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Industries Served - Rentals - Sales - Nationwide Boiler

Ammonia-Free CataStak SCR Systems Achieve Less Than 3ppm

cogen pitchess

Customer Profile
• County of Los Angeles / Pitchess Cogeneration Auxiliary Boilers
• Castaic, CA
• Boilers installed in 1973

Supplied Equipment
• Two (2) Ammonia-free CataStak selective catalytic reduction systems
• Urea injection systems including urea injection skids with PLC, flow meters, injectors and day tanks

Located in the rolling hills of Castaic, on 2,620 acres, is the Peter J. Pitchess Detention Center (PDC). It is the temporary home of approximately 8,600 inmates and was established in 1938 as the Wayside Honor Rancho, a minimum security prison where inmates worked on a farm setting.

The PDC Cogeneration plant was brought on line in 1989 and produces all the electricity and steam needed to operate all PDC facilities. Within the plant are two dual-fuel fired Keeler auxiliary boilers that were mandated to meet the South Coast Air Quality Management District (SCAQMD) boiler NOx requirement of 5 ppm. This project required the installation of an Ammonia-Free Selective Catalytic Reduction (SCR) system on each of the two boilers with separate urea injection control systems. In addition one boiler needed to be operational during the entire installation process in order to provide temporary auxiliary services during unexpected downtime.

Nationwide Boiler supplied two Ammonia-Free CataStak™ SCR systems that utilized urea injection systems. The SCR systems utilize a common and readily available 32% urea solution called DEF (diesel exhaust fluid), providing PDC with proven SCR performance without the use of ammonia. DEF can easily be handled by boiler operators and does not require special HAZMAT compliance programs or procedures. The design and construction of the complete solution offered meets all standards, codes and specification including ASME, ANSI, NEC, and ASTM.

Nationwide Boiler contracted with California Boiler, Inc. for the installation of the SCR and the urea injection systems. This included removal of the top portion of each boiler’s stack to facilitate the insertion of the SCR reactor housing, duct work and support frames.

Overall, the advanced Ammonia-Free CataStak™ SCR system easily reduced NOx emissions from 30 ppm to less than 3 ppm NOx with ammonia slip under 2 pp,m. The system also complies with Rule 1146 without concerns about meeting future NOx emission limits, providing PDC with superior NOx performance and hassle-free, dependable operations.

This breakthrough CataStak™ SCR technology enables Nationwide Boiler to provide industry with a cost effective, ammonia-free SCR system that achieves up to 95% NOx reduction at a very low capital and operating cost. Boiler owners and operators adverse to ammonia are now able to economically obtain the superior performance of SCR technology without being limited to the poor operating and energy intensive performance of Ultra Low NOx burners.

High Pressure Superheat Rental Boiler Supplied During Fast Track Oil to Gas Conversion Project

high-pressure-superheat twinrivers

Customer Profile
• Twin Rivers Technology
• Facility in Quincy, MA
• Manufacturer of fatty-acids and USP glycerin
• Former Procter & Gamble soap plant, purchased in 1994

Supplied Equipment
• New, in stock 75,000 lb/hr Babcock & Wilcox 750 psig design / 750 F superheat design boiler
• EconoStak Economizer

One of the largest oleochemical companies in North America, Twin Rivers Technologies, has a production line of over 80 different types of fatty acids. The company’s facility in Quincy, MA is designed and operated as a world-class fatty acid and USP glycerin production site.

Twin Rivers relied on the burning of heavy fuel oil for high pressure process steam required to manufacture fatty acids used in many common consumer products. With the cost of fuel oil rising, green house gas emission regulations changing and opportunity looming, Twin Rivers made the decision to convert their primary fuel source to natural gas. This process involved many hours of planning as well as new equipment selection. Once the decisions were made the project was fast-tracked with work commencing day and night until the new equipment was ready for operation.

Because high pressure steam was so critical to the company’s process, a temporary boiler was required to avoid downtime and reduce lost production time resulting in lost profits. Working with Twin Rivers on the retrofit project, BMR Thermal contacted Nationwide Boiler seeking a high pressure, superheat trailer-mounted rental boiler to supplement steam during the conversion project.

Nationwide Boiler had a boiler in stock that met all requirements; a brand new, never used Babcock & Wilcox 75,000 lb/hr, 750 psig design / 750 F superheat package watertube boiler with a fuel efficient EconoStak Economizer. The boiler was available for immediate shipment directly from the boiler OEM located in West Point, MS. The equipment arrived to the facility on time and ready for installation. Nationwide Boiler also supplied a separate fuel oil skid for oil firing which shipped from Fremont, CA.

The rental boiler remained on site for over two months during the retrofit process. Once the rental boiler was removed, Twin Rivers’ operations continued with their newly converted boilers fired primarily on natural gas. Overall, the project was a success. The new boilers are not only saving Twin Rivers in fuel and maintenance costs, but they are also producing less emissions and easily comply with local air regulations.

New 200,000 lb/hr Boiler & CataStak SCR System Helps Refinery Lower Emissions

new200k Calumet

Customer Profile
• Petroleum Refinery
• United States: Southwest Texas
• Total Capacity: 128,000 bpd
• Owns/Operates two refineries
• Produces gasoline, diesel, and jet fuel

Supplied Equipment
• New, in stock 200,000 lb/hr Babcock & Wilcox 750 psig design / 750F superheat design boiler
• 19% Aqueous Ammonia CataStak Selective Catalytic Reduction System
• EconoStak economizer
• SIL 2 Rated Burner Management System

A 128,000 bpd refinery located in Southwest Texas had to replace aging equipment and lower NOx emissions to demonstrate system-wide
compliance. These limits included a NOx
reduction at all heaters and boilers, achieved with the installation of ultra low NOx controls sufficient to meet the federal mandated limits.

The refiner selected Nationwide Boiler Inc. as the company's one source supplier for a complete boiler NOx reduction solution that would replace the company's existing equipment with a reliable and efficient boiler solution. Nationwide Boiler was the only supplier that could provide a new, in stock 200,000 lb/hr Babcock and Wilcox FM120-124 750 psig design pressure, 750F superheat design temperature package boiler complete with a low NOx burner available for quick delivery.

To meet NOx levels of 12 ppm (and future single digit NOx requirements), Nationwide Boiler also supplied a 19% Aqueous Ammonia CataStak™ SCR System with a vaporizer and 10,000 gallon aqueous ammonia storage tank with forwarding pumps, unloading station and controls.
A ground-mounted EconoStak economizer, ladder and platforms were also supplied, in addition to an upgraded SIL 2 rated Burner Management System. The refinery also chose to install a refurbished Elliott steam turbine to the boiler’s force draft (FD) fan as an alternative to a standard Nationwide Boiler TEFC motor, resulting in added efficiency gains.

The complete boiler/CataStak™ SCR solution easily exceeded NOx requirements of 12 ppm and start-up results were less than 5 ppm NOx and 5 ppm NH3 slip. The new boiler and EconoStak economizer also met initial reliability and efficiency expectations. Overall, the solution provided by Nationwide Boiler exceeded the customer's expectations and easily achieved desired NOx levels for complete compliance.

Two Watertube Boilers Easily Meet AQMD NOx Requirements With Ammonia-Free CataStak SCR System


Customer Profile
• NRG Energy Center
• San Francisco, CA
• Provides services to over 170 customer buildings

Supplied Equipment
• 5 ppm Ammonia-free CataStak™ selective catalytic reduction system
• Urea injection system including urea injection skid with PLC, flowmeters, pump, injectors and day tank

NRG Energy Center San Francisco supplies energy-efficient district heating services to over 170 customer buildings in a 2-square mile area within the central business district of San Francisco, California. Steam is used for space heating, domestic hot water, air conditioning and industrial processes, representing more than 37 million square feet of space.

NRG’s central district heating plant housed two (2) 55,000 lb/hr (71.4 MMbtu/hr) natural gas fired Keeler boilers that were required to comply with the Bay Area Air Quality Management District’s (BAAQMD) Reg. 9 Rule 7 NOx emission requirement of 9 ppm (a total reduction of 90% at all conditions). Overall, the project requirements included an easy to operate and energy efficient space saving solution.

A single Ammonia-Free CataStak™ SCR system that utilized a urea injection system was supplied by Nationwide Boiler. The SCR system used a common and readily available 32% urea solution called DEF (diesel exhaust fluid), providing NRG with confident SCR performance without the use of ammonia. To meet the constraints of the tight boiler room configuration, Nationwide Boiler also designed and supplied a rail hoisting system which helped expedite the entire installation process.

The Ammonia-Free CataStak™ SCR system easily reduced NOx emissions from 30 ppm and was tested at 1 ppm NOx throughout the firing range. The system was also optimized from 20-65% load (65% is full load). The system remains to operate dependably without any performance issues or concerns about meeting future NOx emission limits, providing the customer with hassle-free operations and confident, efficient performance.

Working closely with engineers and performing actual fire testing on package boilers, Nationwide Boiler proved that the urea injection can be supplied for both package firetube and watertube boilers. This breakthrough technology enables Nationwide to provide a cost effective, ammonia-free SCR system to achieve up to 95% NOx reduction at a very low capital and operating cost. Additionally, boiler owners and operators adverse to ammonia can economically obtain the superior performance of SCR technology and not be limited to the poor operating and energy intensive performance of 9 ppm burners.


Duke University Relies on Temporary Boiler During Major Fuel Conversion Project


Customer Profile
• Duke University
• Durham, North Carolina
• West campus steam plant built in1929
• Produced as much as 1.3 billion pounds of steam per year
• Goal to be carbon neutral by 2024 

Supplied Equipment
• 82,500 lb/hr trailer-mounted rental boiler
• EconoStak economizer

Built in 1929, Duke University’s West Campus steam plant produced as much as 1.3 billion pounds of steam a year. The plant was fueled from a mountain of 4,000 to 6,000 tons of coal on Coal Pile Drive. On April 12, 2011, Duke burned the last of its remaining stock of coal and began renovations to convert the plant from a coal to natural gas burning plant, similar to the East campus steam plant. This is all part of Duke’s Climate Action Plan and the University’s goal to become carbon neutral by 2024.

A local engineering firm working with Duke on the project contacted Nationwide Boiler to provide an 82,500 lb/hr trailer-mounted rental boiler with an economizer to supplement steam as a result of the plant retrofit. A long-term rental boiler was required that was readily available and would operate reliably during the fabrication of three new high capacity natural-gas fired package boilers the University purchased.

Nationwide Boiler supplied the University with a nearly-new Nebraska mobile trailer-mounted rental boiler. The unit met their requirements and was available for immediate shipment from Nationwide Boiler’s storage yard in Bessemer, AL (ADCO Companies Ltd.). The boiler was thoroughly inspected, tested and checked before it was shipped to the end-user. In addition, Nationwide Boiler mounted Duke University’s famous Blue Devil logo on each side of the boiler, proudly promoting the University during its transit from Alabama to Durham, NC.

The trailer-mounted boiler was delivered, made its way up Coal Pile Drive and was installed in the obsolete coal handling building. Nationwide Boiler performed boiler start-up and operator training to ensure proper operation and maintenance of the equipment. Based on the success of the first rental, Nationwide Boiler again supplied an 82,500 lb/hr trailer-mounted boiler to support the final phase of the coal-togas construction project, while C&C Boiler Sales & Service, Inc., Nationwide's local representative, provided start-up services.

Overall, the conversion of Duke's steam plants have helped the University take a significant step towards its goal of becoming carbon neutral by 2024. Avoiding the use of coal has reduced greenhouse gas emissions by 40% and reduces the campuses overall emissions by 15%.

BPS Upgrade with E2Stak Yields Energy Savings, Decreased NOx Emissions, and Improved Operations


Customer Profile
• Major food processor
• Located in the San Joaquin Valley Air Pollution Control District in California
• Received $150,000 rebate check at the completion of the project

Supplied Equipment
• Low temperature CataStak™ Selective Catalytic Reduction System
• Stack-mounted EconoStak economizer on an existing 150,000 lb/hr boiler
• Low NOx burner with no FGR

A major food processor in California installed a 150,000 lb/hr boiler in 1999 to help meet their increased seasonal demand. To meet low NOx regulations at the time, a high flue gas recirculation (FGR) burner and a large forced draft (FD) fan were installed for 9 ppm NOx operation.

To meet sub-10 ppm NOx requirements, the ULN burner resulted in high FGR rates that often compromised the operational limits of the boiler equipment. These included limited turndown capabilities, flame pulsations, unstable operation, and the unit could not properly follow the normal plant loads. The burner was also operating with high excess air (4.5% O2) resulting in poor efficiency. A solution was needed to improve boiler efficiency, provide a better operating boiler and meet the newest air
standards of 5 ppm NOx.

The existing boiler was upgraded with Nationwide's "Best Performance Standards" (BPS) boiler technology. The high FGR burner was replaced with a new low NOx burner that required no FGR and resulted in 10:1 turndown and low excess air operation (3%). New E2Stak efficiency upgrades were also installed including an extended surface EconoStak economizer designed for maximum heat recovery. To meet NOx emissions a CataStak™ selective catalytic reduction system was installed to easily achieve 5 ppm NOx or less.

The BPS solution provided immediate efficiency savings, emission reductions and a quick return on investment. The burner upgrade decreased FD fan horsepower requirements by almost 200 HP and coupled with the EconoStak economizer, existing stack temperature was reduced by an additional 40°F, resulting in a 1% increase to the current boiler's fuel to steam efficiency. The immediate energy cost savings resulted in a utility rebate check of almost $150,000 to the end-user, offsetting the costs of the project.

The customer was more than satisfied with the overall performance of the system and commented that, "This was the first year we could operate the boiler in automatic!".

The yearly savings in both fuel and electricity further demonstrates how a BPS boiler upgrade assures that the latest efficiency gains and low NOx emission performance can be achieved.


Rapid Response and On-Site Support Meet Emergency Requirements


Customer Profile
• Consolidated Edison
• New York, NY
• Merged with the New York Steam Company in 1952
• Operates the largest district steam system in the United States

Supplied Equipment
• Two (2) 70,000 lb/hr, low NOx, trailer-mounted package boilers
• Stack-mounted EconoStak economizer on each boiler
• 300 gpm boiler feedwater treatment van

The horrific events in New York City on September 11, 2001 caused destruction of the steam delivery infrastructure and left many buildings near Ground Zero without heat and other necessary steam-based facilities. Prior to the terrorists attacks, Consolidated Edison (Con Ed) provided steam to numerous residential and office buildings in the area. The devastation of the area, however, included a 20-inch steam main used by Con Ed for delivery of the steam to users.

As a part of restoring activity around the damaged area of Ground Zero, facilities, including steam delivery, had to be replaced. The extent of the damage was so great that temporary replacements were sought. Included among these was a complete temporary steam plant, including water treatment capability, that could be brought online in a short time and could continue to operate for an indefinite time with minimum interference to ongoing operations.

Shipping arrangements for a complete 140,000 lb/hr steam plant were initiated within hours of receiving the go-ahead from Con Ed. An area within close proximity to the damaged steam main was selected for placing and operating the steam plant. A 70,000 lb/hr trailer-mounted boiler was readied and dispatched from the Nationwide Boiler East facility in Delanco, New Jersey. Concurrently, a self-contained water treatment van and a second boiler were dispatched from Nationwide Boiler headquarters in Fremont, California. The equipment was assembled on the selected site at Ground Zero and prepared for startup by a Nationwide Boiler startup crew.

Operating on a fast-track basis, a complete 140,000 lb/hr steam plant was delivered, brought on-line and readied for operation at Ground Zero in a matter of days. The system steam main was connected to temporary steam distribution lines. As soon as they were habitable, offices and residences in the area were provided with heat and the other steam-based services and able to continue their everyday activities and operations.

Self-contained Systems Give U.S. Navy Transportable, Low NOx Steam Plant Capability


Customer Profile
• United States Navy’s Facilities Command
• Washington Navy Yard

Supplied Equipment
• One (1) Firetube boiler rated at 5,000-20,000 lb/hr net output at 15-60 psi saturated, including safety valves and automatic level and pressure controls.
• Low NOx burner capable of firing natural gas, propane, or propane air. The burner utilized induced flue gas recirculation to limit NOx emissions to below 30 ppm
• Make-up, deaerator/condensate and feedwater system with pumps, valves, controls, and instrumentation necessary to receive returning condensate, deaerate make-up water, and pump feedwater to the boiler
• A 480 VAC, 3 phase, 60 Hz, 225 amp electrical distribution system
• Boiler blowdown and heat recovery system
• Natural gas/propane supply system
• Combustion air system and flue gas recirculation system
• Chemical treatment system
• Heating and ventilating system
• Water sample system

The U.S. Navy requires temporary steam supplies under many different circumstances. Most common among them are as back-up to facility boilers at Navy installations throughout the world, and as alternate steam sources for ships in port when their boilers are undergoing repairs. Transportability, meeting stringent low NOx regulations and compliance with MIL-SPECs are just a few of many requirements these systems meet.

Nationwide Boiler received a contract from the U.S. Navy Facilities Command to provide eight complete boiler systems, model NBI Low NOx Transportable Steam Plant. The contract included the following tasks: conceptual and detail design engineering, including CAD drawings, equipment selection, production fabrication and assembly, efficiency and emission compliance testing, quality assurance, and project engineering and management. All of these tasks were performed in full compliance with appropriate MIL- SPECs and contract requirements.

The NBI Low NOx Transportable Steam Plant is a self-contained unit mounted in a metal van-type enclosure attached to a steel base frame. The plant is designed to be shipped by rail, sea or over-the-road and to operate continuously with ambient temperatures ranging from -250 degrees to 110 degrees Fahrenheit at elevations from sea level to 5,000 feet.

The project was completed successfully with all requirements met and the eight transportable steam plants shipped to the customer in a timely manner. Today, Nationwide Boiler has in stock a variety of low NOx and ultra-low NOx transportable steam plants for rental or permanent use.

Completing a Fast-track Program Involves Team Relationship with Engineering Services Contractor


Customer Profile
• Tesoro Refining (formerly Tosco Refining’s Avon Refinery)
• Martinez, CA
• Capacity of 166,000 bpd
• Plant produces motor fuels, conventional gasoline and diesel fuel

Supplied Equipment
• 120,000 lb/hr, 600 psi / 750F superheat skid-mounted package rental boiler
• New 120,000 lb/hr spray-type deaerator with water storage, two (2) high pressure feed pumps, and two (2) 250 hp motors

Steam is essential in processing crude oil. The facility boiler that provides process steam at a large Bay Area refinery required refurbishment. The refinery owner retained a major engineering firm to manage all aspects of engineering, procurement, installation and operation of a temporary steam supply while the facility boiler refurbishment program was underway. In addition to a large, high-pressure, high-temperature boiler, the requirements included providing a boiler feedwater system and meeting stringent Bay Area Air Quality Management District (BAAQMD) emission limits of 30 ppm NOx.

Tosco Refining Company's Avon Refinery in Martinez, California (currently owned by Tesoro), required a 120,000 lb/hr, 600 psig, 750 degree Fahrenheit boiler and a companion feedwater system for a period of two months. Boiler emissions had to meet local air quality standards. The feedwater system required a 10-minute storage capacity of deaerated and chemically treated feedwater and a minimum pumping capacity of 300 gpm at 700 psig. Bechtel Corporation was retained by the owner to manage the project, including all aspects related to the boiler and feedwater system. The entire complement of equipment needed to be delivered to the job site within 30 days of contract award.

Engineers from Bechtel and Tosco visited Nationwide Boiler facilities in Fremont, California, to evaluate the company's engineering, fabrication and test capabilities. Following a plant tour and meetings with Nationwide Boiler engineers, a contract was awarded for design and production of a feedwater deaerating and pumping system and the rental of a skid-mounted 120,000 Ib/hr, 600 psig 750 degree package boiler. Nationwide Boiler engineers designed and built the feedwater system to specifications developed by Bechtel engineers. It took slightly over three weeks to design, build and test the system. Once assembled, the structure was 22 ft high and weighed 35,000 Ibs. It was partially disassembled for transit to Tosco Petroleum. Major components included a 120,000 lb/hr spray-type ASME deaerator with 2,700 gal treated-water storage and two high-pressure feed pumps, each powered by a 250 hp motor.

For temporary use, a 120,000 Ib/hr superheat package boiler in Nationwide Boiler's inventory was outfitted with a low NOx burner and a PLC-based burner management system. A flue-gas recirculation (FGR) system was installed to assure that the stringent NOx and CO emission levels would be met.

Just over one month following authorization to proceed, the temporary feedwater deaerating and pumping system and low NOx, superheat boiler were installed and placed in operation. All equipment designs were approved by Bechtel engineers. Boiler stack emissions were below the established limits due to the use of FGR. The system operated successfully at full-load conditions for two months and was removed.

Lessons Learned with the CataStak SCR System


"As NOx emissions evolved we were apprehensive of investing in technology that was not well proven and would not meet future compliance. Choosing SCR technology was the best choice we ever made. We no longer have to worry about upgrading our rental equipment and it performs reliably now and will continue to do so in the far future." - Larry Day, Vice President, Nationwide Boiler Inc.

Since the 1980's Nationwide Boiler's rental fleet compliance strategy has evolved in parallel with NOx emission regulations. After several decades of utilizing best available control technologies (BACT), Nationwide today relies on selective catalytic reduction (SCR) technology, proven to reduce NOx emissions by as much as 90% or more. The CataStak™ SCR system is Nationwide's ultra low NOx compliance solution, capable of meeting stringent emission requirements, which are predicted to be reduced to <5 ppm by 2015.

Users in California and other regions affected by strict NOx emission limits have upgraded their boiler systems several times over the last twenty years in order to meet NOx limits in their area. They demand equipment that not only provides reliability, ease of maintenance and energy efficiency, but also provides a long-term, compliance solution.

After Clean-Air Act Amendments were passed in the early 1990's Nationwide Boiler utilized combustion control methods to address NOx emission requirements. When NOx levels of 30 ppm were adopted, Nationwide invested in current BACT technology and retrofitted it's boiler rental fleet with burner combustion control technology. When NOx limits were even further reduced to 9 ppm, Nationwide's rental units were no longer capable of meeting new regulations and additional costly burner retrofits were required .

Nationwide concluded that this was just the beginning of a country-wide movement of clean air regulation and the company evaluated post combustion technologies. After several years of field R&D testing on numerous rental projects, Nationwide's engineers selected SCR technology as the answer to NOx compliance. It was the most economical, efficient, reliable and easy to operate solution, capable of exceeding 9 ppm. Also, when packaged with EconoStak economizers it provided energy efficiency gains (the E2Stak). This marked a major shift in control technology solutions for Nationwide and thus the CataStak™ SCR system for ultra low NOx emissions was born.

Nationwide's proactive decision to adopt SCR technology proved to be wise and cost effective. Currently, NOx emission requirements are as low as 5 ppm in some areas, and it is predicted that after 2015 these limits will be decreased even further, once current rules expire. In contrast to users with 9 ppm boiler burner controls, Nationwide's current boilers equipped with CataStak™ SCR systems easily perform at current NOx levels and will easily meet future levels as low as 2.5 ppm, without additional costly burner upgrades.

When evaluating a low NOx solution call Nationwide Boiler, the largest low NOx solution provider. For complete, worry-free NOx compliance, select the CataStak™ SCR system - the one time compliance investment that will provide proven results year-after-year.

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