energy efficiency trade ally workshops gti super boiler advanced heat recovery april & may, 2011...
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Energy Efficiency Trade Ally Workshops GTI Super Boiler Advanced Heat Recovery
April & May, 2011Curt BermelBusiness Development Manager - R&[email protected]
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WHO WE ARE
Gas 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
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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
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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
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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 sensible and latent heat
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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
Fuel in
Steam Out
Boiler
Deaerator/ Make-Up
Tank
Ambient air
LTEHTE
Flue gas out
TMC
Make-up water
BFW
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Preheated air
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
Fuel in
Steam Out
Boiler
Deaerator/ Make-Up
Tank
Ambient air
LTEHTE
Make-up water
Flue gas out
TMCAH
Condensate return
BFW
*U.S. Patent No. 7,066,396
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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
Warm humid flue
gas in
Warm water out to
deaerator
Cool feed water
in
Cool dry flue
gas out
* U.S. Patent No. 6,517,607, 2008 Chicago Innovation Award
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1st and 2nd Generation Membrane Bundles
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TMC Version 2.1 in Duct
Warm water to deaerator
Cool feed water in
Warm moist flue
gas in
Cooler Dryer flue gas out
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Heat Recovery:Alabama Field Demo
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Heat Recovery:Alabama Field Demo
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Heat Recovery:California Field Demo
> Clement Pappas & Co. in Ontario CA─ Heat recovery system (HRS)
similar to Alabama site─ HRS mounted above boiler
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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
Transport Membrane Condenser (TMC)
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Heat Recovery:California
Baxter BioScience
Thousand Oaks, CA─ October, 2009 Installation
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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
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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
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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
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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
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Contact Information
Curt Bermel (847) 768-0649
Gas Technology Institute
Chris Giron (724) 335-8541
Cannon Boiler Works