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Unternehmen Weishaupt German Technology at the Basis of an Energy Solutions Concept Energy Efficiency Innovation Seminars Purdue University, October 22, 2012
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  • Unternehmen Weishaupt

    German Technology at the Basis of an Energy Solutions Concept

    Energy Efficiency Innovation Seminars

    Purdue University, October 22, 2012

  • Unternehmen Weishaupt

    1819 1970

    1952 1962

    Experience. We have been delivering first-class quality

    burners for almost 60 years

  • Unternehmen Weishaupt

    Burner Product Range

  • Unternehmen Weishaupt

    Weishaupt Headquarters in Schwendi, Germany

  • Unternehmen Weishaupt

    Research and Development

  • Unternehmen Weishaupt

    Test boilers up to 75,000 MBTU/H

  • Unternehmen Weishaupt

    Aerodynamic chamber / Test boiler

  • Unternehmen Weishaupt

    Gas mixing station

  • Unternehmen Weishaupt

    Innovation and reliability

  • Copyright by Max Weishaupt GmbH, D-88475 Schwendi

    A Solutions Based Provider of Process Combustion Systems & Services to

    Institutions and Industry

  • Copyright by Max Weishaupt GmbH, D-88475 Schwendi

    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;

  • Copyright by Max Weishaupt GmbH, D-88475 Schwendi

    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.

  • Copyright by Max Weishaupt GmbH, D-88475 Schwendi

    Where we are How are current boilers performing? steam supply side

    Where we want to be What are the sites 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

  • Copyright by Max Weishaupt GmbH, D-88475 Schwendi

    Software Models

    Sustainable Solutions

    Measuring and Controlling Performance with :

    CSIs Boiler Consultant Process

    Surveys

  • Copyright by Max Weishaupt GmbH, D-88475 Schwendi

    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

  • Copyright by Max Weishaupt GmbH, D-88475 Schwendi

    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

  • Copyright by Max Weishaupt GmbH, D-88475 Schwendi

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

    Critical Information: Boiler efficiencies

    Boiler steam generation capabilities

  • Copyright by Max Weishaupt GmbH, D-88475 Schwendi

    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

  • Copyright by Max Weishaupt GmbH, D-88475 Schwendi

    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

  • Copyright by Max Weishaupt GmbH, D-88475 Schwendi

  • Copyright by Max Weishaupt GmbH, D-88475 Schwendi

    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)

  • Copyright by Max Weishaupt GmbH, D-88475 Schwendi

    Valuable upgrade to current inefficient burners

    Valuable upgrade for facilities with down-cycle losses

    Valuable upgrade for facilities looking for high reliability equipment

  • Copyright by Max Weishaupt GmbH, D-88475 Schwendi

    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