90% efficiency without boiler replacement
TRANSCRIPT
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90% Efficiency without Boiler Replacement
T R U E G R E E N S O L U T I O N S
Patent Pending
NEW
3911
007
EcoFlex 90+ System Modulating
Fan-Powered Economizer
EcoFlex90+ System– Because They Are Your Btus
System Components
The unique design of the EcoFlex90+ System makes is very easy to service if necessary. The entire drive unit (motor, impeller and mounting) can be removed without removing the fan unit. The same goes for the heat recovery unit, which can slide out of the housing after removing the eight bolts holding the access panel in place.
IPVB-ECO – Fan-Powered EconomizerThe main system component is a true inline boiler draft fan with an integrated, small footprint heat recovery module. The fan is built in stainless steel so it can be used with any type of conden-sing our non-condensing heating appliance. The variable speed motor assures that the air flow through the economizer is always optimal while the draft maintained at the boiler outlet guarantees perfect operating conditions.
The radiator style finned tube heating coil is built into a housing made of stainless steel. The housing has an access door through which the heat recovery unit can slide in and out for easy service or maintenance. Flexible tubes makes this really easy.
The coils are available with copper tubing and copper fins as well as 316 stainless steel with stainless steel fins.
EBC35 Draft and CO Safety ControllerThis controller monitors the boiler draft and automatically mo-dulates the fan speed so the boilers experience perfect draft no matter the load. This control alone can improve a boiler system’s efficiency with a few percentages. In addition, the control’s safety functions make sure the boiler system shuts down in case of fan or economizer failure as required by code.
The single point control can also send and receive a variable signal for a variable speed pump. If desired the controller can coordinate the flow of water based on the temperature of the water passing through the economizer. This coordination allows for a much tigh-ter and consistent delta tee, which means the load can be shed more reliably and utilized more effectively.
EcoFlex 90+ System - a packaged modulating fan-powered economizer – may be the single design that combats all the chal-lenges in the typical economizer. It opens the energy recovery up to practically any combustion appliance application.
With the EcoFlex 90+ System the designer can now view the application as a complete “boiler plant” as the full load to work with, instead of one economizer per boiler. And the “boiler plant” can consist of a combination of boiler types such as forced draft boilers and atmospheric water heaters that utilize a single modulating demand-controlled economizer.
And what is even better – all boilers will always have the perfect draft conditions due to the variable speed boiler fan controlled by a modulating fan controller.
The bottom line is: Design flexibility, reduced emissions, improved boiler efficiency, high return on investment.
• Single EcoFlex90+ for multiple boilers
• For atmospheric, fan-assisted, and forced draft boiler – or any combination!
• Always perfect boiler draft conditions
• Variable or constant water flow
• Easy upgrade, fast payback!
ModulatingController
Fan Powered Economizer
The EcoFlex90+ System concept is a huge leap forward for the energy and cost conscious engineer and building owner. It is possible to install the heat recovery unit in virtually any boiler system – new installation or retrofit, single or multiple appliances, modulating or on-off boilers, condensing or non-condensing boilers.
System consisting of multiple atmo-spheric water heaters. The EcoFlex 90+ System is installed inline in the vertical section – but could also have been installed in the horizontal section.
System consisting of multiple atmospheric water heaters. The EcoFlex 90+ System is installed inline in the horizontal section allowing the system to be sidewall vented and save space and venting material
System consisting of an existing forced draft boiler and an atmospheric water heater. The EcoFlex 90+ System is installed inline in the common horizon-tal section – but could also have been installed in the vertical section.
System consisting of multiple forced draft boilers. The EcoFlex 90+ System is installed inline in the common vertical section – but could also have been installed in the horizontal section and it could have been sidewall vented.
Individual economizers are less cost-effective
Most economizers serve a single boiler. If only one boiler and economizer is operating, other economizer used for lead-lag or redundancy can’t provide any savings which has a major effect on the return of the investment. The lack of a modu-lating fan also makes the system more prone to operating in-effiencies and operating problems.
Any way You Want it!
Solutions for By-passFor applications where a by-pass is required, the chimney flue can be split into two sepa-rate vertical sections as shown. The control will use the dampers to direct the flow in the right direction based on whether by-pass is necessary or not.
Energy and Operating Savings – Ultra Short Payback with Great ROI!
There are many ways of taking advantage of the EcoFlex 90+ System’s ability to recover energy, save installation cost, and reduce emissions. Below are examples of possible savings.
The two typical system examples both consist of 2 x 1,500MBH and 2 x 750MBH atmospheric boilers – 2 with draft hoods and 2 with barometric dampers. The systems operate 4,000 hours per year – 600 hrs at full capacity, 2,000 hrs at 50% capacity and 1,400 hrs at 25% capacity.
This example shows a new installation that integrates an EcoFlex 90+ System. The venting system is down-sized with a substantially reduced diameter which is made possible by the IPVB-ECO fan is installedin the horizontal stack section. The installation cost is limited to the reduced cost of acquiring and installing the venting system of a reduced diameter, the EcoFlex 90+ System, and connect necessary piping. In this example the overall system installation costs are estimated to $20,000.
System Varying Load Full Load (40% average)Fuel Type Natural GasLoad 4,000 hrs/year 8,760 hrs/yearBurner Input 4,500MBHExhaust Flow Rate 1952 CFMExhaust Temp In 307 degF Exhaust Temp Out 140 degFWater Flow Rate 20 GPMWater Temp In 100 degFWater Temp Out 115 degFTotal Heat recovered 236,463 Btu/hr Heat Saved 282,466 Btu/hr (0.80357 therm)
The net savings are estimated to (at $0.80 per Therm):
Varying Load Full Load
Overall system cost Including chimney flue $20,000 Savings
Annual savings less Fan power consumption $4,519 $24,744
Payback 4.4 years 0.8 years
This example shows a retrofit installation of an EcoFlex 90+ System. The original venting system is maintained and the IPVB-ECO fan is installed in the vertical stack section. The installation cost is limited to the cost of acquiring and installing the EcoFlex 90+ System and connect necessary piping. In this example the overall system installation costs are estimated to $30,000.
System Varying Load Full Load (40% average)Fuel Type Natural GasLoad 4,000 hrs/year 8,760 hrs/yearBurner Input 4,500MBHExhaust Flow Rate 1952 CFMExhaust Temp In 307 degF Exhaust Temp Out 140 degFWater Flow Rate 20 GPMWater Temp In 100 degFWater Temp Out 115 degFTotal Heat recovered 236,463 Btu/hr Heat Saved 282,466 Btu/hr (0.80357 therm)
The net savings are estimated to (at $0.80 per Therm):
Varying Load Full Load
Overall system cost $30,000
Annual savings less Fan power consumption $4,519 $24,744
Payback 6.6 years 1.2 years
Retrofitting the EcoFlex90+ System
New Boiler and Chimney Installation Incorporating the EcoFlex 90+ System
Less than 2 years
Payback!
Less than 1 years
Payback!
EcoFlex90+ System Performance.....
The following tables are examples of the EcoFlex 90+ System’s perfor-mance when used with Natural Gas. The tables below are based on a boiler system with a nominal effiency of 86%, a flue gas temperature at the economizer inlet of 290°F and a water flow of 20 GPM. How to read:
1) Determine your max. exhaust air flow (ACFM) from your system’s max. Btu input, 2) go to the red (copper) or blue (Steel) curve to read the corresponding boiler system efficiency (left) after the EcoFlex 90+ System is added, 3) read the corresponding energy recovered (right) and 4) based on the area limited by the dashed lines, select the EcoFlex system size shown at the top header.
0 1000 2000 3000 4000 ACFM
93
92
91
90
89
88
Air Flow
Eff
icie
nc
y
500
400
300
200
100
0
En
erg
y R
ec
ov
ere
d
EcoFlex (Copper)
350 400 500
104°130°155°180°
104°
130°
155°
180°
180°
180°
180°
180°121°
140°
160°
121°
140°
160°
104°
130°
155°
155°
130°
104°
MB
TU
%
kW
0 500 1000 1500 2000 L/S
125
100
75
50
25
0
EcoFlex (Copper)
620-7
58°
100°
140°
180°
58°
100°
140°
180°
2000 4000 6000 8000 10000 ACFM
92
91
90
89
88
87
Air Flow
Eff
icie
ncy
1000
800
600
400
200
0
En
erg
y R
eco
vere
d
MB
TU
%
kW
1000 2000 3000 4000 5000 L/S
250
200
150
100
50
0
EcoFlex (Stainless Steel)
350 400 500
40°
100°
40°
70°
100°
130°
40°
60°
80°
100°
70°
130°
40°
100°
70°
130°
40°
100°
70°
130°
40°
60°
80°
100°
0 1000 2000 3000 4000 ACFM
93
92
91
90
89
88
Air Flow
Eff
icie
nc
y
500
400
300
200
100
0
En
erg
y R
ec
ov
ere
d
MB
TU
%
kW
0 500 1000 1500 2000 L/S
125
100
75
50
25
0
EcoFlex (Stainless Steel)
620-7
40°
60°
80°
100°
40°
60°
80°
100°
2000 4000 6000 8000 10000 ACFM
92
91
90
89
88
87
Air Flow
Eff
icie
nc
y
%
1000 2000 3000 4000 5000 L/S
1000
800
600
400
200
0
En
erg
y R
ec
ov
ere
d
MB
TU
kW
250
200
150
100
50
0
ENERVEX Inc.1200 Northmeadow Pkwy.Suite 180Roswell, GA 30076USA
P: 770.587.3238F: 770.587.4731T: [email protected]
ENERVEX Inc.1200 Northmeadow Pkwy.Suite 180Roswell, GA 30076USA
P: 770.587.3238F: 770.587.4731T: [email protected]
V E N T I N G D E S I G N S O L U T I O N S
V E N T I N G D E S I G N S O L U T I O N S
V E N T I N G D E S I G N S O L U T I O N S
V E N T I N G D E S I G N S O L U T I O N S
V E N T I N G D E S I G N S O L U T I O N S
ENERVEX Inc. , P: 770.587.3238, T: 800.255.2923, www.enervex.com
P: 770.587.3238, T: 800.255.2923, www.enervex.com
Visit: www.enervex.com
®
Warranty2 year factory warranty 10 year warranty against corrosion perforation.
Contact ENERVEXNext time you design a boiler or water heater system for a project, contact us for a non-binding venting design proposal. In most cases we can offer you a better and less expensive solution.
Made By Experience ENERVEX combines quality components, superior technology and experienced personnel to deliver a system that is economical environmentally sustainable, aesthetically pleasing and reliable. Our custom engineering and space saving designs ensure that the project meets code requirements, as well as the high standards of today’s architects, engineers and contractors. We don’t build a one-size-fits-all draft system - we understand each project is unique.
The diagrams below show some of the typical applications where the EcoFlex 90+ System can be utilized:
System Examples
CW In
HW In
ECOFLEX 90+
CW In
ECOFLEX 90+
CW In
ECOFLEX 90+
Feedwater TankCW In
ECOFLEX 90+
To Existing Boiler Feed System
Feed-water Tank
BOILER
BOILER
BOILER
BOILER
Preheating Hot Water Return Preheating Boiler Make Up Water
Preheating Steam Boiler Feedwater Preheating Circulating Make Up Water
Valve ValveValveValve
Pump ThermometerGate Valve Pressure relief valve
3911
007
EcoFlex 90+ System Modulating
Fan-Powered Economizer