Improving Energy Efficiency through Burner Retrofit
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Overview
ƒ
Typical Boiler Plant Cost Factors
ƒ
Biggest Efficiency Losses in a boiler system
Radiation Losses
Incomplete Combustion
Blowdown
Stack Losses
Boiler Design
Excess Air
ƒ
W i h
Weishaupt
t burner
b
as a solution
l ti tto E
Excess Ai
Air
ƒ
Conclusion
ƒ
Burner installation/retrofit examples
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Typical Boiler Plant Cost Factors
3%
2% 1%
1%
10%
9%
Labor
Fuel
74%
Source: GE Infrastructure Water& Process Technologies
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Biggest Efficiency Losses in a boiler system
1%
76%
20%
100%
3%
Example of Losses in a Boiler System
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Efficiency Losses in a boiler system
ƒ Radiation Losses
Insulate where possible
ƒ Incomplete Combustion
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Complete Combustion with Weishaupt
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Efficiency Losses in a boiler system
ƒ Blowdown
Even with the best pretreatment programs feedwater contains impurities.
Water must periodically be “blown down” to take care of these impurities
Improper blowdown causes increased fuel consumption, the need for more
chemicals and heat loss
Blowdown heat can be recovered and reused in the boiler operations.
ƒ Stack Losses
Biggest Factor in the equation (up to 20%)
35-40 °F of stack temperature equals approx. 1% in energy loss
Stack temperature is dependent on the steam pressure (i.e. 100 PSI = 338 °F)
Older Boilers before 1970 were not built with stack temp. In mind. Here an economizer
can help
help.
NOW – let‘s look at Excess Air!
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Combustion with Excess Air
Some burners use more than 100% excess air
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Excess Air vs
vs. Oxygen
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Quality Engineered Burner Heads mean REPEATABILITY
Low NOx
Ultra Low NOx
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Moving Diffuser for Increased Turndown and Low Excess Air
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Linkage Less Control Components
Servo drives
WFM Main Module
100 & 200
AZL Programming
Module
Flame
Detector
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Conclusion
ƒ Usually the Conclusion would be to service the burner as well as
possible and reduce excess air to the minimum of what the burner can
use and still combust environmentally friendly.
ƒ With Weishaupt a new option is available:
Burner Retrofit
ƒ Let‘s look at some examples in the Chicago area:
Hinsdale Hospital
AON Center
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Adventist Hinsdale Hospital
Hospital, Hinsdale
Hinsdale,IL
IL
The 436-bed hospital is recognized as a leader in a wide range of medical
fields, where university-level care and medical breakthroughs are
achieved each day.
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Hinsdale Hospital
Savings 13%
63000 USD
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Healthcare Facilities
Energy conservation contributes directly to operating income.
Research of the Environmental Protection Agency (EPA) shows that
facilities that implement energy conservation measures outperform their
competitors
co
pet to s be as much
uc as 10%
0% in net
et ope
operating
at g income.
co e
The EPA estimates that for Hospitals:
,
in energy
gy savings
g is
Æ$100,000
ÆEqual to the margin earned from $2,000,000 in new revenues.
Regardless
g
the age,
g high
g performing
g hospitals use as little as one-fourth
of the energy used by like facilities which are at the bottom of the
performance scale.
EPA Study, Boosting Your Bottom Line through Improved Energy Use, June 2005
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AON Center
Savings 16%
85000 USD
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