Transcript 1. - FMA Summits

Application & Design
Introduction for
Forced Circulation
Steam Generators
and Electric Boilers
What is a
Steam Generator ?
A steam generator is a boiler that is able to
produce steam quickly.
Several reasons to use a
Steam Generator:
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High Pressure
Fast Start-up
Compact size and low weight
Full Modulation
Safe Operation
High Pressure
1500
3100
0
PSIG
Steam pressure up to 3100 psig
Fast Start-up
Full output in five minutes or less.
Vapor Power ( 5 minutes )
Natural Circulation ( 30 minutes to 2+ hours )
Compact Size and
Low Weight
• Small footprint allows installation in tight
boiler rooms (approx. 50 to 60% smaller)
• Quick and inexpensive installation
• Easy entrance through small doorways
(complete or in sections)
450 BHP
250 BHP
Full Modulation
• High burner and output turndown (10 to 1)
• Quick response to changing loads
• High efficiency maintained over complete
firing range
• Firing rate is controlled by steam pressure
or fluid temperature
Maintain High Efficiency During Load
Changes
Under fluctuating load conditions a natural circulation boiler lags on increased firing and has a
“Flywheel” effect on decreased firing due to the large mass to reflect changes to.
Rated Output
Natural Circulation
Wasted Fuel
Wasted Fuel
80%
50%
Steam Out
Excess Steam
Decreased Demand
Vapor Power International boilers have quick start ups and respond immediately to changes in firing rate.
Vapor Power
80%
50%
Decrease Demand
Under fluctuating loads Vapor Power International Boilers are up to 10% more efficient than
natural circulation boilers and just as efficient under steady loads.
Safe Operation
The small water content of a Vapor
Steam Generator makes them very
safe regardless of the operating pressure.
Natural circulation boilers contain between
40 to 50 times more
water than a Vapor Steam Generator.
Using Coil-Type Steam Generators
in Conjunction with Natural
Circulation Boilers.
Natural Circulation firetube and watertube
boilers have long dominated the high pressure
steam heating market. So, when would you
need a coil-type steam generator in the same
plant?
Retrofit Applications
Where additional steam is needed and floor
space, head space, or physical access is limited.
Not only does the steam generator have a 4060% smaller footprint, it can be disassembled
and re-assembled on site without any field
welding.
Summer Loads
Where there are significant cyclical or seasonal
load fluctuations, such as facilities that
experience drastically reduced steam loads during
the summer, the steam generator can carry the
reduced load. This allows the natural circulation
boilers to be removed from service during these
periods, saving fuel and maintenance costs.
Short Duration Load Swings
Operations that use a portion of the steam for
domestic hot water and has peak periods of use,
the natural circulation boilers can be base loaded
for normal operation and the swings absorbed by
the steam generator. Because the steam generator
can be left cold until needed, fuel savings alone
can often justify the cost.
Critical Standby Demands
Hospitals and health care facilities depend on
their boiler room for critical function and they
must have standby or backup steam capability.
Often, there is no room left in the existing boiler
room for another conventional boiler and new
construction costs can be prohibitive. A compact
steam generator located in the boiler room or
even the engine generator shed may be the
solution.
Hydro Steam Industries
• High Voltage Electrode Boilers:
“The Original – BBJ”
 3000
- 34,000 KW (300-3400 BHP)
 10,000 - 110,000 lb/hr
 100 - 500 psi
 4,160 - 13,800 volts
• High Voltage boilers for auxiliary systems,
backup steam, and load leveling applications.
• Ideal for utilities, Co-Gen applications, and
NOx restricted areas
Hydro Steam Industries
Hydro Steam Industries
• Resistance Type Steam Boilers
– 4,320 KW
 102 – 14,700 lb/hr
 15 – 2,000 psi design
 208 - 600 volts
 30
• General purpose Steam for
process and heating
applications
Hydro Steam Industries
• Resistance Type Hot Water Heaters
 30
- 4,320 KW
 102 - 14,740 MBtu/hr
 30 - 415 psi design
 208 - 600 volts
• General purpose Hot Water for process and
heating applications
Hydro Steam Industries
• Resistance Type Circulation Heaters
 7.5
- 4000 KW
 15 - 2,000 psi
 70 - 1200ºF
• Versatile general purpose heaters
 Liquid
Circulation heaters
 Thermal Fluid heaters
 Gas heaters
 Steam Superheaters
Business Issues
• Rising natural gas and oil cost
• Uncertainty of future fossil fuel costs
• Volatility of world events and weather
• Rising natural gas and fuel oil prices increases
production cost of business.
• Stability of electric rates
• Facilities need a stable energy price rather than
volatility associated with fossil fuel prices
Business Solutions
• Develop energy option – hedge against rising
fossil fuel costs
• Install electric boiler in parallel with fossil-fired
boiler(s)
• Capture savings from energy, operating,
maintenance and labor costs
• Negotiate power rates (78% of time is “off peak”)
• Automate fuel switching to eliminate human error
Sample Applications/Industries
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Corrugation
Hospitals
Plant Heating
Valve Testing
Marine
Barge Heating
Steel Pickling
Process Steam
Rubber Curing
Petroleum
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Food Processing
Resin Production
Cable Production
Glass Production
Chemical Production
Textile Production
Laundry Services
Plastic Production
Carpet Manufacturing
Defense
There are two types of Vapor
steam generators.
Modulatic (once-through type)
Circulatic (recirculating type)
Modulatic
Steam Generator
The Modulatic
Steam Generator
• 18 BHP to 300 BHP
• up to 3100 psig
• up to 10,350 lbs/hr
The Modulatic
Steam Generator
A once through, forced circulation, watertube
boiler in which water under pressure
circulates at high velocity through a series
of coils while forced draft combustion gases
travel across the coils. The hot gases
envelop the entire tube surface to achieve
very high heat transfer rates.
Cut away of the Modulatic
The flow diagram of the
Modulatic
How the Modulatic works
The Modulatic is a once through watertube boiler with a positive
displacement pump to provide a constant flow of feedwater.
The water by-pass regulator continuously regulates the amount of
feedwater that is sent to the coils in response to changes in
steam pressure. By-passed water is returned to the feedwater
tank.
The servo control changes the amount of fuel and combustion air in
direct proportion to the flow of water being sent to the coils.
Ninety percent of the water is converted into steam in the coils.
Dry steam is then produced in the steam separator. The water
remaining is removed by a steam trap.
Circulatic
Steam Generator
The Circulatic
Steam Generator
• 75 BHP to 600 BHP
• up to 530 psig
• up to 20,700 lbs/hr
The Circulatic
Steam Generator
A recirculating, forced circulation, watertube
boiler in which water under pressure
circulates at high velocity through a set of
nested parallel connected coils, while forced
draft combustion gases travel across the
coils. The hot gases envelop the entire tube
surface to achieve very high heat transfer
rates.
Cut away of the Circulatic
The flow diagram of the
Circulatic
How the Circulatic works
The Circulatic is a forced recirculation watertube boiler that uses a
drum as a steam separator and a reservoir of water to supply the
coils.
A recirculating pump draws the water from the drum and forces it
through a set of parallel connected coils at the rate of 3 to 4
times the maximum steaming rate.
The water is then pushed through a steam lance and a series of
baffles in the drum where some of the water is flashed into
steam and separated. The dry steam is released and the water is
recirculated through the coils.
The fuel and combustion air is controlled by a modulating motor
that responds to steam pressure.
The feedwater is controlled by a water level control system and
modulating feedwater valve.
Fuels
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Natural Gas
Light Fuel Oils
Propane
Others...
Contact Vapor Power
Vapor Power International
www.vaporpower.com
630-694-5500
Marc Dupuis
[email protected]