DOE OSTI2013
The objective of this project was to engineer, design, fabricate, and field demonstrate a Boiler Burner Energy System Technology (BBEST) that integrates a low-cost, clean burning, gas-fired simple-cycle (unrecuperated) 100 kWe (net) microturbine (SCMT) with a new ultra low-NOx gas-fired burner (ULNB) into one compact Combined Heat and Power (CHP) product that can be retrofit on new and existing industrial and commercial boilers in place of conventional burners. The Scope of Work for this project was segmented into two principal phases: (Phase I) Hardware development, assembly and pre-test and (Phase II) Field installation and demonstration testing. Phase I was divided into five technical tasks (Task 2 to 6). These tasks covered the engineering, design, fabrication, testing and optimization of each key component of the CHP system principally, ULNB, SCMT, assembly BBEST CHP package, and integrated controls. Phase I work culminated with the laboratory testing of the completed BBEST assembly prior to shipment for field installation and demonstration. Phase II consisted of two remaining technical tasks (Task 7 and 8), which focused on the installation, startup, and field verification tests at a pre-selected industrial plant to document performance and attainment of all project objectives. Technical direction and administration was under the management of CMCE, Inc. Altex Technologies Corporation lead the design, assembly and testing of the system. Field demonstration was supported by Leva Energy, the commercialization firm founded by executives at CMCE and Altex. Leva Energy has applied for patent protection on the BBEST process under the trade name of Power Burner and holds the license for the burner currently used in the product. The commercial term Power Burner is used throughout this report to refer to the BBEST technology proposed for this project. The project was co-funded by the California Energy Commission and the Southern California Gas Company (SCG), a division of Sempra Energy. These match funds were provided via concurrent contracts and investments available via CMCE, Altex, and Leva Energy The project attained all its objectives and is considered a success. CMCE secured the support of GI&E from Italy to supply 100 kW Turbec T-100 microturbines for the project. One was purchased by the project’s subcontractor, Altex, and a second spare was purchased by CMCE under this project. The microturbines were then modified to convert from their original recuperated design to a simple cycle configuration. Replacement low-NOx silo combustors were designed and bench tested in order to achieve compliance with the California Air Resources Board (CARB) 2007 emission limits for NOx and CO when in CHP operation. The converted microturbine was then mated with a low NOx burner provided by Altex via an integration section that allowed flow control and heat recovery to minimize combustion blower requirements; manage burner turndown; and recover waste heat. A new fully integrated control system was designed and developed that allowed one-touch system operation in all three available modes of operation: (1) CHP with both microturbine and burner firing for boiler heat input greater than 2 MMBtu/hr; (2) burner head only (BHO) when the microturbine is under service; and (3) microturbine only when boiler heat input requirements fall below 2 MMBtu/hr. This capability resulted in a burner turndown performance of nearly 10/1, a key advantage for this technology over conventional low NOx burners. Key components were then assembled into a cabinet with additional support systems for generator cooling and fuel supply. System checkout and performance tests were performed in the laboratory. The assembled system and its support equipment were then shipped and installed at a host facility where final performance tests were conducted following efforts to secure fabrication, air, and operating permits. The installed power burner is now in commercial operation and has achieved all the performance goals.
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