Gas Condensing Technology Markus Telian Director Marketing und

Gas Condensing Technology Markus Telian Director - Marketing und Development Heating Technology Division H 2 O Hovalwerk AG 01. 09. 2002 1

Gas Condensing Technology Content Hovalwerk AG Ø Physical basics Ø Combustion Ø Efficiency Ø State of the art in boiler technology 01. 09. 2002 2

Gas Condensing Technology Energy sources and their carbon / hydrogen ratio H C C C C H C C C H H C coal Coronen H: C = 0. 5 : 1 C 4 H 8 H C C H H H Propane H H C C C H C 3 H 6 H H H oil H H H H H Butane H H C H C C H Decan H: C = 2 : 1 H C C C C C H H H C H H Natural gas Methan H: C = 4 : 1 H H Hovalwerk AG 01. 09. 2002 3

Gas Condensing Technology CO 2 -formation of different energy sources in kg CO 2 / k. Wh fuel input lignite wood coal oil natural gas 0. 40 Hovalwerk AG 0. 36 0. 33 01. 09. 2002 0. 26 0. 20 4

Gas Condensing Technology CO 2 - production by comparison old or new. . . in kg CO 2 / k. Wh useful energy 0, 40 0, 31 0, 29 0, 25 old Oil hges = 0. 65 Hovalwerk AG old new hges = 0. 65 hges = 0. 90 N. Gas 100% old combustion engineering Oil new Oil Condensing hges = 1. 04 01. 09. 2002 0, 22 new N. Gas hges = 0. 90 0, 18 48% optimized combustion engineering new Gas Condensing hges = 1. 09 5

Gas Condensing Technology Fuels Physical basics for condensation firing fuel oil or gas Fuel Oil Gross calorific value(Ho) 12. 56 k. Wh/kg 11. 14 k. Wh/m 3 net calorific value (Hu) 11. 80 k. Wh/kg 10. 06 k. Wh/m 3 0. 76 k. Wh/kg 1. 08 k. Wh/m 3 theoretical condensing power generation (Ho-Hu) theoretical accrual condensing water 1, 3 kg HEL 1. 6 m 3/ Erdgas H steam dew point 47°C 56°C acidity - p. H-value ~2 -4 ~3 - 5 at Lambda 1. 2 Hovalwerk AG Natural Gas 01. 09. 2002 6

Gas Condensing Technology Combustion of 1 m 3 natural gas Chemical reactions: O C O = CO 2 H O H = H 2 O (carbon dioxid) (water vapour) H O S O = SO 2 (sulphur dioxid) CO 2+ 2 H 2 O Schematic representation Hovalwerk AG gas CH 4 After the combustion 01. 09. 2002 H C H H 7

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 20 K gives an increase of the efficiency of 1%. b) Condensation fo the water steam in the flue gas (latent heat: 0. 66 k. Wh/kg condensate) Hovalwerk AG 01. 09. 2002 8

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 2 O „fluid" Hovalwerk AG Gained quantity of heat at full combustion 1. ) 2) Referred efficiency determination on Hu (100 %) net calorific value (Hu) H 2 O "vaporous" fuels 2. ) Natural Gas H* PROPANE BUTANE HEIZÖL EL** HEIZÖL EL gross (Ho) 11. 14 k. Wh/m 3 28. 11 k. Wh/m 3 37. 17 k. Wh/m 3 12. 56 k. Wh/kg 10. 68 k. Wh/l net (Hu) relation Ho / H u 10. 06 k. Wh/m 3 25. 88 k. Wh/m 3 34. 32 k. Wh/m 3 11. 80 k. Wh/kg 10. 08 k. Wh/l 1. 11 1. 09 1. 08 1. 06 * russian natural gas ** Specifikation ÖMV "Futura" 01. 09. 2002 9

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 10

Gas Condensing Technology Flue Gas Boiler Shell Dew point Boiler Water Flue Gas 52 - 57 °C CO 2 Fuel Natural Gas Combustion Hovalwerk AG 01. 09. 2002 Dew Point specific amount of condensation Theor. max. CO 2 -Content *) ~ 56°C 0. 16 kg/k. Wh 11. 8 % PROPANE ~ 52°C 0. 12 kg/k. Wh 13. 7 % BUTANE ~ 51°C 0. 12 kg/k. Wh 14. 1 % Fuel Oil EL ~ 47°C 0. 09 kg/k. Wh 15. 3 % *) ÖNORM M 7510, T 2 11

Gas Condensing Technology 60 50 Dew point °C 40 30 20 10 0 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Water Contnet (Vol. -%) 4 CO 2 -Content Vol. -% Dew point in dependence of the fuel and the CO 2 -content 6 8 10 12 Natural Gas Net CV = 10, 04 k. Wh/m 3 CO 2 max = 12, 0 % 14 16 Hovalwerk AG 01. 09. 2002 Cole Net CV = 7, 91 k. Wh/kg CO 2 max = 20, 6 % Fuel. Oil EL Net CV = 11, 86 k. Wh/kg CO 2 max = 15, 3 % 12

Gas Condensing Technology Amount of condensate and efficiency in dependence of the return temperature Amount of Condesate g/k. Wh 110 1 2 Efficiency % 105 Co air ratio 1. 1 natural gas H nd en sa te 3 100 Efficiency 95. . Depends on the temperature difference in the boiler shell 90 20 30 Return Temperature °C Hovalwerk AG 40 50 60 120 110 100 90 80 70 60 50 40 30 20 10 0 Condensate in real (Theory = 100%): ~70 -75 % ~60 -65 % ~45 -50 % 01. 09. 2002 natural gas 13

Gas Condensing Technology Ultra. Gas® efficiency -comparison ( ) Low temperature-boiler Condensing boiler-oil gross (GCV) net (LCV) 90 % gross (GCV) Not used condensation heat 100 %gross Available heat Hovalwerk AG Not used condensation heat 106 % net Fluegas losses net (LCV) 100 % gross Not used condensation heat 111 % net Fluegas losses 104 % net 98 % gross Radiation losses 91 %net 85 % gross (GCV) net (LCV) 100 % net 93 % net 87 % gross Condensing boiler-gas 109 % net 98 % gross Radiation losses Fluegas losses Radiation losses 108 % net 97 % gross 103 % net 97 % gross Available heat 01. 09. 2002 Available heat 14

Gas Condensing Technology Ultra. Gas® 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 Hovalwerk AG comparable figure for boilers (heating mode) 01. 09. 2002 15

Gas Condensing Technology Ultra. Gas® State of the art in boiler technology Ø Ø Ø A single pass, natural gas down fired, firetube boiler. Fully condensing capable, hot water boiler sizes with capacity range of 50 k. W through 650 k. W single and from 250 k. W to 1300 k. W as double unit available. Hovalwerk AG 01. 09. 2002 16

Gas Condensing Technology General plan of types modulating ratio power range at 40/30°C Ultra. Gas® (50) Ultra. Gas® (60) Ultra. Gas® (80) Ultra. Gas® (100) Ultra. Gas® (125) Ultra. Gas® (150) Ultra. Gas® (200) Ultra. Gas® (250) Ultra. Gas® (300) Ultra. Gas® (350) Ultra. Gas® (400) Ultra. Gas® (450) Ultra. Gas® (500) Ultra. Gas® (650) Hovalwerk AG 13 13 21 21 25 32 44 49 55 55 99 99 99 94 01. 09. 2002 - 52 k. W 62 k. W 82 k. W 101 k. W 125 k. W 150 k. W 202 k. W 250 k. W 300 k. W 350 k. W 400 k. W 450 k. W 500 k. W 650 k. W 17

Gas Condensing Technology General plan of types modulating ratio power range at 40/30°C Ultra. Gas® (250 D) Ultra. Gas® (300 D) Ultra. Gas® (400 D) Ultra. Gas® (500 D) Ultra. Gas® (600 D) Ultra. Gas® (700 D) Ultra. Gas® (800 D) Ultra. Gas® (900 D) Ultra. Gas® (1000 D) Ultra. Gas® (1300 D) Hovalwerk AG 25 32 44 49 55 55 99 99 99 94 01. 09. 2002 - 246 k. W - 300 k. W - 404 k. W - 500 k. W - 600 k. W - 700 k. W - 800 k. W - 900 k. W - 1000 k. W - 1300 k. W 18

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 01. 09. 2002 19

Gas Condensing Technology alu. Fer® Ø 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. Ø The tube consists of an outer stainless steel 1. 4571 (316 Ti) tube (waterside) and an aluminium profile on the flue gas side. Ø The Clearfire is also qualified for the use of inhibitors. I. e. used in heating systems with oxygen diffusion. Hovalwerk AG 01. 09. 2002 20

Gas Condensing Technology alu. Fer® Ø Aluminium has a ten times higher heat conductivity compared to stainless steel. Ø The complex aluminium profile with fins and micro structures produce a huge heat transfer surface. Ø The micro structure causes a complex turbulent flow pattern and intensities the heat transfer. Ø The vertical position of the tubes enables a self-cleaning effect. A reduction in efficiency due to deposits on the surface is avoided. Ø each alu. Fer® tube is divided into eight flow channels. Ø As a result, turbulent flue gas flow is created and a hot core stream is avoided Hovalwerk AG 01. 09. 2002 21

Gas Condensing Technology Ultraclean®burner system Ø extremely clean combustion Ø turn down ratio 1 : 6. 5 Ø low noise Ø minimum electrical power consumption Hovalwerk AG 01. 09. 2002 22

Gas Condensing Technology Ultraclean® schematic diagram Venturi Fan Air Ignition p Burner Gas valve Hovalwerk AG 01. 09. 2002 23

Gas Condensing Technology Ultraclean® Ø The Clearfire®-premix burner is made of a high temperature resistant Fecralloy metal fibre Ø almost flameless combustion of the homogeneous gas / air mixture. Ø The solid body radiation of the burner surface cools the flame and enables extremely low emissions. Ø The flexible metal fabric prevents thermal stresses, resulting in a long lifetime of the Ultraclean®-premix burner. Ø Ultra Low NOx Performance Hovalwerk AG 01. 09. 2002 24

Gas Condensing Technology Ultra. Gas® (300, 350, 600 D, 700 D) emissions NOx / CO in [mg/m] 3 NOX and CO in relation to the burner load (dry, 3 % O 2) 80 70 60 50 40 30 20 10 0 0 10 20 30 40 50 60 70 80 90 100 burner load [%] NO(x) Ultra. Gas® (300, 350, 600 D, 700 D) Hovalwerk AG 01. 09. 2002 CO Ultra. Gas® (300, 350, 600 D, 700 D) 25

Gas Condensing Technology Summary Condensation Maximum efficiency Saves money Less primary energy used Less CO 2 (approx 42%) Protects the Environment Hovalwerk AG 01. 09. 2002 26