50% of project cost Combustion Controls Heat Recovery Insulation 43

44 MA Commercial Gas HEHE Program incentives for 2010 List of qualifying equipment is at 44

45 2010 MA Statewide Commercial Kitchen Incentives High-Efficiency Fryers ENERGY STAR $1,000 High-Efficiency Large Vat $1,000 ENERGY STAR Food Steamer $1,000 ENERGY STAR Griddles $500 ENERGY STAR Convection Oven $1000 High Efficiency Conveyor, Rack, & Combi Ovens $1000 High Efficiency Pre-Rinse Spray Valve $25 On Demand H2O $700 Condensing H20 $500 Go to for a list of qualifying models 45

46 Custom Measures Retrofit incentives have increased, now up to 50% of project cost Combustion Controls Heat Recovery Insulation 46

47 In Summary Visit for information on energy efficiency incentives Contact your local program administrator early and often for potential projects 47

48 48 QUESTIONS???