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M o d u l a r O n - D e m a n d S t e a m S y s t e m s
GVA Northwest LLC / Miura Boiler.
John Hilton
503-233-8811

Accounting for the Environment:
• The global environment & economies are on a crash
course with each other that will in the end leave
them inseparable
• CO 2 is the new currency of the “green” economy
• Energy efficiency is the “first fuel” for addressing
environmental challenges
=

Sustainable Business Principles:
• “Triple Bottom Line”:
Social Responsibility
• Extended Product Stewardship
• Online Maintenance System
• Safe & Easy Operation
Environmental
Stewardship
• Reduced
Fossil Fuels
Consumption
• Reduced GHG
Emissions
• Reduced Water
Consupmtion
Economic
Prosperity
• Reduced Fuel
Costs
• Reduced
Operation Costs
• Increased
Operational
Efficiency

Boiler Fuel Consumption
(TBtu / yr)
U. S. Boiler Market Survey:
Energy Consumption
• U.S. Industrial Boilers – Energy Consumption (2005): ~ 6.5 Qbtu / yr
or up to 40% of all energy at industrial facilities
2,500
2,000
1,500
1,000
500
Food
Paper Chemicals Refining Primary
Metals
Other
Mfg

Boiler Units
Boiler Capacity
(MMBtu / hr)
U.S. Boiler Inventory:
Distribution by Region
• U.S. Industrial Boilers – Breakdown by Region (2005):
• West Coast:
Total Capacity ~ 130 Billion Btu / hr
25,000
500,000
20,000
400,000
15,000
300,000
10,000
200,000
5,000
100,000
ENC ESC MA
MTN NE PAC SA WNC WSC

Boiler Capacity
(MMBtu / hr)
U. S. Boiler Market Survey:
Age Distribution
• U.S. Boilers – Age Distribution of Boilers > 10 MMBtu/hr (2005):
• C/I Boiler Inventory – 163,000 units w/ capacity of 2.7 Trillion Btu/hr
1,200,000
1,000,000
47% of existing inventory – 40+ yrs. old
76% of existing inventory – 30+ yrs. Old
800,000
600,000
400,000
200,000
Pre-1964 1964 -
1978
1969 -
1973
1974 -
1978
1979 -
1983
1984 -
1988
1989 -
1993
1994 -
1998
1999 -
2002

Unlocking U.S. Energy Efficiency
Bang for Buck – Industrial Sector
• 2009 McKinsey EE Report for DOE / EPA:
http://www.mckinsey.com/clientservice/electricpowernaturalgas/US_energy_efficiency
Steam Systems
Waste Heat Recovery
Energy Mgmt for
E/I Processes
~ 13 Quadrillion Btu’s at an avg.
capital investment of ~ $7 / MMBtu

FEMP Guidelines:
Boiler Selection Criteria
• FEMP = Energy Star for larger
energy-using equipment
• Minimum boiler efficiency
guidelines
• Boiler system selection & sizing
guidelines
“If building loads are highly
variable, as is common in
commercial buildings, designers
should consider installing
multiple small (modular) boilers.”
“Modular systems are more
efficient because they allow each
boiler to operate at or close to
full rated load most of the time,
with reduced standby losses.”

U.S. GHG Emissions:
• U.S. CO2 Emissions (Gigatons CO 2 e) – 1990 - 2030:
• 29% of GHG’s Traced to Site Emissions in the
Commercial / Industrial Sectors

U. S. Boiler Market Survey:
• What are the roots of the boiler technology currently operating in the
U.S.?
• Miura is focused on energy efficiency technology transfer to bring
the U.S. boiler inventory into the 21 st century…

Reducing Boiler “Footprint”
• Physical Footprint:
• Reduced space requirements
• Reduced energy plant construction costs
• Reduced boiler “hardware”
• Energy Footprint:
• Reduced energy consumption / wasted energy
• Reduced explosive energy
• Reduced embodied energy
• Environmental Footprint
• Reduced consumption of natural resources
• Reduced harmful emissions
• Reduced carbon footprint
60%
20%
20% -
70%

Innovative Design – Summary:
Key Benefits
• Modularity
• Highly efficient load management with back-up capability
& flexibility for changing steam demands
• Size
• New Construction - Cut boiler room size up to 50%
• Existing Applications - Double your steam capacity in the
same space or free up space for other uses
• Efficiency
• Startup-to-steam in 5 minutes
• Average 20% in annual fuel savings via improved system efficiency
• Reduced Environmental Impact
• Reduced harmful emissions (NOx & CO 2 )
• Safety
• Reduced water volume = reduced explosive energy in the boiler
• Low Maintenance / Durable Design
• “Floating Header” design eliminates damage caused by thermal stress

Managing Energy Load Variability:
Conventional Systems
• Conventional boiler systems expend large amounts of energy to
meet variable load conditions
• Design limitations of conventional boilers prevent them from
efficiently responding to every-changing load demands
• Result: Significant wasted energy & emissions at load swings
Single
1000 BHP
Boiler

Managing Energy Load Variability:
Modular On-Demand Systems
• Modular on-demand boiler systems reduce energy consumption
required to meet variable loads by dividing the output capacity
among multiple small units (like gears in a transmission)
• Modular systems are designed specifically to meet varying load
demands
• Result: Significantly reduced energy & emissions at load swings
5-200 BHP
Modular Boilers

Optimized Energy Management via
Modularity
• Modular design concept:
200HP
TDR=1:3
Step(H,L)
200HP
TDR=1:3
Step(H,L)
200HP
TDR=1:3
Step(H,L)
200HP
TDR=1:3
Step(H,L)
200HP
TDR=1:3
Step(H,L)

Optimized Energy Management via
Modularity
• Modular design concept:
• Each boiler unit acts like a single piston in
the overall boiler system
1000HP boiler system
TDR=1:15
(15 steps of modulation)

Understanding Boiler Efficiency:
In-Service Efficiency
Boiler Efficiency =
Steam /
Hot Water
Output Energy
Input Energy
Gas

Understanding Boiler Efficiency:
“Combustion Efficiency” (E c )
• The effectiveness of the burner to ignite the fuel
• Per ANSI Z21.13 test protocol
“Thermal Efficiency” (E t )
• The effectiveness of heat transfer from
the flame to the water
• Per the Hydronics Institute BTS-2000 test protocol
• Recognized by ASHRAE 90.1 standard
“Boiler Efficiency”
• Often substituted for combustion or thermal efficiency
“Fuel-to-Steam Efficiency” (A.K.A. Catalog Efficiency)
• The effectiveness of a boiler operating at maximum
capacity and a steady state, with flue losses and
radiation losses taken into account.

Understanding Boiler Efficiency:
• Fuel-to-Steam vs. In-Service Efficiency
• Understanding operating efficiency = tracking energy losses
Radiation Loss
FUEL
IN
Exhaust Loss
Fuel-to-Steam
Efficiency
Start-up Losses
Pre- & Post-purge Losses
Blow-down Losses
Loss @ High Turndown
Changing Loads
Radiation Loss @
Idle / Stand-by
IN-SERVICE
EFFICIENCY

Increasing Efficiency = Reducing Losses:
Radiant Losses
• With energy efficiency, size matters…
• Increase efficiency via reduced boiler thermal footprint
FUEL
IN
Fuel-to-Steam
Efficiency
IN-SERVICE
EFFICIENCY
200 BHP
Firetube
Boiler
1,000+
Gallons
VS
200 BHP
Modular
Boiler
65+
Gallons
Smaller Boiler Surface Area =
Significant Reduction
in Radiant Losses

Increasing Efficiency = Reducing Losses:
Radiant Losses
• Radiant Losses: 12 MMBtu/hr input at 100% output
• Option A – Conventional System:
• Single 12 MMBtu/hr unit input
• Rated at 2% radiant loss
• 240,000 Btu/hr energy loss
• Option B – Modular System:
• 3 x 4 MMBtu/hr unit input
• Rated at 0.5% radiant loss
• 3 x 20,000 Btu/hr losses =
60,000 Btu/hr energy loss
0.5%
2%
0.5%
FUEL
IN
0.5%
Fuel-to-Steam
Efficiency
IN-SERVICE
EFFICIENCY

Increasing Efficiency = Reducing Losses:
Radiant Losses
• Radiant Losses: 12 MMBtu/hr input at 33% output
• Option A – Conventional System:
• Single 12 MMBtu/hr unit at 33% =
4 MMBtu/hr input
FUEL
IN
Fuel-to-Steam
Efficiency
IN-SERVICE
EFFICIENCY
• 240,000 Btu/hr energy loss
• Results in 6% total radiant loss
6%
• Option B – Modular System:
• 3 x 4 MMBtu/hr units (only 1 operating)
• 1 x 20,000 Btu/hr losses =
20,000 Btu/hr energy loss
• Only 0.5% total radiant loss
0.5%
0%
0%

Space Savings – Addition by Subtraction:
• Small boiler footprint (good for point-of-use applications)
• No tube-pull space required
• Double the boiler output of a typical boiler room (existing facilities)
• Reduce required boiler room area by over 50% (new construction)
Without Tube-Pull & Door-
Swing Space
Modular Systems Offer
Substantial Space Savings

Space Savings – Addition by Subtraction:
• The 21 st century boiler plant…
• Take advantage of freed-up space to:
• Increase capacity
• Incorporate other systems (CHP, etc.)
• Incorporate other functions
(in lieu of costly new construction)

Increasing Efficiency = Reducing Losses:
Exhaust Losses
• Utilize feed-water economizer for built-in
waste heat recovery
• Feed-water economizers increase efficiency by
capturing waste exhaust gases to preheat feedwater
entering the boiler
FUEL
IN
Fuel-to-Steam
Efficiency
IN-SERVICE
EFFICIENCY
• Boiler efficiency can be increased by 1% for
every 40 o F decrease in stack gas temperature

Increasing Efficiency = Reducing Losses:
Start-up Losses
• Thermal shock/stress is the #1 cause
of fire-tube boiler damage & repair
• Conventional boiler performance is limited
by thermal stress resulting in inefficiency by
requiring slow boiler start-up & perpetually
idling operation
FUEL
IN
Fuel-to-Steam
Efficiency
IN-SERVICE
EFFICIENCY
• Firetube boilers typically require as much
as 90 minutes for cold start-up & must
remain idling when in stand-by mode
resulting in significant wasted energy
& emissions

Increasing Efficiency = Reducing Losses:
Start-up Losses
• Utilize “Floating Header”
pressure vessel design to
eliminate thermal shock
• Direct contact furnace-less
design
Upper Header
Fuel / Air Intake
FUEL
IN
Fuel-to-Steam
Efficiency
IN-SERVICE
EFFICIENCY
Steam Out
• Strategic placement / density of
fin tubes create uniform thermal
expansion / contraction from
burner to exhaust outlet
• Single-pass design for even
temperature distribution
Burner
• Allows for steam production in 5
minutes from cold start
Water In
Lower Header

Increasing Efficiency = Reducing Losses:
Blow-down Losses
• U.S. DOE steam systems BEST PRACTICES
recommendation:
“Improve boiler efficiency and reduce water
consumption by utilizing automatic surface
blow-down in lieu of continuous and/or
manual blow-down.”
• Utilize a boiler control system that includes
automatic blow-down for optimization of blowdown
for highest efficiency operation
• Automatic blow-down is managed via a
proportional flow system and/or back-up
conductivity probe that monitor TDS to
maximize boiler performance and efficiency
FUEL
IN
Fuel-to-Steam
Efficiency
IN-SERVICE
EFFICIENCY

Increasing Efficiency = Reducing Losses:
Pre- & Post-Purge Losses
• Utilize a control system that includes an intelligent
purge system to optimize boiler performance
FUEL
IN
Fuel-to-Steam
Efficiency
• “Purge Cancel” function interrupts post purge when
fast restart is required, eliminating heat loss and
improving response time
IN-SERVICE
EFFICIENCY
• Optimized response time (w/in 10 seconds) =
increased efficiency + reduced emissions
Boiler stop
Restart signal
Typical
controller
Post-purge
Pre-purge
Boiler start sequences
“Smart”
controller
Post-purge = Pre-purge
Boiler start sequences

Increasing Efficiency = Reducing Losses:
Losses at High Turn-down
• Modular boiler system:
FUEL
IN
Fuel-to-Steam
Efficiency
MT1
Twisted pair cable
MP1
IN-SERVICE
EFFICIENCY

Boiler Scale Detection & Prevention:
Heat Transfer Losses - Scale
• An eggshell thickness of scale can reduce boiler
efficiency as much as 10%* (25% for 1/8” thickness,
40% for 1/4” thickness)
FUEL
IN
Fuel-to-Steam
Efficiency
IN-SERVICE
EFFICIENCY
*Just 1/32” of scale thickness multiplied times each
industrial boiler in the U.S. inventory ~
• Over $7 billion in wasted energy / yr (@ $1.00/therm)
• Over 50 million metric tons of CO 2 emissions / yr

Boiler Scale Detection & Prevention:
Integrated Water Softener System
• “Smart” water softener system
• Enhanced performance / reduced salt usage
via split-flow regeneration
• Automatically alternates between primary /
regeneration tanks for optimized performance
• Monitors brine tank level & alarms thru BL Controller
• Interfaces with Colormetry, BL Controller & Online
Monitoring System
NEW
Miura Boilers
ML2
Panel
MW
CMU-H

Miura Online Maintenance:
“M.O.M.” System
• Utilize online maintenance
system that interfaces with
boiler control system as thermal
energy management “dashboard”
• Speeds maintenance by
diagnosing fault conditions
• Alerts maintenance staff to
warnings before they become
problems
• Provides monthly reports
• Standard with every boiler
shipped
• 6 months monitoring with
monthly reports free with
boiler system purchase

Benchmarking to Save Energy:
First Steps
• Why benchmark?...
You are not managing what you do not measure…
• Benchmarking thermal energy systems first and foremost
confirms that existing systems are sized appropriately for
current load demands
• Benchmarking assesses energy performance of existing
systems in comparison with the current “state of the shelf” in
available technology
• Benchmarking allows facilities to better evaluate the carbon
intensity of their operations
• Benchmarking data can be used to identify opportunities for
energy savings & reduced emissions via systems upgrades
• Benchmarking data can be used as the basis of capital
planning and/or award for energy efficiency rebates / grants

In-Service Efficiency Analysis:
Benchmarking Tools
• Miura’s Data Logger records metered usage to benchmark
existing efficiency:
Tank
Radiant Losses
Steam
Steam Demand
Water
Water Meter
Gas Meter
Gas
Existing Boiler
Blow-down
Miura
Data Logger

In-Service Efficiency (%)
Understanding Boiler Efficiency:
In-Service Efficiency
• In-Service Efficiency by Boiler Type:
• Miura’s modular systems provide increased energy efficiency
at around 85% consistently from low to high load factors
100
80
60
40
20
20
40 60 80 100
Load (%)

“Power-Plant-in-a-Box” Concept:
Modular Micro-Cogen System
• Complete Packaged On-Demand Heating, Cooling
& Power Generation
Carrier
A United Technologies Com
A United Technologi
Steam @ high pressure
(B)
Chilled water in / out
(G)
Steam @
low pressure
(A)
Gas
(E)
Cooling water in / out
(C)
(F)
Miura Boiler
(D)
Condensate
Carrier Micro-Steam
(back-pressure turbine)
Carrier Absorption Chiller
Condensate