The Department of Energy (DOE) announced the successful one-year operation of the first-generation “Super Boiler,” which can deliver 94% thermal efficiency, while producing fewer emissions than conventional boiler technologies.

DOE’s Industrial Technologies Program has supported the development of the Super Boiler since research and development began in 2000. Since then, DOE has provided $4.2 million in funding to support this project.

The Super Boiler was developed by the Gas Technology Institute, Des Plaines, IL. The one-year operation of the boiler is a step toward transforming the energy efficiency of industrial steam generation. Additional tests are planned at Clement Pappas & Co. (Ontario, CA) and Third Dimension Inc. (West Jordan, UT).

The Super Boiler resides at Specification Rubber Products Inc., a subsidiary of American Cast Iron Pipe Co. that manufactures rubber parts for the water works industry. In July 2006, the Gas Technology Institute and Cleaver-Brooks installed a 300-horsepower, high-pressure steam Super Boiler which has been running 24 hours a day, five days a week with promising results. After more than 6,000 hours of operation, fuel to steam efficiency has been consistently in the 93-94% range and annual gas savings have averaged nearly 13%.

The Super Boiler is the culmination of DOE-sponsored research and development by the Gas Technology Institute (Des Plaines, IL) and its partner, Cleaver-Brooks Inc. (Milwaukee, WI). This work has also been supported by Utilization Technology Development (Des Plaines, IL), the Southern California Gas Co. (Los Angeles, CA), the South Coast Air Quality Management District (Diamond Bar, CA), the California Energy Commission (Sacramento, CA) and the California Air Resources Board (Sacramento, CA).

For more information on DOE’s Industrial Technologies Program, visit: http://www.eere.energy.gov/industry.