LxE Performer Series - The Bottom Line

Buying Combustion Equipment Is A Business Decision.
Don’t Throw Away Millions To Save Thousands!

When purchasing combustion equipment, there are many factors to consider: Durability · Reliability · Serviceability · Ease of operation · Current & future emission regulations · Initial cost · Operating costs. Of all of these items, initial cost is the easiest to compare, but too often the most influential. Don’t be enticed by a lower purchase price, only to find out later that you have to pay more for fuel and electricity every month for as long as you own the equipment.

Comparing Operating Costs

Collect Data

At what excess air levels can the proposed burner really operate?
- Firing oil?
- Firing gas?

What is the burner’s total electrical power consumption?
- FD fan motor horsepower?
- Oil pump horsepower?
- Air compressor horsepower?
Is the manufacturer willing to provide actual operating data and references to support burner performance? Faber Burner Company believes in supplying customers with ample product information, as well as performance data. We back up our facts with firm guarantees, while others may only make performance and emission “predictions” or “expectations.”
Will the burner operate as efficiently and consume less power than the LxE burner, while still meeting all the project’s emission requirements?

Evaluate Data

Use The Simplified Formulas Below to Determine Efficiency and Fuel Consumption:
- Determine the approximate boiler efficiency
  - Boiler efficiency for oil firing = 85.49 – 0.4578 x (% O2 in flue gas)*
  - Boiler efficiency for gas firing = 81.72 – 0.3756 x (% O2 in flue gas)*
- Determine annual fuel consumption
  - Annual oil consumption (Gallons) =
    Steam Flow (lb/hr) x 6,346.5* / Boiler Efficiency (%)*
  - Annual gas consumption (SCF) =
    Steam Flow (lb/hr) x 876,876* / Boiler Efficiency (%)*

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Example:

Brand (X) burner firing oil at 5.2% O2 yields a boiler efficiency of 83.11%.

An LxE burner firing oil at 3.0 % O2 yields a boiler efficiency of 84.12%

The LxE burner will provide (84.12% – 83.11% = 1.01%) more efficiency than the brand (X) burner while firing #2 fuel oil.

In determining the approximate fuel consumption for a 600HP oil fired boiler that will operate at an annual average firing rate of 55% (10,725 lb/hr steam) of its rated capacity to meet the production demands:

The boiler with the brand (X) burner, firing oil at an efficiency of 83.11%, will consume 818,989 gallons of #2 fuel oil.

The boiler with a LxE burner, firing oil at an efficiency of 84.12%, will consume 809,156 gallons of #2 fuel oil.

Fuel Savings
Due to its ability to operate more efficiently, the LxE burner will use 9,833 gallons less than the brand (X) burner. At $1 per gallon, this is an annual savings of $9,833.00.

Compare the electrical operating costs:
- Total the required horsepower to operate each combustion system.
- Convert horsepower to annual kilowatt hours by using this formula:
  Annual kilowatt hours = Total horsepower x 6532

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Example:

A brand (X) 600HP low NOx dual fuel package burner requires a 40HP FD fan motor, a 7.5HP air compressor motor, and a 3/4HP oil pump motor. Total required horsepower = 48.25.

A Faber 600HP L3E low NOx dual fuel package burner requires a 20HP FD fan motor, a 10HP air compressor motor, and a 1HP oil pump motor. Total required horsepower = 31.

The LxE burner uses 17.25 less horsepower than the brand (X) burner.

The brand (X) 600HP low NOx burner will consume 315,169 kilowatt hours annually if operated continuously.

The Faber 600HP L3E low NOx burner will consume 202,492 kilowatt hours annually at continuous operation.

Electrical Savings
The LxE burner will consume 112,677 kilowatt hours less than the brand (X) burner. At $0.09 per kilowatt hour, this is an annual savings of $10,140.93.

Conclusion
When selecting combustion equipment for your upcoming project, it is extremely important to perform a comprehensive product evaluatation by analyzing all aspects of the burner equipment, especially operating costs. Choosing the wrong equipment can be a very frustrating and extremely costly experience. In the above example, a 600HP steam boiler operating continuously for one year and firing oil at approximately 55% load, the LxE burner results in a potential annual operational savings of $19,973.93.

* Calculations based on ASME PTC 4.1 Efficiency Test Form with inputs of 100 PSIG saturated steam operating pressure, 220ºF feedwater, 425ºF boiler stack temperature, 1000 BTU/ft3 Natural Gas, 138,166 BTU/Gallon #2 fuel oil.

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LxE Performer Series - The Bottom Line

Buying Combustion Equipment Is A Business Decision. Don’t Throw Away Millions To Save Thousands!

Comparing Operating Costs

Buying Combustion Equipment Is A Business Decision.
Don’t Throw Away Millions To Save Thousands!