Advanced Firetube Design Breakthroughs Cleaver-Brooks CBEX - PowerPoint PPT Presentation

Advanced Firetube Design Breakthroughs Cleaver-Brooks CBEX Firetube Boilers

Slow Development In Firetube Technology Breakthroughs Packaged High High Integrated Integrated Boiler vs. Turndow n Boiler Field Burners Controls Erected Decades Ago Today Integral Burner vs. Ultra Low Low NO Low NO x Packaged NO x Burner

Technology Hindrances • “Rules Of Thumb” Philosophy p y Five Square Foot Rule Of Heating Surface Four- vs. Three- vs. Tw o-Pass Dryback vs. Wetback • Unavailable Sophisticated Modeling • Sophisticated modeling did not exist or was not Sophisticated modeling did not exist or was not financially feasible • Relied on trial and error from the field or R&D lab

New Sophisticated Design Techniques Computational Fluid Finite Element Dynamic Modeling Dynamic Modeling Analysis Analysis • Computer software • Computer software • Breakdown of complex • Breakdown of complex solves conservation solves conservation engineering problems engineering problems equations equations equations equations into finite elements into finite elements into finite elements into finite elements • Visualizations created • Visualizations created • Finite elements broken • Finite elements broken showing distribution of showing distribution of down to sets of linear down to sets of linear key parameters key parameters equations equations • Changes made to • Changes made to • Equations solved using • Equations solved using model, testing model, testing matrix algebra matrix algebra improvements improvements • Used for predictive • Used for predictive • Provides for design • Provides for design • Provides for design • Provides for design performance and performance and performance and performance and optimization optimization evaluating new evaluating new concepts concepts

The Benefit Of Modeling Integrated Components • By modeling the boiler, burner, heat y g , , recovery, and other components together, more accurate calculations for the values of velocity temperature chemical species velocity, temperature, chemical species, and other properties are determined from the boundary conditions

CBEX – The Most Advanced Firetube Ever Built Primary Primary Secondary Secondary Smaller Footprint / Smaller Footprint / Higher Efficiency Higher Efficiency Less Weight Less Weight Low est Possible Low est Possible Quicker Steam-Up Quicker Steam-Up Emissions Emissions E t E t Extended Pressure Extended Pressure d d P d d P Vessel Life Vessel Life

Cleaver-Brooks Uses New Technology To Advance Firetube Design • Key elements of advancement to create the y CBEX – the most advanced firetube design 1. Heat 2. Furnace 3. Combustion Transfer Of Geometry Geometry Performance Performance The Tubes

1. Heat Transfer Of The Tubes The Fundamentals Typical Boiler Tube T b l B il i T

1. Heat Transfer Of The Tubes Cleaver-Brooks Advanced Heat Transfer Tubes

1. Heat Transfer Of The Tubes An Optimized Heat Transfer Tube Cleaver-Brooks Advanced Cleaver-Brooks Advanced Heat Transfer Tube

2. Furnace Geometry Important Considerations • Balance of high heat transfer of the radiant g zone w hile minimizing pressure • Low er and more uniform flame temperature and flame stability in the furnace • Reduce heat release rates of the furnace • Current firetube average is 150,000 BTU/hr/cubic feet

2. Furnace Geometry Cleaver-Brooks Answer To Furnace Optimization • Maximized the heat transfer w ith the low est possible pressure drop • Low er heat release rate enables a more uniform flame temperature • Reduced furnace heat release rates to release rates to 125,000 BTU/hr/cubic feet

3. Combustion Performance Excess Air Is An Important Factor • Some excess air needed to reduce unw anted emissions and surface fouling • Controlling excess air reduces flame instability • Too much excess air causes a decrease in efficiency • An ideal balance calls for a 15% excess air level

3. Combustion Performance As Excess Air Increases, Efficiency Decreases

3. Combustion Performance Excess Air Increases As The Firing Rate Decreases

3. Combustion Performance Efficiency Drops Dramatically At Lower Firing Rates

The Integrated Package By integrating the burner and controls, combined w ith the optimization of the furnace, superior , p combustion can be achieved

The Highest Operating Efficiency Of Any Firetube 10:1 turndow n 10:1 turndow n Typical Boiler Typical Boiler w hile w hile Firing Range maintaining 3% maintaining 3% O 2 across the O 2 across the O 2 across the O 2 across the firing range firing range

Higher Efficiency Over The Entire Firing Range

Optimized Combustion Results In Lower NOx • Optimized furnace provides low er heat release and near- perfect combustion • Combined w ith the Haw k, emissions are reduced to unprecedented levels • Prior to the CBEX, sub-5 ppm NOx w ithout SCR had never been achieved * Select models

CBEX Firetube Boiler Line

• • B Best operating efficiency of any firetube ever built Best operating efficiency of any firetube ever built B t t ti ti ffi i ffi i f f fi fi t b t b b ilt b ilt • • Completely integrated boiler, burner, controls, and Completely integrated boiler, burner, controls, and heat recovery system heat recovery system heat recovery system heat recovery system • • Minimum excess air across the operating range Minimum excess air across the operating range • • Ultra-low NOx emissions w ithout SCR Ultra-low NOx emissions w ithout SCR • • Can meet 10 ppm CO emissions requirements (at Can meet 10 ppm CO emissions requirements (at 30 ppm NOx) 30 ppm NOx) 30 ppm NOx) 30 ppm NOx) • • 15% reduction in footprint vs. traditional designs 15% reduction in footprint vs. traditional designs

• • EX technology in a high- EX technology in a high- value solution value solution • • Completely integrated Completely integrated p p y y g g boiler and burner system boiler and burner system • • High-efficiency, next High-efficiency, next generation firetube generation firetube generation firetube generation firetube • • Can meet 9 ppm NOx and Can meet 9 ppm NOx and low emissions low emissions requirements requirements requirements requirements • • Smaller footprint than Smaller footprint than traditional firetubes traditional firetubes

How Can You Find Out More? • The follow ing tools can be found on the Cleaver- Brooks Website: • CBEX Elite & Premium Product Brochures • CBEX Technology – Boiler Heating Square Footage • CBEX Technology – Burner Efficiency and Firing Rate • CBEX Technology – Excess Air and Boiler Efficiency • CBEX Technology – Advanced Tube Design • • CBEX Dimensions & Ratings Chart CBEX Dimensions & Ratings Chart • CBEX Boiler Book • CBEX Elite & Premium Specifications • CBEX Elite & Premium Technical Drawings • CBEX Case Studies

Total Integration Goes Far Beyond Boilers