2004 DTE Energy Conference And Exhibition

2004 DTE Energy Conferenceand ExhibitionFebruary 18, 2004David ThornockJohnston Boiler CompanyPresentation Overview Description of Companies and Product Lines Stickle Deaerators Johnston Boiler Company– 3 and 4- Pass Water Backed Firetube Boilers– Waste Heat Boilers– Combined Waste Heat and Fired Boilers Johnston Burner Company––––Standard BurnersLow NOx (30 ppm)Ultra Low NOx (Under 10 ppm)Demonstrations and Installations SummaryJohnston Boiler Company1

A New Company with nearly140 Years of ExperienceJohnston Boiler CompanyWe have built boilers for 140years and Burners for 60 yearsJohnston Boiler Company2

Company OverviewEnergy Solutions GroupJohnston Boiler CompanyFire-tube BoilersStickle DeaeratorsDeaerators andHeat Recovery SystemsJohnston Burner CompanyBurners for New andRetorfit BoilersJohnston Boiler CompanyJohnston Boiler Company Water Backed Design – 3 and 4 Pass BoilersJohnston Boiler Company3

Johnston 3 and 4 PassFiretube Boilers Reputation as the best and most efficient firetubeboiler on the market Each boiler is built to fit the individual application 50 hp to 2500 hp Section IV Heaters up to 160 psi Water and 15 psiSteam Section I Steam Generation up to 450 psiSaturated SteamJohnston Boiler CompanyJohnston 3 and 4 PassFiretube Boilers Continued 15 Year Warrantee on the Tube Sheets andFlue boxes Generous tube sheet ligament distances 100% penetration welds Water backed design for all boiler sizes Boilers can be customized to meetindividual needsJohnston Boiler Company4

Johnston’s Approach toHeat Recovery Waste Heat Recovery Units– Industrial turbines up to 25 MW– Other industrial process waste heat applications Fire Tube Boilers– Single Pass– XID tubes– Combined Waste Heat and Fresh Air FiredJohnston Boiler CompanyWaste Heat/Fresh Air Fired BoilerJohnston Boiler Company5

Waste Heat/Fresh Air FiredBoiler DesignJohnston Boiler CompanyWaste Heat/Fresh Air FiredBoiler DesignWaste HeatTube SurfaceJohnston Boiler CompanyTwo Pass Water-Back FiretubeBoiler Section w/XID Tubes6

Waste Heat/Fresh Air FiredBoiler Design Firetube BoilerSection– 2-Pass Boiler withXID Tubes– 900 hp or 31,050Lbm Stm/hr Waste Heat Section– 9744 Lbm/hr WasteGas Flow Rate– Inlet Temp 1022 F– Outlet Temp 384 F– Generates 1000 LbStm/hrOne Boiler Shell Contains Both Boiler SurfacesDesign Pressure 200 psi and Operates at 140 psiJohnston Boiler CompanyStickle Deaerators Spray and tray designsContinuous blowdown heat recoveryHigh pressure condensate recoveryIntermittent blowoffVented receiversJohnston Boiler Company7

Johnston Burner Company In the burner business for 40 yearsSupply burners on Johnston Boiler ProductsFormed as a new company in Sept 2001Committed to supply new and retrofitburners– All boilers up to 200 MBtu/hr– Gas and Oil– Low NOxJohnston Boiler CompanyJohnston Burner Products “A” Burner– Gas and Oil Burner– Standard emissions– Low NOx Option uses FGR “AR” Burner– Gas and Oil Burner– Standard emissions– Low NOx Option uses FGR “S” Burner–––– “J” Burner––––Gas and Oil burnerStandard emissionsNo Low NOx version50 hp to 200 hp “FIR” Burner– Gas only– Low NOx – Under 9 PPM– No External FGR is usedGas and Oil BurnerStandard emissionsLow NOx Option uses FGR1800 hp to 2500 hpJohnston Boiler Company8

Johnston’s FIR Burner The FIR Burner was chosen to address theUnder 20 PPM to Under 9 PPM NOxrequirement Gas only applications Targeted towards the non-attainment areaslike California, Texas, and isolated areas onthe east cost New and retrofit burner salesJohnston Boiler CompanyFIR BURNER Burner was developed at theGas Technology Institute Licensed Technology toJohnston Boiler Co. Funded by SMP, GRI,SoCalGas, and DOE Retrofit or new Premixed staged combustion Forced internal recirculation Lowest cost premiumJohnston Boiler Company9

FIR Burner Cross SectionHigh Velocity Premixed NozzlePilotAssemblyGasSupplyRecirculation SleeveAirInletJohnston Boiler CompanyFIR Burner MechanicsHigh Velocity Premixed NozzleFlue Gas RecirculationRecirculation SleeveJohnston Boiler Company10

Fullerton College Two 10.5 million Btu/h (250 hp) boilersused for heating applications 15 psig steam design Natural gas firing Requires under 12 vppm NOxJohnston Boiler CompanyFullerton CollegeJohnston Boiler Company11

Fullerton CollegeJohnston Boiler CompanyFullerton College Load Requirements– Seasonal heating winterthe highest and summernon-existent– Early morning largestday load– Load tapers off in theafternoon and eveningJohnston Boiler Company12

Fullerton CollegeNOx Emissions Over the FiringRange1009080NOx, vppm706050403020100LowMidHighFiring Pin NumberJohnston Boiler CompanyFullerton CollegeExcess Oxygen Over the FiringRange400350Stack Temperature, FBaselineBoiler No. 1300250Boiler No. 2200150100500Min1Max2345678910Firing Pin NumberJohnston Boiler Company13

Fullerton CollegeStack Temperature Comparison87Baseline6O2, %5Boiler No. 14Boiler No. 23210Min1Max2345678910Firing Pin NumberJohnston Boiler CompanyFullerton CollegeEfficiency Over the Firing Range8685Efficiency, %Boiler No. 284Boiler No. 18382Baseline8180Min1Max2345678910Firing Pin NumberJohnston Boiler Company14

Predictive Cost SavingsJohnston Boiler CompanyFullerton Summary The FIR burner is an efficient solution forfiretube boiler low NOx applications(under 10 vppm)– Simple controls– Standard boiler packages The FIR burner optimizes energy use– No external FGR– No need for large hp fans to push extraFGR or Excess AirJohnston Boiler Company15

Firetube Boiler Installations FIR burners are installed on several differentfiretube boilers––––4 million Btu/h (100 hp) Kewanee10.5 million Btu/h (250 hp) Johnston 4-pass15 million Btu/h (350 hp) Johnston 4-pass21 million Btu/h (500 hp) Williams & Davis Johnston Boiler Company and GTI and committedto move the FIR Burner and all of its benefits intothe firetube market placeJohnston Boiler CompanyFiretube Boiler InstallationsJohnston Boiler Company16

Summary The Johnston Companies Supply all BoilerRoom Products and Services We understand needs for steam and hotwater production System efficiency is our priority We have burner products for your needs –standard firing or ultra low NOx We are committed to stay at the front oftechnology introductionJohnston Boiler Company17

firetube boilers – 4 million Btu/h (100 hp) Kewanee – 10.5 million Btu/h (250 hp) Johnston 4-pass – 15 million Btu/h (350 hp) Johnston 4-pass – 21 million Btu/h (500 hp) Williams & Davis Johnston Boiler Company and GTI and committed to move the FIR Burner and all of its benefi