Overview of Heat Recovery • Boiler Systems and Operating ... down Heat recovery... · • Boiler Systems and Operating Costs • Factors Effecting Blowdown ... Blowdown from steam

• Overview of Heat Recovery• Boiler Systems and Operating Costs• Factors Effecting Blowdown• Blowdown Heat Recovery “The Energy Tank”

• Unbiased, Third-Party, Water & Energy Management Consulting Firm :

- Not affiliated with any equipment or chemical suppliers.

- Provide clients with sound technical advice and recommendationsto effectively manage and reduce their Operating Costs.

- Provide Root Cause Failure Analysis of Failed equipment orprocesses not performing to Design Criteria.

- 15 Years Industrial Water Treatment back-ground.

- 12 Years conducting Energy Audits and working with clients onrecycle / reuse projects.

- Use Utility Mapping Process to systematically define all operating costs in Steam / Hot Water / Process Cooling applications.

- Defined costs can be used to identify cost effective projectsdesigned to reduce system operating costs.

Generalized Industry Overview

Of Boiler Plant Costs

Boiler(s)Fuel:

Direct Cost $

Water:

Direct Cost $

Flue Gas:

Direct Loss $ Steam:

Direct Loss $

Cost to Process $

Simplified Boiler Plant Operating CostAs viewed by Capture H2O

City Water $

Regen. or Power $

Waste $Treated Water $+

Boiler Feedwater$++ Treated Water / Chemicals / Steam

Boiler(s)Fuel $

Flue $

Vent $

Blowdown $Typically between 1 – 20% of Steam Load. Effected by Treated Water

Combination of Large Bottom and Small Surface Blowdown

Energy / Water / Chemicals

City Water $

Steam $+++

Traps

Condensate $

Treated Water / Energy

Vent $

Steam to heat Boiler Feedwater

$+++

BLOWDOWN HEAT RECOVERY (BHR)Patented Process: Canada No.: 2,414,611 USA No.: 6,938,583

“THE ENERGY TANK ”Trade Name Registered

Blowdown from steam boilers is a necessary function. This function however releases significant energy from the

Steam Generation Process.

The BHR process effectively recovers essentially all this energy and routes it back to the boiler feedwater system.

This simplified process reduces Fuel Consumption, Greenhouse Gas Emissions and Water Usage.

How the Patented BHR Process Saves

City Water $

Treated Water $+

Boiler Feedwater$++

Boiler(s)Fuel $

Flue $

Blowdown $

Typically between 1 – 20% of Steam Load

Cooled by Treated Cold Make-up Water

City water cooling eliminated

Steam $+++

Vent $Flash SteamRecovered to steam going to Feedwater

Cold Make-up

Hot Make-up – less steam needed to heat feedwater

Steam to FeedwaterReduced$+++

Canada Patent No.: 2,414,611 USA Patent No.: 6,9 38,583

The Patented BHR Process1) Flash Steam generated due to pressure drop is recovered to

Low Pressure Steam System (steam going to deaerator) or Atmospheric Water Tank (vented feedwater tank or condensate receiver).

2) Large Storage section allows for retention time of remaining blowdown volume for heat recovery to make-up. Make-up passed through series of stainless steel coils to recover sensible heat in the hot blowdown water.

3) Due to cooling blowdown water with the make-up, the need for cooling with City Water before the drain is eliminated.

How is it Different / Better??1. Simplified straight-forward approach with no moving parts. “The Energy Tank” tm

serves as you Boiler Room blowdown/blow-off vessel.A BHR Energy Tank will pay for itself in less than 1 year compared to the 100% non-recoverable cost of a replacement blowdown tank!

2. Captures 100% of all blowdown streams– Large Bottom blowdown, Intermittent Surface Skim, Level Column blowdown all recovered. Any other process can only recover Intermittent/Continuous Surface Skim due to size/pressure rating limitations.

3. Due to large “Storage Section” capacity/retention time, “Hit and Miss” potential of typical Continuous Blowdown Heat Recovery processes is eliminated. Thermal stresses, “flash steam hot” to “make-up cold”, realized in Continuous Blowdown Heat Exchanger is eliminated – prolonging life expectancy of heat exchanger.

4. Any repairs or maintenance can be done on-site / in-situ with nothing more than a set of wrenches. Entire heat exchanger coil system can be removed and re-installed in a couple of hours.

StandardBlowdown

Tank

Standard BlowdownPlus

Continuous Blowdown Heat Recovery

BHR ProcessWith

"The Energy Tank" tm

$5,000 - $12,000 $12,000 - $30,000 $5,000 - $40,000

Depressurizes all blowdown streams

Depressurizes manual/bottom blowdown

Depressurizes ALL blowdownstreams

Releases steam to atmosphere

Recovers some flash steam to Feedwater/deaerator

No flash steam lost to atmosphere

Consumes city water to cool blowdown

Consumes city water to cool bottomblowdown and some

continuous blowdown

No “Hit or Miss” due to large storage section

residence time

Need to replace every 20 – 30 yrs

“Hit and Miss” process due to intermittent flows of blowdown

or make-up

No mechanical equipmentto maintain / monitor / fail

Needs a Level Control Device to maintain level in Flash Pot

(valve or steam trap)

No additional space required.Fits in same space as standard

blowdown tank

Thermal stress (hot/cold) on heat exchanger due to

intermittent flow

Does Notconsume city waterto cool blowdown streams

Need to repair/replace componentsevery 12 – 24 months

Heat Exchanger protected from thermal stresses

Need to replace every 20 – 30 yrs

UtilitiesOptimized

6399 Olde Drive, Appin, Ontario N0L - 1A0P/F: 519-289-5246 C: 519-668-8714

P

BHR-XXHM "Energy Tank"

Cold Blowdown Water to Sewer

Cold Softened Make-up toBHR-XXHM

Heated Softened Make-up to Deaerator

4-inch Atmopshere Vent Line

Blowdown (Timed & Intermittent)To Flash Chamber on BHR-250HM

PRV Station to reduceSteam to less than 7 psig going to deaerator

BHR-XXHM Flash Steamoutlet line feeding to down-steamside of PRV, c/w check valveto prevent backfeeding toBHR-XXHM

Boiler Feedwater

Steam to users

Typical Installation of BHR-XXHM "Energy Tank"

Deaerator5 - 7 psig

Typical “The Energy Tank” tm Internals

Steam Muffler

Loop Drain

BLOWDOWN HEAT RECOVERY – ADDITIONAL SAVINGS OPPORTUNITY Average Load

No Heat Recovery Average Load

CBD Heat Recovery Steam Load, #/Hr 70,000 Blowdown Load, #/Hr 3,500 1,150 Gas Savings, $ / CM Based on $0.25/CM Gas Cost

>$50,600

>202,000 CM

>$16,000

>64,000 CM Water Savings, CM City water eliminated at blowdown tank

>10,000 CM

>$10,000

>4,600 CM

>$4,600 Environmental Savings Tons Carbon Dioxide gas emissions

>425 Tons

>134 Tons

NET SAVINGS : GAS: >64,000 CM $16,000 ABOVE CURRENT SAVINGS EMISSIONS: >134 TONS OF CARBON DIOXIDE GAS WATER : >4,600 CM CITY WATER >$4,600

Already Have Continuous BlowdownHeat Recovery?

Here’s what you are missing from a 1 ½-inch Manual Bottom Blowdown!

PLANT LOCATION: Food Plant in Toronto

Boiler Horsepower: 400 BHPProjected Load: 85 %Efficiency (Fuel to Steam) 70 %Cycles of Concentration: 15 CyclesSteam Pressure: 100 psigSteam Temperature: 338 Deg. FSensible Heat at Steam Pressure: 309 BTU/#Make-up Water Temperature: 60 Deg. FProjected Make-up Temperature: 100 Deg. FPercent Condensate Returns: 85 % of Steam FlowCondensate Temperature: 160 Deg. FHours of Operation per Day: 24 HoursDays Operation per Week: 5 DaysCost of Gas: $0.3500 $/CM

How GREEN are your BLUE Numbers?BHR Energy Calculation available at

www.blowdownheatrecovery.com

Calculated Steam Load: 11730 #/HrCalculated Blowdown Losses: 782.0 #/HrTotal Boiler Feedwater Flow: 12512 #/HrFlash Steam Potential: 11.4 % to 7 psig dea.Flash Steam From Blowdown: 89.1 #/HrFlash Energy Available: 102428.1 BTU/HrEnergy to Heat Condensate to Steam Temp.: 1774749.0 BTU/HrEnergy to Heat Make-up to Steam Temp.: 706537.0 BTU/HrProjected Energy to Heat Make-up: 604877.0 BTU/HrEnergy to Heat Boiler Feedwater - Existing: 2481286.0 BTU/HrEnergy to Heat Boiler Feedwater - Projected: 2277197.9 BTU/HrEnergy Saved: 6997306.6BTU/DayEquivalent Gas Saved: 195.2CM/DayDaily Savings: $68.33 $/DayAnnual Savings: $17,766.60$/Year

How GREEN are your BLUE Numbers?BHR Energy Calculation available at

www.blowdownheatrecovery.com

CASE STUDY

Major Pharmaceutical Company, NJ USA

Installation Detail

Pharmaceutical Plant, NJ – Test Data (August 2009 – 1 Minute Time Stamps)

One Minute Time Stamp Intervals from Externally Mounted Thermocouples2 x CB-300HP Boilers / Manual and Conductivity Controlled Blowdown

Blowdown Heat Recovery Process - Temperature Evaluation

Flash Steam and Make-up Outlet Temperatures

50

100

150

200

250

300

1 1285 2569 3853 5137 6421 7705 8989 10273 11557 12841 14125 15409 16693 17977 19261 20545 21829 23113 24397 25681 26965 28249 29533 30817

Time in Minutes (August 1st - 31th, 2009)

Tem

pera

ture

(D

eg. F

)

Flash Steam and Make-up Outlet Temperatures August 1st

50

100

150

200

250

300

1 42 83 124 165 206 247 288 329 370 411 452 493 534 575 616 657 698 739 780 821 862 903 944 985 1026 1067 1108 1149 1190 1231

Time (Minutes)

Tem

pera

ture

(D

eg. F

)

Blue Line = Make-up Outlet TemperatureThermocouple on outside of piping.Wavy lines represent on/off flow and changing velocity.

Red Line = Flash Steam Outlet TemperatureThermocouple on outside of piping. Temperatures above 212F confirm steam flow to heat pipe above atmospheric steam temperature.

• Project Cost: $46,500

• Savings: $24,000/yr• Funding Source: CPA

• Time to Implement: 3 Months From CPA Approval

“Energy Tank” Project