Ashrae Condensing Technology

CONDENSING BOILER TECHNOLOGY
Presented by:
Jim Cooke
Mechanical Solutions NW
1125 Andover Park W. Bldg. D
Seattle, WA 98188
Email: jim@msinw.com
Foil 1
Ashrae Presentation Nov 2005
What is condensing boiler
technology?
Foil 2
CONVENTIONAL BOILER TECHNOLOGY
Non-condensing construction
Fin tube boiler Cast-iron sectional boiler

Foil 3
ENERGY CONTENT OF NATURAL GAS
LATENT HEAT
10.2%
SENSIBLE HEAT
89.8%
Latent – Definition:
Latin for “hidden”
Heat that can be measured or

felt by a change in temperature
Foil 4
NATURAL GAS COMBUSTION
Carbon Dioxide
Natural - CO2
gas
CH4
Combustion Water vapor
N N N N N N N N
Oxygen
N N N N N N N N
N N N N N N N N Nitrogen
N N N N N N N N +
Nitrogen Oxides
Nitrogen Light
Air Heat
Foil 5
CONVENTIONAL BOILER HEAT FLOW
Fuel input = 100 %
Latent Heat
10.2 %
Sensible heat
=89.8%
Up chimney Flue gas loss = 3 to 5 %
Up chimney
Latent Heat
Heat Loss Boiler stand-by and
jacket loss =3 to 5 %
= 10.2 %
Into
mechanical
Seasonal
efficiency of
room
conventional
Boilers
=80%+
Foil 6
Ashrae Presentation
Useful heat Nov 2005
Latent heat + Flue gas losses
=15%
CONVENTIONAL
BOILER HEAT FLOW
Useful
heat
80%
Fuel Boiler stand-

input Boiler by and jacket
=100 % loss =5% Foil 7
HEAT RECOVERY FROM FLUE GASES
Water vapor (steam)

containing latent
heat
How do we
capture the
latent heat?
 Simplified Chemical Combustion Formula:

CH4 + 2 O2 CO2 +2 H2O
Foil 8
LATENT HEAT RECOVERY
Energy
released
WATER
VAPOR LIQUID
 Water vapor turns to liquid when

it is reduced in temperature.
 Energy is released when vapor
turns to liquid
Foil 9
LATENT HEAT RECOVERY
1 pound of water
Water vaporizing
(Latent heat of Steam
condensation)
970 Btus
Ice melting
(Latent heat of fusion)
Ice 144 Btus
Foil 10
WATER VAPOR DEW POINT
oF o
C Natural Gas (95% CH4)
140 60
131 55  Water vapor

Dew point water vapor
condenses below
122 50
the dew point
113 45 temperature
104 40
 CO2 % of flue gas
influences dew
95 35 point temperature
86 30
77 25
2 3 4 5 6 7 8 9 10 11 12
Foil 11
Ashrae Presentation CO2 in Vol % Nov 2005
CONDENSING BOILER HEAT FLOW
Fuel input = 100 %
Latent Heat
10.2 %
Sensible heat
=89.8%
Latent Heat
Heat Loss < 2 % Flue gas loss < 1 %
Seasonal
efficiency of Boiler stand-by
conventional and jacket loss< 1%
boilers
=82%+
Seasonal
efficiency
condensing
boilers=
96%+
Foil 12
Latent heat + Flue gas losses
=3%
CONDENSING
BOILER HEAT FLOW
Useful
96% heat
Fuel Boiler stand-

input Boiler by and jacket
=100 % loss =1% Foil 13
EFFICIENCY INCREASES DUE
TO FLUE GAS CONDENSATION
Combines the following:
1. Additional latent heat gain from condensate
2. Lower flue gas loss:

 The flue gas temperature is lower because the
sensible and latent heat is almost completely
transferred to the boiler water
3. Lower radiant standby losses:

 Due to lower boiler water temperatures
Foil 14
Why use condensing boiler
technology?
Foil 15
Gas-fired TYPICAL
condensing BOILER
boiler EFFICIENCIES
Old constant
Efficiency in %
temperature
ON/OFF boiler
Boiler capacity in % Foil 16

Nov 2005
Ashrae Presentation
MORE USABLE HEAT THROUGH
CONDENSATION
Condensing boiler
Total Heating
heating Sensible heat Useable
heat system
value
Condensation
Latent
heat What influences
the rate of
condensation?
Foil 17
FACTORS INFLUENCING EFFECTIVENESS
OF CONDENSING TECHNOLOGY
Burner
Fuel
type
Effective
Heating use of Piping
system condensing layout
technology
Govt Return
regula- water
tion temp Foil 18
Effective
Heating use of
system condensing
technology
Return
water
Ashrae Presentation temp Foil 19
Nov 2005
SIMPLIFIED CONDENSING BOILER
OPERATION
98
96
Dew Point
Steady state boiler efficiency %
94 of Natural Gas
92
90
88
86
Condensing Non-Condensing
84 mode mode
82
80
60 80 100 120 140 160 180 200
Foil 20
Ashrae Presentation Boiler return water temp oF Nov 2005
RETURN WATER TEMPERATURE
Boiler return water

temperature determines Foil 21
Ashrae Presentation condensing operation Nov 2005
TYPICAL HYDRONIC WATER
TEMPERATURE REQUIREMENTS:
High temperature:
 Finned tube baseboard 140 - 190 oF
 Air heat fancoils 140 - 180 oF High-temperature RFH
under wood sub-floor
 Pool/spa heat exchangers 160 - 180 oF 70oF-150oF
 DHW production 150 - 190 oF
Medium temperature:
 Cast iron radiators 100 - 140 oF
 Low mass radiant floor
ie: wood joist floors 100 -150 oF
Low temperature:
 High mass radiant floor
ie: concrete floors 80 - 120 oF
 Snowmelting systems 80 - 120 oF Foil 22
HYDRONIC WATER TEMPERATURES
oF oC
Boiler water
195 90
temperature
maintained
Boiler Water Temperature
176 80 Traditional
167 75
On/off control boilers must
158 70 be kept hot
140oF
60 Dew point
133
Natural gas
50
117
104 40
Boiler water
86 30 temperature
modulated
72 22
+20 +10 0 -10 -20 oC
+65 +50 32 +14 -4 oF
Foil 23
Ashrae Presentation Outside Temperature Nov 2005
IMPACT OF SYSTEM TEMPERATURES
ON CONDENSATION
Example 1: Supply/return temperature:
90/70oC, 194/158oF Fin tube
oF oC
90oC/194oF
194 90 Condensation range
176 80
System water temperature
70oC/158oF
158 70
140 60 Dewpoint temp

57oC/135oF
122 50
104 40
86 30 -2.5oC 25.5oF
68 20
15 10 5 0 -5 -10 -15 oC
20
59 50 41 32 23 14 5 oF
68
Outside temperature Foil 24
ON CONDENSATION
75/60oC, 167/140oF Hydro-Air
oF oC Radiators
194 90
176 80 Condensation range 75oC/167oF

158 70
60oC/140oF
140 60 Dewpoint temp 57oC/135oF
122 50
104 40
86 30 -11.5oC 11.3oF
68 20
15 10 5 0 -5 -10 -15 oC
20
59 50 41 32 23 14 5 oF
68
Outside temperature Foil 25
ON CONDENSATION
40/30oC, 104/86oF Radiant floor
oF oC
158 70
Condensation range
140 60 Dewpoint temperature (natural gas 57oC/135oF)
122 50
40oC/104oF
104 40
30oC/86oF
86 30
68 20
20 15 10 5 0 -5 -10 -15 oC
68 59 50 41 32 23 14 5 oF
Foil 26
Outside temperature
CONDENSING / NON CONDENSING RATIO
ASHRAE weather data for Boston, MA
oF
Design temperature
176 Condensation range Boston: +7oF
158 2258 hr Supply 160oF

36.5%
Return 140oF
140
135 Dewpoint temp
1675 hr
1497 hr 27%
122
24.3%
Ashrae weather
104 data, hours of
occurrence:
Sept - May
86 627 hr
10% 124 hrs
11 hrs
2%
72 0.2%
+68 +54 +41 +28 +14 0 -13 oF
97% 3%
Ashrae Presentation
Condensing Non-condensing Foil 27
Nov 2005
CONDENSING / NON CONDENSING RATIO
ASHRAE weather data for Boston, MA
Design temperature
Boston: +7oF
oF Condensation
176 range Supply 180oF
158 2258 hr Return 160oF

36.5%
140
135
1675 hr
Dewpoint temp
1497 hr 27%
122
24.3%
Ashrae weather
104 data, hours of
occurrence:
Sept - May
86 627 hr
10% 124 hrs
2% 11 hrs
72 0.2%
+68 +54 +41 +28 +14 0 -13 oF
75% 25% Foil 28

Ashrae Presentation Condensing Non-condensing Nov 2005
SYSTEM WATER TEMPERATURE DROP
180oF
What about
Typical a
system
higher temperature
20oF Temperature
drop?
drop
30oF……40oF?
160oF
150
Foil 29
TRUE SYSTEM EFFICIENCY
System Components
Fan coil sizing 180OF
Air flow
160OF
Same BTU’s
delivered
140OF
Air flow
120OF
Foil 30
ANNUAL FUEL UTILIZATION EFFICIENCY
For residential boilers < 300 MBH
Heated,
humidified
O2%, space, max
Vent CO ppm Measured 90oF, 80% RH
Damper Tflue gas in test:
Tair
Jacket Cold Water in
losses
considered 140oF Constant
to be zero
Boiler load
Air Input 120oF Heat
exchanger
Fuel Input Hot Water out
Condensate measured for

condensing boilers test Foil 31
COMBUSTION EFFICIENCY
Testing for non-condensing gas commercial boilers
ANSI Z21.13 / CSA 4.9-2000
∆T=100°F
CO2%
Tflue gas
Constant
Tair load
180oF
Boiler
Heat
Air Input 80oF exchanger
Fuel Input
Condensate measured for Foil 32

Ashrae Presentation condensing boilers test Nov 2005
Burner
type
Effective
use of
condensing
technology
Foil 33
WATER VAPOR DEW POINT
oF o
C Natural Gas (95% CH4)
140 60
CO2% of flue gas

131 55
influences dew point
Dew point water vapor
122 50
temperature
Higher CO2
113 45
=Higher Dew point
=More Condensation
104 40
95 35
Lower CO2
86 30 =Lower Dew point
=Less Condensation
77 25
2 3 4 5 6 7 8 9 10 11 12
Foil 34
Ashrae Presentation CO2 in Vol % Nov 2005
What influences the CO2% ?
THE BURNER!
Foil 35
Excess air
1 part gas
10 parts air
Foil 36
Atmospheric Burner technology
60% Excess Air

6% CO2
8% O2
Gas
Air
Foil 37
Power-fired burner technology
25% Excess Air

9.5% CO2
4% O2
Air
Ashrae Presentation
Gas Foil 38
Nov 2005
BURNER REQUIREMENTS FOR
CONDENSING BOILERS
 Combustion with minimal excess air
 CO2: 9.5 to 10%
 Excess air: 20 – 25%
 Fully modulating input
 Precise calibration thru entire firing range
 Low NOx and CO emissions
Foil 39
DEW POINT AND ALTITUDE
Fo Dew Point of Natural Gas Co

Based on 1000 btu/ft3, 50% RH and 60oF Room Air
140 60
138 58.8
Dew Point Temperature
136 57.7
134 56.6
132 10.3 55.5
% CO
130 2
54.4
128 53.3
126 8% C 52.2
O2
124 51.1
122 50
120
0 1000 2000 3000 4000 5000 6000 7000 8000 9000
Altitude – Feet above sea level
Foil 40
FACTORS INFLUENCING
EFFECTIVENESS OF CONDENSING
TECHNOLOGY
Effective
use of Piping
condensing layout
technology
Foil 41
USE OF MIXING VALVES WITH
CONDENSING BOILERS
4-way
mixing 3-way
valve mixing
valve
Boiler return water No boiler return water

temperature elevation temperature elevation
INCORRECT CORRECT
Foil 42
CONDENSING BOILERS IN TWO
TEMPERATURE SYSTEMS
High temp system
Low
temp
system
Foil 43
CONDENSING BOILERS IN HIGH
FLOW SYSTEMS
High temp system
Hydraulic
system
decoupling
Low
temp
system
Foil 44
INJECTION PUMPING WITH
CONDENSING BOILERS
INCORRECT
Foil 45
COMBINATION OF BOILERS
System System
Supply Return
Boiler
Non-Condensing boiler Condensing boiler

LAG BOILER LEAD BOILER
Foil 46
MULTIPLE FUNCTION, MULTIPLE
TEMPERATURE SYSTEM
Indirect High Temp Low Temp
DHW Heating - Fan coil Heating - RFH
tank
M M
3 way M
mixing
valve
Boiler
System Foil 47
Ashrae Presentation water fill Nov 2005
Construction requirements of
condensing boiler technology
Foil 48
PHYSICAL REQUIREMENTS OF THE
HEAT EXCHANGER SURFACES
Best material for

Flue condensing
Gas boilers:
194oF  Single wall
 Highly conductive
158oF
 Smooth surface
131oF
Dew Point
Boiler Natural gas
Water 122oF
122oF
Heat Flow
Condensate
formation Foil 49
PHYSICAL REQUIREMENTS OF THE FLUE
GAS AND CONDENSATE PASSAGE WAYS
Flue gas
Boiler Water
Boiler Water
Flue gas and
condensate must
Condensate
Condensate
flow in the same

direction (parallel
flow)
Flue gas
CORRECT INCORRECT Foil 50

CONDENSING BOILER CONSTRUCTION
Condensing HS Condensing boiler

boiler
requirements:
Hot Flue gas
 Counterflow principle
for flue gas and boiler
HR water – optimal heat
transfer
HR
Flue gas  Parallel flow direction
for flue gas and
Normal HS condensate – uniform
heating boiler flow with self-cleaning
effect of heat transfer
surfaces
HR
Foil 51
HEAT EXCHANGER CONSTRUCTION
Why is material
construction of the
boiler heat exchanger
so important?
Foil 52
pH VALUES OF VARIOUS FLUIDS
Flue gas Typical household

condensate sewage
Oil Gas
0 1 2 3 4 5 6 7 8 9 10 11 12
pH-Value
Acidic Basic
0 1 2 3 4 5 6 7 8 9 10 11 12
Battery acid Vinegar Clean rain
water Tap
Gastric acid water
Ammonia
Lemon Lake
juice Rain Distilled water
water water
(neutral)
Foil 53
MATERIAL REQUIREMENTS FOR
CONDENSING BOILERS
 Highly corrosion
resistant
 High strength with thin
wall thickness
 Formable
 Long term reliability
Foil 54
FINNED TUBE HEAT EXCHANGERS
New aluminum fin

heat exchanger
surface
Same heat exchanger

surface after short term
use
Foil 55
CONDENSATE DISPOSAL
How much condensate will

be produced?
What do we do with it?
Foil 56
Components Drinking Water Wine Vertomat
Tested Limits 05 - 89
DIN-DVGW Test
mg/ltr. mg/ltr. mg/ltr.
Lead 0.04 0.1 - 0.3 < 0.01 Comparison

Cadmium 0.005 0.001 < 0.005 of condensate
Chrome 0.05 0.06 - 0.03 < 0.01
components
Copper 3.0* 0.5 < 0.01
Nickel 0.05 0.05 - 0.03 < 0.01
Mercury 0.001 0.00005 < 0.0001
Vanadium - 0.26 - 0.06 not determined
Zinc 5.0* 3.5 - 0.5 < 0.05
Tin - 0.7 - 0.01 < 0.05
Sulphate 240 5 - 10 4.6
pH Value 6.5 - 9.5 3-4 3.5 - 5

(at 1.9 - 07 g/ltr. Without
Foil 57
tartaric acid) neutralization
CONDENSATE FLOW RATE
Amount of condensate
Flue gas temperature

Ashrae Presentation
Boiler return water temperature Foil 58
Nov 2005
CONDENSATE FLOW RATE
124,000
btuh 104F
boiler (at supply
full firing
rate)
22 86F
USG/day return
Foil 59
CONDENSATE DISPOSAL
 Plastic pipe (CPVC,

ABS, PEX) sloped
towards drain
M  NO Copper!
 P trap required
pH 3-4
To floor drain, or
condensate pump
Foil 60
CONDENSATE NEUTRALIZATION
 Neutralization unit
 Filled with granular
neutralizing material
M
pH 7-8
To floor drain, or
condensate pump
Foil 61
CONSTRUCTIVE AND PHYSICAL
REQUIREMENTS FOR CONDENSING
BOILERS
 Combustion with minimal excess air (high CO2)
 Fully modulating burner
 Low heat exchanger surface temperatures
 Parallel flow of flue gas and condensate
 Counter-flow of flue gas and heating water
 Highly corrosion resistant material

Foil 62
SYSTEM DESIGN REQUIREMENTS FOR
CONDENSING BOILERS
 Low temperature heat release surfaces
 Modulate water temperatures with outdoor

reset controls
 Higher system water temperature drops
 Piping layouts to reduce boiler return water

temperatures
Foil 63
THANK-YOU
Jim Cooke
Mechanical Solutions NW
1125 Andover Park W. Bldg. D
Seattle, WA 98188
E-mail: jim@msinw.com
Foil 64

Ashrae Condensing Technology

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CONDENSING BOILER TECHNOLOGY

Fin tube boiler Cast-iron sectional boiler

Heat that can be measured or

Combustion Water vapor

Fuel Boiler stand-

Water vapor (steam)

 Simplified Chemical Combustion Formula:

 Water vapor turns to liquid when

131 55  Water vapor

Fuel Boiler stand-

Combines the following:

1. Additional latent heat gain from condensate

2. Lower flue gas loss:

3. Lower radiant standby losses:

Boiler capacity in % Foil 16

Boiler return water

 DHW production 150 - 190 oF

140 60 Dewpoint temp

176 80 Condensation range 75oC/167oF

158 2258 hr Supply 160oF

158 2258 hr Return 160oF

75% 25% Foil 28

Fan coil sizing 180OF

Condensate measured for

Condensate measured for Foil 32

CO2% of flue gas

What influences the CO2% ?

60% Excess Air

25% Excess Air

Fo Dew Point of Natural Gas Co

Boiler return water No boiler return water

Non-Condensing boiler Condensing boiler

Best material for

flow in the same

CORRECT INCORRECT Foil 50

Condensing HS Condensing boiler

Flue gas Typical household

New aluminum fin

Same heat exchanger

How much condensate will

What do we do with it?

Lead 0.04 0.1 - 0.3 < 0.01 Comparison

Nickel 0.05 0.05 - 0.03 < 0.01

Mercury 0.001 0.00005 < 0.0001

Vanadium - 0.26 - 0.06 not determined

Zinc 5.0* 3.5 - 0.5 < 0.05

Tin - 0.7 - 0.01 < 0.05

Sulphate 240 5 - 10 4.6

pH Value 6.5 - 9.5 3-4 3.5 - 5

Flue gas temperature

 Plastic pipe (CPVC,

 Combustion with minimal excess air (high CO2)

 Fully modulating burner

 Low heat exchanger surface temperatures

 Parallel flow of flue gas and condensate

 Counter-flow of flue gas and heating water

 Highly corrosion resistant material

 Low temperature heat release surfaces

 Modulate water temperatures with outdoor

 Higher system water temperature drops

 Piping layouts to reduce boiler return water

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