Nationwide Boiler was recently asked to take part in a survey-type article for the May issue of Power Engineering magazine. The focus was on the latest trends and best practices for burner and combustion system operation and maintenance. Below is our response and it includes where we think the industry is heading.
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Submitted by Larry Day, Vice President, Sales & Marketing, Nationwide Boiler Inc.
As a user and a supplier of rental boilers, Nationwide Boiler Inc. has vast knowledge and experience with supplying and servicing equipment. When the company evaluates new equipment for our rental fleet or provides solutions for new boilers or boiler upgrades, we evaluate equipment that is easy to maintain, provides reliable performance for demanding applications, is the most energy efficient and is able to meet the strictest air emission requirements. We cannot risk onsite equipment failures, therefore we only evaluate quality products that provide immediate efficiency gains.
Energy efficiency is and has been a growing trend over the last five years. Best performance standards (BPS) exist today that we view as a basic requirement for any new boiler system. These standards utilize proven methods for achieving the highest thermal efficiency possible, all based on proven technology. One item boiler owners and operators should not overlook is the installation of VFD fan controls, offering instant energy savings when a unit is not operating at its peak capacity.
For proven burner performance, a minimal or no FGR low excess air burner with O2 trim should also be evaluated. This type of burner not only results in high turndown, but also offers better flame stability compared to ultra low NOx burners, utilizing high FGR or excess air, which are often times slow to respond to load swings and can rely on oversized FD fans that increase energy consumption.
For those operators who must comply with ultra low NOX emission standards, we view back-end technology as the most proven solution. Compared to burners, SCRs eliminate burner flame stability concerns, slow response time and high horsepower FD fans required by front-end technology. In most cases there is no need to increase fan sizes or change burner controls and a SCR is a long term compliance solution, able to reduce NOx up to 95% with emissions as low as 2.5 ppm.
In terms of controls, we are seeing more units equipped with fully metered PLC combustion control systems with innovative touch screen operator interface. This removes a lot of the guesswork out of the operation of the boiler and may save valuable field service time. Also, having the ability to monitor operations remotely and gather historical data and trends provide meaningful and valuable information.
Overall, the trend for energy efficiency is not going away. It is important for boiler owners and operators to take a BPS technology approach when faced with a new boiler purchase or boiler upgrade decision. Many plants that have implemented this approach have benefited and Nationwide Boiler predicts that more will follow.
Boiler Blog | Nationwide Boiler Inc.
Have you been considering steam system improvements in your plant, but do not know where to begin? Do you want to potentially save 10% or more in fuel costs, while reducing emissions?
The U.S. Department of Energy's (DOE) Industrial Technologies Program can help answer those questions for you and has developed the Steam System Scoping Tool (SSST) for energy coordinators, facility managers and plant electricians to help evaluate your steam system's performance. The software (available in MS Excel or Visual Basic formats) asks 26 questions about different areas of your steam system including system profiling, steam system operating practices, boiler plant operating practices, and distribution and recovery operation practices. Based on your responses, the software will indicate opportunities for improvements and will suggest a range of ways to save steam energy and boost productivity. It also compares your system against similar facilities in your industry and identifies best practices.
According to the DOE, six DOE Industrial Assessment Centers used the SSST in 2001 to assess steam systems at 18 small and medium-sized facilities. Overall, the software identified 89 system improvements with an average fuel savings of 12.5%. Collectively, the total improvements yielded a total annual savings of $2.8 million.
To learn more about this free software, visit the DOE's website.
Call Nationwide Boiler at 800-277-1966 to let us know how much energy you are able to save. We can also provide you with valuable information about our energy efficient equipment for sale or for rent, including EconoStak economizers, Best Performance Standards (BPS) boilers and CataStak SCR systems for boilers and gas-fired turbines.
Are you looking for a boiler that offers the latest boiler technology in emissions and efficiency? Does your boiler need to meet an upcoming compliance deadline date and you are not sure what to do? If so, you have come to the right place.
Nationwide Boiler continually seeks technology that offers the maximum emission reductions and the highest thermal efficiency that may provide valuable emission credits and energy rebates. Our Best Performance Standards Boiler keeps this tradition alive and is equipped with the latest technology to ensure you are operating with the greatest efficiency possible.
The BPS boiler is designed with the latest efficiency upgrades (high turndown controls, O2 trim, VFDs, and extended surface economizers) and includes the CataStak SCR System for 2.5 ppm NOx. Nationwide's patent pending NOx reduction control system is also included for precise ammonia flow control.
The yearly efficiency savings and emission reductions that are quickly achieved with a BPS boiler provide a greater return on investment and most importantly, peace of mind with compliance assurance for years to come.
Call us today to obtain a free product bulletin and to learn more about our BPS solution.
