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Hovalwerk AG 01.09.2002 1 Gas Condensing Technology H2OH2O Director - Marketing und Development Heating Technology Division Markus Telian.

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Presentation on theme: "Hovalwerk AG 01.09.2002 1 Gas Condensing Technology H2OH2O Director - Marketing und Development Heating Technology Division Markus Telian."— Presentation transcript:

1 Hovalwerk AG Gas Condensing Technology H2OH2O Director - Marketing und Development Heating Technology Division Markus Telian

2 Hovalwerk AG Gas Condensing Technology  Physical basics  Combustion  Efficiency  State of the art in boiler technology Content

3 Hovalwerk AG Gas Condensing Technology HCCCCCCCCCCH HHHHHHHHHH HHHHHHHHHH H H C C C C C C C C H H C C C C C C C C C C C C CC CC H HH H HH HH CH H H H CCC HHH HH HHH HCCCC HHHH H HHHH coal Coronen H:C = 0.5 : 1 oil Decan H:C = 2 : 1 Natural gas Methan H:C = 4 : 1 Propane C 3 H 6 Butane C 4 H 8 Energy sources and their carbon / hydrogen ratio

4 Hovalwerk AG Gas Condensing Technology natural gas oil coal wood lignite in kg CO 2 / kWh fuel input CO 2 -formation of different energy sources

5 Hovalwerk AG Gas Condensing Technology CO 2 - production by comparison old or new 0,40 0,31 0,29 0,22 0,18 100% old combustion engineering 48% optimized combustion engineering old Oil  ges = 0.65 old N.Gas  ges = 0.65 new N.Gas  ges = 0.90 new Gas Condensing  ges = 1.09 new Oil  ges = in kg CO 2 / kWh useful energy 0,25 new Oil Condensing  ges = 1.04

6 Hovalwerk AG Gas Condensing Technology Fuels Physical basics for condensation firing fuel oil or gas Gross calorific value(H o ) net calorific value (H u ) theoretical condensing power generation accrual condensing water power generation (H o -H u ) theoretical accrual condensing water steam dew point at Lambda 1.2 acidity - pH-value kWh/kg kWh/kg 0.76 kWh/kg 1,3 kg HEL 47°C ~ kWh/m kWh/m kWh/m m 3 / Erdgas H 56°C ~3 - 5 Fuel Oil Natural Gas

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

8 Hovalwerk AG 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 20K gives an increase of the efficiency of 1%. b) Condensation fo the water steam in the flue gas (latent heat: 0.66 kWh/kg condensate)

9 Hovalwerk AG Gas Condensing Technology (H u ) H 2 O "vaporous" (H o ) H 2 O „fluid" Gained quantity of heat at full combustion 2.) 1.) net & gross calorific value kWh/m kWh/m kWh/m kWh/kg kWh/l kWh/m kWh/m kWh/m kWh/kg kWh/l Natural Gas H* PROPANE BUTANE HEIZÖL EL** HEIZÖL EL gross (H o )net (H u ) relation H o / H u fuels 2) Referred efficiency determination on Hu (100 %) * russian natural gas ** Specifikation ÖMV "Futura" 1) the larger the difference between gross and net calorific value the larger the energy gain! Influence and characteristics gross calorific value net calorific value

10 Hovalwerk AG Gas Condensing Technology Return Flow Condensate Drain Flue Gas Fuel and Combustion Air °C First part of the heat exchanger Second part of the heat exchanger °C ~ 40 °C < 35 °C Burner Design: Atmospheric Burner, Premix Burner, Pressure Jet Burner Schematic picture of a condensing boiler Temperatures are examples!

11 Hovalwerk AG Gas Condensing Technology Boiler Shell Dew point Flue Gas °C Boiler WaterFlue Gas Combustion CO 2 Fuel Dew Pointspecific amount of condensation Theor. max. CO 2 -Content *) Natural Gas ~ 56°C ~ 52°C ~ 51°C ~ 47°C 0.16 kg/kWh 0.12 kg/kWh 0.09 kg/kWh 11.8 % 13.7 % 14.1 % 15.3 % PROPANE BUTANE Fuel Oil EL *) ÖNORM M7510,T2

12 Hovalwerk AG Gas Condensing Technology Dew point °C CO 2 -Content Vol.-% Water Contnet (Vol.-%) Natural Gas Net CV = 10,04 kWh/m 3 CO 2max = 12,0 % Cole Net CV = 7,91 kWh/kg CO 2max = 20,6 % FuelOil EL Net CV = 11,86 kWh/kg CO 2max = 15,3 % Dew point in dependence of the fuel and the CO 2 -content

13 Hovalwerk AG Gas Condensing Technology Efficiency % Amount of Condesate g/kWh Return Temperature °C air ratio 1.1 natural gas H Efficiency Condensate Depends on the temperature difference in the boiler shell 2 Amount of condensate and efficiency in dependence of the return temperature Condensate in real (Theory = 100%):  ~70-75 %  ~60-65 %  ~45-50 % natural gas

14 Hovalwerk AG Gas Condensing Technology UltraGas ®  efficiency -comparison (  ) Available heat 90 % gross 100 % net 93 % net 87 % gross 91 %net 85 % gross Radiation losses Not used condensation heat Fluegas losses 100 % gross 111 % net 109 % net 98 % gross 108 % net 97 % gross Low temperature-boilerCondensing boiler-gasCondensing boiler-oil 100 %gross 106 % net 104 % net 98 % gross 103 % net 97 % gross gross (GCV) net (LCV ) Radiation losses Fluegas losses Not used condensation heat Not used condensation heat gross (GCV) net (LCV ) Available heat

15 Hovalwerk AG Gas Condensing Technology UltraGas ® efficiency comparison (  ) acc. to DIN / 60 °C 40 / 30 °C LT-boilerCondensing boiler 86 % (gross) 95 % (net) 95 % (gross) 105 %(net) 98 % (gross) 109 % (net) è The efficiency calculated according to DIN is an objective and comparable figure for boilers (heating mode)

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

17 Hovalwerk AG Gas Condensing Technology General plan of types modulating ratio power range at 40/30°C UltraGas ® (50) kW UltraGas ® (60) kW UltraGas ® (80) kW UltraGas ® (100) kW UltraGas ® (125) kW UltraGas ® (150) kW UltraGas ® (200) kW UltraGas ® (250) kW UltraGas ® (300) kW UltraGas ® (350) kW UltraGas ® (400) kW UltraGas ® (450) kW UltraGas ® (500) kW UltraGas ® (650) kW

18 Hovalwerk AG Gas Condensing Technology General plan of types modulating ratio power range at 40/30°C UltraGas ® (250D) kW UltraGas ® (300D) kW UltraGas ® (400D) kW UltraGas ® (500D) kW UltraGas ® (600D) kW UltraGas ® (700D) kW UltraGas ® (800D) kW UltraGas ® (900D) kW UltraGas ® (1000D) kW UltraGas ® (1300D) kW

19 Hovalwerk AG Gas Condensing Technology Optimised stratification, a counter flow heat exchanger design to provide optimal heat transfer Heavy Polymer flue gas collection box prevents acidic corrosion. Design

20 Hovalwerk AG Gas Condensing Technology  The extended heating surface design provides the ideal solutionfor the demands of a condensing boiler and helps to recover virtually all the latent heat of the flue gas.  The tube consists of an outer stainless steel (316 Ti) tube (waterside) and an aluminium profile on the flue gas side.  The Clearfire is also qualified for the use of inhibitors. I.e. used in heating systems with oxygen diffusion. aluFer ®

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

22 Hovalwerk AG Gas Condensing Technology  extremely clean combustion  turn down ratio 1 : 6.5  low noise  minimum electrical power consumption Ultraclean ® - burner system

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

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

25 Hovalwerk AG Gas Condensing Technology UltraGas ® (300,350,600D,700D) emissions NO X and CO in relation to the burner load (dry, 3 % O 2 ) burner load [%] NO x / CO in [mg/m] 3 NO(x) UltraGas ® (300,350,600D,700D)CO UltraGas ® (300,350,600D,700D)

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


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