Electrode Boiler Technology Analysis

prepared for New China Laundry

and

Swedish Trading Company

Electric Boiler Technology

Presentation Outline
Elpanneteknik Overview
Company Overview and Capabilities
Electrode Boiler Reference Plants

Electrode Boiler Technology Comparison

Principles of Operation for Immersion-Type Boiler

Comparison between Elpanneteknik and ZETA Boilers
Principles of Operation for Jet/Spray-Type Boiler
Comparison between Precision and CB/ACME Boilers
Evaluation of Electrode Boiler Technologies with all four vendors

Elpanneteknik Boiler Proposal for NCL Group

Proposed Steam Boiler Specifications
Proposed Steam Boiler Plant Layout

Elpanneteknik Introduction

Elpanneteknik is Swedish for Electric Boiler Technology and is

reflected in our complete line of resistance and electrode boilers.
Elpanneteknik was established more than 15 years ago and is a
provider of numerous electric resistance/electrode boilers to many of
the worlds Fortune 50 companies.
Elpannetekniks founders, Leif and Lars Kring, are both experts in
high-voltage electrode boilers, each with more than 25 years
experience in the design, installation and service of electrode boilers
throughout Europe.
Elpannetekniks Engineering and Sales Headquarter is located in
Nykoping, Sweden, 100km (1 hour) south of Stockholm.

Product Line
We only focus on offering two types of Electric Boilers:

Electrode Boilers
Supply Voltage: 6 14 kV
Power Output: 6 to 60 MW

Electric Resistance Boilers

Supply Voltage: 380 690 V
Power Output: Up to 6 MW

Electric Resistance and Electrode boilers are:

~99% Efficient with Zero-Emissions
Extremely reliable with few moving parts
Produce very low noise level during operation
Able to take advantage of off-peak electricity rates

Company Details
Quality System
Company complies with ISO 9001 Certification
Audited and approved by Alstom and Siemens

Worldwide Presence
Sales Presence in Europe, China and US
Swedish-Based Factory meeting PED code
requirement for European Customers
China-Based Factory to meet ASME / China
Pressure Code for Asian customers

Industries Served
Our Electric Boilers have been installed in a variety of industries including:
Nuclear Power Plants
Mining Industry
Marine Industry

Manufacturing
General Industrial Use
General Heating

Finlands Olkiluoto 3 Nuclear Plant

In 2006, Elpanneteknik was chosen to supply the auxiliary steam power plant to
Finlands Olkiluoto 3 Nuclear Power Plant. While Frances Areva is the main
contractor for the Nuclear Reactor, Elpannetekniks Electrode boiler plant is part of
the turbine island, which is being managed by Siemens.
The reactor is of the 3rd generation type with a power output of 1600MW
the largest in the world.
Early in 2001, Framatome
and Siemens merged their
nuclear businesses to form
Framatome ANP, with
AREVA holding a 66% share
in the new company and
Siemens holding 34%.

Elpanneteknik Auxiliary Steam Boiler Specifications

Max power: 2 x 15MW

Supply Voltage: 10kV
Steam capacity: 46,000 kg/h

Op. pressure: 12 bar

Op. temperature: 192C

Olkiluoto 3 Aux. Steam Boilers

Elpanneteknik was commissioned by Siemens to provide
the design, manufacture and installation of the complete
Nuclear Power Auxiliary Steam Plant, which includes the
following major items:

Two Electrode Steam Boilers

Feedwater tank with deaerator
Dosing Equipment, Flash Tank, Silencers
Pumps, pipes, service platforms, electrical installation

Auxiliary steam boilers for NPPs are used during startup

and maintenance of the reactors to provide gland steam
and heating.
Elpannetekniks Electrode Boilers were chosen for its high
steam quality and purity, high stability during operation,
high reliability, fast startup time, resistance to arcing and
low maintenance requirement.

Olkiluoto 3 Plant Layout

Protection Cage

Silencer

Feedwater pumps

Circulation pump

Feedwater tank with deaerator

Blowdown Separator

Electrode Boiler

Electrode Boiler at AstraZeneca

Electrode Steam Boiler at
AstraZeneca:

Installed Power: 1 x 25MW

Supply Voltage: 11kV
Design Temp: 240C
Design pressure: 32 bar
Steam rate: 38,000 kg/h

AstraZeneca is one of the worlds largest pharmaceutical companies.

AstraZeneca Control Cabinet

PLC: Siemens S7-400

HMI: Beijer Electronics (Mitsubishi) Touch Screen

HMI Touch-Screen Pictures

Other Boiler Installations

Weve provided more than 100MW in element
(resistance) boilers throughout Europe:
Element Boiler sizes up to to 6MW
Design pressure from 6 50 bar[g] (0.6 5MPa / 87 725 PSI)
Installed in power plants, factories, buildings, ships

Volvo

Boliden Mineral
Alstom Marine

Partial List of Customers

Electric Boiler Technology

Electrode Boiler Technology

Immersion Electrode Boilers

Electrical
Connections
Electrodes
(3-6)
Insulated
Inner Vessel
(neutral point)
Inner vessel
level control
valve
(not shown)

PTFE Spreader
Pipes (3-6)
Feedwater Inlet
Spreader Pipe

Steam Outlet

Ceramic
Insulators
PTFE Level
Gauge Pipe
PTFE
Blowdown Pipe

Outer Vessel

Standby
Heater

Major Components - Immersion

Pressure Vessel and Inner Vessel

Electrodes and Ceramic Insulators

The electrodes and water circulation system are designed and optimized to minimize wear
and eliminate arcing. The expected electrode life time is more than 10 years. When a change
must be done, its only the electrode rods which need to be replaced. The electrode plate
and bolts will last much longer.
The one-piece ceramic insulators are specially designed to resist electrical and water
leakage and are expected to last more than 5 years.

Circulation Pump and Standby Heater

The Boiler Pressure Vessel (outer vessel) is a pressure rated and ASME registered pressure
vessel.
The Inner Vessel, which constitutes the neutral point, is electrically insulated from the outer
vessel and ground. This design limits the current to ground, should an unbalance between
phases occur.

The circulation pump transfers water form the outer vessel to the inner vessel and the level in
the inner vessel determines the power output of the boiler.
There is a low voltage immersion heater in the outer vessel to maintain steam pressure and
water temperature of the boiler during standby for fast start-up and for avoiding material
exhaustion when there are many on/off maneuvers, e.g. at so called off-peak operation.

Automatic Blowdown and Chemical Dosing

The automatic blowdown system limits the conductivity of the boiler water. The blowdown
losses can be recovered by using our Blowdown Separator with built-in Heat Recovery
System.
The dosing equipment maintains proper chemical content by adjusting the conductivity and
pH.

Electrodes and Insulators

Water/Steam Flow Diagram

Ceramic Insulator

Steam Output
Ceramic Insulator

For Safety Valves

Control Valve

Inner Vessel

Ceramic Insulator

Electrode Rod
Manholes

Blowdown
Level Control Actuator

Recirculation and level control

Outer Vessel

PTFE
Circulation Pipe

Blowdown
Feedwater and volume control

Circulation

Principles of Operations - Immersion

Feedwater Supply

Demineralized and deaerated water is pumped from the feedwater

tank into the outer vessel to maintain constant overall water volume.

Water Circulation

The circulation pump transfers the water from the outer vessel to the
inner vessel. For redundancy two pumps are installed. If the pump in
operation fails, the other pump starts automatically.
Water level in the electrically insulated inner vessel is regulated by
the amount of water pumped in and the inner vessel control valve
that allows water to drain out into the outer vessel.

Power and Steam Output

Power and steam output is determined by the water level in the

inner vessel in contact with the electrodes and the conductivity of
the water. Power can be regulated from 0% to 100%.

Blowdown

Automatic surface blowdown maintains the appropriate conductivity

in the boiler water, and we expect efficiency loss with a blowdown
recovery device to be less than 0.1%.

Elpanneteknik Immersion Electrode Boilers

High Electrical Stability

Elpannetekniks Electrode Boilers have no problems with foaming and
arcing, because of the design, the requirement for demineralized
make-up water and because of the strict control of boiler water
conductivity.
Elpannetekniks Electrode Boilers have an electrically insulated neutral
point (the inner vessel), with high resistance to earth (minimizing earth
current short of around 10amps), therefore allowing our boilers to
connect directly to the common electrical grid without using a
dedicated grounded transformer.
High Steam Quality and Purity
Elpannetekniks boilers are designed with steam quality in mind, with a
large steam space and boiler water surface (similar to fire-tube boilers)
and low steam velocity that minimizes water droplet formation.
Our steam quality and purity is high enough to run turbines in Nuclear
Power Plants, and can achieve steam quality of over 99.9%.
Due to our strict control in boiler water quality, we can assure a high
steam purity with a low salt content in the steam (which otherwise can
cause corrosion, coatings and other problems in connected
equipment)

Elpanneteknik Immersion Electrode Boilers

High Reliability
The only major moving parts in our system are our circulation
pumps and we can provide redundancy in the circulation system to
maintain a near 100% uptime.
Immersion Boilers are simple in concept and in operation and does
not have complicated nozzle arrangements present in jet/spray-type
boilers that wear out and require frequent adjustments to function
optimally.
Elpannetekniks boilers meet the strict reliability requirements as
dictated by Europes largest nuclear power plant operators.

Ease of Maintenance
Elpannetekniks boilers have long-life and low-maintenance
electrodes and ceramic insulator designs and do not require
external cranes to remove and service the boilers.

High Efficiency
Elpannetekniks boilers utilize blowdown recovery device to
minimize energy loss due to blowdown. The overall efficiency,
including blowdown losses, is more than 99.9%.
Immersion electrode boilers can operate from 0% to 100% power
level with the same efficiency of close to 100%.

Immersion Electrode Boiler Safety Features

A-type alarm functions that shut down the boiler directly via power connection:
HighHigh pressure (also disables heating elements)
HighHigh water level in outer vessel
LowLow water level in outer vessel
Circulation pumps failure (both pumps)
Alarms from 11kV switchgear (i.e. protection devices that trips the power
breaker)
HighHigh conductivity
Emergency Stop
Examples of B-type alarm functions that warn the operator, but dont shut
down operation:
High pressure
High water level in outer vessel
Low water level in outer vessel
Circulation pump failure
High conductivity
Signal out of range (for each 4-20mA transmitter signal)

Elpannetekniks advantages over ZETA Boilers

Elpannetekniks Boilers are similar to ZETA boilers from Zander & Ingestrom, but
has been significantly improved in a number of ways, e.g.:
Leak-free gaskets, improved electrodes and ceramic insulators
Elpannetekniks boilers benefit from significant improvements in our gasket designs, which
provide a leak free interface for our electrodes and insulators, reducing maintenance and
downtime.
The ceramic insulators have been redesigned with higher-grade materials for maximum
resistance to electrical and water leakage and offers longer wear-life.
The electrodes have been improved for increased life and improved current and wear
characteristics.
The PTFE spreader pipes have been improved to optimize the flow to the electrodes and keep
a leveled surface in the whole power range.
Improved control systems and HMI
All Elpanneteknik boilers are offered using the latest, top of the line, PLC control systems and
HMI interfaces.
The control panel is kept clean. All mechanical switches, except for Emergency Stop, are
replaced by virtual switches on the Touch Screen Operators Panel.
Only Electric Boilers and Approved for Nuclear Power Plants
Finally, were not distracted by other lines of unrelated businesses with our singular focus of
producing the best electric boilers in the world.
In that regard, the most significant vote of confidence in Elpannetekniks Electrode Boilers is our
recent contract with Olkiluoto 3 nuclear power plant from Germanys Siemens Systems

HMI Features
The operator interface (HMI) is a touch screen, Beijer Electronics /
Mitsubishi, with the following functions:

Overview picture of boiler plant, with animated process values and operational
conditions.
Picture with operational modes and choices
Pictures of controllers and controller parameters.
Pictures for setting parameters, set points and alarm limits.
Trend curves on pressure, steam flow and electric power (10kV to boilers).
Alarm handling.
Historic values of operational data.
External communication (e.g. to main control room MCR) is either done by hard wire, which
provides the most important system data and functions for external start, stop and
supervision of the system, or by PROFIBUS. Ethernet is also an option.
The traditional electrical switches on the control cabinet have been replaced by virtual
graphical switches on a touch screen operators panel.
The only traditional switch on the cabinet is the emergency stop.
Start and stop are done locally from the control cabinet, or remotely from the control room.
Provided that certain functions are ready for operation, e.g. that make-up water, cooling
water and electric power are made available, and that all manually operated valves are in
the right position, the system can be started automatically.
The start procedure will follow a sequence that is visualized on the operators panel.
The stop procedure will also follow a sequence that is visualized on the operators panel.

Immersion vs. Jet-type

Immersion Boilers
Elpanneteknik / ZETA

Improved Jet-type Boilers

CB-ACME

Jet-type Boilers
Precision

Jet-type Electrode Boilers

Jet boilers were developed in Europe but no longer
manufactured there
The original jet-type design was developed in Switzerland, but
currently is only being marketed in the US by Precision boilers and is
distinguished by variable water pressure/water column in the nozzle
header to control steam output.
CB/Acme Boiler is based on a modified design, also developed in
Europe. The main difference is its use of a high-powered pump to
maintain constant water pressure in the nozzle header and control
output by covering a higher or lesser number of nozzles by means of
a shield that is operated via drawbar and a motor actuator on top of
the boiler.
Although jet boilers were developed in Europe, they are no longer
marketed in Europe due to its low steam quality and nagging arcing
issues.

Narrower but Taller Profile

Jet-type boilers are narrower than immersion boilers because they do
not have an inner vessel, but jet boilers requires normally 1 to 2
meters additional installation height. A crane or other lifting device
must be installed for maintenance and replacement of the nozzle
header, which is a very space demanding job.

Jet-type Electrode Boilers

Electrical Grid Compatibility Issues

Due to the lack of an insulated inner vessel and lack of high-resistance
to ground, jet-type boilers should not be connected directly to the
common electrical grid. The power company/distributor will normally
require the boiler to be connected and directly grounded to (a costly)
transformer, dedicated for the boiler only.
Jet-type Electrode Boilers are prone to arcing due to foaming problems
and stray water sprays hitting the grounded vessel. Arcing has been
shown to decrease transformer and breaker life, with increases in
maintenance costs and intervals. Frequent trips of the power breaker
are not appreciated by the operator as intervention to reset alarms and
restart boiler is required each time.
(See http://www.electricity-today.com/et/june99/trans.html)
The frequent energization as well as the number of short-circuits of the boiler were damaging
the contact points of the tap changers. Electricity Today, June 99

Accumulated heat and steam buffer

Jet-type boiler has a very little water volume that can act as a buffer at
momentarily large or fast steam consumption.
The Immersion type boiler has a large water volume which acts as a
steam buffer.

Jet-type Electrode Boilers

Steam Quality and Purity
Jet-type boiler produces steam in the surface of the
water jets that strikes the electrodes. As the water
surface where the steam escapes is so small, the
velocity of the steam must be extremely high. Large
amount of water droplets are then carried by the
steam.
Jet-type boilers allow boiler water to accumulate a
significant amount of dissolved solids, which
combined with low steam quality, result in steam that
carries high level of erosive and corrosive impurities
that can damage downstream equipment.

Precision Electrode Boilers

Precision Boilers are especially prone to arcing

The boiler controls output by varying the height of the water column
(level) in the nozzle header.
As the water in the nozzle header is not pressurized, the spray pattern
is not optimal. Often, stray water jets hit the grounded vessel resulting in
arcing.
Precision has recognized arcing as a serious problem and has added
shields and Teflon coating to minimize these problems but the durability,
reliability and effectiveness of these fixes has yet to be proven. The
underlying problem is still there.
Foaming is a problem in this type of boiler, much due to the acceptance
of a high salt content. Foaming is one cause of arcing.

Internal Pump Design excludes Redundancy

Precision Boilers HVJ-228 and up (> 7MW @ 11kV) have internal
pumps (of mixed flow type) and lack the ability to have redundant
recirculation pump configurations - this can cause extended system
downtime when the internal pump malfunctions.
If redundancy is required, external pumps must be used and they will
require a certain minimum NPSH, which will increase required
installation height and increase the installation cost.

C-B/ACME Electrode Boilers

Complex Jet-Knife Spray Control
CB-Acme Boilers maintain a constant water pressure in the
nozzle header and regulates the amount of water spraying on
the electrodes by using a shield and knife to block the unneeded
nozzles. This system ensures a better water spray pattern and
reduces the risk for arcs.
The shield and knife system requires a relatively complex
system of drawbar, stuffing box, motor etc, to raise and lower the
nozzle-blocking shield. The system increases required
installation height and also increases the need for maintenance.
Although arcing is not as evident in the early life of the boiler, the
wear pattern of the nozzle can create arcing as the boiler ages.

Higher power consumption

The constant high jet pressure creates elevated wear on the
nozzles due to constant pressure on the water jets and creates
more wear and also results in increased power consumption
from the circulation motor (power of motor is more than 4 times
larger than in immersion boilers).

Competitive Analysis
Reliability
Immersion Boilers are extremely reliable due to its simple
design and redundant circulation pump arrangements.
The type has been proven in Process Industries and Nuclear
Power Plants all over Europe. It is, and has been, the preferred
type of electrode boiler in Europe, with both customers and
power distributors.
The largest electrode boilers in the world (70MW) are of the
immersion type and are installed in European process industry.
Jet-type boilers have a greater need of service and
maintenance, problems with foaming and arcing and therefor
lesser availability.
Jet-type boilers produces a steam of lower quality and purity.
This has mainly to do with a higher salt content and a higher
rate of carry-over. (A demister and water separator, e.g. a
cyclone filter, can handle part of this problem, but a steam
superheater is not a solution as you will have problems with the
steam superheaters elements).

Competitive Analysis
Serviceability
Jet-type boilers require maintenance of the nozzle header and
they are accessed by lifting the full length of the nozzle header
via an overhead crane on the top of the boiler, which increases
headroom requirement of the boiler room.
Jet-type boilers have a greater wear on electrodes which must
be changed at shorter intervals.
Immersion boilers dont require any extra space above the
protection cage, on the top of the boiler.
Elpannetekniks boilers service requirement is limited to a yearly
inspection and perhaps a change of insulators every 3 to 5
years. Electrode rods are expected to last at least 10 years and
when a change is needed it is done inside the boiler, which is
accessed through a manhole on the side of the boiler.

Competitive Analysis
Grid Compatibility
Immersion boilers, due to its insulated neutral point design, with
a high resistance to ground, can be connected to the common
electrical grid directly, reducing capital cost requirement of a
separate grounded transformer.
Precision / CB-Acme require a costly separate transformer
because they have a grounded neutral design, with no current
limitation to ground in case of dissymmetry faults that causes a
potential in the neutral point.
Elpannetekniks boilers do not have foaming or arcing issues
due to its design and feedwater quality requirements.
Jet-type boilers are prone to arcing which reduces transformer
and breaker life, damaging contact points and tap changers.
Precisions boilers are regulating the power too fast and the
power company complains of power oscillations which causes
voltage fluctuations.

Competitive Analysis
Efficiency
All electrode boilers are high in efficiency due to the principle of
using water as a resistor, so whether its immersion or jet-type
boilers, overall efficiency (including blowdown and insulation
losses) are approximately 99%.

Steam Quality
Immersion Boilers have extremely high steam quality of 99.5%+
and Elpannetekniks boilers can incorporate an optional internal
demister that increases steam quality to above 99.8%, when
required.
In addition, due to strict water quality control in immersion boilers,
the resulting steam purity is much higher than in jet boilers, which
means less corrosion, scaling and depositing on steam pipes.
Jet-type boilers have much lower steam quality and steam purity
due to design with small steam evaporation surface, high steam
velocity, high salt content and high rate of carry-over.

Competitive Analysis Summary

Elpanneteknik
Immersion
Boilers

Precision
Jet Boilers

CB-ACME
Jet Boilers

Reliability &
Availability

High

Low

Medium

Serviceability

High

Medium

Low

Grid
Connectability

High

Low

Low

Efficiency

High

High

High

Steam Quality

High

Low

Low

Steam Purity

High

Low

Low

Proposed Steam Boiler Spec for NCL

Based on the specifications of 13 t/h of net steam output
at 10 bar[g], we suggest the following:
Electrode Steam Boiler, type ETSH10Mi, 9.1MW 11kV 12bar[g]
dimensioned for heating of makeup water, deaeration and
blowdown losses.
Steam Boiler Dimension: 2.3m x H5.2m, incl. 150mm heat
insulation (mineral wool covered with aluminum or steel plates).
Overall Height Requirement: 6.3m (includes requirement for a
1.4m x 0.7m x 1.1m deep pit)
Water-filled weight: ~ 14 tonnes
High resistive neutral point for connectability to standard
common electrical grid.
Overall efficiency of 99.9% with the use of a blowdown recovery
device and 50% condensate return

Summary of Differences
Immersion Boilers characteristics:

High reliability and resistant to arcing

Can connect directly to electrical grid
High quality and high purity steam
Lower and wider design profile
Low maintenance requirement

Jet-type boilers characteristics:

Requires maintenance to nozzles and jet shield and knife
mechanism and prone to foaming and arcing
Requires a separate grounded transformer to connect to
electrical grid
Low steam quality and steam purity
Taller and narrower design profile
Small, if any, steam buffer capacity
High maintenance requirement