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REPORT
Danish population of gas boilers
above 120 kW
Project report
October 2015
Danish Gas Technology Centre • Dr. Neergaards Vej 5B • DK-2970 Hørsholm • Tlf. +45 2016 9600 • www.dgc.dk • dgc@dgc.dk
Evaluation of the NOx emissions
of the Danish population of gas boilers
above 120 kW
Report
Category : Project Report
ISBN : 978-87-7795-384-2
DGC-report 1
1 Introduction ........................................................................................................................... 3
1.1 Summary ............................................................................................................................. 3
3 Results ................................................................................................................................. 21
3.1 Phase1: Identifying the appliance population in detail (by brand and model) in the
installation database ................................................................................................................... 21
3.1.1 Ranking ................................................................................................................. 22
3.1.2 Appliance type....................................................................................................... 22
3.2 Phase 2: Evaluating the nominal NOx emissions of each brand and model ...................... 24
3.2.1 GASTECH data ..................................................................................................... 24
3.2.2 Additional data measured by DGC ....................................................................... 28
3.2.3 Data and information from Weishaupt .................................................................. 28
3.3 Results of Phase3: Evaluating the total annual NOx emissions by combining the
information from 1 and 2 (linking the population database to GASTECH database) ............... 29
3.3.1 Allocating a reference for NOx emission source at each line of the population
database (= appliance types) ............................................................................................... 29
3.3.2 Final calculation of the NOx emission factor ........................................................ 34
3.3.3 Uncertainty calculation ......................................................................................... 35
5 Conclusion .......................................................................................................................... 44
6 References ........................................................................................................................... 45
Annexes
Annex 1: Data from Weishaupt and comparison with existing data
Annex 2: Units and conversions
Annex 3: Appliances on the market and gas consumption
Annex 4: What is the reference data (for NOx emissions) we have connected to each line of
the population database?
Annex 5: Calculations
Annex 6: Ecom-J2KN pro industry analyser specifications
Annex 7: Conversion factor for various gases: details of calculation
DGC-report 3
1 Introduction
Following the work done on appliances < 120kW [1], this project consists in
evaluating as accurately as possible the overall real NOx emissions from
larger gas boilers on the Danish market. The results of the work are to be
used to build up knowledge on the environmental impact of gas utilisations
that is useful for instance for the present discussion of the actual taxation of
NOx emissions of appliances.
Similarly to the study done on boilers below 120 kW, we have a quite accu-
rate and detailed picture of the population of appliances including brand,
model and gas consumption that are registered by the Danish gas distribu-
tion companies. The NOx emission for a great number of appliances is or
has been measured by GASTECH. The work consisted in combining the
two sources in order to assess the overall emissions of the entire market
population. The GASTECH data was supplemented by DGC measurements
aiming at crosschecking the measured data and to cover some segments hav-
ing a large impact, for which no data was available.
As for the boilers below 120 KW, the boilers above 120 kW are used for
space heating, but many are used for other purposes in the industry (process
etc.) and for district heating.
1.1 Summary
The present figure (calculated with 2011 data) for the emission factor of
large gas boilers/burners (population above 120 kW of heat input) is 34,4
g/GJ.
The figure is expected to decrease in the future with the replacement of old-
er burners with new technologies. The pace of decrease could very much
depend on the regulation that would apply in the future. Currently the an-
nual decrease is about 0,3g/GJ.
DGC-report 4
2.3 Definitions
The following definitions are used in the report
or CO2 measured in the flue gas [1], and ANNEX 2 describes in detail how
this is done, and how values measured in the flue (in ppm) are converted to
neutral combustion dry gas (dry-air free or “daf”) (in ppm) or in other units
such as mg/kWh.
The value in dry-air free emission in ppm (NOx 1) is calculated from the
measured concentration in the flue (NOx 0),
either using O2m measurement with:
O2 air
NOx 1 = (NOx 0)m [ppm]
O2 air O2 m
or using CO2m measurement with:
CO2 n
NOx 1 = (X0)m [ppm]
CO2 m
O2air is the concentration of O2 in the combustion air.
CO2n is the neutral combustion CO2 percentage for the given gas.
To make it simple:
NOx 2 = F NOx 1
Note that , Vfd and Hi are calculated with the gas composition of Table 2.
DGC-report 8
The following calculations and results are made with a conversion fac-
tor of 1,768 as calculated for Danish gas (2014) and not with the stand-
ard value.
1) Phase 1
Establishing from the boiler/burner population database a clean and
DGC-report 9
detailed list of existing appliance population (by brand and model) and
the gas demand of installations.
2) Phase 2
Making statistics for NOx from emissions of each brand and model in
the GASTECH database. This also includes a validation of the data
measured by GASTECH.
3) Phase 3
Evaluating the total annual NOx emission by combining the information
from 1 and 2.
Note that the list we have used was created from different lists/tables cover-
ing different installation sizes (see 4.1).
In many cases, the same burner or boiler type can be found in several/tables
(most of the burners' modulation range can be adjusted, with the result that
they appear in several lists) (see 4.1).
This resulted in a total of 3700 measurements (valid data) (on the 11700
available), so about 31% were effectively used for the work done.
We proceeded with a (more or less) line per line check, looking at each
measurement Note that in the original file as shown above there are two
lines per burner/boiler: one at Pmax (M2) and one at Pmin (M1) Lines with
missing information (NOx/O2 or CO2) - not allowing NOx emission assess-
ment - were removed.
The two sets of data obtained are shown in Figure 4 (NOx emission daf).
From the results obtained we can conclude that the NOx emission difference
measured is low, also considering that external parameters (air temperature,
humidity etc.) are influencing the real emissions of the burners.
DGC-report 15
2.5.3 Method for Phase 3: Evaluation of the total annual NOx emis-
sions
The next phase consisted in evaluating the NOx emission for each individual
model of the aggregated population and calculating the sum of these group
values.
Before we can proceed, we need to know how to take into account the pa-
rameters that we know may have an influence, and in particular the load.
We, therefore, made preliminary observations and analyses of GASTECH
data for the NOx emissions.
Figure 5 Relative variation of NOx emissions for the burner WG40 in-
stalled on various boilers
Data: GASTECH Forbrændingsdata industriinstallationerv03. Sheet2
This, however, is not always true, as some specific installation may show
another result: In the above figure the emissions of a given burner are in fact
clearly higher on steam boilers. This is expected to be due to a higher tem-
perature. Apart from this, the emissions are at the same level (avg. 49,1 ppm
daf with a Standard deviation of “only” 13, and 9 without the steam boilers).
DGC-report 16
The variations are low and are more or less in the range of repeatability that
is observed at DGC for NOx emission measurements on smaller boilers
(< 120 kW).
The same type of result was seen on the other burners showing a very nar-
row emission range, and sometimes outliers that can be explained. The next
example on the Weishaupt G3 burner shows a single burner within the
group with a low NOx emission. This is explained by a very high air excess
(O2 about 14% instead of about 6% for all the other burners). We have no
further information on this installation; perhaps the process requires such
high air excess.
100
80
NOx ppm (daf)
60
40
O2 = 14%
20
0
0 10 20 30 40 50 60
Burner
Conclusion 1: In the vast majority of the cases, there are only small var-
iations of NOx emissions of the same burner when installed on various
boilers, unless the boiler is a steam boiler or used for a specific process.
Figure 7 Comparison of NOx emissions at Pmax and Pmin for the burner
WG40 installed on various boilers
Data: GASTECH Forbrændingsdata industriinstallationerv03. Sheet2
Again here this is true, but not for the few steam boilers.
As the steam boilers have a very small part of the market, the impact on the
overall NOx emission is not determining.
Table 5 compares the emissions obtained at Pmin and Pmax for the 3700
valid data. The largest differences are obtained by a "smaller" boiler in the
smaller range of the heat input (e.g. Buderus Logano, Viessmann boilers).
These are technologies for which it is known that emissions at Pmin are
much lower [1].
Burner/Boiler Name Kolonne1 Kolonne2 Kolonne3 Kolonne4 Kolonne5 Kolonne6 Kolonne7 Kolonne8 For n>2 only
Burner Bentone BG 100 and BG 150 35 43 9 19
Burner Bentone BG 200 72 75 14 151 85 78 7 14 3 4%
Burner Bentone BG 300 94 71 17 194 141 67 13 118 -3 -5%
Burner Bentone BG 400 & 450 137 75 15 260 250 98 396 190 23 24%
Burner Bentone BG 500-2 256 85 15 60 417 75 16 58 -9 -13%
Burner Bentone BG 600-650-700 422 78 13 43 691 70 15 31 -7 -10%
Burner BENTONE OTHER 129 73 17 224 315 71 18 84 -2 -2%
Burner BENTONE RG 90-2 274 68 9 31 497 68 8 30 0 1%
Burner Bentone SG 140-2 465 77 13 9 860 76 12 8 -1 -2%
boilers Buderus Logano Plus GB 312/241 67 12 6 34 227 27 12 28 15 54%
boilers Danstoker DHA 2036 108 18 4 1741 98 13 4 -10 -10%
boilers Danstoker Global 646 37 10 8 2183 42 13 7 6 14%
boilers Danstoker TDC 1207 42 26 7 4429 36 8 6 -6 -16%
boilers Danstoker TVB 1193 85 18 25 2303 85 16 25 -1 -1%
boilers Danstoker VB 227 72 10 25 379 72 11 25 0 0%
boilers Danstoker VBN 443 73 21 49 788 74 24 46 1 2%
Burner Danstoker VEH 542 79 6 10 1701 78 13 9 -2 -2%
burners Dunphy all 162 57 22 133 512 60 19 121 3 6%
Burner ELCO EG 02.14 131 32 0 1
Burner ELCO OTHER 531 75 21 21 1166 73 20 19 -2 -2%
boilers Eurotherm overall 1012 86 1 3 1959 86 3 3 1 1%
boilers LOOS OVERALL 426 70 20 9 679 74 26 9 5 6%
boilers LOOS ULS 712 48 7 2 1464 55 11 3 7 13%
Burner Ray BCEG 1000 3744 99 4 2 4577 101 5 2 1 1%
burners RAY PG 519 88 39 12 587 121 73 9 33 27%
burners Rendamax R9/105 107 91 32 27 276 163 71 27 73 44%
Burner Riello Gas 5/2 283 64 16 4 523 71 11 4 7 10%
burners Riello GAS All 172 80 14 24 297 82 15 17 1 2%
Burner Riello RS 28 Gulliver 110 86 6 7 240 78 7 7 -8 -11%
burners Sacke GLS 55 1184 34 2 4 3908 39 6 3 6 14%
Burner Viessmann VITOCROS 300 and other 64 22 13 82 231 27 11 76 5 19%
Burner Viessmann Vitocrossal 200 90 32 5 4 234 42 11 3 10 23%
Burner Weishaupt WKGL 40/2-A & WKGL 1466
70/Z-A ZMD109 13 9 3743 102 13 9 -7 -6%
Burner Weishaupt G1/1-E 114 74 14 13 240 69 13 12 -4 -6%
Burner Weishaupt G10/1-D-ZDM 739 93 15 22 1848 88 8 18 -5 -6%
Burner Weishaupt G11/1-D 739 93 15 22 1848 88 8 18 -5 -6%
Burner Weishaupt G3/1-E 215 72 15 97 383 67 13 92 -6 -8%
Burner Weishaupt G30/2-A 264 49 21 2 0 46 0 2
Burner Weishaupt G40/1-A 211 77 12 2
Burner Weishaupt G5/1 - D ZMAD - LN 253 49 6 2 468 41 5 2 -8 -20%
Burner Weishaupt G5/1-D 356 68 15 51 629 69 15 49 0 0%
Burner Weishaupt G50/1-B 542 60 9 2 1278 55 6 2 -5 -9%
Burner Weishaupt G50/2-A 753 99 26 4 1966 83 24 5 -16 -19%
Burner Weishaupt G60/2-A 712 91 14 5 1742 93 11 4 2 2%
Burner Weishaupt G7/ 1-ZMD 521 64 18 47 1013 60 19 43 -3 -5%
Burner Weishaupt G70/2-A 785 49 6 3 1548 52 9 3 3 5%
Burner Weishaupt G-8/1-D 739 93 15 22 1848 88 8 18 -5 -6%
Burner Weishaupt G9/1D 739 93 15 22 1848 88 8 18 -5 -6%
burners WEISHAUPT OTHER 159 62 21 311 433 64 26 169 3 4%
Burner Weishaupt RG 70/1-A - ZM 1157 87 2 2 0 91 5 2
Burner Weishaupt RGL 50/1-D ZMD & RGL720 60-1-A 120 8 6 2988 100 13 6 -20 -20%
Burner Weishaupt WG 20 61 55 27 143 133 47 21 105 -9 -18%
Burner Weishaupt WG 30 90 58 24 28 217 52 21 25 -6 -11%
Burner Weishaupt WG 40 N/1-A 148 48 12 94 357 44 13 69 -4 -10%
Burner Weishaupt WG-30N 138 64 21 200 274 59 21 163 -5 -8%
Burner Weishaupt WM G10/3-A 156 59 18 6 103 66 28 4 7 11%
Burner Weishaupt WM-G20/2-A 183 38 6 2
Burner Weishaupt WTC-GB 54 22 8 4 235 41 7 4 19 47%
burners Zantingh OTHER 405 64 10 5 506 73 4 5 9 12%
burners Zantingh RKB 600 960 61 0 1 2628 86 0 1 25 29%
boilers Ålborgt Værft 932 52 0 1 1633 54 0 1 3 5%
AVG 3%
TE= E1 + E2
With:
TE = Total emissions
E1 = Emission of the population, for which we have measurements
E2 = Emission of the population, for which we do not have measurements
Ei = ni Qi EMFi [kg] : Sum of the emissions for the whole group of appli-
ances of the given model “i”, where Qi is the average gas consumption of
the group of appliances of the same model "i".
E1 = ∑Ei
E2 emission is calculated with default emission factor (the same weighted
average emission factor as used for E1).
There are few differences between the value of emission factor by group
when we use the average emission measured and the emission weighted
with the volume of gas used. In some cases the emission factor is larger, in
some case it is smaller. Based on 650 data, the weighted average results in
an emission factor that is 1% higher compared to the emission factor
calculated as a plain average of the individual emission factors.
As a result, we can accept the simplification that the average emission factor
of a group of appliances of a given model does not depend on the individual
gas consumption of all appliances used to calculate the emission factor av-
erage. The main reason for that is that emissions and gas consumption with-
in a single group of a given model do not vary so much.
This is, of course, only applicable for a group of appliances of the same type
(= same brand and same model).
DGC-report 21
3 Results
3.1 Phase1: Identifying the appliance population in detail (by
brand and model) in the installation database
The database originally used was divided in 4 tables covering 4 different
ranges of heat input:
- From 120 kW to 1 MW
- From 1 MW to 2 MW
- From 2 MW to 5 MW
- Above 5 MW
1 1336 DGC >10 HNG EJ KENDT 11 22283 1990 3534966 38885 38885 4% No 0 0 0%
2 802 DGC 120-1 WEISHAUPT WG 40 N/1-A 409 424 2004 41005 16771 55656 6% 16771 16771 2%
3 1282 DGC 5-10 WEISHAUPT G70/2-A 15 7295 1994 800793 12012 67668 8% 12012 28783 3%
4 1312 DGC >10 DANSTOKER TDB 1 34364 2000 11910084 11910 79578 9% No 0 28783 3%
5 729 DGC 120-1 WEISHAUPT G 3/1-E, GL 3/1-E, RGL 3/1-E, G3/1-E ZMI 258 421 1989 42108 10864 90442 10% 10864 39647 4%
6 993 DGC 1-2 WEISHAUPT G7/1D 300-1750 KW 104 1350 1993 101161 10521 100962 11% 10521 50168 6%
7 795 DGC 120-1 WEISHAUPT WG 30N/1-A 632 223 1993 16510 10434 111396 12% 10434 60602 7%
8 1395 DGC >10 AALBORG INDUSTRIES
MISSION TM OM 25t/h 1 19380 2001 10000000 10000 121396 14% No 0 60602 7%
9 1365 DGC >10 Saacke/Bentone SG 60/80/100/150 10 13094 1986 897281 8973 130369 15% No 0 60602 7%
10 741 DGC 120-1 WEISHAUPT G3/1-E 235 432 1992 36795 8647 139016 15% 8647 69249 8%
11 975 DGC 1-2 WEISHAUPT G 7/1-D, GL 7/1-D, RGL 7/1-D, G7/1-D ZMI 81 1253 1991 103693 8399 147415 16% 8399 77648 9%
12 1338 DGC >10 HOLLENSEN GASMASTER 6 17075 1996 1387398 8324 155740 17% No 0 77648 9%
13 1284 DGC 5-10 WEISHAUPT RGL 70 1/A 10 7359 2001 820516 8205 163945 18% 8205 85853 10%
14 1162 DGC2-5 WEISHAUPT G9/1-D GL9/1-D 36 2577 1990 218575 7869 171813 19% 7869 93721 10%
15 1132 DGC2-5 WEISHAUPT G 50/2-A 17 3600 2006 460085 7821 179635 20% 7821 101543 11%
16 732 DGC 120-1 WEISHAUPT G 5/1-D, GL 5/1-D, RGL 5/1-D.ZMI 126 643 1991 61394 7736 187370 21% 7736 109279 12%
17 1141 DGC2-5 WEISHAUPT G10/1-D, GL10/1-D,RGL 10/1-D 33 2836 1991 234160 7727 195098 22% 7727 117006 13%
18 1354 DGC >10 RAY BGE 1500 3 14124 1999 2568838 7707 202804 23% No 0 117006 13%
19 1271 DGC 5-10 WEISHAUPT G 70/2-A, RGL 70/2-A, RGMS 70/2-A 10 8208 1991 745111 7451 210255 23% 7451 124457 14%
20 748 DGC 120-1 WEISHAUPT G5/1 122 684 1993 59615 7273 217528 24% 7273 131730 15%
This differentiation (column A3) was not really used in the project, and the
tables were merged into a single one; but for practical reason we have con-
tinued to keep this reference/info in the database. As a result the same burn-
er or boiler can sometimes be found in two (or more) lines of the merged
Table 6.
Once cleaned, the population database looks like Table 6 that first can be
used to assess what is the degree of market coverage when looking at the
known data available from GASTECH.
3.1.1 Ranking
For each line (= burner/boiler type) in the population database we calculate
the total gas consumption by multiplying the number of installed appliances
with the average gas consumption. The result (total gas consumption) is
used to get an approximate ranking of the most influential appliances on the
overall emission factor (a more exact ranking should take the emissions into
account, but this will eliminate from the list the appliances, for which we do
not have emissions.
For each line we check if we do or do not have GASTECH data on the very
specific burner or boiler. This is done for the 1397 lines of the database.
The last column shows a first result which is the coverage of the data avail-
able when only using the data from GASTECH on the very specific burner
or boiler type.
The final figure is 37% of the total gas consumption covered by NOx emis-
sion statistics, but as we will see we can considerably improve this figure
when using additional tests done by DGC and extension of result to similar
burners/boilers (see next section).
Figure 8 shows how much the first ranked appliance types are influencing
the overall figure of emissions.
Figure 8 The first 200 appliances types represent 80% of the total gas
consumption
Taking “only” the top 200 appliance types will cover already 80% of the
market. This is achieved by a few single users with a huge consumption
(e.g. AALBORG INDUSTRIES) and a number of popular burners (e.g.
WEISHAUPT WG 40 and WG 30) with more than 1000 burners installed.
The first 200 appliance types in the ranked list represent more than 5600
appliances on a total of about 10500 of the total installed in Denmark.
This means that keeping the focus on the top 200 or so would be most
cost-effective for the project. (We have, however, used all appliance
types to perform the calculations as seen later on, but put special atten-
tion to the top 200 and less attention to the next 1100 or so).
NOx or air excess (O2 or CO2) measurement was not executed, so we elimi-
nated those from the statistics (e.g. lines 2225 and 2226 in the table). Also
burner names can be spelled differently so we have also checked this and
corrected when possible in order to harmonize with the population database
so that the names in GASTECH database match the “Appliance type” names
defined for the population database.
For some burners, only Pmin (indicated M1) or only Pmax (M2) were
measured (e.g. line 2056). The available test was integrated in the statistics
(if not excluded for the reasons above).
- Efficiency (Virkn)
- NOx calculated as air free (ppm) (NOxst in Table 9)
This work in the GASTECH database is repeated for all burners that are
identified from the population database (there is no need to do this work
for all burners of GASTECH list if we cannot find them in the population
database.) We have in this way created Table 10 Emission reference list
table.
Note that “Riello GAS ALL” are all burners of type Riello Gas, whatev-
er the model, and the statistics do not include the other Riello burners.
Table 10 Emission reference list table
NOx emissions statistics Pmin NOx emissions statistics Pmax
Pmin NOx Std Number Pmax NOX Std Number
kW ppm-daf ppm-daf - kW ppm-daf ppm-daf -
Burner/Boiler Name Kolonne1 Kolonne2 Kolonne3 Kolonne4 Kolonne5 Kolonne6 Kolonne7 Kolonne8
Burner Bentone BG 100 and BG 150 35 43 9 19 0 43 9 19
Burner Bentone BG 200 72 75 14 151 85 78 7 14
Burner Bentone BG 300 94 71 17 194 141 67 13 118
Burner Bentone BG 400 & 450 137 75 15 260 250 98 396 190
Burner Bentone BG 500-2 256 85 15 60 417 75 16 58
Burner Bentone BG 600-650-700 422 78 13 43 691 70 15 31
Burner BENTONE OTHER 129 73 17 224 315 71 18 84
Burner BENTONE RG 90-2 274 68 9 31 497 68 8 30
Burner Bentone SG 140-2 465 77 13 9 860 76 12 8
boilers Buderus Logano Plus GB 312/241 67 12 6 34 227 27 12 28
boilers Danstoker DHA 2036 108 18 4 1741 98 13 4
boilers Danstoker Global 646 37 10 8 2183 42 13 7
boilers Danstoker TDC 1207 42 26 7 4429 36 8 6
boilers Danstoker TVB 1193 85 18 25 2303 85 16 25
boilers Danstoker VB 227 72 10 25 379 72 11 25
boilers Danstoker VBN 443 73 21 49 788 74 24 46
Burner Danstoker VEH 542 79 6 10 1701 78 13 9
burners Dunphy all 162 57 22 133 512 60 19 121
Burner ELCO EG 02.14 131 32 0 1 0 32 0 1
Burner ELCO OTHER 531 75 21 21 1166 73 20 19
boilers Eurotherm overall 1012 86 1 3 1959 86 3 3
boilers LOOS OVERALL 426 70 20 9 679 74 26 9
boilers LOOS ULS 712 48 7 2 1464 55 11 3
Burner Ray BCEG 1000 3744 99 4 2 4577 101 5 2
burners RAY PG 519 88 39 12 587 121 73 9
burners Rendamax R9/105 107 91 32 27 276 163 71 27
Burner Riello Gas 5/2 283 64 16 4 523 71 11 4
burners Riello GAS All 172 80 14 24 297 82 15 17
Burner Riello RS 28 Gulliver 110 86 6 7 240 78 7 7
burners Sacke GLS 55 1184 34 2 4 3908 39 6 3
Burner Viessmann VITOCROS 300 and other 64 22 13 82 231 27 11 76
Burner Viessmann Vitocrossal 200 90 32 5 4 234 42 11 3
Burner Weishaupt WKGL 40/2-A & WKGL 1466
70/Z-A ZMD109 13 9 3743 102 13 9
Burner Weishaupt G1/1-E 114 74 14 13 240 69 13 12
Burner Weishaupt G10/1-D-ZDM 739 93 15 22 1848 88 8 18
Burner Weishaupt G11/1-D 739 93 15 22 1848 88 8 18
Burner Weishaupt G3/1-E 215 72 15 97 383 67 13 92
Burner Weishaupt G30/2-A 264 49 21 2 0 46 0 2
Burner Weishaupt G40/1-A 211 77 12 2 0 77 12 2
Burner Weishaupt G5/1 - D ZMAD - LN 253 49 6 2 468 41 5 2
Burner Weishaupt G5/1-D 356 68 15 51 629 69 15 49
Burner Weishaupt G50/1-B 542 60 9 2 1278 55 6 2
Burner Weishaupt G50/2-A 753 99 26 4 1966 83 24 5
Burner Weishaupt G60/2-A 712 91 14 5 1742 93 11 4
Burner Weishaupt G7/ 1-ZMD 521 64 18 47 1013 60 19 43
Burner Weishaupt G70/2-A 785 49 6 3 1548 52 9 3
Burner Weishaupt G-8/1-D 739 93 15 22 1848 88 8 18
Burner Weishaupt G9/1D 739 93 15 22 1848 88 8 18
burners WEISHAUPT OTHER 159 62 21 311 433 64 26 169
Burner Weishaupt RG 70/1-A - ZM 1157 87 2 2 0 91 5 2
Burner Weishaupt RGL 50/1-D ZMD & RGL720 60-1-A 120 8 6 2988 100 13 6
Burner Weishaupt WG 20 61 55 27 143 133 47 21 105
Burner Weishaupt WG 30 90 58 24 28 217 52 21 25
Burner Weishaupt WG 40 N/1-A 148 48 12 94 357 44 13 69
Burner Weishaupt WG-30N 138 64 21 200 274 59 21 163
Burner Weishaupt WM G10/3-A 156 59 18 6 103 66 28 4
Burner Weishaupt WM-G20/2-A 183 38 6 2 0 38 6 2
Burner Weishaupt WTC-GB 54 22 8 4 235 41 7 4
burners Zantingh OTHER 405 64 10 5 506 73 4 5
burners Zantingh RKB 600 960 61 0 1 2628 86 0 1
boilers Ålborgt Værft 932 52 0 1 1633 54 0 1
DGC-report 28
(*) For Tflue < 200 C, Combustion room type 3ZF and combustion room load = 1- 3
MW/m3
Small boilers
Some boilers have integrated burners, for example the Buderus Logano Plus
GB 312/241 which is a relatively small condensing boiler (Pmax from ap-
prox. 90 to 280 kW) and is therefore registered as a boiler in the databases.
In this case, of course, we use the boiler name as “appliance type”.
Large boilers
For large boilers (e.g. Danstoker) that are used for district heating etc., the
size is several MW, and in addition to the boiler model the emissions very
DGC-report 31
much depend on the burner installed. In many cases, we do not have the
burner names installed on Danstoker boilers.
Therefore, we have chosen not to use results of tests from one large boiler
to other boilers of the same brand, but different model. For example for
DANSTOKER TVB we have test data that are used for all DANSTOKER
TVB boilers, but not extended to DANSTOKER VB, for which we do not
have measured data.
Table 13 shows which data from the Emission reference list table was used
for each of the lines of the population database.
In many cases, the choice is straightforward as the names from both the ref-
erence list (based on GASTECH data) and appliance population database
are well “connected”. In other cases, we had to make individual decisions
on which reference to use or not to use, based on the explanation given pre-
viously in this section.
Table 13 Ranked population database with affiliation of a reference for
the NOx emissions
A1 B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11
Rank Appliance type Appliance used from GASTECH database Pmin NOX Std n Pmax NOX Std n Data source (indicated for
measurements the TOP200): for the rest
see B2
kW ppm Std n kW ppm Std n
daf daf
avg 59,9 63,1 7,294
1 HNGEJ KENDT no data
2 WEISHAUPT WG 40 N/1-A Weishaupt WG 40 N/1-A 148 48 12 94 357 44 13 69 DATA GASTECH
3 WEISHAUPT G70/2-A Weishaupt G70/2-A 785 49 6 3 1548 52 9 3 DATA GASTECH
4 DANSTOKER TDB Ray BCEG 1000 3744 99 4 2 4577 101 5 2 DGC measurement --> RAYBGE C-1000
5 WEISHAUPT G 3/1-E, GL 3/1-E, RGL 3/1-E, G3/1-E
Weishaupt
ZMI G3/1-E 215 72 15 97 383 67 13 92 DATA GASTECH
6 WEISHAUPT G7/1D 300-1750 KW Weishaupt G7/ 1-ZMD 521 64 18 47 1013 60 19 43 DATA GASTECH
7 WEISHAUPT WG 30N/1-A Weishaupt WG 30 90 58 24 28 217 52 21 25 DATA GASTECH
8 AALBORG INDUSTRIES MISSION TM OM 25t/h DGC data 85 1 85 1 DGC in situ measurement
9 Saacke/Bentone SG 60/80/100/150 Bentone SG 140-2 465 77 13 9 860 76 12 8 statistics other burners /same manufacturer
10 WEISHAUPT G3/1-E Weishaupt G3/1-E 215 72 15 97 383 67 13 92 DATA GASTECH
11 WEISHAUPT G 7/1-D, GL 7/1-D, RGL 7/1-D, G7/1-D
Weishaupt
ZMI G7/ 1-ZMD 521 64 18 47 1013 60 19 43 DATA GASTECH
12 HOLLENSEN GASMASTER DGC data 63 1 63 1 DGC in situ measurement
13 WEISHAUPT RGL 70 1/A Weishaupt RG 70/1-A - ZM 1157 87 2 2 0 91 5 2 DATA GASTECH
14 WEISHAUPT G9/1-D GL9/1-D Weishaupt G9/1D 739 93 15 22 1848 88 8 18 DATA GASTECH
15 WEISHAUPT G 50/2-A Weishaupt G50/2-A 753 99 26 4 1966 83 24 5 DATA GASTECH
16 WEISHAUPT G 5/1-D, GL 5/1-D, RGL 5/1-D.ZMIWeishaupt G5/1-D 356 68 15 51 629 69 15 49 DATA GASTECH
17 WEISHAUPT G10/1-D, GL10/1-D,RGL 10/1-D Weishaupt G10/1-D-ZDM 739 93 15 22 1848 88 8 18 DATA GASTECH
18 RAY BGE 1500 RAY OTHER 0 0 0 0 0 0 0 0 statistics other burners /same manufacturer
19 WEISHAUPT G 70/2-A, RGL 70/2-A, RGMS 70/2-A
Weishaupt G70/2-A 785 49 6 3 1548 52 9 3 DATA GASTECH
20 WEISHAUPT G5/1 Weishaupt G5/1-D 356 68 15 51 629 69 15 49 DATA GASTECH
This was done for approx. 1400 lines from the population database (see ex-
tended list in Annex 3).
As mentioned, attention was given to the top 200 of the ranked list, and as
the bottom of the list has almost no impact on the global NOx emission fac-
tor, less effort was made to find the most appropriate reference for each of
the appliances in the population database.
With the method described, we have achieved all in all a very fine coverage
of the appliance population database and found reference NOx emissions for
about 73% of the gas consumption of the entire population of appliances
Gas consumption
For the appliances, for which emission data are known 73%
For the appliances, for which emission data are not known 27%
DGC-report 34
A1 Rank
C1 The average emissions Pmin/Pmax: (B4+ B8)/2 ppm
C2 The converted value above in mg/kWh (*) mg/kWh
C3 Total gas used (*) kWh
C4 Emissions (= C2.C3)/106 kg
C5 U3 extrapolation (Uncertainty see para. 3.3.3) % rel.
C6 U4 Pmax / Pmin (Uncertainty see para. 3.3.3) % rel.
C7 U Total (Uncertainty see para. 3.3.3) % rel.
C8 Total NOx (in 1000 kg) = C4/1000 for appliances with data only 1000 kg (t)
C3' Total heat input: same as C3, but for appliances with data only kWh
C9 Gas consumption in GJ (= 0,036. C3’) GJ
(*) GAS USED FOR THE CALCULATIONS = natural gas DK 2014 See Annex 7
1397
TE =
C8i [kg]
i 1
TGC=
C 9i [GJ]
i 1
From the above we can now calculate the overall emission factor:
EF= TE/1000.TGC
The final value obtained for the emission factor is 34,4 g/GJ
U1 = 5%
𝐔𝟐 = √𝟓𝟐 + 𝟓𝟐 + 𝟓𝟐 = 8,7%
With n being the number of samples measured for a given appliance type.
As seen previously, correcting from gas volume used does not bring much
difference in the results, and therefore we have not weighted the uncertainty
with gas consumptions. The gas consumption will, however, be taken into
account when calculating a total overall uncertainty with all appliance types.
For a number of cases we only have a single measurement and thus a stand-
ard deviation of 0. In these cases, we used the hypothesis that extrapolating
the results to the entire population of the same appliance would lead to an
uncertainty of 18% (Fixed value in the upper range of observed value for the
appliances where we have several measurements).
Overall
We carry out the a total uncertainty calculation with the following hypothe-
sis:
- we suppose that the emissions of the appliances, for which we have
no emissions data, have the same emission factor as the average
weighted emission factor of appliances, for which we have emission
data.
- We suppose that EF calculation by appliance types are independent
from each other .
DGC-report 39
The TOTAL uncertainty resulting from the calculation with the figures and
hypotheses given here leads to a final uncertainty of 7,1% rel. on the
value given of EF.
DGC-report 40
Regulatory limit
Regulatory limit
It appears that
- new regulations are impacting the NOx emissions
- there is a technology evolution (becoming visible when making average
(see next figure)
DGC-report 41
The next figure is perhaps a more obvious way of visualizing the decrease
of the EF. It also shows that the trend is not only due to regulation changes
as the decrease has started before the introduction of the new limits.
Regulatory limit
Regulatory limit
The blue data points in Figure 14 represent single installations and the pur-
ple solid line represents the NOx emission limit for new boilers. The dotted
purple line represents the emission limit for an old (before 2001) boiler that
is upgraded with a new burner. Hence, the data points between the regula-
tion lines for the period 2001 to 2013 do not represent installations in con-
flict with regulation unless they are completely new installations. The year
of installation we have available in our database is for the latest burner in-
stallation. The few data points above the dotted line after 2001 represent
sites with a too high NOx emission.
DGC-report 42
The evolution of the EF can depend very much on the regulations for new or
existing installations. The above evolution is supposed to represent the actu-
al evolution in case the present regulation is unchanged.
There are several boilers and burners on the market, for which EF is below
20 g/GJ (some very close to 10 g/GJ), that would be able to contribute effi-
ciently to a faster decrease of the overall EF.
4.2 Overall
Figure 16 shows that the values of EF are not correlated to appliance types
having low or high consumption (in this way, no action on specific market
segment will have a high impact).
DGC-report 43
5 Conclusion
The study demonstrated that actual emission factor for NOx is about 34,4
g/GJ based on 2011 data.
The background data for the conclusion is solid as we have an extended
detailed database of existing appliances (population database), for which the
model of appliance and the actual gas consumption is recorded.
The information was combined with almost 14.000 individual test results of
NOx emission executed by GASTECH, and it covers very well the existing
population of appliances. We estimated to have data for a population con-
suming 73% of the gas (either directly from GASTECH or by estimates on
basis of similar burners; some DGC tests have also been carried out).
6 References
[1] Evaluation of the NOx emissions of the Danish population of gas boilers
below 120 kW. DGC 2014
[2] GUM - Guide to the expression of uncertainty in measurement (ISO)
[3] Contract SMT4 – CT95 1606 Improvement of inter-laboratory repro-
ducibility for NOx and CO measurement. 1996-1998. DGC and several
European partners
DGC-report 46
(*) For Tflue < 200 C, Combustion room type 3ZF and combustion room load = 1- 3 MW/m3
DGC-report 47
The figures below show how the values measured by GASTECH compare with the nominal val-
ues given to DGC by Weishaupt. The column "measured value “in Weishaupt's table was used
for this comparison. We had some uncertainty, as the nomenclature used to record appliances in
the GASTECH database did not conform 100% to the one received by Weishaupt.
However, it is clear that for the models, for which we have no doubts, that the values measured
compare well with the data given by Weishaupt.
DGC-report 48
1. Definitions
(CO)m and (NOx)m: Measured concentrations expressed in ppm (volume/volume), in the
sample taken during the combustion test [(NOx)m = (NO)m + (NO2)m]
(CO2)m and (O2)m: Measured concentrations expressed in % (volume/volume), in the
sample taken during the combustion test.
(CO2)n: The maximum carbon dioxide content of the dry-air free combustion products in
% (volume/volume).
O2 air: Percentage (vol/vol) of O2 in air (O2 air = 20.95% is to be used when no other
value is known).
The value in dry-air free emission in ppm (X1) is calculated from the measured concentration in
the flue (X0),
either using O2 measurement with:
O2 air
X1 = (X0)m [ppm]
O2 air (O2 ) m
Where
Hi is the net calorific value: Expressed in MJ/m3 at 15°C (gas volume at 15°C and 101,
325 kPa)
Vfd: Volume of dry combustion products per unit of volume or mass of gas during stoi-
chiometric (neutral) combustion m3/m3 or m3/kg.
O2 = 0%
O2 = 3%
O2 = 0%
O2 = 3%
We have used the above conversion for G20 for the work of this report. The fact is that the con-
version factor does not vary much with the gas composition (example for G30 is quite far from
G20 it is 1.792 instead of 1.764).
DGC-report 52
1 1336 DGC >10 HNG EJ KENDT 11 22283 1990 3534966 38885 38885 4% No 0 0 0%
2 802 DGC 120-1 WEISHAUPT WG 40 N/1-A 409 424 2004 41005 16771 55656 6% 16771 16771 2%
3 1282 DGC 5-10 WEISHAUPT G70/2-A 15 7295 1994 800793 12012 67668 8% 12012 28783 3%
4 1312 DGC >10 DANSTOKER TDB 1 34364 2000 11910084 11910 79578 9% No 0 28783 3%
5 729 DGC 120-1 WEISHAUPT G 3/1-E, GL 3/1-E, RGL 3/1-E,258
G3/1-E ZMI 421 1989 42108 10864 90442 10% 10864 39647 4%
6 993 DGC 1-2 WEISHAUPT G7/1D 300-1750 KW 104 1350 1993 101161 10521 100962 11% 10521 50168 6%
7 795 DGC 120-1 WEISHAUPT WG 30N/1-A 632 223 1993 16510 10434 111396 12% 10434 60602 7%
8 1395 DGC >10 AALBORG INDUSTRIES
MISSION TM OM 25t/h 1 19380 2001 10000000 10000 121396 14% No 0 60602 7%
9 1365 DGC >10 Saacke/Bentone SG 60/80/100/150 10 13094 1986 897281 8973 130369 15% No 0 60602 7%
10 741 DGC 120-1 WEISHAUPT G3/1-E 235 432 1992 36795 8647 139016 15% 8647 69249 8%
11 975 DGC 1-2 WEISHAUPT G 7/1-D, GL 7/1-D, RGL 7/1-D,81
G7/1-D ZMI
1253 1991 103693 8399 147415 16% 8399 77648 9%
12 1338 DGC >10 HOLLENSEN GASMASTER 6 17075 1996 1387398 8324 155740 17% No 0 77648 9%
13 1284 DGC 5-10 WEISHAUPT RGL 70 1/A 10 7359 2001 820516 8205 163945 18% 8205 85853 10%
14 1162 DGC2-5 WEISHAUPT G9/1-D GL9/1-D 36 2577 1990 218575 7869 171813 19% 7869 93721 10%
15 1132 DGC2-5 WEISHAUPT G 50/2-A 17 3600 2006 460085 7821 179635 20% 7821 101543 11%
16 732 DGC 120-1 WEISHAUPT G 5/1-D, GL 5/1-D, RGL 5/1-D.ZMI
126 643 1991 61394 7736 187370 21% 7736 109279 12%
17 1141 DGC2-5 WEISHAUPT G10/1-D, GL10/1-D,RGL 10/1-D
33 2836 1991 234160 7727 195098 22% 7727 117006 13%
18 1354 DGC >10 RAY BGE 1500 3 14124 1999 2568838 7707 202804 23% No 0 117006 13%
19 1271 DGC 5-10 WEISHAUPT G 70/2-A, RGL 70/2-A, RGMS 70/2-A
10 8208 1991 745111 7451 210255 23% 7451 124457 14%
20 748 DGC 120-1 WEISHAUPT G5/1 122 684 1993 59615 7273 217528 24% 7273 131730 15%
21 1236 DGC 5-10 RAY BGEC700 4 7924 1985 1752670 7011 224539 25% No 0 131730 15%
22 1094 DGC2-5 RAY EG 500 5 4744 1984 1397426 6987 231526 26% No 0 131730 15%
23 1065 DGC2-5 HNG EJ KENDT 12 3036 1999 571900 6863 238389 27% No 0 131730 15%
24 1270 DGC 5-10 WEISHAUPT G 70 / 2 - A (1000 - 10500KW 6 7908 2009 1130780 6785 245174 27% 6785 138515 15%
25 1190 DGC 5-10 DANSTOKER DHA 10 6921 1998 641760 6418 251591 28% No 0 138515 15%
26 978 DGC 1-2 WEISHAUPT G 8/1-D, GL 8/1-D, RGL 8/1-D 61 1635 1991 102470 6251 257842 29% 6251 144765 16%
27 1314 DGC >10 DANSTOKER TVB 10 24130 1998 623842 6238 264080 29% No 0 144765 16%
28 1260 DGC 5-10 SAACKE SKVJG 4 6500 1998 1552386 6210 270290 30% No 0 144765 16%
29 1311 DGC >10 DANSTOKER Solo kedel 4 18936 1995 1514685 6059 276349 31% No 0 144765 16%
30 1238 DGC 5-10 RAY EG 500 7 5846 1990 858496 6009 282358 31% No 0 144765 16%
31 1393 DGC >10 ZANTINGH RKB 1000 ND 9,0 MM G 5 12749 2009 1201154 6006 288364 32% No 0 144765 16%
32 1245 DGC 5-10 SAACKE GLS 95 3 8300 2007 1995665 5987 294351 33% No 0 144765 16%
33 1362 DGC >10 Saacke DG100 3 15657 1992 1959134 5877 300228 33% No 0 144765 16%
34 733 DGC 120-1 WEISHAUPT G 7/1-D, GL 7/1-D, RGL 7/1-D,70
G7/1-D ZMI
875 1995 78867 5521 305749 34% 5521 150286 17%
35 1324 DGC >10 Dunphy HBG - 6.140 1 11812 2006 5438065 5438 311187 35% No 0 150286 17%
36 1295 DGC 5-10 WEISHAUPT WKGL 70/2 - A 4 7470 2005 1350677 5403 316590 35% 5403 155689 17%
37 1153 DGC2-5 WEISHAUPT G50/2-A 15 3632 1999 352136 5282 321872 36% 5282 160971 18%
38 1390 DGC >10 ZANTINGH RKB 1000 5 12679 1993 1051321 5257 327129 36% No 0 160971 18%
39 1296 DGC 5-10 WEISHAUPT WKGL 70/2-A(ZMH) 5 9355 2003 1030426 5152 332281 37% 5152 166123 19%
40 909 DGC 1-2 HNG EJ KENDT 24 1375 1996 213591 5126 337407 38% No 0 166123 19%
DGC-report 54
A1 B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11
Rank Appliance type Appliance used from GASTECH database Pmin NOX Std n Pmax NOX Std n Data source (indicated for
measurements the TOP200): for the rest
see B2
ANNEX 5: Calculations
A1 Rank
C1 The average emissions Pmin/Pmax: (B4+ B8)/2 ppm
C2 The converted value above in mg/kWh (*) mg/kWh
C3 Total gas used (*) kWh
C4 Emissions (= C2.C3) g
C5 U3 extrapolation (Uncertainty see para. 3.3.3) % rel.
C6 U4 Pmax / Pmin (Uncertainty see para. 3.3.3) % rel.
C7 U Total (Uncertainty see para. 3.3.3) % rel.
C8 Total NOx (in kg) = C4/1000 for appliances with data only Kg
C3' Total heat input: same as C3, but for appliances with data only kWh
C9 Gas consumption in GJ (= 0,036 . C3’) GJ
A1 C1 C2 C3 C4 C5 C6 C7 C8 C3' C9
Rank Avg Total gas used Emissions U3 U4 Pmax / U Total Total Nox Total heat Gas
emissions extrapolat Pmin input consumpti
ion on
Table1 of the report shows conversion factor for various gases. This annex shows how the F fac-
tor was calculated for Danish gas 1993 and 2014.
For G20, G25 and G31, the value below are standard values given by [3]
We have recalculated the value for CH4, just to make sure that the method used above was cor-
rect. This is confirmed as the value calculated is the same as the standard value.