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Boiler NOx Emissions and Energy Efficiency

Boiler NOx Emissions and Energy Efficiency. CPAU Facilities Managers Meeting March 10, 2011. 250 Hamilton Avenue Palo Alto, CA 94301. Agenda. Review of Regulations (Julian Elliot, BAAQMD) Bay Area Air Quality Management District

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Boiler NOx Emissions and Energy Efficiency

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  1. Boiler NOx Emissions and Energy Efficiency • CPAU Facilities Managers Meeting • March 10, 2011 250 Hamilton AvenuePalo Alto, CA 94301

  2. Agenda • Review of Regulations (Julian Elliot, BAAQMD) • Bay Area Air Quality Management District • Energy Efficiency Opportunities (Jeff Guild & Tim Huang, Enovity) • Combining Energy Efficiency with NOx Reduction • Example Energy Efficiency Measures • Financial Incentive Eligibility • Services Offered • Question & Answer Discussion

  3. March 2011Bay Area AQMD Requirements for BoilersJulian ElliotSenior Air Quality Engineerwww.baaqmd.gov

  4. Contact Information Current rules are available at: www.baaqmd.gov/Divisions/Planning-and-Research/Rules-and-Regulations.aspx Proposed rules will be posted at: www.baaqmd.gov/Divisions/Planning-and-Research/Rule-Development/Rule-Workshops.aspx Julian Elliot: jelliot@baaqmd.gov │ 415 749 4705 Slide 2

  5. BAAQMD Jurisdiction Slide 3

  6. BAAQMD Boiler Regulation • BAAQMD regulates air emissions of NOx and CO. • Permits are required for some devices (Reg 2-1-114.1): • - natural gas & LPG-fired: input rating ≥10 MM BTU/hr. • - all other fuels: input rating ≥1 MM BTU/hr. • Online registration is required for natural gas & LPG-fired devices rated >2 to <10 MM BTU/hr. • Rules apply to heater emissions and operation: • - Reg 9, Rule 6: natural gas-fired up to 2 MM BTU/hr. • - Reg 9, Rule 7: >2 MM BTU/hr for natural gas/LPG. • ≥1 MM BTU/hr for all other fuels. Slide 4

  7. Recent BAAQMD Actions Reg 9, Rule 6 – Natural Gas Water Heaters & Boilers (2007) New NOx standards effective 2009 through 2013. Emissions limits apply only to new heaters (up to 2 MM BTU/hr). Reg 9, Rule 7 – Boilers, Steam Generators, Process Heaters (2008) New NOx standards go into effect 2011 and later. New efficiency requirements go into effect 2009 through 2011. Registration in 2011 for boilers that do not need permits. Standards apply to new AND existing heaters (“retrofit rule”). NOx / efficiency standard dates may be extended in Q2 2011. Slide 5

  8. Regulation 9, Rule 7Permits & Registration Operators who modify or replace a device to comply with Reg 9-7 must submit a permit application if modified or replacement device is subject to permit requirements. Registration for heaters that do not require permits: - Natural gas & LPG-fired heaters rated >2 to <10 MM BTU/hr. - One-Time Registration fees: $446 per facility with an affected heater plus $53 for each heater after the first one. - Available on BAAQMD website: www.baaqmd.gov/Divisions/Engineering/Equipment-Registration/Boiler- Steam-Generator-Process-Heater.aspx Slide 6

  9. BAAQMD Regulation 9, Rule 7 Exemptions to New Requirements Device using <10% of “annual maximum heat capacity” each year are not subject to new NOx or efficiency requirements: 1 to <10 MM BTU/hr (non-gas-fired) and >2 to <10 (gas-fired): - perform annual tune-up, operate fuel meter, keep fuel records. 10 MM BTU/hr and higher: - 30 ppmv NOx limit. - operate fuel meter, keep fuel records to verify exempt status. District may approve fuel-use monitoring other than a fuel meter. (Regulation 9-7-504.1) Slide 7

  10. BAAQMD Regulation 9, Rule 7Annual Maximum Heat Capacity Exemption Example: Boiler with 3 million BTU/hr input rating Less than 10% of annual maximum heat capacity = < (3,000,000 BTU/hr) (8,760 hr/yr) (therm/100,000 BTU) (0.10) < 26,280 therm/yr So if this boiler used less than 26,280 therms per year of fuel, it would qualify for an exemption. Slide 8

  11. BAAQMD Regulation 9, Rule 7 Natural Gas & LPG NOx Limits *Proposed changes will be posted on BAAQMD website. Slide 9

  12. BAAQMD Regulation 9, Rule 7 De-Rating is Allowed A boiler may be physically modified to have a lower input heat rating to avoid NOx limits and other requirements applicable to a larger boiler. Multiple-Heater Facilities If there are other heaters at the facility subject to the same NOx limit as the 1st heater, then: - at least 33% of heaters must comply on 1st effective date - at least 66% of heaters must comply 1 year after 1st effective date - all heaters must comply 2 years after 1st effective date Slide 10

  13. BAAQMD Regulation 9, Rule 7Other Fuels – NOx Limits *Proposed changes will be posted on BAAQMD website. Slide 11

  14. BAAQMD Regulation 9, Rule 7 Energy Efficiency Measures Note: Heaters using <10% of “annual max heat capacity” are exempt Insulation Requirement (1/1/2010): Exposed surfaces limited to 120°F Other exemptions in Regulation 9-7-311.1 through 311.5 Stack Gas Temperature Limits (1/1/2011 - possible extension to 1/1/2013*): Limits stack gas temperature limits to ensure reasonable heat transfer to heated material (see table in Regulation 9-7-312) Applies only to boilers and steam generators (not process heaters) May allow AHRI or other certification of combustion efficiency ≥ 80% instead of temperature limits.* *Proposed changes will be posted on BAAQMD website. Slide 12

  15. BAAQMD Regulation 9, Rule 7 Energy Efficiency Measures Note: Heaters using <10% of “annual max heat capacity” are exempt Annual Tune-Up - Effective 1/1/2009 Elements of Tune-Up: - Compliance verification for insulation - Compliance verification for stack gas temperature - Minimization of Excess Air - Optimization of Liquid Blowdown - See BAAQMD Manual of Procedures, Volume 1, Chapter 5 Slide 13

  16. BAAQMD Regulation 9, Rule 7 Manufacturer Certification 2008 Requirements: Pre-certification by manufacturer required for sale or installation once NOx requirements went into effect (1/1/2011 for devices rated >2 to 5 MM BTU/hr. No manufacturers have certified compliant devices by performing BAAQMD source test results. Possible 2011 Changes*: May extend certification requirement to 1/1/2013. May allow CARB, US EPA test methods to establish compliance with NOx limits. *Proposed changes will be posted on BAAQMD website Slide 14

  17. Combining Energy Efficiency with NOx Upgrades • Facilities Managers Meeting • March 10, 2011 250 Hamilton AvenuePalo Alto, CA 94301

  18. Agenda • Introduction • Combining Energy Efficiency with NOx Reduction • Benefits • Example Energy Efficiency Upgrades • Getting Financial Incentives through the Commercial Industrial Energy Efficiency Program (CIEEP) • Eligible Customers • Services Offered • Incentives and Rebates • Getting Started • Questions

  19. About Enovity • Enovity: • Is an energy engineering and sustainability consulting firm • Offers an array of services: • Utility Programs • Energy Services • Building Commissioning • Building Automation • Advanced Operations and Maintenance • Sustainability Services • Has a team of 90+ mechanical and controls engineers, project managers, O&M, and admin staff • Operates offices in San Francisco, Sacramento, Irvine, and Phoenix

  20. New BAAQMD Nox Emission Regulation

  21. Overview of Boiler Nox Formation • Boilers have burners which use combustion to produce heat to make hot water or steam • NOx is a by-product of combustion • NOx is a pollutant contributing to: • Ozone, Particulate Matter, Acid Rain • 3 Types of NOx Formation: • Thermal NOx • Prompt NOx • Fuel Bound NOx (not a concern if PUC gas)

  22. Overview of Boiler Thermal Nox • Thermal NOx is the largest contributor to the overall total NOx • Combustion: Fuel + Air(O2+N2) + Ignition • Ideal Combustion: • CH4 +O2+N2 =>CO2 +H2O+N2+O2 +Heat • Under high temperatures of combustion (> 2600F), Thermal NOx is formed: • N2 + O2 + Heat => NOx • Thermal NOx is an exponential function of flame temperature

  23. Overview of Boiler Thermal Nox

  24. Overview of Nox Reduction Strategies • Burner Modifications or New Burner: • Available down to 9 ppm NOx • Less than 7 ppm NOx burners being developed • Less expensive than exhaust treatment / SCR • Cost effective on boilers < 20 MM Btu • Can decrease efficiency depending on the NOx level & burner type, without additional upgrades • Exhaust Treatment (SCR): • Selective catalytic reduction (SCR): equipment added to treat the NOx after combustion • NOx reduction less than 5 ppm • To date, installed on water-tube boilers >50 MMBtu • More expensive than burner options • Less impact on efficiency

  25. Overview of Nox Reduction Strategies

  26. Why Include Energy Efficiency? • Reasons to include energy efficiency with NOx upgrades include: • Mitigating efficiency decrease and/or operating cost increase from NOx reduction • Energy and utility cost savings • Some advantages of implementing as a single project: • Downtime is limited • Upgrades may be more cost-effective • Project can generate a ROI • Greenhouse gas emission reductions • Taking advantage of rebates available for energy efficiency upgrades • Increasing boiler capacity • Improving operations and maintenance • Replacing aged equipment

  27. New Boilers • When replacing a boiler, consider: • High-efficiency boilers • Condensing boilers • Direct-contact water heaters • Steam generators • Switching from steam to hot water

  28. Condensing boiler installation

  29. Condensing boiler installation

  30. Hot water boiler replacement

  31. Heat Recovery Opportunities • Pipe, tank, and other heated surface insulation • Exhaust stack economizers (feedwater or condensing) • Blowdown heat recovery • Condensate recovery • Mechanical vapor recompression or other custom efficiency upgrades for evaporators • Flash steam recovery • Thermosorber heat pump • Process heat recovery

  32. Repairs and Setting Changes • Replace old or failed steam traps • Repair/replace control linkage • Repair/replace failed blowdown controls or reduce excessive blowdown • Reduce or eliminate boiler cycling • Repair/replace dirty heat exchanger or boiler economizer • Replace boiler refractory • Reduce boiler steam pressure or hot water supply temperature set points • Repair/replace failed VFD

  33. CIEEP Overview • The Commercial & Industrial Energy Efficiency Program (CIEEP): • Is a CPAU Third Party Program • Offers incentives and no-cost technical services to commercial and industrial customers • Investigates opportunities for energy efficiency • Achieves installed and verified energy savings

  34. Services • Consultation with customer to understand general facility characteristics and financial criteria for implementing energy projects • Detailed facility assessment to identify and quantify energy reduction opportunities. • Implementation coordination assistance • Reporting on reductions in facility energy use, cost, and greenhouse gas emissions • Cash incentives based on verified energy savings

  35. Program Eligibility • Customers must: • Purchase gas or electricity from CPAU • Own or operate a facility • Larger than 30,000 sqft, OR • With a maximum demand of 50 kW or more • Have funds available to implement energy efficiency projects • Hospitals • High-tech facilities and labs • Office buildings • State and local government • Retail • Manufacturing • Colleges and schools Facilities include: Other eligibility requirements may apply. Please contact Enovity to confirm eligibility.

  36. Cash Incentives • Based on the one-year energy savings for a project: • $0.10 per kWh saved • $1.00 per therm saved • One-time payment upon project verification

  37. CONTACT ENOVITY Jeff Guild • Senior Project Manager • 415-983-3655 • JGuild@enovity.com • http://enovity.com/programs/cpau • 100 Montgomery Street, Suite 600, San Francisco, CA 94104 • Phone: 415.974.0390 Fax: 415.974.0399

  38. CONTACT CPAU General Phone Number for Account Representatives • 650-329-2241 • 250 Hamilton Avenue, Palo Alto, CA 94301

  39. Questions

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