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Energy Efficiency Trade Ally Workshops GTI Super Boiler Advanced Heat Recovery. April & May, 2011 Curt Bermel Business Development Manager - R&D curt.bermel@gastechnology.org. WHO WE ARE Gas Technology Institute.

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energy efficiency trade ally workshops gti super boiler advanced heat recovery
Energy Efficiency Trade Ally Workshops GTI Super Boiler Advanced Heat Recovery

April & May, 2011

Curt Bermel

Business Development Manager - R&D

curt.bermel@gastechnology.org

who we are gas technology institute
WHO WE AREGas Technology Institute
  • Leading U.S. research, development, and training organization serving the natural gas industry and energy markets
    • An independent, 501c (3) not-for-profit

Serving the Energy Industry Since 1941

  • > Over 1,000 patents

> Nearly 500 products commercialized

super boiler background
Super Boiler Background
  • U.S. industrial and commercial steam boilers
    • Consume over 6 quads of natural gas per year
    • Wide range of steam uses from process steam to space heating
  • Installed base of steam boilers
    • Largely over 30 years old
    • Average efficiency 76%
    • Typical NOx emissions 85 ppmv
    • Significant potential for improved technology
project origin goals
Project Origin & Goals
  • Super Boiler program
    • Started by DOE and gas industry in 1999
    • GTI team selected to carry out project
  • Goals:
    • Maximum efficiency
    • NOx and CO less than 5 ppmv
    • Reduced footprint and weight
    • Cost-effectiveness
heat recovery
HEAT RECOVERY
  • Natural gas combustion produces about 18% water from oxidation of H in fuel
  • Water vapor up the stack accounts for 10% of fuel energy input, or 65% of stack loss
  • Key to higher energy efficiency is to recover both sensibleandlatent heat
heat recovery general approach

Deaerator/ Make-Up Tank

Steam Out

LTE

HTE

Boiler

Fuel in

BFW

TMC

Flue gas out

Ambient air

Make-up water

Heat Recovery:General Approach
  • Flue gas heat recovery
    • Remove sensible heat with two economizers
    • Remove latent heat with Transport Membrane Condenser (TMC)
    • Suitable for end users with high make-up water usage
heat recovery expanded system
Heat Recovery: Expanded System*
  • Applications with high condensate return
    • Limited make-up water reduces TMC capacity
    • Recycle water through air heater (AH)
    • Allows for heat recovery even for boilers with high condensate return

Deaerator/ Make-Up Tank

Condensate return

Steam Out

LTE

HTE

Boiler

Fuel in

BFW

Preheated air

AH

TMC

Flue gas out

Ambient air

Make-up water

*U.S. Patent No. 7,066,396

heat recovery tmc concept

Warm humid fluegas in

Warm water out to deaerator

Cool feed water in

Cool dry fluegas out

Heat Recovery:TMC Concept*
  • Transport Membrane Condenser (TMC)
    • Nanoporous ceramic membrane tubes
    • Water vapor permeation via capillary condensation
    • Partial vacuum on shell side
    • Counter-flow configuration

* U.S. Patent No. 6,517,607, 2008 Chicago Innovation Award

tmc version 2 1 in duct
TMC Version 2.1 in Duct

Cooler Dryer flue gas out

Cool feed water in

Warm moist fluegas in

Warm water to deaerator

heat recovery california field demo
Heat Recovery:California Field Demo
  • Clement Pappas & Co. in Ontario CA
    • Heat recovery system (HRS) similar to Alabama site
    • HRS mounted above boiler
transport membrane condenser tmc
Transport Membrane Condenser (TMC)
  • TMC Module
  • Nanoporous membrane tubes selectively remove water through low-pressure-drop capillary condensation
  • Extracts pure water molecules from the effluent and with the water comes the latent heat (normally considered low-grade)
  • Applicable to wide range of combustion applications
    • Industrial and commercial boilers
    • Steam power plants, engines and turbines
    • Industrial drying and dewatering processes
heat recovery california
Heat Recovery:California

Baxter BioScience

Thousand Oaks, CA

  • October, 2009 Installation
oak ridge national lab
Oak Ridge National Lab
  • Accomplished in the demo
    • Installation completed in April 2010;
      • Data on 100% makeup water application
    • 2nd generation TMC demonstrated
  • Measured benefits
      • ~95% efficiency, 50% recovery of water vapor
      • Integrated boiler/AHRS control panel
      • 1st 200 psig design
richardson brands candies
Richardson Brands Candies
  • Accomplished in the demo
    • Installation completed in May 2010, expect
      • Data on very high makeup water application
    • 2nd generation TMC demonstrated
    • Injection molded end caps = savings
  • Market influence
    • Verify performance on high makeup systems
    • Verify improved ROI
  • Measured benefits
    • TBD; expect
      • ~94% efficiency, 40% recovery of water vapor
summary
Summary
  • Super Boiler technology proven at five industrial sites
  • Additional Super Boiler systems contracted
  • Commercial license agreement for TMC-based heat recovery signed with Cannon Boiler Works
  • Expanded use of TMC for other applications
    • Utility-scale boilers (working with Alliant and US-DOE)
    • Industrial drying applications
    • Home humidification (two units installed)
    • Non-boiler applications such as in sludge processing
other markets projects
Other Markets/Projects
  • Transport Membrane Humidifier
    • Funded by SMP
    • Humidification using products of combustion
    • >12% efficiency increase
  • TMC for coal-fired power plants
    • Funded by DOE NETL
    • 70% water recovery from exhaust gases
    • Larger bundles
  • TMC for non-boiler applications
    • Funded by CEC & UTD
    • Scrubbers, dryers, etc.
    • Demo fall 2010 at L&N Costume Cleaners
  • TMC for Industrial boilers
    • Market need but no funding to date
contact information
Contact Information

Curt Bermel (847) 768-0649

Gas Technology Institute

curt.bermel@gastechnology.org

Chris Giron (724) 335-8541

Cannon Boiler Works

sales@cannonboilerworks.com