BOILER BURNER CONSORTIUM
INTERIM REPORT
ON
LOW NOX BOILER/BURNER TECHNOLOGIES
ENERGY SOLUTIONS CENTER
MAY 2004
R. BILJETINA , A. ZAIDI, R. RYBA
INTRODUCTION
In 2002, the Energy Solutions Center formed a Boiler Burner Consortium to assist member
companies with customer needs and inquiries on available and emerging technologies for large
commercial and industrial boilers. Topics of interest include automation and controls, efficiency,
low-emissions burners, and compact boiler systems. A working group determined that initial work
efforts should be focused on low NOx technologies. The proposed work effort would:
 Prepare gas utility representatives to be a primary channel for inquiries related to low
NOx burners and boilers.
 Deliver value-added information products and tools needed to target large commercial
and industrial customers
 Develop program strategies to assist the commercialization of new emerging
technologies, and if necessary demonstrate new state-of-the-art low NOx burners.
 Work with government, environmental agencies, as well as local and national
trade allies to increase awareness and accelerate deployment of clean-burning
natural gas technologies for steam production.
Six companies joined the consortium in 2001. They are:
 CANMET Energy Technology Center
 DTE Energy /MichCon
 Enbridge Consumers Gas
 NiSource
 Southern California Gas, and
 Union Gas
In 2004, Gas Technology Institute (GTI) joined the consortium as the seventh member. The
product champions for this consortium are Aqeel Zaidi, Union Gas (Phone: 416-496-5221, e-mail:
azaidi@uniongas.com) and Randy Ryba, NiSource (Phone: 219-853-5234, e-mail:
rfryba@nisource.com). The Energy Solutions Center Coordinator is Richard Biljetina (Phone:
202-251-8902, e-mail: biljet@att.net).
This interim report summarized the work completed by the consortium in support of low NOx
boiler burner systems. As originally planned, this initial work effort focused on low NOx
technologies was completed in a two year work effort and included the conduct of several
workshops hosted by member companies and the creation of a comprehensive website dedicated
to clean and efficient boiler operations. See www.CleanBoiler.org
MARKETPLACE NEED FOR LOW NOX BOILER TECHNOLOGIES
In many regions within the US and Canada, emission standards and in particular NO x standards
are being phased in that significantly lower the emissions levels for new natural gas boiler
installations. It is anticipated that California will be regulated to levels well below 10 vppm NOx;
some states are setting limits below 30 vppm; and other areas need burner systems that can
meet emission limits between 30 and 50 vppm NOx. Conventional systems generally emit over
twice that amount.
As an example, in Canada the Ontario Ministry of the Environment (MOE) has taken action to
reduce emissions of NOx and VOCs by 45%, compared to 1990 levels by the year 2015. The
baseline is 1990 levels. In March 2001, the MOE announced an environmental policy (MOE
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Policy Guideline A-9) to control NOx emissions from industrial boilers and heaters. The policy
adopted the recommendations made by the Canadian Council of the Ministers of Environment
(CCME) guidelines, published in 1998. It states that all new and modified boilers and heaters
that have greater than 10 MMBtu/hr fuel input will be required to comply with this new policy
before obtaining a Certificate of Approval.
New and emerging burner systems are entering the market designed to meet new
regulations in Canada and the US. It is important that these low-NOx technology choices
be provided with a minimal increase in cost over conventional systems and with a
minimal loss in efficiency. As over 40% of industrial natural gas is consumed in boilers,
these low NOx standards and the choice of technologies to meet them are expected to
have an increasing impact on the industrial natural gas market. For instance, the current
growth rate of industrial steam demand in the US is approximately 2% per year or 336
BCF per year. It is expected that low NOx boilers will capture a significant portion of that
market.
LOW NOX PROGRAM PLAN AND RESULTS
The following program plan was developed for the low NOx
technology area.
Workshops: To organize, on a fast track, the delivery of highly focused workshops to end-users
and gas utility representatives. The workshops were designed to cover the following elements:
1. Regional guidelines, policies and regulations for NOx emissions
2. Generic information on NOx formation, reduction and control technologies for large
commercial and industrial boilers over 10 MMBtu/hr.
3. Low NOx burner and boiler technologies
4. Boiler efficiency improvements for emission reduction
The goal was to hold one workshop in each member’s service territory. Members had the
choice to hold joint workshops.
Result: Over a two year period, the consortium developed the workshop outline, developed the
content with the assistance of Sunil Kumar of MacViro Consulting Inc.(subcontract), and held four
workshops at member company locations: Union Gas, Enbridge, NRCan (CANMET Energy
Technology Center), and DTE. The remaining members have opted not to hold a workshop in
their service territory. Workshop details are provided in Addendum A.
Develop Information Technology Products: To develop a website, CD-ROM, or
application guide that will serve as the “core technology information data base” for
consortium members and their customers. Its primary purpose will be to establish the
Energy Solutions Center and the consortium members as leaders in gathering and
disseminating information about the availability and effectiveness of low-NOx natural gas
burners and boilers in meeting regional energy and environmental requirements. The
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program will also develop a network of environmental and equipment specialists that can,
if needed, deliver the consortium’s information in a more customized format to specific
end-users.
Result: A comprehensive website was developed with the assistance of Bob Fegan of
DTE as an information tool for our commercial and industrial key accounts managers.
See www.CleanBoiler.org
The site has three main sections:

Vendors and Products

Sales Tools

Learn About (A comprehensive guide to low-NOx technologies)
The Sales Tool area includes links to flyers and brochures, case studies, work sheets,
manual and guides, and consortium materials reserved for members.
Network with Trade Allies: To coordinate consortium activities with DOE’s Office of
Industrial Technology, NRCan and groups such as CIBO and ABMA in disseminating
information on available technologies, case histories, and product information. This will
put the consortium in a position to further define new markets and influence purchasing
decisions.
Result: In an on-going effort, the Energy Solutions Center maintains a relationship with
ABMA, the US Department of Energy (DOE), and NRCan. Information is shared
between these parties and information links and e-mail notifications provide members
with the latest information on program initiatives such as the DOE Best Practices area
addressing steam generation.
Technology Assessments and Demonstrations: To obtain information, provide a
technical screening, and assess the market advantages and commercial readiness of
state-of-the-art low NOx burners that have been demonstrated at various customer sites.
The Center will work with manufacturers and consortium members to identify funding
opportunities for demonstrations in member service territories. Members may elect to
provide additional funding for demonstrations within their service territories.
Result: The consortium continues to track low NOx technology developments for boiler
systems including such new technologies as the FIR burner developed by GTI and the
manufacturing team effort to develop a super boiler which is currently funded by DOE.
On a regular basis, manufacturers have been asked to present their latest developments
as well as current product line at our Technology and Market Assessment Forums
(TMAF). These TMAF meetings are held three times a year. Consortium members
continue to monitor candidates for demonstration efforts and will advise the Energy
Solutions Center if a demonstration effort should be considered. It is expected that
additional funding will be required to support such an effort.
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BUDGET
It was anticipated that a budget level of $100,000 would meet the initial funding level
required to complete the low NOx program objectives. Seven member companies
provided commitments to participate in this consortium at a contribution level of $15,000
US.
The low-NOx program was completed under budget essentially because some members
elected not to hold a workshop in their service territory.
CONSORTIUM MEETINGS
The consortium meets regularly in conjuction with ESC TMAF to review program
progress and to plan and develop future activities.
FUTURE ACTIVITIES
Consortium members are reviewing a proposal to use the remaining funds to expand the
website content to include tools and information related to automation/controls, efficiency,
and compact boiler systems; and to maintain/refresh the website for a minimum of five
years.
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ADDENDUM A
WORKSHOPS
Workshop Content Development Outline
The following outline was submitted to MacViro as a guide in developing the content for the
regional low NOx workshops:
1. Regional low NOx Issues


Gather information on US and Canadian federal, state/provincial guidelines, policies and
regulations for NOx emissions for new and retrofit boilers having input capacities of greater
than 10 MMBtu/hr. This information will be gathered for each consortium member service
area as the issues will vary by region.
Identify and arrange speaker(s) to address the regional environmental issues. The local
consortium member will assist in identifying and arranging regional speaker(s).
2. NOx Formation and Reduction and Control Technologies


Develop generic training material on NOx formation and reduction and control technologies
for industrial boilers.
Present or arrange a speaker to present this information at the workshops.
3. Low NOx Burner and Boiler Technology





Contact leading equipment suppliers of low NOx package boilers and burners for industrial
boilers. Obtain technical literature. Some vendors to be contacted include: Alstom Power,
Coen, Johnston Boilers, Natcom, Peabody, TODD/John Zink, Cleaver-Brooks, Nebraska
boiler, B&W and Foster Wheeler. Available products shall be identified for three control
ranges. Less than 75 vppm NOx, less than 30 vppm NOx, and less than 10 vppm NOx.
Arrange vendor speakers for the workshop, in consultation with the sponsoring member
company.
Obtain technical information that would be presented at the workshop. This information may
vary by region as some regions have more stringent criteria than the others. The technology
information will be gathered to cover both retrofit and new installations.
Obtain case studies, preferably in member service areas.
Assemble technical information and presentation material that can be added as a training tool
to the Consortium web-site.
4. Boiler Efficiency Improvements


Work with the following organizations to gather materials that improve boiler efficiency and
that identify new trends in steam generation: DOE Steam Best Practices, ABMA and NRCan.
The intent is to add this information to the Consortium web-site.
Discuss the needs of each consortium member to cover this topic in their workshop, and
arrange speaker(s) accordingly.
5. Training Materials
 Provide electronic copies of all material for inclusion in the consortium website.
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The Union Gas Workshop.
Union Gas held a complimentary one-day work shop to provide information on low NOx boiler
systems, low NOx burners for boilers and boiler energy efficiency improvements on Wednesday,
November 13, 2002 in Cambridge, Ontario
WORKSHOP AGENDA
Morning
8:00
Registration Desk Opens
8:45
Welcome and Introduction
Program Chair
8:50
Opening Remarks
Union Gas Limited
8:55
Ontario Guidelines for NOx Emissions from Boilers
Tom Markowitz, Ontario Ministry of the Environment
9:25
NOx Fundamentals: Formation, Reduction, Control Techniques, Impact of Fuels
Martin Thomas, Research Engineer, Advanced
Combustion Technologies, Natural Resources Canada
10:05 Refreshment Break
10:20 Low NOx Solutions for Industrial Boiler Applications: Part One
William Testa, Director of North American Sales,
John Zink/Todd Combustion
11:10 Low NOx Solutions for Industrial Boiler Applications: Part Two
Normand Brais, Vice President Product Development
Cleaver Brooks/Natcom/Nebraska Boiler
12:00 Lunch
Afternoon
1:00
Low NOx Solutions for Industrial Boiler Applications: Part Three
Stephane Laurin, Sales Manager, Coen Canada
1:50
Emissions Trading Overview
Sunil Kumar, MacViro Consultants Inc.
2:15
Low NOx Solutions for Industrial Boiler Applications: Part Four
Ernie Smoker, Regional Sales Engineer
Peabody Engineering
3:05
Refreshment Break
3:20
Boiler Energy Efficiency: Opportunities and Case Studies
Aqeel Zaidi, Union Gas Limited
Dan Valente, Vexco Corporation
4:10 Concluding Remarks & Adjournment
The workshop was attended by 85 people. Ninety three per cent of the attendees rated the
overall value of the workshop at 4 or 5 out of a 5 point scale.
Enbridge Workshop.
Enbridge held a complimentary one-day work shop to provide information on low NOx boiler
systems, low NOx burners for boilers and boiler energy efficiency improvements on Thursday,
November14, 2002 in Richmond Hill, Ontario.
WORKSHOP AGENDA
8:00
Registration Desk Opens
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8:45
8:50
8:55
9:25
10:05
10:20
11:10
12:00
1:00
1:50
2:15
3:05
3:20
4:10
Welcome and Introduction – Program Chair
Opening Remarks – Enbridge
Ontario Guidelines for NOx Emissions from Boilers –
Tom Markowitz, Ontario Ministry of the Environment
NOx Fundamentals: Formation, Reduction, Control Techniques, Impact of Fuels
Martin Thomas, Research Engineer, Advanced Combustion Technologies,
Natural Resources Canada
Refreshment Break
Low NOx Solutions for Industrial Boiler Applications: Part 1
William Testa, Director of North American Sales,
John Zink/Todd Combustion
Low NOx Solutions for Industrial Boiler Applications: Part 2
Normand Brais, Vice President, Product Development,
Cleaver Brooks/Natcom/Nebraska
Lunch
Low NOx Solutions for Industrial Boiler Applications: Part 3
Stephane Laurin, Sales Manager, Coen Canada
Emissions Trading Overview
Sunil Kumar, MacViro Consultants Inc.
Low NOx Solutions for Industrial Boiler Applications: Part 4
Ernie Smoker, Regional Sales Engineer - Peabody Engineering
Refreshment Break
Boiler Energy Efficiency: DSM Programs, Opportunities and Case Studies
Bob Griffin, Industrial Energy Consultant, Enbridge Gas
Concluding Remarks and Adjournment
The workshop was attended by 79 people. Ninety two per cent of the attendees rated the overall
value of the workshop at 4 or 5 out of a 5 point scale.
NRCan Workshop.
The Federal Industrial Boiler Program (FIBP) of Natural Resources Canada provided a
complimentary one-day workshop to provide information on low NOx boiler systems, low NOx
burners for boilers and boiler energy efficiency improvements.
The workshop was held at the Delta Ottawa Hotel in downtown Ottawa on March 6, 2003. A total
of 103 people attended the meeting. An evaluation form was provided to all participants. Of those
who attended, 45 completed the evaluation form.
WORKSHOP AGENDA
8:30
8:35
8:40
Welcome and Introduction
Opening Remarks
NOx Fundamentals: Formation, Reduction, Control Techniques, Impact of Fuels
Martin Thomas, Research Engineer, Advanced Combustion Technologies,
Natural Resources Canada
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9:10
Guidelines for NOx Emissions from Boilers
Manfred Klein, Environment Canada
9:40 Low NOx Solutions for Boiler Applications – Part 1
Greg Meyer, Weishaupt Corporation
10:30 Refreshment Break
10:45 Emissions Trading Overview
Sunil Kumar, MacViro Consultants Inc.
11:05 Low NOx Solutions for Boiler Applications - Part 2
Dr. Normand Brais, Aqua-Chem/Cleaver Brooks
11:55 Lunch Break
1:00 Low NOx Solutions for Boiler Applications – Part 3
Stephane Laurin, Coen Canada
1:45 Boiler Energy Efficiency Opportunities – Overview
Bob Griffin, Industrial Energy Consultant, Enbridge Gas Distribution
2:35 Refreshment Break
2:50 Non-Destructive Testing of Boilers
André Faguy, Federal Industrial Boiler Program, Natural Resources Canada
3:10 Design of Efficient Heating Plants
Paul Dockrill, Federal Industrial Boiler Program, Natural Resources Canada
3:40 FBI Project Case Studies
John Brennan, Federal Buildings Initiative, Natural Resources Canada
4:10 Concluding Remarks and Adjournment
Overall Satisfaction with Workshop
Overall, participants were satisfied with the workshop, with 91% of participants scoring very
satisfied (62%) or satisfied (29%) and no scoring dissatisfied or very dissatisfied.
DTE Boiler Workshop.
The workshop was added as a separate track to the DTE Customer Meeting held on February
18th, 2004 in Livonia (NW Detroit). Pre-registered attendance was about 225, not including DTE
staff, vendors and exhibitors. Attendance in the Boiler Track break-out sessions averaged about
30. Between each break-out session DTE scheduled open exhibition time where vendors had the
opportunity to speak to everyone at the meeting. There were two other presentation tracks and
about 60 exhibitors.
The Boiler Track program included the following speakers:
Session 1:
Mark Utzinger - Miura Boiler
John Foss - Cleaver-Brooks
Session 2:
Chad Forester - Clayton Industries
Kim Black - Johnston Boiler
Session 3:
Greg Merlo - Merlo Steam
Allen - Ceramic Insulation Systems (assisted in Merlo presentation.
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Training Materials
The boiler burner website www.CleanBoiler.org contains a comprehensive learning module based
on the material developed for the workshops. This training material can be accessed through the
following link:
http://www.cleanboiler.org/Workshop/BoilerFrameSet.htm
Visitors to the site can access the following information sites:
Combustion Basics
Vendor Technologies
What is NOx?
Boilers
How is NOx Formed?
Burners
Boiler Types
Boiler and Steam Improvement Opportunities
Uncontrolled Emission Rates
Glossary of Terms
Reduction and Control Technologies
Conversion Factors and Calculators
Comparison of NOx for Various Fuels
Workshop Presentations
NOx Control Regulations for Boilers
A Boiler Primer
Emissions Trading
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