AR No.

--- - Install High Efficiency Burners

(ARC 2.1221.2)
Recommended Action
It is recommended to replace the current burners on the makeup air units machines with high
efficiency burners, recupertors, and air/fuel controls.
Estimated Energy Savings = 1914.67 MMBtu/yr (19,146 therms/yr)
Estimated Cost Savings = $12748/yr
Estimated Implementation Cost = $12000
Simple Payback Period = 0.94 years
Background
Currently, at this facility, makeup air units are equipped. According to facility personal, on
average, the makeup air units are used 8 hours per day, 4 days per week, and 52 weeks per year
for about 1664 hours.
Based on manufacturer literature provided by several burner manufacturers, it is estimated that
the efficiency of the current top burners could be increased by a fraction of about 15%. That
could be achieved by utilizing new burners equipped with recuperates, and automatic air/fuel
controls.
Anticipated Savings
The annual gas savings, ES, which could be realized by using high efficiency burners are
estimated as follows:
ES

N x BR x FL x OH x FS / K

N
BR
FL
OH
FS
K

=
=
=
=
=
=

number of burners considered, 3 burners

burner rating, 3,345,000 Btu/hr
estimated fraction of total load at which kiln operates, 25%
annual operating hours of the kiln, 5088hrs/yr
estimated savings fraction, 15%
conversion constant, 1,000,000 Btu/MMBtu

where

Thus,
ES
ES

=
=

3 x 3345000 x 0.25 x 5088 x 0.15 / 1,000,000

1914.67 MMBtu/yr

The annual cost savings, CS, are then estimated to be:

CS
CS
CS

=
=
=

ES x (effective gas cost)

1914.67 MMBtu/yr x ($ 6.658/MMBtu)
$12748/yr

Implementation Cost
The implementation cost of this recommendation is estimated to be the cost of labor and material
needed to retrofit the kiln. It is estimated that each burner costs about $4000 to be replaced.
Thus, the total implementation cost is estimated to be about $12000. The cost savings of
$12748/yr would pay for the implementation cost in about 0.94 years.