4000 gallons of hot water an HOUR?

Dave Mayer -3 Sons Heating

Gentlemen:
I am a service manager of an oil company in Massachusetts. My owner, today, approached me with the possibility of replacing a failed gas boiler that produces 3000 gallons an hour of hot water. The customer wants his new boiler to produce 4000 gallons per hour as the old boiler runs out from time to time. The water is used to make concrete from October to April. The new boiler will be used almost solely for this purpose, I may ad a couple of small modines the customer has into the mix. Any ideas or experiences? I have many possibilities running through my mind but I am curious if anyone out there has played with this type of hot water demand. Thank You in advance, Dave

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kf_2

hot water

Dave,

What is the temperature rise? In other words, what is the temperature coming in before it is heated and what does it need to be heated to.

The calculation is pretty simple.

What kind of gas boiler was there before? Was there any storage, direct or indirect.


kf

Al Letellier

lotsa hot water

Try staging multiple boilers or tankless heaters. Rinnai claims they can meet almost any hot water demand with "banked heaters" May be too big for them, but the concept is sound. Multiple heaters are more efficient.

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flange

even if you assumed a 100 degree rise, thats not an awfully big boiler. is this water being reused or is it going into the cement? this would help to determine how to approach the job. if it were me, i'd think about multiple boilers two or three unless there is constant demand.

Dave Mayer -3 Sons Heating

4000 gallons

Thank You, The incoming water is street temperature (40-55 degrees). The optimum temperature for the water is 180 degrees. The plant is currently using a 2,000,000 BTU gas boiler. Obviously it is going to be oil (the new one). The current boiler is using a tankless. The water is being used to make the concrete, 500 gallons at a whack, that is 500 gallons every 5-7 minutes. The even funner part is this boiler also produces live steam which is supplied with a 2"main and bushed to 3/4" that is "sprayed" on the frozen aggregate as it is loaded into the concrete hopper. This live steam is not used every day only during frigid weather so therefore I will probably utilize a large residential boiler for this and the 4 modines. I have looked into big Bock direct fired (the 200 series). My original plan was to use 3 and stage them as need requires with a large tank to "buffer" the demand. The bocks will produce circa 1350 gallons per hour a piece but the price per unit is exorbidant. Thank You, Dave

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kevin coppinger_4

does TFI/everhot have something?

they have some pretty neat HX to offer. Check out tfi/everhot.com The EA series can do some big #'s kpc

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kf_2

hot water

Dave,

In order to produce the amount of hot water you need at a 140 degree rise calls for a boiler with an output of 4,664,800 BTU/hr.
BTU= amount of energy required to raise 1 POUND of water 1 degree F.

4000 gal x 8.33 lbs/gal x 140 degree rise = 4,664,800 BTU's

kf