Field tests begin on new GTI "Super" Boiler

Pipeline & Gas Journal, Sept, 2006

Gas Technology Institute (GTI) is developing a new industrial steam-generation system that provides increased efficiency, reduced emissions, and lower fuel costs. GTI has teamed with Cleaver-Brooks--a leader in packaged boilers for industrial, institutional, and commercial applications--to focus efforts on bringing technological advances to the marketplace.

Now in field demonstration, the advanced gas-fired boiler dubbed the "Super Boiler"--has shown significant performance improvement over alternative technologies, says GTI. In addition, the boiler has a 40-50% smaller footprint and half the weight of conventional boilers. A critical part of the system design is its ability to meet future nitrogen oxide emissions regulations without the need for expensive post-combustion flue-gas treatments.

"The development of this technology is being driven primarily by rising energy prices combined with increasingly stringent emissions regulations," said GTI's Rick Knight, R&D Manager, Power Generation.

While steam boilers account for about 35% of industrial energy use, 80% of the currently operating steam boilers are more than 25 years old. Energy efficiency for gas-fired boilers is typically in the 75-83% range and uncontrolled NOx emissions are about 70 parts per million. The goal for the Super Boiler is to achieve fuel-to-steam efficiency greater than 94% while maintaining NOx and CO levels below 5 parts per million.