The home heating oil industry has a long and proud history, and Fuel Oil News has been there supporting it since 1935. It is an industry that has faced many challenges during that time. In its 77th year, Fuel Oil News is doing more than just holding
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38 MARCH 2016 | FUEL OIL NEWS | www.fueloilnews.com C ontractors, architects, engineers and others who specify com- mercial and industrial boilers continually seek systems that are more cost-effective, energy efficient and environmentally- friendly. The boiler industry has responded by making significant advances in both construction and design, with new systems offering greater efficiencies, cutting-edge technologies, advanced controls and the ability to integrate with renewable energy. Condensing Boilers Gain Momentum The boiler market has been slowly shifting from standard, non- condensing boilers to more efficient condensing units over the last couple of decades. Reasons for the switch to condensing technology include a desire for operating efficiencies that result in lower operat- ing costs, increased awareness of energy-efficient products and the growing number of governmental policies and incentive programs. Energy-efficient condensing boilers first appeared in the U.S. market in the late 1990's and their sales have grown exponentially. The movement accelerated when the energy crisis several years ago spiked fuel costs. The shift toward green building design and LEED certifications for installing high-efficiency equipment has also driven the trend Many predicted that condensing boilers would make up half of the market by 2016, but the trend has been slower than antici- pated. North American economies are not growing as quickly as anticipated, making it more difficult for some businesses and homeowners to approve pricier technology. Additionally, federal rebates, which play a major role in encouraging installation of condensing technology, are no lon- ger available, though state and local municipalities offer rebates. Though the market today is still dominated by cast iron non- condensing boilers—which make up about 60% of installations—it's likely that condensing boilers will continue to experience growth and play an even larger role in the hydronic heating industry by 2017. Efficiencies Drive Purchases With an operating life measured in decades, purchasing a new or replacement condensing or non-condensing boiler is a significant decision. Most specifying engineers today seek the most energy- efficient heating design. Since September 2012, the minimum boiler efficiency require- ment or AFUE in the United States is 82% for gas hot water boilers and 84% for oil hot water boilers. Some jurisdictions in the U.S. have building or energy codes that require the reporting of the efficiency ratings of boilers and other heating products. Standard efficiency is anything below 90% annual fuel utiliza- tion efficiency while more than 90% is considered high efficiency. To reach levels above 90%, specifiers should consider installing a condensing boiler, as these units offer the greatest thermal efficien- cies. Typical aluminum or stainless steel condensing models offer efficiencies greater than 90% AFUE. A condensing boiler extracts additional heat from the exhaust gases by condensing its hot water vapor to liquid water, thus recovering its latent heat of vaporization. By capturing some of the waste heat, the condensing boiler heat exchanger can be up to 10% more efficient than a conventional boiler operating in the proper conditions. Some boiler manufacturers currently add a secondary heat exchanger or recuperator to improve the efficiency of conven- tional, non-condensing boilers. In this case, a secondary heat exchanger recovers the latent exhaust heat from the flue gases, condensing water vapor in the process. In theory, you can increase the efficiency of a standard cast iron boiler by up to 10% to achieve higher efficiencies, lower energy costs and qualify for utility rebates. Maintaining optimum boiler efficiency is critical to minimizing carbon dioxide emissions, conserving fuel resources and lowering building operating costs. Advanced Controls Spur Growth Boiler manufacturers are re-gaining HVAC market shares by offer- ing systems with more powerful and advanced controls. Condensing boilers feature significant advancements in ease of installation and controls when compared to traditional non-condensing boilers. Multiple preset systems are another popular new boiler control feature. These units feature pre-set heating systems for typical operating conditions built into the controller so installers don't have to enter specific supply or return temperatures during instal- lation. The contractor only inputs the specific application—such as radiant heat, snow removal or domestic hot water—which reduces installation costs and time while increasing reliability. In addition to ease of installation, condensing boilers feature significant advancements in boiler control that include remote control and diagnostics, boiler-to-boiler communications, modu- lating from maximum input to minimum input, rotating lead lag and integration with building automation systems. Facility managers want immediate access and control of a mechanical room no matter the location. Boilers today can be controlled through an iPhone and Android phone, computers and tablets and other devices, allowing an operator to change and optimize settings, review alarms and adjust parameters to changes in weather. Many schools, churches and hospitals, have multiple boiler setups for reliability. Other facilities have installed or retrofit- ted to multiple, modular boilers for various reasons like cost or space restrictions. In this case, installation of an intelligent boiler sequence control can provide significant energy savings. Modern condensing boilers also have the ability to communicate with building automation systems. By: John Kopf Senior Product Manager, Weil-McLain ADVANCES IN BOILER CONSTRUCTION AND DESIGN