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White papers

Your Library of white papers on products and application of those products.

 

Retrofit or Replace Boilers?

Returning Wealth to the Business With the current economic situation causing stress on every front from the crisis on Wall Street to the falling housing market to the failing auto industry, we in the energy conversion industry (including anybody who operates a boiler for heating or process) are also facing some tough economic times, and energy consumption is at the heart of much of it.

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Boiler Retrofits Can Reap Benefits

One-third of a facility’s energy bill stems from the boiler room, and system inefficiency leads to high energy costs. Many people think purchasing a new high-efficiency boiler or replacing an older boiler is the only way to achieve significant energy savings, but that’s just not true.

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Burner Retrofit Options to Increase Efficiency and Reduce Emissions

If your boiler/burner (package) is like more than 200,000 commercial and industrial boiler packages in operation today, then it’s more than 20 years old. Which means it’s probably only 60 to 70 percent efficient and large amounts of fuel and associated cash are simply being wasted every minute the equipment is being operated.

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Properly Treat Boiler Water for Efficient Long-Term Operation

To ensure a boiler runs properly over the course of its lifetime, treating the water that circulates within the system is mandatory. If the water is not treated properly, the boiler will begin to have problems within the first year, and its useful life will be significantly shortened. Boiler symptoms resulting from untreated water include overheating, failure to produce hot water or steam, a drop in the boiler flow rate and an overall loss of efficiency.

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Effects of Ultra-High Turndown in Hydronic Boilers Today

Hydronic boilers are producing greater efficiencies than previously thought possible, all due to the advancements of condensing technology. It is the science behind condensing that many people do not take the the time to understand, which can lead to misunderstandings and the perpetuation of myths. One of the largest areas of confusion concerns high turndown.

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Gas Technology: Condensing Hydronic Boilers

Condensing hydronic boilers can operate at efficiencies in the mid-90s and above. The key to these fantastic efficiencies is to have incoming feedwater at temperatures below 140° F, and to be able to either modulate the boiler or have sufficient redundancy that operating units can be held near their efficiency “sweet spot.”

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Maximizing Boiler Efficiency with Hybrid Boilers

A hybrid boiler plant is defined as a hydronic heating plant combining condensing and non-condensing boilers. This system is designed to take advantage of the best properties of both types. Through the proper system design, control and boiler selection, we may be able to save the same amount of energy associated with a properly designed full condensing plant at a cost of one third to one half of an all condensing plant.

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How to Balance Steam Loads Efficiently

• An understanding of the load vs. efficiency relationship is a guide for better decisions about boiler operation. • The oxygen content in turbine exhaust gases is sufficient to support the combustion needed for a downstream waste heat boiler. • The heat recovery steam generator uses about 8% to 10% less fuel input to produce the same amount of steam as a package boiler.

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The Lowdown on Low-Water Volume

Low-Mass Boilers All boilers designed and manufactured for steam production have several factors in common. Regardless of whether the boiler is a firetube or watertube design, it is important to evaluate key factors that will influence the operational efficiency of the equipment and impact its return on investment.

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Selecting a Boiler Stack

Selecting a Boiler Stack Key Considerations for Selection and Installation By: Marc Andr Sguin Successful boiler operation is highly dependent on exhaust-system design and installation, as boiler inefficiency, burner shutdown, and flame-ignition failure upon startup can result from a poorly designed stack system.

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Uncovering the Myth of the Industry-Standard Boiler Efficiency Measurement

Today’s published boiler efficiency ratings are calculated by manufacturers using a 15% excess air level, regardless of a burner’s actual ability to operate at that condition throughout the firing range during normal online operation. This “theoretical” boiler efficiency rating is inflated and typically unachievable outside of controlled lab conditions.

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Cleaver-Brooks Large Flextube Boiler is Engineered for High Efficiency and Low Emissions

When Cleaver-Brooks engineers commenced to design a large flexible watertube boiler, capable of 12.5 to 25 MMBTU, they wanted to engineer a product that would raise the bar for both efficiency and emissions in the category. Their goals were for the Large FLX boiler to obtain 81% efficiency on 125 psig steam and 85% efficiency on hydronic heating applications.

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EX Firetube Boiler Changed by Advances in Design Technology

Recent advancements in computational fluid dynamics (CFD) and other analytical design techniques have given these engineers the ability to perform the sophisticated calculations necessary to design the next generation firetube boiler. See how Cleaver-Brooks has changed the game in Firetube Technology.

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Designing Large Packaged Boilers

Designing large package boilers rated at over 400,000 lb/h steam production is a challenge because of shipping limitations within the U.S. and Canada. Field-erected boilers, on the other hand, are very expensive and take more time for commissioning. Minimizing field assembly time is crucial to cutting costs and shortening the construction schedule on such large projects.

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Engineering the First Steam Ready Industrial Watertube

Boiler Design engineers at Cleaver-Brooks have been making modifications to its integrated watertube boiler/burner system in order to improve productivity, reduce emissions and increase energy efficiency. Building upon its proven, high-quality design, engineers have applied advanced computational fluid dynamics and mathematical modeling to optimize and standardize the boiler system. As a result, the industry-leading, IWT system is now available on a fast-track timeline.

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Trends in Packaged Boiler Design

Designing large package boilers is more challenging than ever. Demand from the marketplace is increasing for special features including low emissions, quick startup requirements, hot standby operation, heavy cycling ability, high turndown and increased efficiency, to name a few.

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Forced Circulation Steam Generators for SAGD Applications

Steam-Assisted Gravity Drainage, better known as SAGD, is considered to be the most viable and environmentally safe recovery technology for extracting heavy oil and bitumen. The process, which has been utilized for more than a decade, uses an advanced form of steam stimulation to extract oil from a pair of horizontal wells drilled into a reservoir.

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Superheater Problems in Steam Generators

Oil- and gas-fired package steam generators are used in chemical plants, power plants and petroleum refineries and in cogeneration plants to generate steam for process and power-generation applications.

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Alternative Fuel Application for Gain

There are a number of innovative solutions that companies have successfully implemented to improve their energy and environmental performance. Among these solutions is the combustion of alternative fuels, such as biogas refinery fuels, hydrogen and flammable liquids, to produce usable power.

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