Hybrid Boiler Solution Saves Biopharma Company 30% in Fuel Costs

Just a few short years after a large biopharmaceutical company in the San Francisco Bay Area installed new flextube boilers in several of its buildings, the Bay Area Air Quality Management District (BAAQMD) issued more rigorous regulations. BAAQMD lowered the allowed flue gas temperature for boilers, decreased the level of NOx emissions permitted, and imposed regulations on small boilers ranging in size from 2,000 - 5,000 MBTU/hr.

 

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Challenge:

Even though the flextube boilers were new, company management had to decide on a course of action to meet the new regulations. They could install heat recovery units on the boiler exhaust systems to meet the flue gas temperature requirement and change to an electronic combustion control system from the current mechanical linkage system, as well as replace their existing burners with low NOx units. Or, they could purchase new, low emissions boiler systems.

Solution:

The company decided to replace half of its flextube boilers with equivalent-capacity, condensing boilers even though the flextube boilers were new. Initially, nine ClearFire boilers were installed in four research buildings on campus. Installing multiple condensing boilers improved system turndown capability while adding maintenance redundancy, which was also appealing to the management team.

In each of the buildings, the company was allowed to keep one of its existing flextube boilers. A hybrid boiler system management control was also incorporated to ensure coordinated control of condensing and non-condensing boilers for maximum operational efficiency. 

Results:

The boiler systems outperformed expectations, saving the company more than 30% in fuel costs. The company's energy savings for one building alone was more than $90,000 the first year, and it will recognize a ROI for the equipment investment and installation costs in less than two years. In addition, the company is taking advantage of an incentive from its local utility that has enabled it to double its energy savings. 

Company management is pleased with the performance of the ClearFire condensing boilers and control system and has purchased additional ClearFire boilers and controls to install in other buildings on campus.

ClearFire boilers

The company's energy savings for one building alone was more than $90,000 the first year, and it will recognize a ROI for the equipment investment and installation costs in less than two years.

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