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Nationwide Boiler news and events, industry updates, technical resources and more. You hear it first on The Nationwide Boiler Blog!

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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Seven Immediate Energy Saving Ideas

1    Operate Boilers At or Close to Design Capacity. This decreases fuel consumption per unit of production and can result in an estimated energy savings range of 1 percent to 5 percent.  Likewise, if your facility or plant requires excess capacity, visit the Nationwide Boiler website to obtain a current list of boilers for rent or for sale.  Nationwide Boiler provides new and used boilers that can ship immediately, anywhere around the world (conditions apply, contact Nationwide Boiler for details).
2    Reduce Combustion Excess Air. Measure and control air-fuel ratio or oxygen and carbon monoxide content of flue gases from process heating equipment such as furnaces, ovens, and boilers for the entire range of operation. This has an estimated energy savings range of 2 percent to 15 percent. Think about installing a standard low NOx / low excess air burner (compared to an ULN / high excess air burner) on your boiler.  Complemented with a Nationwide CataStak™ Selective Catalytic Reduction System (SCR), a new burner retrofit and SCR installation will not only provide immediate energy savings, but will also reduce NOx emissions and decrease your carbon footprint.
3    Clean Heat Transfer Surfaces. Cleaning heat transfer surfaces lowers flue gas temperature and increases efficiency by improving heat transfer. Doing so can save an estimated 1 percent to 5 percent at a moderate cost.
4    Reduce Radiation Losses from Openings. Reducing radiation losses can save an estimated 1 percent to 2.5 percent at a relatively low cost.
5    Use Proper Oven, Furnace or Boiler Insulation to Reduce Wall Heat Losses. Reducing wall losses produces energy savings of 1 percent to 2 percent with only a moderate investment.
6    Insulate Steam Lines Leaving the Boiler as well as Air- or Water-Cooled Surfaces Exposed to the Oven or Furnace Environment. With an estimated energy savings range of 1 percent to 5 percent, piping insulation can be completed for a moderate investment.
7    Install Air Preheaters or Other Heat Recovery Equipment. This type of equipment recovers available heat from exhaust gases and boiler blowdown and transfers it back into the system by preheating. The potential energy savings range id from 1 percent to 25 percent, depending on process temperatures and other variables.  Consider a Nationwide Boiler EconoStak Economizer or a Heat Recovery (HR) Blowdown Pak to recover valuable heat that can be reused, allowing you to save money in the long-term.

Adapted from Process Heating Magazine, March 21, 2012.

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Analyze Your Steam System for Free

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Have you been considering steam system improvements in your plant, but do not know where to begin? Do you want to potentially save 10% or more in fuel costs, while reducing emissions?

The U.S. Department of Energy's (DOE) Industrial Technologies Program can help answer those questions for you and has developed the Steam System Scoping Tool (SSST) for energy coordinators, facility managers and plant electricians to help evaluate your steam system's performance. The software (available in MS Excel or Visual Basic formats) asks 26 questions about different areas of your steam system including system profiling, steam system operating practices, boiler plant operating practices, and distribution and recovery operation practices. Based on your responses, the software will indicate opportunities for improvements and will suggest a range of ways to save steam energy and boost productivity. It also compares your system against similar facilities in your industry and identifies best practices.

According to the DOE, six DOE Industrial Assessment Centers used the SSST in 2001 to assess steam systems at 18 small and medium-sized facilities. Overall, the software identified 89 system improvements with an average fuel savings of 12.5%. Collectively, the total improvements yielded a total annual savings of $2.8 million.

To learn more about this free software, visit the DOE's website.

Call Nationwide Boiler at 800-277-1966 to let us know how much energy you are able to save. We can also provide you with valuable information about our energy efficient equipment for sale or for rent, including EconoStak economizers, Best Performance Standards (BPS) boilers and CataStak SCR systems for boilers and gas-fired turbines.

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Steamlines Newsletter - Fall 2010 Edition

The Nationwide Boiler Steamlines Newsletter is now available to view online. This edition includes information on our new 82,500 pph boilers, a CataStak-GT success story, the signing of our new eastern Canadian representative, Le Groupe Simoneau, emergency contingency planning for the new year, and new briefs. Visit our website to subscribe to our monthly newsletter and stay current with the latest news from Nationwide Boiler.

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