Transcript Gas Condensing Technologie

Gas Condensing Technology
Markus Telian
Director - Marketing und Development
Heating Technology Division
H2O
Hovalwerk AG
01.09.2002
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Gas Condensing Technology
Content
Hovalwerk AG

Physical basics

Combustion

Efficiency

State of the art in boiler technology
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Gas Condensing Technology
Energy sources and their carbon / hydrogen ratio
H
H
C
C
C
H C
C
C
C
H C
H C
C
C
C
H C
C
C
H
coal
Coronen H:C = 0.5 : 1
Butane
H H H H
C H
C
C
C H
C
C H
C
C H
C
H
C4H8
H C C C C H
H H H H
Propane
H H H
H C C C H
C3H6
H H H
oil
Decan H:C = 2 : 1
H H H H H H H H H H
H C C C C C C C C C C H
H
H C H
Natural gas
Methan H:C = 4 : 1
H
H H H H H H H H H H
Hovalwerk AG
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Gas Condensing Technology
CO2-formation of different energy sources
in kg CO2 / kWh fuel input
lignite
wood
coal
oil
natural gas
0.40
Hovalwerk AG
0.36
0.33
01.09.2002
0.26
0.20
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Gas Condensing Technology
CO2- production by comparison old or new
... in kg CO2 / kWh useful energy
0,40
0,31
100%
old
combustion
engineering
0,29
0,25
0,22
0,18
old
Oil
hges = 0.65
Hovalwerk AG
old
new
hges = 0.65
hges = 0.90
N.Gas
Oil
new
Oil
Condensing
hges = 1.04
01.09.2002
new
N.Gas
hges = 0.90
48%
optimized
combustion
engineering
new
Gas
Condensing
hges = 1.09
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Gas Condensing Technology
Fuels
Physical basics for
condensation
firing fuel oil or gas
Fuel
Oil
Natural
Gas
Gross calorific value(Ho)
12.56 kWh/kg
11.14 kWh/m3
net calorific value (Hu)
11.80 kWh/kg
10.06 kWh/m3
0.76 kWh/kg
1.08 kWh/m3
theoretical condensing
power generation (Ho-Hu)
theoretical
accrual condensing water
1,3 kg HEL
steam dew point
1.6 m3/ Erdgas H
47°C
56°C
~2-4
~3 - 5
at Lambda 1.2
acidity - pH-value
Hovalwerk AG
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Gas Condensing Technology
Combustion of 1m3 natural gas
Chemical reactions:
O
H
C
O
O
= CO2
H
= H 2O
(carbon dioxid)
(water vapour)
H
O
S
Schematic representation
Hovalwerk AG
O
= SO2
gas
CH4
(sulphur dioxid)
CO2+ 2H2O
After the combustion
01.09.2002
H
C
H
H
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Gas Condensing Technology
Wherein lie the most important savings of
energy?
a) Lowering the flue gas temperature
Conventional boiler: flue gas temperature 140 °C up to 190 °C
Condensing boiler: flue gas temperature 5 K up to 20 K above return temp.
approxmimate value:
Reduction of the flue gas temperature by 20K gives an increase of the
efficiency of 1%.
b) Condensation fo the water steam in the flue gas
(latent heat: 0.66 kWh/kg condensate)
Hovalwerk AG
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Gas Condensing Technology
Influence and characteristics
gross calorific value
net & gross calorific value
(Ho)
1) the larger the difference between
gross and net calorific value the
larger the energy gain!
H 2O
„fluid"
Hovalwerk AG
Gained quantity of heat at full
combustion
1.)
2) Referred efficiency
determination on Hu (100 %)
net calorific value
(Hu)
H2O
"vaporous"
fuels
2.)
Natural Gas H*
PROPANE
BUTANE
HEIZÖL EL**
HEIZÖL EL
gross
(Ho)
11.14 kWh/m3
28.11 kWh/m3
37.17 kWh/m3
12.56 kWh/kg
10.68 kWh/l
net
(Hu)
relation
Ho / Hu
10.06 kWh/m3
25.88 kWh/m3
34.32 kWh/m3
11.80 kWh/kg
10.08 kWh/l
1.11
1.09
1.08
1.06
1.06
* russian natural gas
** Specifikation ÖMV "Futura"
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Gas Condensing Technology
Schematic picture of a condensing boiler
First part of the heat
exchanger
120 - 180 °C
Second part of the heat
exchanger
Flow
< 35 °C
Return
1200 - 1600 °C
~ 40 °C
Flue Gas
Fuel and
Combustion Air
Condensate Drain
Burner Design:
Atmospheric Burner, Premix Burner, Pressure
Jet Burner
Temperatures are examples!
Hovalwerk AG
01.09.2002
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Gas Condensing Technology
Flue Gas
Boiler Shell
Dew point
Boiler Water
Flue Gas 52 - 57 °C
CO2
Fuel
Combustion
Dew Point
specific amount
of condensation
Theor. max.
CO2-Content *)
Natural Gas
~ 56°C
0.16 kg/kWh
11.8 %
PROPANE
~ 52°C
0.12 kg/kWh
13.7 %
BUTANE
~ 51°C
0.12 kg/kWh
14.1 %
Fuel Oil EL
~ 47°C
0.09 kg/kWh
15.3 %
*) ÖNORM M7510,T2
Hovalwerk AG
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Gas Condensing Technology
60
50
40
Dew point °C
Dew point
in dependence
of the
fuel and the
CO2-content
30
20
10
0
5
6
7
8
9 10 11 12 13 14 15 16 17 18 19 20
Water Contnet (Vol.-%)
4
CO2-Content Vol.-%
6
8
10
12
Natural Gas
Net CV = 10,04 kWh/m3
CO2max = 12,0 %
14
16
Hovalwerk AG
01.09.2002
Cole
Net CV = 7,91 kWh/kg
CO2max = 20,6 %
FuelOil EL
Net CV = 11,86 kWh/kg
CO2max = 15,3 %
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Gas Condensing Technology
Amount of condensate and efficiency
in dependence of the return temperature
Amount of Condesate
g/kWh
110
1
2
air ratio 1.1
natural gas H
105
3
Efficiency %
100
95
.... Depends on the temperature
difference in the boiler shell
90
20
30
40
50
60
natural
gas
120
110
100
90
80
70
60
50
40
30
20
10
0
Return Temperature °C
Hovalwerk AG
Condensate in real (Theory = 100%):
 ~70-75 %
 ~60-65 %
 ~45-50 %
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Gas Condensing Technology
UltraGas®  efficiency -comparison ( )
Low temperature-boiler
Condensing boiler-oil
gross (GCV)
gross (GCV)
Not used
condensation
heat
100 %gross
Fluegas losses
93 % net
87 % gross
Hovalwerk AG
100 % gross
Not used
condensation
heat
111 % net
Fluegas losses
104 % net
98 % gross
Radiation losses
Available heat
net (LCV)
Not used
condensation
heat
106 % net
100 % net
91 %net
85 % gross
gross (GCV)
net (LCV)
net (LCV)
90 % gross
Condensing boiler-gas
109 % net
98 % gross
Radiation losses
Fluegas losses
Radiation losses
108 % net
97 % gross
103 % net
97 % gross
Available heat
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Available heat
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Gas Condensing Technology
UltraGas®
efficiency comparison ( ) acc. to DIN 4702 - 8
98 % (gross)
95 % (gross) 109 % (net)
105 %(net)
86 % (gross)
95 % (net)
75 / 60 °C
40 / 30 °C
75 / 60 °C
LT-boiler
Condensing boiler
 The efficiency calculated according to DIN 4702 - 8 is an objective and
comparable figure for boilers (heating mode)
Hovalwerk AG
01.09.2002
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Gas Condensing Technology
UltraGas®
State of the art in boiler technology



A single pass, natural gas down
fired, firetube boiler.
Fully condensing capable, hot water
boiler.
boiler sizes with capacity range of
50kW through 650kW single and
from 250kW to 1300kW as double
unit available.
Hovalwerk AG
01.09.2002
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Gas Condensing Technology
General plan of types
modulating ratio
power range at 40/30°C
UltraGas® (50)
UltraGas® (60)
UltraGas® (80)
UltraGas® (100)
UltraGas® (125)
UltraGas® (150)
UltraGas® (200)
UltraGas® (250)
UltraGas® (300)
UltraGas® (350)
UltraGas® (400)
UltraGas® (450)
UltraGas® (500)
UltraGas® (650)
Hovalwerk AG
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21
25
32
44
49
55
55
99
99
99
94
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-
52 kW
62 kW
82 kW
101 kW
125 kW
150 kW
202 kW
250 kW
300 kW
350 kW
400 kW
450 kW
500 kW
650 kW
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Gas Condensing Technology
General plan of types
modulating ratio
power range at 40/30°C
UltraGas® (250D)
UltraGas® (300D)
UltraGas® (400D)
UltraGas® (500D)
UltraGas® (600D)
UltraGas® (700D)
UltraGas® (800D)
UltraGas® (900D)
UltraGas® (1000D)
UltraGas® (1300D)
Hovalwerk AG
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32
44
49
55
55
99
99
99
94
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- 246 kW
- 300 kW
- 404 kW
- 500 kW
- 600 kW
- 700 kW
- 800 kW
- 900 kW
- 1000 kW
- 1300 kW
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Gas Condensing Technology
Design
Optimised stratification, a
counter flow heat
exchanger design to
provide optimal heat
transfer Heavy Polymer flue
gas collection box prevents
acidic corrosion.
Hovalwerk AG
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Gas Condensing Technology
aluFer®
 The extended heating surface design provides the
ideal solution for the demands of a condensing boiler
and helps to recover virtually all the latent heat of the
flue gas.
 The tube consists of an outer stainless steel 1.4571
(316 Ti) tube (waterside) and an aluminium profile on
the flue gas side.
 The Clearfire is also qualified for the use of inhibitors.
I.e. used in heating systems with oxygen diffusion.
Hovalwerk AG
01.09.2002
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Gas Condensing Technology
aluFer®
 Aluminium has a ten times higher heat
conductivity compared to stainless steel.
 The complex aluminium profile with fins and
micro structures produce a huge heat transfer surface.
 The micro structure causes a complex turbulent flow
pattern and intensities the heat transfer.
 The vertical position of the tubes enables a self-cleaning effect. A reduction in
efficiency due to deposits on the surface is avoided.
 each aluFer® tube is divided into eight flow channels.
 As a result, turbulent flue gas flow is created and a hot core stream is avoided
Hovalwerk AG
01.09.2002
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Gas Condensing Technology
Ultraclean®burner system
 extremely clean combustion
 turn down ratio 1 : 6.5
 low noise
 minimum electrical power consumption
Hovalwerk AG
01.09.2002
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Gas Condensing Technology
Ultraclean®
schematic diagram
Venturi
Fan
Air
Ignition
p
Burner
Gas
Gas valve
Hovalwerk AG
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Gas Condensing Technology
Ultraclean®
 The Clearfire®-premix burner is made of a high
temperature resistant Fecralloy metal fibre
 almost flameless combustion of the
homogeneous gas / air mixture.
 The solid body radiation of the burner surface
cools the flame and enables extremely low
emissions.
 The flexible metal fabric prevents thermal
stresses, resulting in a long lifetime of the
Ultraclean®-premix burner.
 Ultra Low NOx Performance
Hovalwerk AG
01.09.2002
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Gas Condensing Technology
UltraGas® (300,350,600D,700D) emissions
NOx / CO in [mg/m] 3
NOX and CO in relation to the burner load (dry, 3 % O2)
80
70
60
50
40
30
20
10
0
0
10
20
30
40
50
60
70
80
90
100
burner load [%]
NO(x) UltraGas® (300,350,600D,700D)
Hovalwerk AG
01.09.2002
CO UltraGas® (300,350,600D,700D)
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Gas Condensing Technology
Summary
Condensation
Maximum efficiency
Saves money
Less primary energy used
Less CO2 (approx 42%)
Protects the Environment
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01.09.2002
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