Fulton’s PURE Technology approach achieves world-first steam boiler design
Fulton’s all-new gas-fired, vertical spiral-rib tubeless steam boiler, the VSRT, is the first to emerge from a new ‘PURE Technology’ approach. This is an initiative that results in a world-first design that is durable, long-lasting, and boasts the highest efficiencies and ultra-low NOx emissions.
The VSRT adopts a systems-engineering approach in implementing PURE Technology. The result is a clean-slate design approach that combines new people with new skills bringing a new approach to the design and optimisation of heat transfer solutions. Fulton’s VSRT radically challenges the heat transfer and mechanical design principles of traditional steam boilers. It’s also claimed to be the most radical change to vertical steam boiler design since Fulton pioneered the vertical tubeless boiler in 1949.
Commenting, Fulton’s Leigh Bryan says: “To meet stringent industry and environmental standards, PURE Technology looks to enhance heat transfer, provide class-leading efficiencies, improve steam quality, and reduce NOx emissions. Rather than improve existing products to achieve this, PURE Technology radically challenges conventional boiler design by engineering solutions that are fit-for-purpose and application.”
With over 15 patents pending in three continents, the VSRT’s attains industry-leading heat transfer rates due to a unique spiral-rib heat exchanger. This achieves low stack temperatures by passing the flue gases through a spiral-wound heat exchanger that is fully immersed in water.
The spiral-rib design benefits from an extended heat transfer path and dual-direction heat flow, with the spiral annulus designed and optimised to create high heat transfer rates. This optimises heat transfer to improve efficiency and create a longer-lasting boiler. With virtually zero thermal stress, a thick-walled construction and featuring vertical tubeless design architecture, Fulton believes it will beat the competition in every category of durability.
A fully-water-backed pressure vessel is wrapped in high-density insulation to achieve minimal thermal losses and low outer surface temperatures; and the tubeless design has created a compact boiler with minimal footprint. No refractory also means significantly lower weight to ease installation.
The VSRT’s combustion technology achieves ultra-low NOx emissions of <20ppm and features a fully-matched modulating burner and furnace that have been purposely-designed as a single component. This helps to achieve >10:1 turndown capabilities and industry-leading performance of >82.5 per cent gross thermal efficiency and 99.75 per cent steam quality at 8 bar. When correctly sized for applications, the exceptionally high turndown will result in savings above-and-beyond those gained from the stated efficiencies.
With a tubeless design, no internal refractory, industrial control platform and easy access to the pressure vessel, the VSRT is easy to maintain and operate. Maintenance is further improved due to a revolutionary air filter where, for applications where contaminated air can reduce boiler uptime. A cyclonic air filter separates debris and damaging particles from the combustion air and eliminates the need for replacement filters.
The VSRT is currently available with outputs from 160-960 kg/h, complies with the City of London Air Quality Strategy and anticipated MCPD regulations, is constructed to BS EN 12953 and CE marked to PED. Its pressure vessel and burner are backed by a five-year guarantee as standard.
With manufacturing facilities in the U.S, the UK, and China, Fulton is a global manufacturer of steam, hydronic and thermal fluid heat transfer systems. Backed by over 60 years of research, innovation and experience, Fulton is building on a tradition of success and is focused on improving life through heat transfer solutions. The company also provides sales and application advice, with full commissioning and after sales service, to a growing customer base in numerous sectors including pharmaceutical, process, petrochemical, healthcare, food & beverage, processing, etc.
For additional information about Fulton, please visit www.fulton.co.uk.