1. Application & Design Introduction for Forced Circulation Steam Generators and Electric Boilers

2. What is a Steam Generator ? A steam generator is a boiler that is able to produce steam quickly.

3. Several reasons to use a Steam Generator: High Pressure Fast Start-up Compact size and low weight Full Modulation Safe Operation

4. High Pressure Steam pressure up to 3100 psig 3100 0 1500 PSIG

5. Fast Start-up Full output in five minutes or less. Vapor Power ( 5 minutes ) Natural Circulation ( 30 minutes to 2+ hours )

6. 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

7. 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

8. Natural Circulation Vapor Power 80% Decreased Demand Wasted Fuel Excess Steam Rated Output Wasted Fuel Steam Out 50% 80% Decrease Demand 50% 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. Vapor Power International boilers have quick start ups and respond immediately to changes in firing rate. Under fluctuating loads Vapor Power International Boilers are up to 10% more efficient than natural circulation boilers and just as efficient under steady loads. Maintain High Efficiency During Load Changes

9. Safe Operation Natural circulation boilers contain between 40 to 50 times more water than a Vapor Steam Generator. The small water content of a Vapor Steam Generator makes them very safe regardless of the operating pressure.

10. Using Coil-Type Steam Generators in Conjunction with Natural Circulation Boilers 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?

11. 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 40- 60% smaller footprint, it can be disassembled and re-assembled on site without any field welding.

12. 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.

13. 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.

14. 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.

15. 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

16. Hydro Steam Industries

17. Resistance Type Steam Boilers  30 – 4,320 KW  102 – 14,700 lb/hr  15 – 2,000 psi design  208 - 600 volts General purpose Steam for process and heating applications

18. 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

19. 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

20. 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

21. 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

22. Sample Applications/Industries Corrugation Hospitals Plant Heating Valve Testing Marine Barge Heating Steel Pickling Process Steam Rubber Curing Petroleum Food Processing Resin Production Cable Production Glass Production Chemical Production Textile Production Laundry Services Plastic Production Carpet Manufacturing Defense

23. There are two types of Vapor steam generators There are two types of Vapor steam generators. Modulatic (once-through type) Circulatic (recirculating type)

24. Modulatic Steam Generator

25. The Modulatic Steam Generator 18 BHP to 300 BHP up to 3100 psig up to 10,350 lbs/hr

26. 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.

27. Cut away of the Modulatic

28. The flow diagram of the Modulatic

29. 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.

30. Circulatic Steam Generator

31. The Circulatic Steam Generator 75 BHP to 600 BHP up to 530 psig up to 20,700 lbs/hr

32. 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.

33. Cut away of the Circulatic

34. The flow diagram of the Circulatic

36. 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.

37. Fuels Natural Gas Light Fuel Oils Propane Others...

38. Contact Vapor Power Vapor Power International www.vaporpower.com 630-694-5500 Marc Dupuis mdupuis@vaporpower.com