Success Stories

An image of the installation of a boiler and heat recovery system at the Alabama Field Demonstration Site

Boiler and Heat Recovery System at the Alabama Field Demonstration Site (PDF 1.2 MB) Download Adobe Reader.

Industrial Technologies Program's (ITP) Combustion Sub-program has sponsored many successful combustion research projects relevant to the Industries of the Future. Several projects have resulted in technologies that are currently commercially available or are likely to emerge on the market in the next year or two, while other projects have provided key knowledge for combustion system improvements.

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First Super Boiler Field Demonstration (PDF 1.2 MB)

In the U.S. manufacturing sector, steam generation represents the largest use of energy, accounting for over 30% of the total energy consumption. The U.S. manufacturing boiler inventory consists of 33,000 boilers with capacities greater than 10 million Btu/hr. At least 80% of these boilers were purchased over 30 years ago and the technology they employ has only marginally advanced since the late 19th century, resulting in average fuel-to-steam efficiencies around 75%.

Starting in 2000, the U.S. Department of Energy and natural gas industry launched a new R&D program to improve the energy efficiency and reduce the environmental impact of steam boiler systems. As a part of this "Super Boiler" program, the Gas Technology Institute (GTI) and Cleaver-Brooks developed and demonstrated a novel flue gas heat recovery system with specialized controls to maximize energy efficiency and maintain stable performance under industrial conditions.

The Super Boiler uses heat recovery from flue gas to increase energy efficiency and state-of-the-art combustion to reduce emissions. The boiler is capable of a 93-94% fuel to steam efficiency conversion, while releasing less than 9 ppmv (parts per million by volume) of NO_X. The first field demonstration of the Super Boiler is on a 12.2-million-Btu/h (3.5 MWth) unit at Specification Rubber Products, Inc., a manufacturer of rubber gaskets in Alabaster, Alabama.

Forced Internal Recirculation Burner (FIR)

The FIR Burner combines staged, premixed combustion with forced internal flue gas recirculation to minimize the formation of both thermal and prompt NO_X. The burner's unique design provides excellent flame retention for stable combustion at low emission levels. These capabilities enable the burner to meet the stringent requirements found in California, Houston, and other non-attainment zones.

The FIR Burner is applicable to a wide range of watertube boilers used in the forest products, chemicals, petroleum refining, food, and steel industries.

This revolutionary burner design promises increased system efficiency, NOx emissions below 9 vppm, CO emissions below 50 vppm, and total hydrocarbon (THC) emissions below 50 vppm. The burners are currently offered for sale by Johnston Burner Company and have been successfully demonstrated at Detroit Stoker Company, Vandenberg Air Force Base, and Miller Brewing Company. Project partners for this effort include the Gas Technology Institute, Detroit Stoker Company, University Of Illinois, Gas Research Institute, and Johnston Burner Company.

UltraBlue Burner

Developed by Callidus Technologies, UltraBlue burners are designed to maximize fired-heater efficiency and help the petroleum and chemical industries meet stringent environmental regulations. Project partners are now integrating the UltraBlue burner into a new generation of highly efficient process heater systems with extremely low emissions. By 2020, advanced heaters incorporating ultra-high efficiency and ultra-clean combustion burners have the potential to save over 84 trillion Btu/year and reduce NOx emissions by 150,000 tons annually

By late 2003, over 1,300 UltraBlue burners had already been sold to the petroleum industry alone. Project partners include Exxon Mobil Research and Engineering Company, Callidus Technologies, Inc., and TIAX LLC.

Ultra-Low NOx Burners

These burners achieve ultra-low NOx emissions by combining a unique type of clean-burning combustion technology called ultraclean, low-swirl combustion (UCLSC), with premixed flames. High energy efficiency is achieved in this type of combustion because the appropriate ratios of air and fuel are mixed to burn completely. In addition, the characteristically lifted flame of the burner provides for highly efficient heat transfer because no heat is transferred from the flame to the burner.

Ultra-Low NOx Burners emit 10 to 100 times less nitrogen oxide than conventional burners. Also, the cost of these burners is comparable or lower than that of many conventional burners.

Backed by more than ten years of research, ultra-low NOx burners are currently offered for sale by Maxon Burner Corporation (MPAKT burner). Project partners include Lawrence Berkeley National Laboratory, Coen Company, CMC Engineering, John Zink Company, Gasunie Research, Maxon Corporation, MIT Plasma Science, and Fusion Center.