Retaining

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Retaining Increasing Burner Tips with New
Technology

Ron Snedic Executive Director, Business
Development Gas Technology Institute April 19,
2006
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GTI Facilities Staff

• Main Facility 18-Acre Campus Near Chicago
• Over 200,000 ft2 of laboratory space
• 28 specialized laboratories and facilities
• More than 250 employees
• 70 are scientists and engineers

Flex-Fuel Test Facility
Energy Environmental Technology Center
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Ongoing Activity

• Over 30 active projects developing and improving
  natural gas appliances equipment
• Crossing all markets of utilization
• Projects are primarily funded by LDCs via SMP and
  UTD, Federal Government, State Agencies and
  Manufacturers
• New improved technology, increased efficiency,
  reduced emissions, competitive first cost

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Gas Technology Advisor

• Commercial Industrial
• 9 Industrial Modules
• Commercial Foodservice Under Development

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Gas Technology Advisor Benefits

• Comprehensive Tool for Utility Representatives
• Access to extensive information about gas and
  electric options in a comprehensive and focused
  format
• Introduction to technology that can improve
  process operations, lower costs and reduced
  pollution
• Maximize value of energy systems through
  efficient utilization of energy resources
• Customer relationship building

For more info contact Steve.sikirica_at_gastechnolog
y.org
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New Technologies
Alternative Fuel Lawn Mower
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Power-Vent Residential Gas Water Heater

• A.O. Smith
• .77 Energy Factor
• 50 gallon, 75,000 Btu/Hr
• Lower first cost than comparable models
• 2006 Product Roll-Out
• Over 30 Units in field test as combo systems
  across North America

Great Product for Combo System
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Pressure Fryer Development

• For over 50 years, pressure fryers have been used
  in the restaurant industry because of their
  unique qualities when compared to other food
  preparation methods
• Users KFC, Popeyes, Wendys
• Gas Market Share lt 20
  (total 250,000 units)
• New gas fired unit with Pitco
• Increased Efficiency
• Increased Reliability

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Pressure FryerBenefits

• To Consumers
• Faster cooking
• Retention of product moisture
• Less oil absorption into the food
• Trademark flavor benefits
• Fuel cost savings
• To the Gas Industry
• Currently 250,000 units, with less than 20 of
  these units being gas-fired
• Potential increased market share to 50
  increase of 95 million therms/year

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Low Cost Combi Oven

• The combi oven has become a popular appliance in
  the commercial foodservice industry
• A single oven can operate in cooking modes that
  include baking, steaming, poaching, roasting and
  rethermalizing
• Users K-12 schools, colleges, restaurants,
  military kitchens and institutional foodservice
• Typical Cost gt 10,000
• Gas Market Share lt 15 (total of 70,000 units)

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Low Cost Combi Oven

• Design a new low-cost combi based on GTIs
  current design for a crossflow convection oven
• Crossflow Oven
• Improved baking
  uniformity compared to
  similar sized bakery
  ovens
• GTI Patent
• Commercialization
  Partner Avantec

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Low Cost Combi OvenBenefits

• To Consumers
• Faster Cooking
• Retention of Product Moisture
• Three Cooking Modes (steam, convection or steam
  with convection)
• Low Cost (lt 8,000)
• Fuel Cost Savings
• To the Gas Industry
• Currently 70,000 units, with less than 15 of
  these units being gas-fired
• Potential increased market share to 30
  increase of 12 million therms/year

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High Efficiency, Flexible CHP

• With rising energy costs, customers need ways to
  save money
• 35 BCF potential market growth
• CHP can provide both, but...
• Market penetration has been limited, due to
• High engineering costs
• Restricted power-to-heat ratio
• Inability to deliver low emissions and high
  efficiency in the same package
• More flexible CHP options are needed

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High Efficiency, Flexible CHP

• POGT module
• Non-catalytic PO reactor
• Reduced compressor demand
• Extremely low NOx formation
• Steam gen module
• PO exhaust gas burned to raise steam
• Low excess air
• Advanced heat recovery system
• .4 to 20.0 Mw range

Natural gas
Steam (optional)
Air
POGT Module
POR
Electricity
AIR COMPRESSOR
TURBO GENERATOR
Fuel gas
Flue gas
Air
Water
ULTRA-EFFICIENT STEAM GENERATOR
PROCESS EQUIPMENT
HEAT RECOVERY
Steam
BLOWER
Product
Steam Generation Module
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High Efficiency, Flexible CHPBenefits

• Comparison based on nominal 14-MW turbine
• Efficiency 89 HHV
• Emissions lt 5 ppm NOx CO
• Power/Heat .1 to 1.2
• Annual savings
• 35 trillion Btu
• 2.0 million tons CO2
• 11,000 tons NOx
• 238 million total cost savings

Based on 10 penetration of predicted CHP
market by 2015
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SuperBoiler

• U.S. industrial boilers consume gt2 quads of
  natural gas annually
• Boiler technology is basically 100 years old
• Energy efficiency 75 to 83
• NOx control measures generally decrease
  efficiency
• Boiler designs not optimized for natural gas
• Breakthrough improvements in boiler technology
  will benefit industrial, commercial, and
  institutional gas customers

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Super Boiler

• Built by Cleaver-Brooks
• Initial Roll-Out
• 250 300 bhp
• Product Range
• 150 2000 bhp

STEAM
PRIMARY FURNACE
INTERSTAGE COOLING PASS
SECONDARY FURNACE
CONVECTIVE PASS
FUEL
WATER
ECONOMIZER
TRANSPORT MEMBRANE CONDENSER
FLUE GAS
PREHEATED HUMIDIFIED AIR
HUMIDIFYING AIR HEATER
AIR

• First-generation Super Boiler concept
• Patent granted to GTI
• Boiler section - split-stage combustion with
  interstage cooling and high heat transfer
  firetubes
• Heat recovery section - microchannel economizer,
  TM condenser, humidifying air heater

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Super Boiler Benefits

• Efficiency up to 94
• Emissions lt 5ppmv NOx and CO
• Smaller Footprint
• Potential annual savings
• 205,000 tons NOx
• 18.4 million tons CO2
• 2.5 billion
• Field Test Underway

EFFICIENCY
EMISSIONS
Boiler market 16,720 units with 834 Bbtu/h
total input
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RASERT

• Heat treating furnaces using gas-fired radiant
  tubes need improvement in maintenance and
  downtime to compete with electric furnaces.
• When fired at or near maximum temperatures, alloy
  tubes can fail in less than 10 months.
• Application
• Ferrous and non-ferrous heat treating, forging
  and foundry facilities that use
• Radiant tubes
• Electric heating tube elements

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RASERTDesign
Standard SERT Design
GTI RASERT Concept
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RASERTBenefits

• Increased customer satisfaction
• Reduced downtime maintenance
• Improved heat transfer
• Low NOx emissions between 50-75 ppmv at greater
  than 1000ºF (40 lower than a SOA SERT)
• Protect and grow process load
• Commercializer is North American Manufacturing
  Company (NAMCO)
• Objective Successful field validation of the
  RASERT

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Recently Commercialized Products from GTI
High Efficiency Fryer (Pitco)
Clad Plate Griddle

• Cross Flow Oven (Avantec)

Charbroiler (Magi Kitchn)

• Gas-fired Steamer (Steller)

High Luminosity Burner (Eclipse)
Cyclomax Burner (Maxon)
Dual Conveyor Oven ( Avantec)

• METHANE de-NOX (Takuma, ESA)

FIR Burner (Johnston, Peabody, COEN)
Cyclonic Boiler (Takuma)

• OEAS (Eclipse)