BOILER BURNER CONSORTIUM

INTERIM REPORT ON

LOW NOX BOILER/BURNER TECHNOLOGIES

ENERGY SOLUTIONS CENTERMAY 2004

R. BILJETINA , A. ZAIDI, R. RYBA

INTRODUCTIONIn 2002, the Energy Solutions Center formed a Boiler Burner Consortium to assist member companies with customer needs and inquiries on available and emerging technologies for large commercial and industrial boilers. Topics of interest include automation and controls, efficiency, low-emissions burners, and compact boiler systems. A working group determined that initial work efforts should be focused on low NOx technologies. The proposed work effort would:

Prepare gas utility representatives to be a primary channel for inquiries related to low NOx burners and boilers.

Deliver value-added information products and tools needed to target large commercial and industrial customers

Develop program strategies to assist the commercialization of new emerging technologies, and if necessary demonstrate new state-of-the-art low NOx burners.

Work with government, environmental agencies, as well as local and national trade allies to increase awareness and accelerate deployment of clean-burning natural gas technologies for steam production.

Six companies joined the consortium in 2001. They are: CANMET Energy Technology Center DTE Energy /MichCon Enbridge Consumers Gas NiSource Southern California Gas, and Union Gas

In 2004, Gas Technology Institute (GTI) joined the consortium as the seventh member. The product champions for this consortium are Aqeel Zaidi, Union Gas (Phone: 416-496-5221, e-mail: azaidi@uniongas.com) and Randy Ryba, NiSource (Phone: 219-853-5234, e-mail: rfryba@nisource.com). The Energy Solutions Center Coordinator is Richard Biljetina (Phone: 202-251-8902, e-mail: biljet@att.net).

This interim report summarized the work completed by the consortium in support of low NOx boiler burner systems. As originally planned, this initial work effort focused on low NOx technologies was completed in a two year work effort and included the conduct of several workshops hosted by member companies and the creation of a comprehensive website dedicated to clean and efficient boiler operations. See www.CleanBoiler.org

MARKETPLACE NEED FOR LOW NOX BOILER TECHNOLOGIESIn many regions within the US and Canada, emission standards and in particular NOx standards are being phased in that significantly lower the emissions levels for new natural gas boiler installations. It is anticipated that California will be regulated to levels well below 10 vppm NOx; some states are setting limits below 30 vppm; and other areas need burner systems that can meet emission limits between 30 and 50 vppm NOx. Conventional systems generally emit over twice that amount.

As an example, in Canada the Ontario Ministry of the Environment (MOE) has taken action to reduce emissions of NOx and VOCs by 45%, compared to 1990 levels by the year 2015. The baseline is 1990 levels. In March 2001, the MOE announced an environmental policy (MOE

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Policy Guideline A-9) to control NOx emissions from industrial boilers and heaters. The policy adopted the recommendations made by the Canadian Council of the Ministers of Environment (CCME) guidelines, published in 1998. It states that all new and modified boilers and heaters that have greater than 10 MMBtu/hr fuel input will be required to comply with this new policy before obtaining a Certificate of Approval.

New and emerging burner systems are entering the market designed to meet new regulations in Canada and the US. It is important that these low-NOx technology choices be provided with a minimal increase in cost over conventional systems and with a minimal loss in efficiency. As over 40% of industrial natural gas is consumed in boilers, these low NOx standards and the choice of technologies to meet them are expected to have an increasing impact on the industrial natural gas market. For instance, the current growth rate of industrial steam demand in the US is approximately 2% per year or 336 BCF per year. It is expected that low NOx boilers will capture a significant portion of that market.

LOW NOX PROGRAM PLAN AND RESULTS

The following program plan was developed for the low NOx technology area.

Workshops: To organize, on a fast track, the delivery of highly focused workshops to end-users and gas utility representatives. The workshops were designed to cover the following elements:

1. Regional guidelines, policies and regulations for NOx emissions2. Generic information on NOx formation, reduction and control technologies for large

commercial and industrial boilers over 10 MMBtu/hr. 3. Low NOx burner and boiler technologies4. Boiler efficiency improvements for emission reduction

The goal was to hold one workshop in each member’s service territory. Members had the choice to hold joint workshops.Result: Over a two year period, the consortium developed the workshop outline, developed the content with the assistance of Sunil Kumar of MacViro Consulting Inc.(subcontract), and held four workshops at member company locations: Union Gas, Enbridge, NRCan (CANMET Energy Technology Center), and DTE. The remaining members have opted not to hold a workshop in their service territory. Workshop details are provided in Addendum A.

Develop Information Technology Products: To develop a website, CD-ROM, or application guide that will serve as the “core technology information data base” for consortium members and their customers. Its primary purpose will be to establish the Energy Solutions Center and the consortium members as leaders in gathering and disseminating information about the availability and effectiveness of low-NOx natural gas

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burners and boilers in meeting regional energy and environmental requirements. The program will also develop a network of environmental and equipment specialists that can, if needed, deliver the consortium’s information in a more customized format to specific end-users.

Result: A comprehensive website was developed with the assistance of Bob Fegan of DTE as an information tool for our commercial and industrial key accounts managers. See www.CleanBoiler.org

The site has three main sections:

Vendors and Products

Sales Tools

Learn About (A comprehensive guide to low-NOx technologies)

The Sales Tool area includes links to flyers and brochures, case studies, work sheets, manual and guides, and consortium materials reserved for members.

Network with Trade Allies: To coordinate consortium activities with DOE’s Office of Industrial Technology, NRCan and groups such as CIBO and ABMA in disseminating information on available technologies, case histories, and product information. This will put the consortium in a position to further define new markets and influence purchasing decisions.

Result: In an on-going effort, the Energy Solutions Center maintains a relationship with ABMA, the US Department of Energy (DOE), and NRCan. Information is shared between these parties and information links and e-mail notifications provide members with the latest information on program initiatives such as the DOE Best Practices area addressing steam generation.

Technology Assessments and Demonstrations: To obtain information, provide a technical screening, and assess the market advantages and commercial readiness of state-of-the-art low NOx burners that have been demonstrated at various customer sites. The Center will work with manufacturers and consortium members to identify funding opportunities for demonstrations in member service territories. Members may elect to provide additional funding for demonstrations within their service territories.

Result: The consortium continues to track low NOx technology developments for boiler systems including such new technologies as the FIR burner developed by GTI and the manufacturing team effort to develop a super boiler which is currently funded by DOE. On a regular basis, manufacturers have been asked to present their latest developments as well as current product line at our Technology and Market Assessment Forums (TMAF). These TMAF meetings are held three times a year. Consortium members continue to monitor candidates for demonstration efforts and will advise the Energy Solutions Center if a demonstration effort should be considered. It is expected that additional funding will be required to support such an effort.

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BUDGETIt was anticipated that a budget level of $100,000 would meet the initial funding level required to complete the low NOx program objectives. Seven member companies provided commitments to participate in this consortium at a contribution level of $15,000 US.

The low-NOx program was completed under budget essentially because some members elected not to hold a workshop in their service territory.

CONSORTIUM MEETINGS

The consortium meets regularly in conjuction with ESC TMAF to review program progress and to plan and develop future activities.

FUTURE ACTIVITIES

Consortium members are reviewing a proposal to use the remaining funds to expand the website content to include tools and information related to automation/controls, efficiency, and compact boiler systems; and to maintain/refresh the website for a minimum of five years.

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ADDENDUM AWORKSHOPS

Workshop Content Development Outline

The following outline was submitted to MacViro as a guide in developing the content for the regional low NOx workshops:

1. Regional low NOx Issues

Gather information on US and Canadian federal, state/provincial guidelines, policies and regulations for NOx emissions for new and retrofit boilers having input capacities of greater than 10 MMBtu/hr. This information will be gathered for each consortium member service area as the issues will vary by region.

Identify and arrange speaker(s) to address the regional environmental issues. The local consortium member will assist in identifying and arranging regional speaker(s).

2. NOx Formation and Reduction and Control Technologies

Develop generic training material on NOx formation and reduction and control technologies for industrial boilers.

Present or arrange a speaker to present this information at the workshops. 3. Low NOx Burner and Boiler Technology

Contact leading equipment suppliers of low NOx package boilers and burners for industrial boilers. Obtain technical literature. Some vendors to be contacted include: Alstom Power, Coen, Johnston Boilers, Natcom, Peabody, TODD/John Zink, Cleaver-Brooks, Nebraska boiler, B&W and Foster Wheeler. Available products shall be identified for three control ranges. Less than 75 vppm NOx, less than 30 vppm NOx, and less than 10 vppm NOx.

Arrange vendor speakers for the workshop, in consultation with the sponsoring member company.

Obtain technical information that would be presented at the workshop. This information may vary by region as some regions have more stringent criteria than the others. The technology information will be gathered to cover both retrofit and new installations.

Obtain case studies, preferably in member service areas. Assemble technical information and presentation material that can be added as a training tool

to the Consortium web-site.

4. Boiler Efficiency Improvements

Work with the following organizations to gather materials that improve boiler efficiency and that identify new trends in steam generation: DOE Steam Best Practices, ABMA and NRCan. The intent is to add this information to the Consortium web-site.

Discuss the needs of each consortium member to cover this topic in their workshop, and arrange speaker(s) accordingly.

5. Training Materials Provide electronic copies of all material for inclusion in the consortium website.

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The Union Gas Workshop.

Union Gas held a complimentary one-day work shop to provide information on low NOx boiler systems, low NOx burners for boilers and boiler energy efficiency improvements on Wednesday, November 13, 2002 in Cambridge, Ontario

WORKSHOP AGENDAMorning 8:00 Registration Desk Opens8:45 Welcome and Introduction

Program Chair8:50 Opening Remarks

Union Gas Limited8:55 Ontario Guidelines for NOx Emissions from Boilers

Tom Markowitz, Ontario Ministry of the Environment9:25 NOx Fundamentals: Formation, Reduction, Control Techniques, Impact of Fuels

Martin Thomas, Research Engineer, AdvancedCombustion Technologies, Natural Resources Canada

10:05 Refreshment Break10:20 Low NOx Solutions for Industrial Boiler Applications: Part One

William Testa, Director of North American Sales,John Zink/Todd Combustion

11:10 Low NOx Solutions for Industrial Boiler Applications: Part TwoNormand Brais, Vice President Product DevelopmentCleaver Brooks/Natcom/Nebraska Boiler

12:00 Lunch

Afternoon 1:00 Low NOx Solutions for Industrial Boiler Applications: Part Three

Stephane Laurin, Sales Manager, Coen Canada1:50 Emissions Trading Overview

Sunil Kumar, MacViro Consultants Inc.2:15 Low NOx Solutions for Industrial Boiler Applications: Part Four

Ernie Smoker, Regional Sales EngineerPeabody Engineering

3:05 Refreshment Break3:20 Boiler Energy Efficiency: Opportunities and Case Studies

Aqeel Zaidi, Union Gas LimitedDan Valente, Vexco Corporation

4:10 Concluding Remarks & Adjournment

The workshop was attended by 85 people. Ninety three per cent of the attendees rated the overall value of the workshop at 4 or 5 out of a 5 point scale.

Enbridge Workshop.

Enbridge held a complimentary one-day work shop to provide information on low NOx boiler systems, low NOx burners for boilers and boiler energy efficiency improvements on Thursday, November14, 2002 in Richmond Hill, Ontario.

WORKSHOP AGENDA

8:00 Registration Desk Opens

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8:45 Welcome and Introduction – Program Chair8:50 Opening Remarks – Enbridge 8:55 Ontario Guidelines for NOx Emissions from Boilers –

Tom Markowitz, Ontario Ministry of the Environment 9:25 NOx Fundamentals: Formation, Reduction, Control Techniques, Impact of Fuels

Martin Thomas, Research Engineer, Advanced Combustion Technologies, Natural Resources Canada

10:05 Refreshment Break10:20 Low NOx Solutions for Industrial Boiler Applications: Part 1

William Testa, Director of North American Sales, John Zink/Todd Combustion

11:10 Low NOx Solutions for Industrial Boiler Applications: Part 2Normand Brais, Vice President, Product Development, Cleaver Brooks/Natcom/Nebraska

12:00 Lunch1:00 Low NOx Solutions for Industrial Boiler Applications: Part 3

Stephane Laurin, Sales Manager, Coen Canada 1:50 Emissions Trading Overview

Sunil Kumar, MacViro Consultants Inc.2:15 Low NOx Solutions for Industrial Boiler Applications: Part 4

Ernie Smoker, Regional Sales Engineer - Peabody Engineering 3:05 Refreshment Break3:20 Boiler Energy Efficiency: DSM Programs, Opportunities and Case Studies

Bob Griffin, Industrial Energy Consultant, Enbridge Gas4:10 Concluding Remarks and Adjournment

The workshop was attended by 79 people. Ninety two per cent of the attendees rated the overall value of the workshop at 4 or 5 out of a 5 point scale.

NRCan Workshop.

The Federal Industrial Boiler Program (FIBP) of Natural Resources Canada provided a complimentary one-day workshop to provide information on low NOx boiler systems, low NOx burners for boilers and boiler energy efficiency improvements.

The workshop was held at the Delta Ottawa Hotel in downtown Ottawa on March 6, 2003. A total of 103 people attended the meeting. An evaluation form was provided to all participants. Of those who attended, 45 completed the evaluation form.

WORKSHOP AGENDA

8:30 Welcome and Introduction 8:35 Opening Remarks 8:40 NOx Fundamentals: Formation, Reduction, Control Techniques, Impact of Fuels

Martin Thomas, Research Engineer, Advanced Combustion Technologies, Natural Resources Canada

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9:10 Guidelines for NOx Emissions from Boilers Manfred Klein, Environment Canada

9:40 Low NOx Solutions for Boiler Applications – Part 1 Greg Meyer, Weishaupt Corporation

10:30 Refreshment Break 10:45 Emissions Trading Overview

Sunil Kumar, MacViro Consultants Inc. 11:05 Low NOx Solutions for Boiler Applications - Part 2

Dr. Normand Brais, Aqua-Chem/Cleaver Brooks 11:55 Lunch Break 1:00 Low NOx Solutions for Boiler Applications – Part 3

Stephane Laurin, Coen Canada 1:45 Boiler Energy Efficiency Opportunities – Overview

Bob Griffin, Industrial Energy Consultant, Enbridge Gas Distribution 2:35 Refreshment Break 2:50 Non-Destructive Testing of Boilers

André Faguy, Federal Industrial Boiler Program, Natural Resources Canada 3:10 Design of Efficient Heating Plants

Paul Dockrill, Federal Industrial Boiler Program, Natural Resources Canada 3:40 FBI Project Case Studies

John Brennan, Federal Buildings Initiative, Natural Resources Canada 4:10 Concluding Remarks and AdjournmentOverall Satisfaction with Workshop

Overall, participants were satisfied with the workshop, with 91% of participants scoring very satisfied (62%) or satisfied (29%) and no scoring dissatisfied or very dissatisfied.

DTE Boiler Workshop.

The workshop was added as a separate track to the DTE Customer Meeting held on February 18th, 2004 in Livonia (NW Detroit). Pre-registered attendance was about 225, not including DTE staff, vendors and exhibitors. Attendance in the Boiler Track break-out sessions averaged about 30. Between each break-out session DTE scheduled open exhibition time where vendors had the opportunity to speak to everyone at the meeting. There were two other presentation tracks and about 60 exhibitors.

 The Boiler Track program included the following speakers:

 Session 1:    Mark Utzinger - Miura Boiler    John Foss - Cleaver-Brooks Session 2:    Chad Forester - Clayton Industries    Kim Black - Johnston BoilerSession 3:    Greg Merlo - Merlo Steam    Allen - Ceramic Insulation Systems (assisted in Merlo presentation.

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Training Materials

The boiler burner website www.CleanBoiler.org contains a comprehensive learning module based on the material developed for the workshops. This training material can be accessed through the following link:

http://www.cleanboiler.org/Workshop/BoilerFrameSet.htm

Visitors to the site can access the following information sites:

Combustion Basics Vendor Technologies

What is NOx? Boilers

How is NOx Formed? Burners

Boiler Types Boiler and Steam Improvement Opportunities

Uncontrolled Emission Rates Glossary of Terms

Reduction and Control Technologies Conversion Factors and Calculators

Comparison of NOx for Various Fuels Workshop Presentations

NOx Control Regulations for Boilers A Boiler Primer

Emissions Trading

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