WARE Improves Boiler Efficiency and Reduces Emissions

The GEO Specialty Chemicals Company in Lafayette, Indiana was at a crossroads with the boiler system at their Cedartown, Georgia plant. They knew they needed greater reliability to keep their supply of steam coming. What they did know, however, was that they had a limited budget to work with.

THE CHALLENGE: RELIABILITY AND PERFORMANCE

GEO’s Cedartown, Georgia plant is a lynchpin in the company’s ongoing production processes. Because of its crucial role, the plant needed a way to ensure an uninterrupted supply of steam to maintain plant capacity and avoid costly downtime.   

• Their first thought was to install a backup boiler system that would be able to handle the load if their primary system went down.
• The budget was limited, meaning they were probably looking at a remanufactured boiler.
• They consulted with WARE to find the best path forward.

THE WARE RESPONSE: A RANGE OF OPTIONS

When GEO contacted WARE to discuss purchasing a remanufactured boiler, WARE took the initiative to go above and beyond. Rather than simply sell them a remanufactured boiler to serve as a backup, WARE instead leveraged its expertise as an industry leader with more than 70 years of steam experience to analyze GEO’s needs and present them with a range of options that thought beyond just the immediate need.

The first option was to sell GEO the remanufactured boiler they requested. This would satisfy the demand, but wouldn’t offer any additional advantages to GEO’s operation.

The second option was to sell GEO a remanufactured boiler that included a new parallel positioning linkage-less burner, which would offer greater efficiency that the remanufactured boiler would on its own.

The third option was to furnish and install a new 800hp water-backed three-pass boiler with a Limpsfield natural-gas-fired low NOx burner.

WARE DID THE MATH

When WARE presented GEO with its options, WARE went the extra mile with a detailed analysis and performance test of GEO’s existing 500hp four-pass water-backed boiler compared to the suggested 800hp three-pass water-backed boiler, resulting in convincing proof that the new boiler was the best possible option.

• By using their existing boiler with a remanufactured boiler as a backup, the company would get an operating efficiency of 78%.
• By installing the new boiler with the Limpsfield burner system, efficiency jumped to 89%.
• The existing unit operated at an average load of a 39.5% firing rate while producing 6,811 pph
• The new boiler operated at an average load of a 33.7% firing rate while producing 9,312 pph.

Because of the combustion efficiency of the Limpsfield burner system, the new boiler had the added advantage of generating a less than 30 ppm NOx emissions rate, helping GEO be more ecologically responsible in its operations.

• Limpsfield Series LC burners operate at 3% O₂ to maximize combustion rates.
• Limpsfield’s unique burner technology can reduce emissions by as much as 70% compared to uncontrolled emissions.

MORE STEAM WHEN IT’S NEEDED

Using its expertise in boiler performance and operation, WARE went on to show GEO how installing the new boiler with the Limpsfield system would offer a range of other advantages beyond just operating efficiency.

• By studying GEO’s processes, WARE realized that GEO’s manufacturing methods often created sudden load demand which could cause loss of steam pressure that could affect the pace of manufacturing.
• Because of this, WARE specifically chose the 800hp boiler for its liberal steam disengaging area.
• This liberal steam disengaging area serves to minimize increases in steam velocity caused by rapid loss of pressure during sudden load demands.
• Alleviating the sudden loss of pressure would serve to eliminate nuisance low-water demands and moisture entrainment in the steam system.

A SUCCESS STORY IN EVERY WAY

In the end, GEO chose to install the new boiler with the Limpsfield burner system, while moving its existing boiler to the role of backup boiler. To ensure sustained performance and lower emissions, the new system also included an AUTOFLAME electronic parallel positioning control system. Furthermore, by switching to the Limpsfield burner system, GEO now had the ability to burn either propane or natural gas, increasing their operational flexibility.

By leveraging its extensive boiler expertise, WARE helped provide GEO with a better option, while giving GEO greater confidence in their decision to go with the new boiler. Although up-front costs were higher, the new boiler delivered greater payback.

• GEO realized a 14.1% operational improvement.
• GEO lowered its yearly operating costs substantially.
• GEO realized lower emissions.
• GEO no longer had to endure steam pressure loss during periods of high demand, allowing them to maintain uninterrupted steam service.

The research that WARE did as part of the GEO installation also served to disprove several common myths associated with boiler operation. Namely:

• Low-NOx burners provide lower operational efficiency when compared to standard equipment.
• Operating at a higher firing rate is more efficient than operating at a lower firing rate.
• Four-pass boilers are more efficient than three-pass boilers.

If you’re considering a new or remanufactured boiler, let the experts at WARE help you make the best decision for the greatest return on your investment. We’re always here to help.