The Boiler Room

Natural Gas Prices And Emissions Prompt Installations

noreply@blogger.com (Staff) — Tue, 10 Mar 2009 14:00:00 +0000

In February, the Energy Information Administration, which is the official energy statistics from the U.S. government, projected a 2.7 percent decline in U.S. real gross domestic product (GDP), which would trigger decreases in domestic energy consumption for all major fuels.

The downturn is also contributing to a decline in natural gas consumption, particularly in the industrial sector, which has led to lower natural gas prices. The Henry Hub natural gas spot price is projected to decline from an average of $9.13per thousand cubic feet (Mcf) in 2008 to about $5 per Mcf in 2009. However, it is projected to increase in 2010 to almost $6 per Mcf.

Specifically, while consumption growth in 2010 remains largely dependent upon the timing and pace of economic recovery, some projections estimate a 2.2 percent growth in the electric power sector, combined with slight growth in the residential and industrial sectors in 2010. Increased consumption, combined with a continued decline in drilling activity (currently, there are only 970 working rigs), will likely cause significant increases in demand.

In addition, more public facilities are expected to make moves toward natural gas solutions this year. In February, Speaker of the House Nancy Pelosi and Senate Majority Leader Harry Reid released a letter asking the Capitol Architect to switch the Capitol Power Plant from coal to 100 percent natural gas by the end of 2009.

Since manufacturing plants are currently saving money on natural gas prices, the best time to retrofit boilers and improve efficiency might be right now, prior to natural gas increases next year. In addition to meeting the definition of best available technology, Benz Air Engineering solutions successfully exceed all federal emission guidelines.

Many solutions qualify for rebates, including up to 50 percent of the installation cost. Some projects may qualify for additional funds under the terms of the federal stimulus package.

The Combustion Air Flow Control Strategy Is Flawed

noreply@blogger.com (Robert) — Tue, 03 Mar 2009 15:30:00 +0000

After reviewing many boilers with the nearly identical control strategy, I believe there are some substantial issues relating to the simultaneous fan speed and damper control for the control of combustion air flow, not the least of which is a scenario where an explosion can occur. And, while the likelihood of an explosion may be unknown, the use of the strategy for combustion air flow control is fundamentally flawed.

Exploring The Phenomenon

The boiler burner is a parabolic system, pressure drop increasing to the square of the flow through the boiler. A damper will merely increase the pressure drop which pushes the system operating point up that curve, increasing the pressure on the fan while reducing the flow from that fan.

This is true so long as the operating point is on the right of the maximum pressure point of the pressure versus flow fan curve. The control air flow by a damper to the left of this point is nearly impossible since the slope is positive, which means opening the damper will result in a decrease in flow from the fan and closing the damper will result in an increase in flow. Operation in this range typically results in a flame out at synchronous speed which is set as the limit of operation (otherwise known as turndown ratio).

Closing the damper a full speed to cause a pressure drop of 5"wc will decrease the air flow by 18kCFM. To reduce the flow by that same 18kCFM requires the damper to impart just 1.7"wc of pressure drop on a fan running at 50 percent speed. Therefore, the attempt to control air flow by simultaneously controlling fan speed and damper opening is tenuous at best.

Assuming that the opening of the damper is repeatable (the linkage slop making that assumption unreasonable), the control of flow at lower fan speeds is exponentially more sensitive to damper opening, which means that the smallest of damper movement will result in incredible increases or decreases in air volume flow.

Moreover, the flat curve of a slowed fan, makes the transition into the positive slope of the fan curve substantially more likely than that of a synchronous fan. The propensity of the damper to cause operation near or at the maximum pressure point of the fan curve increases the likelihood for the fan to operate on the positive slope portion of the pressure versus flow curve.

In exploring the affects of this phenomenon within a boiler, let's assume that the boiler is operating below its setpoint O2 AND the fan operating point fell on the left side of the curve during the ramp down of the boiler. The O2 trim signal would kick in, opening up the damper (increasing the fan speed would result in the point maintaining its location on the positive slope). However, because the operating point was initially at the left of the maximum pressure point of the fan curve, the volume flow rate of combustion air is reduced.

The lower combustion air results in filling the firebox with CO and unburned fuel. The damper continues to open to a point where the opinion would allow the greatly higher air flow on the negative slope of the fan, instantaneously filling the combustible filled firebox with enough air to cause an explosion.

Please bear in mind that most low NOx burners have a tendency to produce vibrations regardless of the combustion control.

When the burner is a stage fuel burner, the design of which injects fuel through opposing spuds into the firebox in the attempt to lower NOx by stretching the flame over a longer path within the firebox. This design is predisposed to flame detachment, which is exasperated by stratification of recirculated flue gas which reduces flame speed.

As the flame detaches from the burner front, fuel is injected into the firebox accumulating in pockets which combust instantaneously upon reaching the detach flame. We typically redesign the burners to sharply reduce the tendency for flame detachment. (The stage fuel approach for lowering NOx is just one of many approaches sold which have no basis in fact, as a old ring burner will actually get lower NOx with the same amount of FGR.)

*Boiler operators are encouraged to request a fan analysis and supporting documents from Benz Air Engineering.

Providing A Solution

There seems to be an increasing number of installations that have similar control schemes. After reviewing several boilers that have experienced furnace explosions, it seems most likely that the combustion air flow strategy is the cause. If the combustion air flow strategy using a simultaneous fan speed and damper control is not the cause, then it seems to be, at the very least, a contributing factor.

We recommend that any such installations be evaluated before other flawed solutions are implemented to alleviate the symptoms of a considerable problem. For example, one operator had installed buckstays in an attempt to alleviate the noise from combustion vibration, which resulted in concentrating the vibration within the boiler. It was our conclusion that this concentration most likely contributed to the fatigue fractures of their superheater tubes.

Energy And Environment Focus Leads To Rapid Regulation

noreply@blogger.com (Staff) — Tue, 24 Feb 2009 15:30:00 +0000

With the Obama Administration's emphasis on energy and the environment, more people are wondering what this might mean for manufacturing. From what Benz Air Engineering has gleaned from several meetings and presentations, most industry insiders seem to be pointing to the Western Climate Initiative, launched in 2007, and the Regional Greenhouse Gas Initiative (RGGI) as the regulatory drivers for a future national model.

For environmentalists and the energy industry, the most notable feature is that 2012 projections include revenues from a source that does not yet exist: a carbon dioxide cap-and-trade system. Currently, there are two cap-and-trade models being implemented in the Northeast and West.

Some other key points for consideration at Western Climate Initiative meetings:

• Reduce CO2, CH4,N2O, HFCs, PFCs, SF6 emissions to 15 percent below 2005 levels, by 2020.
• Priority reductions, including facilities that emit 10,000 metric tons of C02e by 2010
• Mandatory reporting by all emission producers by 2011
• Future regulations for manufacturers that emit > 25,000 MTCO2e/year by 2012
• Future regulations for electrical generators at the point of first delivery by 2012
• Future regulations for emission sources at the point of emission by 2012
• Future regulations on transportation gasoline and diesel combustion by 2015
• Mandatory implementation of GHG Inventory Management Plan

Benz Air Engineering is already working with several sites to meet future emission mandates while improving efficiencies that result in an immediate fuel cost savings. Most engineering solutions, which optimize efficiency and minimize emissions for industrial, utility and district energy and steam generation facilities, realize an payback in approximately two years. Many qualify for rebates, including up to 50 percent of the installation cost.

Quick Plant Energy Profiler Evaluates Energy Management

noreply@blogger.com (Staff) — Tue, 17 Feb 2009 17:07:00 +0000

Developed by the U.S. Department of Energy (DOE), the Quick Plant Energy Profiler Software Tool is one of several free web-based programs developed by the DOE to help U.S. industry improve energy management at industrial facilities. The software is designed for industrial plant managers and personal who have access to basic information about major energy-consuming systems at their industrial plants.

Simple to use, energy managers or boiler operators can complete a plant profile in about an hour. The Quick PEP tool asks for:

• Average utility bill information
• Average production information
• Major energy-using systems
• Score cards (optional)
• Average energy usage information

Once the information is input, Quick PEP tool can produce a profile that includes:

• The Quick PEP tool will provide the following:
• Energy use and cost per unit of production
• Annual purchased energy graphs and tables
• Potential annual energy savings graphs and tables
• Customized list of next steps, including recommended ITP software tools for further analysis of specific systems

Once registered, the Quick PEP case Quick PEP provides a customized, printable report that shows the details of energy purchases at the plant, how energy is consumed at the plant, potential cost and energy savings at the plant, and a list of next steps that you can follow to get you started saving energy at your plant. There is also an online tutorial, which provides key definitions and step-by-step instructions.

One of the most compelling portions of the report is how much energy each major systems in your plant use on an annual basis. Even if you are unsure of percentages of total electricity or total fuel/steam that each system uses, Quick PEP is equipped with industry averages.

In addition to evaluating the savings opportunities provided by the software, Benz Air Engineering can help your plant review the information and prioritize energy management systems around your boiler. Or, simply fill out and return a brief one-page questionnaire.

A Two-Part Equation: Renewables And Efficiencies

noreply@blogger.com (Staff) — Tue, 10 Feb 2009 15:00:00 +0000

According to The International Renewable Energy Agency (IRENA), energy consumption has doubled between 1971 and 2005 and fossil fuels provide approximately 79 percent of the global supply. But what IRENA, a new intergovernmental organization for renewable energy with 75 member countries, does not spell out is that the majority of the world's population doesn't rely on this supply.

Specifically, it is estimated that 1.6 billion people do not have access to electricity and 2.4 billion people rely on traditional biomass (wood and dung). As people in developing countries require more energy, most will turn to fossil fuels much like China and India have since 1971. (China and India doubled their energy demand since 1990 and are expected to match or surpass OECD countries by 2030.)

Solution: Renewables

IRENA aims to become a driving force in a rapid transition toward the widespread global use of renewable energy. Specifically, the new agency will facilitate access to reliable data on the potential of renewable energy, as well as information about best practices, effective financial mechanisms, and the state of the art in renewable energy technologies. The agency will also develop and promote renewable energy policies on the local, regional, and national level. You can learn more about IRENA goals here.

While the United States has not yet joined the agency, it was represented at the founding meeting by an observer from the U.S. Embassy in Berlin. And, in recent weeks, the United States will join as it moves toward tighter emissions standards and renewable energy. ON Jan. 30, the U.S. Department of Energy (DOE) and the U.S. Department of Agriculture (USDA) announced they will invest up to $25 million over the next four years for the research and development of processes that produce biofuels, bioenergy, and high-value biobased products.

Solution: Efficiencies

Of course, renewable energy is only part of the equation for sustainability. The other component is making more efficient use of the energy we have on hand. For example, one of Benz Air Engineering's recent retrofits in Modesto, Calif., reduced the nitrogen oxide (NOx) emissions of one boiler from 30 parts per million to 6 parts per million. And, because the boiler is operating more efficiently and burning less fuel while delivering the same output, CO2 was reduced 20 percent. Four areas for consideration:

• Efficiency: Solutions require less fuel to produce a given energy output.
• Reliability: Solutions typically retrofit on proven, reliable steam boilers.
• Environmental: Solutions reduce CO2 by requiring less fuel, and reduce NOx.
• Economic: Solutions save manufacturing plants on their energy bills.

For example, if every manufacturing plant in the United States was retrofitted to provide for better efficiency, the United States could reduce its energy demand by as much as 20 percent. It makes sense for companies to consider reducing their energy needs as quickly as possible because most estimates project the global population will reach 9 billion people by 2030.

Considering the combined rate of population growth and the rapid pace of growth among developing countries, supply and demand will likely increase energy prices exponentially. In addition, there seem to be clear indicators that stricter emissions standards will be forthcoming under the new administration.

Del Monte In Modesto, Calif. Benefits From Compu-NOx

noreply@blogger.com (Staff) — Tue, 03 Feb 2009 14:58:00 +0000

When a Del Monte Foods plant operating in Modesto, Calif., was required to reduce NOx emissions to less than a limit of 30 parts per million (ppm) in the 1990s, several special considerations had to be made in order to meet the needs of its seasonal production schedule. Specifically, the boiler, with a 10:1 turndown target, would have to operate with a near full load for three months of the year, but less than 20,000 pounds per hour for re-manufacturing during the rest of the year.

One of several unique features included with the initial bid saved the plant from having to purchase and install a new 300-horsepower fan. Instead, Benz Air Engineering installed a 250-horsepower variable speed drive to control an existing combustion air fan. It also added a 5-horsepower flue gas recirculation fan, which was also controlled by a variable speed drive. These solutions better met the needs of the plant. And, since the 250-horsepower fan operated at less than 400 watts of power, it is estimated the variable fan solution saved as much as $7,000 per month.

There were several other breakthroughs provided by Benz Air with its Compu-NOx solution. For example, Del Monte Foods' initial turndown requirement was 10:1, but the Compu-NOx solution delivered a boiler turndown of 15:1 while maintaining very tight and responsive boiler controls. This, combined with a unique feedwater control that eliminated an old pneumatic control, enabled Benz Air to increase boiler efficiency that resulted in an estimated annual savings of $100,000 in natural gas.

Highlights from the Initial Retrofit

• Reduced NOx emissions to 22 ppm, well below the 30 ppm requirement.
• Reduced CO emissions to 50 ppm, well below the 400 ppm requirement.
• Increased efficiency to ensure low NOx and CO levels attained with .8% O2.
• Meet all emission requirements at full capacity, and with a 25:1 turndown.

Since the initial retrofit, Benz has returned to Del Monte Foods several times to help the plant meet new requirements. To date, Benz has assisted in increasing plant efficiency to greater than 93 percent, reducing NOx emissions to less than 6 ppm, and earning more than $265,000 in efficiency rebates.

How Green Energy Can Fuel Economic Recovery

noreply@blogger.com (Richard Becker) — Tue, 27 Jan 2009 15:00:00 +0000

With the U.S. economy continuing to suffer through a serious economic slowdown and unemployment reaching 7.2 percent nationwide (9.1 in Nevada), there is no better time for green energy — specifically measures already passed by Congress — to become a priority in helping fuel economy recovery.

Just one of these measures, the funding of Energy Independence and Security Act (EISA) Section 471, could create up to 7,000 jobs by the end of 2010. In fact, according to the International District Energy Association (IDEA), job creation could start immediately by focusing efforts on "shovel-ready" projects. IDEA has compiled some 62 member projects that are ready to start in 28 states.

Funding EISA Section 471 creates jobs and sustainable benefits.

• It provides near-term economic stimulus, designing and building new clean energy infrastructure.
• It stimulates local economies in the long term by encouraging investments in local energy supplies and sources.
• It reduces costs at public institutions by cutting energy consumption and reducing emissions.
• It stimulates private investment in green infrastructure, providing near-term and long-term benefits.
• It achieves critical environmental and energy goals by reducing demand on local power supplies.

Along with funding EISA Section 471, IDEA recently released green economic stimulus recommendations as part of its energy and environmental policy for the new administration. These recommendations work because they increase economic productivity, result in labor intensive jobs, and reduce the exportation of stimulus dollars. Some highlights from the full brief:

• Loans and Grants for Institutions. The appropriation of $750 million annually for five years has already been authorized for implementing or improving sustainable energy infrastructure, which benefits institutions of higher education, local governments, municipal utilities, and public school districts.

• Waste Energy Recovery Incentives. Sections 451-453 of EISA draw additional attention to the recovery of industrial waste heat so it can be recycled into usable heat and electricity. The provision establishes waste energy recovery grants.

• CHP Investment Tax Credit. The current CHP investment tax credit (ITC) under Section 48 of the Internal Revenue Service Code only makes eligible the first 15 MW of capacity. Increasing the cap to 50 MW would encourage the implementation of many projects that could quickly result in efficiency increases and reduced emissions.

• Tax-Exempt Financing. Currently, the IRS Code allows tax-exempt bonds to be used for “local district heating and cooling facilities.” However, the interpretation needs to include plant facilities, which would encourage the implementation of job-producing, low-carbon energy systems such as thermal energy production equipment.

• Energy Efficiency Resource Standard (EERS). While the definition of ‘renewable’ varies dramatically from state to state, it generally focuses on solar, wind, biomass, and geothermal energy. IDEA recommends EERS include CHP and other forms of waste energy and waste heat recovery to be included within the definition.

Benz Air Engineering Co. specializes in custom-engineered solutions, combining expertise in various distributed control systems and programmable logic controllers for the implementation of energy efficiency projects. More than 230 boilers have been retrofitted throughout the country by Benz Air, typically providing a return on investment in approximately one year.

Review Your State's Energy Management Programs

noreply@blogger.com (Staff) — Tue, 20 Jan 2009 15:06:00 +0000

The Department of Energy's Federal Energy Management Program (FEMP), which works to reduce the cost and environmental impact of the federal government, recently released its state-by-state assessment of current energy management programs. The report details state energy management programs, including:

• Public-purpose-funded energy efficiency programs, which are administered either by utilities, state agencies or other third parties. These programs generally help fund conservation, energy efficiency, and renewable energy programs.
• Utility energy efficiency programs, which are administered by local utilities to help improve infrastructure through financial, technological, and operational solutions that meet specific criteria.
• Load management/demand response options, which provide incentives to curtail demand and reduce load during peak periods in response to system reliability or market conditions.
• Distributed energy resource options, which include programs that provide incentives for renewable distributed generation.
• Energy efficiency programs sponsored by the state government, which generally include research, development, and demonstration programs such as those offered by California's Public Interest Energy Research (PIER) program.
• Any additional opportunities, including area-wide contracts with GSA and, by extension, all other federal agencies.

For detailed information about specific state programs, visit the Energy-Efficiency Funds and Demand Response Programs and click on your state. In addition to programs, each brief details participating utilities and program partners.

Funding Energy Sustainability And Efficiency for Institutions

noreply@blogger.com (Robert) — Tue, 13 Jan 2009 15:00:00 +0000

In 2007, Congress overwhelmingly passed the Energy Independence and Security Act (EISA), which was then signed by the President. Among many other initiatives and programs, the act authorized a program for Energy Sustainability and Efficiency Grants and Loans for Institutions [Section 471 of Public Law 110-140, incorporated as Section 399a in the Energy Policy and Conservation Act (42 U.S.C. 6371h-1)]. Funded, these projects could:

• Provide near-term economic stimulus by designing and building new clean energy infrastructure that will stimulate high quality construction and green collar jobs.
• Stimulate local economies in the long term by investing in local energy supplies and sources that keep money recirculating in regional economies and improve the U.S. international trade balance.
• Reduce pressure on public institutions because these newer energy assets cut operating costs, reduce emissions and relieve financial pressures on higher education and communities.
• Achieve critical environmental and energy goals, including reduced greenhouse gas (GHG) emissions, increased local power supplies and reduced peak power demand.

However, due to the economic crisis, many clean energy infrastructure and sustainability projects at public institutions made possible by the bipartisan passage of (EISA) Section 471 have been halted at a time when university endowments have shrunk, credit markets have tightened, and local government tax revenues are down.

Since the immediate and long-term benefits include creating jobs, reducing institutional costs, cutting greenhouse gas emissions, diversifying fuels, and saving energy, I believe urgent action is needed for investments in public sector energy infrastructure. And last week, I sent the following letter, along with a three-page program and benefit summary, to U.S. Senator Dianne Feinstein (D-Calif.).

Dear Senator Feinstein:

I urge you to support, as a part of the economic stimulus bill, $1.5 billion in funding for Energy Sustainability and Efficiency Grants and Loans for Institutions as authorized in the Energy Security and Independence Act (EISA) of 2007. The attached three-page summary describes this program and its benefits.*

By funding EISA Section 471, Congress will provide significant near-term job creation benefits. These shovel-ready projects are also transformative, providing sustained economic stimulus by reducing carbon emissions, increasing economic competitiveness, strengthening power grids and enhancing energy security.

The funding can be quickly and effectively delivered through procurement processes being developed by the Department of Energy as directed in EISA.

Thank you for your interest and support in strengthening our nation's energy infrastructure.

Sincerely yours,
Robert Benz

Since these funds still need to be appropriated, I encourage you to do the same. Urge your members of Congress and U.S. senators to fully fund section 471 Energy Sustainability and Efficiency Grants and Loans for Institutions of Public Law 110-140, the Energy Independence and Security Act of 2007. You can also learn more about this section of the act and other energy programs at the UCLA Sustainability Institute of the Environment.

*Available on request

What's The First Boiler Question To Ask In 2009?

noreply@blogger.com (Staff) — Tue, 06 Jan 2009 15:00:00 +0000

"What has been the average percentage of O2 in each boiler stack over the past 24 hours?"

As fuel burns, it produces chemical chain reactions. For example, the presence of nitrogen and excess oxygen radicals in this hot combustion environment promotes the formation of nitrogen oxides, or NOx.

However, by using air mass flow and fuel mass flow solutions as control parameters to maintain specific chemical reaction ratios, the amount of excess oxygen in flue gases can be limited and the possibility of unburned fuel eliminated. In fact, a one percent increase in boiler efficiency can be achieved by lowering excess oxygen in flue gases by two percent.

How can this be accomplished? Benz Air Engineering focuses on boiler retrofits that include technologies and components that were not available when most boilers were built decades ago. The result is more efficient boiler for a fraction of the cost of a new boiler, without sacrificing the reliability of boilers that were built to last more than a hundred years. Payback is typically less than two years.

Benz Air solutions can increase boiler efficiency to better than 95 percent, saving millions of dollars in fuel and energy while meeting all emission regulation guidelines. Many installations also qualify for rebates up to 50 percent, which can be predetermined by Benz Air engineers.

If your plant is considering a boiler replacement or retrofit in 2009, Benz Air can provide a cost comparison to help make the best decision. Simply fill out and return a brief one-page questionnaire and fax it back to Benz Air offices.

IDEA Hosts Campus Energy Conference On Feb. 10-13

noreply@blogger.com (Staff) — Tue, 30 Dec 2008 15:00:00 +0000

The International District Energy Association (IDEA) will present “Today’s Solution for Tomorrow’s Climate Challenges” as part of its 22nd Annual Campus Energy Conference on Feb. 10-13 in Durham, North Carolina.

While many campuses are currently facing budget cuts, declining endowments, and energy price volatility, the conference brings together hundreds of energy professionals to share real-world, practical insights on the most efficient and reliable campus energy systems in the world. By implementing some of these solutions, many campus utility directors, facility professionals, energy managers, and sustainability coordinators have an opportunity to capture energy savings through efficiency gains.

22nd Annual Campus Energy Conference Topics:

• Developing utility master plan processes from budget to completion
• Evaluating fuel flexible solutions while managing operating risk
• Assessing the utility master plan impact on Campus Carbon Footprint
• Evaluating technologies to reduce operating costs, cut emissions, and enhance reliability
• Finding federal and state funding resources to support project evaluation, design, and deployment

The conference will be held in conjunction with the Annual IDEA Distribution Workshop on Feb. 9-10. The workshop will feature panel discussions and training on safety, engineering, and maintenance of thermal distribution systems.

IDEA is a leading association dedicated to advancing global environmental quality through efficient district energy with more than 900 members worldwide. Benz Air Engineering is supporting the conference as an exhibitor. Benz Air has delivered patented engineering solutions that optimize efficiency and minimize emissions at several campuses, including the University of Texas at Austin.

Recognizing Heat As Energy Can Save Fuel

noreply@blogger.com (Richard Becker) — Tue, 16 Dec 2008 15:00:00 +0000

While most manufacturing operators understand that heat can be recovered from steam boiler blowdown to increase boiler efficiency and reduce fuel consumption, not every operator has considered the significant cost savings. In 2006, the U.S. Department of Energy (DOE) EERE released Steam Tip Sheet #10 to help manufacturers do exactly that.

The tip sheet estimates that a plant — where an 80 percent efficient produces 50,000 pounds per hour (lb/hr) of 150 pounds per square inch gauge (psig) steam, increasing its efficiency to 90 percent with a heat recovery system — could save $68,000 per year (assuming the 2006 fuel cost of $8.00 per million Btu). Benz Air Engineering solutions perform even better.

Case Study: A Condensing Heat Exchanger In Action

After evaluating the boilers at Del Monte Fruit Processing and Packaging Facility in Modesto, California, Benz Air Engineering recommended several improvements to two boilers that were operating at about 82 percent efficiency. One of these recommendations included the installation of a CondiMax Condensing Heat Exchanger, which converts previously wasted heat into energy.

The installation resulted in increased efficiency much higher than the DOE tip sheet. In fact, the heat exchanger reduced stack temperature to less than 100 degrees Fahrenheit while increasing boiler efficiency to greater than 94 percent. The installation also resulted in an energy efficiency rebate, which meant an immediate payback for the plant.

In November, Del Monte also received an award for its energy efficiency management program and sustainability efforts at its Modesto facility during the CMTA/Industrial Environmental Association/Chemical Industry Coalition of California’s Annual Environmental Summit. The two retrofitted boilers were highlighted for their ability to significantly reduce fuel consumption, NOx output, and wasted steam through recycling.

Del Monte Foods is one of the country's largest and most well known producers, distributors and marketers of premium quality, branded food and pet products for the U.S. retail market, generating more than $3.4 billion in net sales in fiscal 2007.

RGGI Hopes To Become National Cap-and-Trade Model

noreply@blogger.com (Staff) — Tue, 09 Dec 2008 15:00:00 +0000

The Regional Greenhouse Gas Initiative (RGGI) will hold its second CO2 allowance auction on Dec. 17. Earlier this year, RGGI became the first mandatory, market-based CO2 emissions reduction program in the United States.

RGGI was designed to be a cooperative effort of ten northeast and mid-Atlantic states, including: Connecticut, Delaware, Maine, Maryland, Massachusetts, New Hampshire, New Jersey, New York, Rhode Island, and Vermont. It capped emissions for 233 plants by putting a price on the carbon dioxide they emit.

How The RGGI Cap-and-Trade System Works

• Establishing a multi-state CO2 emissions budget (cap) that will decrease gradually until it is 10 percent lower than at the start
• Requiring electric power generators to hold allowances covering their emissions of CO2
• Providing a market-based emissions auction and trading system where electric power generators can buy, sell and trade CO2 emissions allowances
• Using the proceeds of allowance auctions to support low-carbon-intensity solutions, including energy efficiency and clean renewable energy, such as solar and wind power
• Employing offsets (greenhouse gas emissions reduction or sequestration projects at sources beyond the electricity sector) to help companies meet their compliance obligations

The market opened in September as part of a $1.1 billion pilot project. RGGI hoped the success of the program may serve as a nationwide model to stem global warming. While it is clear President-Elect Barrack Obama has committed to a national cap-and-trade system, it remains unclear whether such a national system would model RGGI or incorporate other state efforts, such as AB-32 in California.

In the first auction, a total of 44 entities won allowances and the bid prices
ranged from $1.86 (the minimum bid allowed) to $12.00. A post settlement of the first auction is available here.

An Engineering Abstract for San Joaquin Valley Boilers

noreply@blogger.com (Marcel) — Tue, 02 Dec 2008 15:00:00 +0000

Looking out over the quiet rolling hills, it almost seems pastoral in the San Joaquin Valley these days. Many of the processing boilers have been shut down and laid up for the season.

But while some people are hibernating, I know the best boiler operators are taking action and caring for their equipment, demonstrating what I can only call a deep affection for detail.

Some of them have to, but many of them just think like me. A 180 mmBTU/hr boiler is more than just a piece of equipment and it never gets the appreciation it deserves.

You see, when most people look at a boiler, they only see some big piece of equipment. They think it costs too much to feed. They complain that it's never quiet, operating every minute of the season. They blame it for arguments because no one ever seems to agree how hard it should work. And lately, everybody says that it pollutes the air too much.

As an engineer, I think about boilers differently. Sometimes, I even ask myself what a boiler might dream about if a boiler could have dreams. Seriously.

I think a boiler might dream about NOx control and boiler efficiency. Or maybe it might dream about acquiring super powers like those super boilers at the University of Texas. Or maybe it would dream about making a transformation during the winter months, allowing it to do anything everyone wants — more steam, even more steam, not so much steam, and so on — all within seconds. Or maybe about using 12 percent less fuel. Or maybe reducing emissions.

Anthropomorphic excursions aside, most boilers need retrofits to become super boilers.

They have to. As NOx regulations reach the strictest possible level and energy costs continue to rise, the only solutions are to take advantage of the energy efficiency incentives available right now and retrofit these boilers well ahead of schedule for immediate cost savings and a faster payback.

In fact, with the right team, the payback on investment is remarkably short — sometimes as little as two years or less. Now you don't have to be an engineer or a boiler operator to appreciate that. But if you're still not sure, then subscribe to some of the case studies and solutions we'll be sharing in the weeks and months ahead.

University of California, San Diego Benefits From Compu-NOx

noreply@blogger.com (Staff) — Tue, 25 Nov 2008 15:00:00 +0000

When the University of California, San Diego needed to meet the San Diego Air Pollution District's emission limit of 30 parts per million (ppm) NOx for three identical Erie City "O" type boilers equipped with Erie Ring Burners with 40 hp blowers, it received bids from seven companies.

Benz Air Engineering delivered a winning retrofit bid that was $750,000 less than all other bids, bids which would have required replacing those burners with less efficient Low NOx burners. By awarding the bid to Benz Air Engineering, the Compu-NOx solution reduced fuel consumption as well as NOx and CO emissions with a lower investment. Here's how the Compu-NOx retrofit solution stacked up:

Before Retrofit
Turndown: 3:1
NOx at Full Load: 80 ppm at 3 percent O2
CO at Full Load: 100 ppm at 3 percent O2
O2 at Full Load: 3.5 percent
Horsepower: 30hp

After Retrofit
Turndown: 20:1
NOx at Full Load: 16 ppm at 3 percent O2
CO at Full Load: 10 ppm at 3 percent O2
O2 at Full Load: 0.9 percent
Horsepower: 10hp

The Compu-NOx solution delivered an annual fuel savings of $58,000 per year and an annual electrical savings of $40,000 per year at the time of the retrofit. With the rising costs of fuel, the annual cost savings is now considerably more.

Since, the University of California, San Diego became the first campus on the West Coast to join the Chicago Climate Exchange to reduce emissions of greenhouse gases. It was also the first university in California to have been recognized by the California Climate Action Registry as a "Climate Action Leader."

UC San Diego's goal is to become a living laboratory for climate solutions by being an early adopter of real-world tools and leading-edge technologies for San Diego and the global marketplace for successfully measuring, certifying and reporting its greenhouse gas emissions to the Registry and the public. For more information about its sustainability programs, visit here.

California AB 32 Scoping Plan Moves Forward

noreply@blogger.com (Staff) — Tue, 18 Nov 2008 15:00:00 +0000

The California Air Resources Board (ARB) will meet on Nov. 20 to discuss the AB 32 Scoping Plan as mandated by the California Global Warming Solutions Act of 2006. The Nov. 20 meeting includes one of the first opportunities for public testimony.

The effort aims at reducing greenhouse gas emissions to 1990 levels by 2020, which equates to an approximate emission reduction of 30 percent, and then an 80 percent reduction below 1990 levels by 2050. Governor Schwarzenegger signed the bill into law in September 2006. Key elements include:

• Expanding and strengthening existing energy efficiency programs and building and appliance standards;
• Obtaining 33 percent of California's electricity from renewables;
• Developing a California cap-and-trade program that links with other Western Climate Initiative partner programs to create a regional market system;
• Establishing targets for transportation-related greenhouse gas emissions for regions throughout California, and pursuing policies and incentives to achieve those targets;
• Adopting and implementing measures pursuant to existing state laws and policies, including California's clean car standards, goods movement measures, and the Low Carbon Fuel Standard; and
• Creating targeted fees, including a public goods charge on water use, fees on high global warming potential gases, and a fee to fund the administrative costs of the state's long-term commitment to AB 32 implementation.

Additional strategies for making these reductions are outlined in the Climate Change Proposed Scoping Plan. The next public meeting will begin on Dec. 11. More information regarding the California Environmental Protection Agency Air Resources Board as it pertains to AB 32 can be found here.

Benz Air Produces WEEC White Paper

noreply@blogger.com (Staff) — Tue, 11 Nov 2008 15:00:00 +0000

On Nov. 4-5, at the same time Benz Air Engineering was developing The Bolier Room, Patricia Spiritus submitted a white paper for consideration at the World Energy Engineering Congress (WEEC) in Washington D.C. The white paper, entitled "Optimize Boiler Efficiency and Reduce NOx, CO, and CO2 with ROI," was well received.

WEEC is attended each year by the nation's leading energy professionals in business, industry, and government who seek the best solutions for all aspects of today's energy cost and supply challenges.

The Overview

Industrial steam boilers are used in power-generating facilities, food processing plants, universities, refineries, and hospitals (among other facilities). In addition to being unmatched in design, engineering, and craftsmanship, they represent the foundation for the industrial revolution and hold a unique opportunity for companies that rely on the steam they produce.

The engineers who produced them achieved their mission to create a reliable steam system that not only produced energy, but also produced it effectively enough that it provides hot water to dorm rooms at universities, packs fruit cocktails for grocery stores, or gives a rug its bright blue color. Without question, steam boilers are responsible for much of what makes up our world today.

Unfortunately, they are also responsible for contributing to greenhouse gases (NOx & CO), carbon footprint (CO2), and consuming large quantities of electricity and other fuel.

The Solution

There are several methods and technologies currently used to reduce nitrogen oxide (NOx) emissions from steam boilers, many of which emerged after the passage of the Clean Air Act of 1990. However, by approaching reliable steam boilers from three approaches — mechanical engineering, combustion engineering, and programming — retrofitted steam boilers can dramatically increase efficiency (which reduces fuel consumption) while reducing emissions (which meets pending regulation).

How much? The white paper, using a real case study, estimates that retrofitting 15,000 steam boilers in the United States with all three approaches mentioned above would equate to the following emission reduction comparisons:

• The emissions generated by 7,725,000 passenger cars in one year
• The emissions produced by 4,590,000 households' electrical usage
• The emissions reduced by recycling 12,015,000 tons of waste put in landfills
• The prevention of 300,000 acres of natural areas preserved from deforestation

These retrofits would also reduce as much as 35,700,000 metric tons of CO2. Assuming natural gas systems account for 25 percent of such retrofits, that would account for a reduction of 5.5 percent of the total CO2 emissions in the United States.

The white paper is available upon request and will be posted as an informational resource in the near future.

An Introduction To The Boiler Room

noreply@blogger.com (Staff) — Tue, 04 Nov 2008 15:00:00 +0000

The Boiler Room is the Benz Air Engineering blog and information center, developed to help manufacturers, industrial plants, boiler operators, legislators, policy makers, and other interested parties stay ahead of the rapidly changing landscape. It is written and maintained by Robert Benz, Patricia Spiritus, Marcel Staedter, and support staff.

Benz Air Engineering matches the right solutions, systems, and technologies to improve the energy consumption of exiting steam, heat, and power systems. For more than 50 years, it has delivered the best available technology to save money, improve efficiency, and reduce emissions.

By evaluating existing steam, heat, and power systems, Benz Air Engineering can determine which solutions will deliver the maximum cost savings. Increasing boiler efficiency, retrofitting boilers, and installing new systems can save millions of dollars in fuel consumption and electrical usage. Many Benz Air solutions also qualify for rebates and incentives.