Energy Efficiency Innovation Seminars Purdue … Efficiency Innovation Seminars Purdue University,...
Transcript of Energy Efficiency Innovation Seminars Purdue … Efficiency Innovation Seminars Purdue University,...
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
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 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”
Copyright © by Max Weishaupt GmbH, D-88475 Schwendi
Software Models
Sustainable Solutions
Measuring and Controlling Performance with :
CSI’s 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
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