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CataStak™ SCR – Best Option for System Upgrades

In February of this year, the Boiler MACT rule was published in the Federal Register, causing the Environmental Protection Agency (EPA) to propose new regulations calling for system upgrades on boilers and auxiliary equipment in many plants.  The costs associated with these upgrades can reach up to $35 billion according to the EPA, but because the costs will be specific to each individual plant, no one will know the real costs until the boiler equipment is evaluated to comply with new and future regulations.  Boiler operators are hesitant to spend the money due to the uncertainty of regulations, but eventually something will need to be done.

There are resources available, and the U.S. boiler and combustion equipment industry is readily able to meet the demand for these system upgrades. Randy Rawson, President of the American Boiler Manufacturer’s Association (ABMA), said, “We have the workforce resources to meet the needs of our customers, as long as our customers don’t push compliance go the last minute.”

The largest air districts in California have passed rules that require NOx compliance as low as 5 ppm by the year 2015.  Few burner manufacturers have been successful with developing new ultra low NOx (ULN) burner technology that easily and safely performs at 9 - 7 ppm NOx.  Many users that have tried ULN burners suffer the consequences of high FGR or excess air rates that compromise not only efficiency, but also the operational limits of boiler equipment, resulting in limited turndown capabilities, flame pulsations and unstable operation.

Today, selective catalytic reduction (SCR) technology has taken over as the best available control technology for complying with ultra low NOx emission requirements.  Nationwide Boiler, having invested in SCR technology for our rental fleet over the last ten years, has both the experience as an user and a supplier of the CataStak™ SCR system.   Our SCR systems have met or exceeded emission requirements for over one hundred boilers, steam generators and gas turbines installations.

The Nationwide Boiler CataStak™ SCR system is proven to decrease emissions, increase energy efficiency, reduce fan horsepower and provide greenhouse gas / carbon reductions. Typical users can save significant energy costs by reducing flue gas recirculation which substantially reduces fan horsepower (HP) and when compared with a typical 9 ppm burner, fan HP can be reduced by as much as half.

If you are concerned or have questions about how your facility is planning to comply with local air quality regulations, send am email to info@nationwideboiler.com and together we can come up with a solution that can perform as low as 2.5 ppm NOx and pass any current air regulation with the lowest carbon footprint.

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Customer in CA Takes Delivery of 75,000 lb/hr BPS Boiler

California, if considered a country, is among the top 20 emitters of CO2 worldwide. Current legislation addressing GHG include California Assembly Bill 32 (AB32), aimed at reducing existing GHG emissions to 1990 levels by 2020, and the California Environmental Quality Act’s (CEQA) Climate Change Action Plan that incorporates Best Performance Standards (BPS) measures into the review process to assist new boiler permit applicants (natural gas-fired units).  The policy relies on the use of BPS to assess GHG emissions on global climate change and standards are incorporated in the overall design and operation of the equipment, providing the most efficient performance measures with major reductions in GHG emissions.

Current BPS examples that provide maximum efficiency benefits include:

    • ? 20ºF Approach Temperature on the Economizer

 

    • ? 15% Excess Air with O2 Trim

 

    • ? 10% FGR

 

    • VFD on Fan

 

    • Heat Recovery on Blowdown if over 8%



Nationwide Boiler recently provided a BPS boiler solution to a CA pulp and paper customer governed by the San Joaquin Valley Air Pollution Control District (SVAPCD).  BPS equipment included a 75,000 pph boiler, CataStak™ SCR system, EconoStak economizer and auxiliary equipment. The system incorporates the latest boiler upgrades and once in operation, will perform well below current NOX standards.

This system is one of many BPS solutions supplied by Nationwide Boiler, and BPS boilers in operation include several prominent food processors located throughout CA.  Each company is committed to operate their boiler systems with the most technologically advanced equipment in the industry, doing their part in helping the environment and lowering overall GHG emissions, while running operations as efficiently as possible.

Nationwide Boiler BPS Boiler System Delivered
Nationwide Boiler BPS Boiler System




For additional information regarding BPS requirements, specific to the San Joaquin Valley, visit: http://www.valleyair.org/Programs/CCAP/bps/BPS_idx.htm#Boilers

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Nationwide Boiler Acquires Two New Representatives

In an effort to expand worldwide sales, Nationwide Boiler Inc. has recently signed two new representatives that will focus on the rental, leasing and sales of boilers and CataStak™ SCR systems: Dade Hamilton (Coral Gables, FL) and Heat Transfer Specialists (Houston, TX).

Dade Hamilton supplies industrial equipment to the oil and gas, petrochemical, utility, pulp and paper, steel, and sugar industries in Latin America and the Caribbean.  This new relationship with Nationwide Boiler will enhance both companies ability to supply new boiler systems internationally, specifically the Babcock & Wilcox Model FM 120-124, 200,000 lb/hr superheated steam package boiler (750 psig / 750°F).  As a partner and stocking distributor for the Babcock & Wilcox Company, Nationwide Boiler can ship the Model FM boiler (or any other boiler system in the company’s inventory) anywhere in the world.

Heat Transfer Specialists (HTS) specializes in supplying combustion equipment that provides the latest technology in energy efficiency and low emissions.  The company serves industrial users in the oil and gas, refining, petrochemical and power industries. Their strategic location in Houston, TX has helped the company grow into a successful manufacturer’s representative and they are well positioned to increase Nationwide Boiler’s market share in the selective catalytic reduction (SCR) heater market, in addition to providing new opportunities for the sale and rental of boiler systems.

Bill Testa, Nationwide Boiler’s Business Development Manager, played a pivotal role in engaging and securing both representatives for Nationwide Boiler. “Dade Hamilton and Heat Transfer Specialists have both proven themselves to be leading suppliers to customers in their territories. They both possess the experience, expertise and continued commitment to serve their customers to the full extent possible, while continuing to add value and unparalleled customer support. Both companies are welcome additions to the company and we look forward to many new opportunities as a result of these new relationships.”


We want to welcome Dade Hamilton and HTS to Nationwide Boiler and we look forward to the many foreseen opportunities with each of these companies.

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Touch Screen CataStak Ammonia Flow Control Skid Supplied to Major Northwest Hospital

Nationwide Boiler recently supplied a single ammonia flow control system, designed to supply three boilers as part of a low NOx CataStak SCR system.  It features a Honeywell touch screen operator interface with a 10” VGA LCD color display and is constructed in accordance with NEMA 4X.  A bottle rack, complete with digital scales, was also supplied and handles three standard 150# ammonia bottles.

The system is currently being installed and another successful start-up for Nationwide Boiler is predicted.

CataStak SCR Ammonia Flow Control Unit
 

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