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RF MacDonald Co. offers sales, packaged systems design, service, installation, and parts for our customers! 

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BACKGROUND: In order to comply with current San Joaquin Valley Unified Air Pollution Control District air pollution control requirements, Franzia winery in Sanger needed to replace an aging “D” style industrial watertube boiler of the 1950s vintage.  The goal was to utilize an existing 31,000 lb/hr boiler that was no longer in service and still in good condition.  This boiler was to be transported from another plant, retrofitted with a new burner and new controls, and then installed with all new accessories (Deaerator, Water Softener, Economizer, Chemical Feed System, Surface Blowdown Conductivity Controller).  The objective was to provide a system with a good payback (based on a short operating season) by minimizing capital expense, maximize system efficiency, meet Air Control Requirements, and provide local/remote monitoring capabilities of system process values and flue gas emissions.

PROJECT: The inception of the project began in 1997 when the plant manager began evaluating his options to replace the boiler.  R.F. MacDonald worked closely with the plant manager to provide initial budgeting and project engineering to evaluate a variety of options, including a new boiler and new accessories.  Because of the limited number of hours the plant operated each year and the desire to maximize the value of capital dollars, the plant manager choose to retrofit an existing boiler that THE WINE GROUP owned.
  
BURNER: The boiler was retrofitted with a POWERFLAME VECTOR-series Low Emission burner to operate at less than 30 ppm NOx and 200 ppm CO. A POWEFLAME AUTOFLAME parallel position system (MICRO-MODULATION) was used in conjunction with the AUTOFLAME EGA (Exhaust Gas Analyzer) module, and DTI (Data Transfer Interface) module.  The EGA system provides O2 trimming and also continuous monitoring of the NOx and CO levels.  The emission, stack temperature, and steam pressure data is logged in the DTI for system evaluation and emission reporting to the local air pollution control district.  The O2 trimming is providing them with optimum efficiency 24 hours a day when the nights are cold and the days are hot.  The efficiency savings is estimated at a minimum 1% fuel savings per year

Economizer:  A CANNON model FJ-8-CC5 Economizer was designed for continuous feed of deaerated water with a low gas side pressure drop.  The fuel savings, based on $0.31/therm at 75% firing rate for 2000 hours of operation per year, are estimated at $9,280/yr.  This will provide FRANZIA with  $92,800 savings over 10 yrs!

Accessories: Franzia ensured the protection of their new boiler system by purchasing a SHIPCO deaerator, Lakeside twin water softener system, Aquatrac surface blowdown conductivity controller, and San Joaquin Chemical Feed system.