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Maximizing Boiler Plant

Efficiency
Presenter: Dan Watkins, LEED BD+C
Sales Engineer
Bornquist, Inc.

Efficient Boiler Design

Boiler Types
Efficiency Definition
Non-Condensing
Condensing

Maximizing Efficiency
Understanding Efficiency
Outdoor Reset
Short Cycle Prevention
Hybrid Systems

Efficient Boiler Design


Combustion Efficiency 100 percent of efficiency minus
the percentage of heat lost up the vent.
Thermal Efficiency The combustion efficiency minus
the jacket losses of the boiler. Based on ANSI Z21.13.
For boilers 300,000 to 12.5 million Btu.
A.F.U.E. The measure of annual efficiency of a boiler
that takes into account the cyclic on\off operation and
associated losses as it responds to changes in load. For
boilers under 300,000 Btu

Efficient Boiler Design

Non-Condensing
Cast Iron
Steel Tube
Copper Fin
Modulating

75-88% Efficiencies

Efficient Boiler Design

Condensing
Cast Aluminum
Stainless Steel
Cast Iron
Dual Heat
Exchanger

85-99% Efficiencies
depending on
operating conditions

Therma
le

fficienc
y

.can reach efficiencies of 98% - and more..


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Condensing Boilers

98% EFFICIENT

MARKETING AND REALITY

ENERGY CONTENT OF NATURAL GAS


LATENT HEAT
10.2%
SENSIBLE HEAT
89.8%
Latent Definition:
Latin for hidden

Heat that can be measured or


felt by a change in temperature
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Condensing Boilers

NON-CONDENSING BOILER HEAT FLOW

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Condensing Boilers

CONDENSING BOILER HEAT FLOW

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Condensing Boilers

What is a Condensing Boiler?

A condensing boiler is a boiler which has a heat


exchanger that is made of materials which will withstand
acidic condensate.

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Condensing Boilers

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MATERIAL CHOICES FOR CONDENSING


BOILERS
Materials on the market:
Aluminum Alloy
SA 240 316Ti
316L
Cast Iron?
Copper Tube w/ secondary heat
exchanger

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Condensing Boilers

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CORROSIVE FLUE GAS CONDENSATE


pH Values of various fluids
Flue gas
condensate

Oil
3
2

Typical household
sewage

Gas
5
4

Battery acid
Gastric acid

3
Vinegar

Lemon
juice

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pH-Value

Acidic
0

Clean rain
water
Rain
water

10

11

12

Basic

Tap
water

Distilled
water
(neutral)
Condensing Boilers

10

11

12

Ammonia

Lake
water

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What about Efficiency?

Condensing boilers are NOT 99% efficient all of the time.

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Condensing Boilers

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120oF return water


100% input
87% efficiency
Where is the
condensation?

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Condensing Boilers

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Condensing/Modulating Boiler

With efficiencies like this . . .


. . . our customers have
reduced their fuel bills by
up to 80%.

Now you can, too!


140F EWT
120F EWT
100F EWT
80F EWT

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Condensing Boilers

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LATENT HEAT RECOVERY

WATER
VAPOUR

LIQUID

Water vapor turns to liquid when it


is reduced in temperature.

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Condensing Boilers

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HEAT RECOVERY FROM FLUE GASES


Water vapor (steam)
containing latent heat

Simplified Chemical Combustion Formula:


CH4 + 2 O2
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CO2 +2 H2O
Condensing Boilers

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LATENT HEAT RECOVERY


1 pound of water
Water vaporizing
(Latent heat of
condensation)

Steam

970 Btus

Ice melting
(Latent heat of fusion)
Ice

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144 Btus

Condensing Boilers

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WATER VAPOUR DEW POINT

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Condensing Boilers

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NATURAL GAS COMBUSTION


+Excess air

1 part gas

10 parts air

More excess air = Lower CO2%


Lower C02% = Lower dew point temperature
Lower dew point temp. = Less condensation
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Condensing Boilers

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WATER VAPOR DEW POINT


oF o
C

Dew point water vapor

140

60

131

55

122

50

113

45

104

40

95

35

86

30

77

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Natural Gas (95% CH4)


CO2% of flue gas
influences dew point
temperature
Higher CO2
=Higher Dew point
=More Condensation

Lower CO2
=Lower Dew point
=Less Condensation
2

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10 11 12

Condensing Boilers

CO2 in Vol %
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Heat Exchanger Design:

PRIMARY HEAT EXCHANGER DESIGN


SECONDARY HEAT EXCHANGER DESIGN

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Condensing Boilers

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PRIMARY HEAT EXCHANGER DESIGN

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Condensing Boilers

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SECONDARY HEAT EXCHANGER

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Condensing Boilers

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Efficient Boiler Design


Condensing Boiler Design Guidelines

Design system for lower water


temperatures
Use larger delta Ts
Radiant floor heat / snow melt
Water Loop Heat Pumps

Select boiler plant for small turndown


capabilities
Save initial cost by using both condensing
and non-condensing boilers when possible

Efficient Boiler Design


Maximizing Efficiency

Outdoor Reset
Designing a Reset Curve

Cycle Efficiency
How the cycle suffers
Adjusting the differential
Buffer Tanks

Piping Systems

Efficient Boiler Design Outdoor Reset

Boiler Plant Cycle Eciency

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CHICAGO, IL

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Cycle Eciency
Curve Analysis

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Energy Use (Therms, DecaTherms, etc.)

Energy Use Per Unit of Load (e.g., HDDs)


Jul Aug Sep Oct Nov Dec Jan Feb Mar Apr May Jun

31

Old Energy Use Per Unit of Load (e.g., HDDs)

New Energy Use Per Unit of Load (e.g., HDDs)


Jul Aug Sep Oct Nov Dec Jan Feb Mar Apr May Jun

32

Old Energy Use Per Unit of Load (e.g., HDDs)

New Energy Use Per Unit of Load (e.g., HDDs)


Jul Aug Sep Oct Nov Dec Jan Feb Mar Apr May Jun

33

Old Energy Use Per Unit of Load (e.g., HDDs)

New Energy Use Per Unit of Load (e.g., HDDs)


Jul Aug Sep Oct Nov Dec Jan Feb Mar Apr May Jun

34

Energy Use (Therms, DecaTherms, etc.)

Energy Use Per Unit of Load (e.g., HDDs)


Jul Aug Sep Oct Nov Dec Jan Feb Mar Apr May Jun

35

Energy Use (Therms, DecaTherms, etc.)

Energy Use Per Unit of Load (e.g., HDDs)


Jul Aug Sep Oct Nov Dec Jan Feb Mar Apr May Jun

36

The E/L Curve Fast Calcula@on


Billing Period

Therms

HDDs

Therms/HDD

December
January

Best ?

February
March
etc

Total Therms

Total HDD

Total HDD x Best Therms/HDD = Whats Possible


Total Therms Whats Possible = What Was Wasted

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To achieve HCE performance, you must


1track small fracPonal loads at high eciency
2make the eciency rise as the load falls
3size boilers so all loads fall within plant modulaPon range
4use low mass boilers for jockey service
5use modulaPng burners
6opPmally match fuel input to real-Pme load

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Piping Design Examples

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Boiler Piping Examples

Boiler Piping Examples

BOILER

BOILER

BOILER

BOILER

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Boiler Piping Examples

Boiler Piping Examples

Boiler Piping Examples

Boiler Piping Examples

Boiler Piping Examples

Boiler Piping Examples

Boiler Piping Examples

Boiler Piping Examples

Hybrid Boiler System

Buffer Tank Example

Using a buffer tank to add 200


gallons will increase firing to almost
3 minutes for a 20 F delta T. Using
reset on the system loop could allow
for a 50 or 60 F delta T. Using a 60
F delta T would mean a minimum
run time of over 8 minutes!

Buffer Tank Example

180

140

Buffer Tank Example

180

140

Buffer Tank Example

Condensing
Boiler

Non-condensing
Boilers

Buffer Tank Example

BuerTank

Condensing
Boiler

Non-condensing
Boilers

Design Guidelines

Utilize Buffer tanks and water temperature


reset
Design for long on/off cycles
Boilers do not need to be same size/style
Use small, modulating boilers as a
jockey boiler
Design for efficiency during light loads

Final Thoughts

System design is typically more important


than individual equipment selections.
Energy retro-fits should be based potential
savings and initial cost.
Every building and every system is
different, so there is no one-size-fits-all
approach to Energy Saving Design.

Thank You!

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