Energy Efficiency Innovation Seminars Purdue … Efficiency Innovation Seminars Purdue University, October 22, ... Aerodynamic chamber / Test boiler . ... Real time ASME PTC 4.1 efficiency

Unternehmen Weishaupt

German Technology at the Basis of an Energy Solutions Concept

Energy Efficiency Innovation Seminars

Purdue University, October 22, 2012


1819 1970

1952 1962

Experience. We have been delivering first-class quality

burners for almost 60 years


Burner Product Range


Weishaupt Headquarters in Schwendi, Germany


Research and Development


Test boilers up to 75,000 MBTU/H


Aerodynamic chamber / Test boiler


Gas mixing station


Innovation and reliability

Copyright © by Max Weishaupt GmbH, D-88475 Schwendi

A Solutions Based Provider of Process Combustion Systems & Services to

Institutions and Industry


Over 38 years of industrial combustion, engineering, and steam experience;

Weishaupt Rep;

B&W Rep;

Have completed over 100 energy audits;

On staff DOE Qualified Steam System Specialist;


As a Solutions based provider makes recommendations for new systems or alterations and improvements to existing systems based on: ◦ Analysis of factual information

◦ A clear understanding of the owners goals, commitments and obligations

Rather than based on what they have to sell.


“Where we are” ◦ How are current boilers performing? – steam supply side

“Where we want to be” ◦ What are the site’s demands that the boilers need to

match - steam demand side

“Best Way to Get There” ◦ Most cost effective solution to efficiently match the

supply to the demand

“Where we are”/ “Where we want to be”


Software Models

Sustainable Solutions

Measuring and Controlling Performance with :

CSI’s Boiler Consultant Process

Surveys


Basis – ASME PTC 4.1 Heat Loss Method ◦ Identifies specific sources of heat loss

Basis for improvement calculations

◦ Does not use rules of thumb

Provides a model of system performance

Recommendations for economical improvements


Real time ASME PTC 4.1 efficiency monitoring ◦ ASME Boiler Efficiency

◦ Overall Boiler Efficiency

◦ Plantwide Boiler Efficiency

◦ % Blowdown

◦ % Make-Up

No “standard” product – Customized to each boiler room


From the surveys and modeling completed, a detailed picture of current boiler operations is known.

Critical Information: ◦ Boiler efficiencies

◦ Boiler steam generation capabilities


65.00%

70.00%

75.00%

80.00%

85.00%

0 100 200 300 400 500 600 700

ASM

E P

TC

4.1

Boiler

Eff

icie

ncy

Boiler Horsepower

Boiler ASME Efficiencies

Boiler 1 Boiler 2

77.00%

79.00%

81.00%

83.00%

85.00%

87.00%

0.0% 10.0% 20.0% 30.0% 40.0% 50.0% 60.0% 70.0% 80.0% 90.0% 100.0%

Com

bu

sti

on E

ffic

iency

Firing Rate

Boiler Combustion Efficiencies

Boiler 1

Boiler 2


Now that current efficiency levels and boiler performance are known, the steam load profile needs to be analyzed ◦ “Where we want to be”

Load profile can be obtained from: ◦ Utility bills

◦ Personnel interviews

◦ Detailed calculations/metering

Most accurate



Turndown is a measurement of the high and low fire capabilities of a burner ◦ 5-1 turndown ratio = 20% low fire

If very constant load, turndown may not be valuable

For loads with significant swings throughout the day, a higher turndown ratio can lead to significant savings ◦ Down-cycle losses (purging losses)


Valuable upgrade to current inefficient burners

Valuable upgrade for facilities with down-cycle losses

Valuable upgrade for facilities looking for high reliability equipment


Energy Savings ◦ Customers that are good candidates for a high

quality, high efficiency burner typically see a 5%-12% reduction in natural gas costs.

◦ Customers have reported savings as high as 24%

Not typical but can be achieved in ideal scenarios

Maintenance Savings ◦ Customers have reported positive long-term burner

reliability performance leading to maintenance savings

Energy Efficiency Innovation Seminars Purdue … Efficiency Innovation Seminars Purdue University, October 22, ... Aerodynamic chamber / Test boiler . ... Real time ASME PTC 4.1 efficiency

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