1. Armstrong Flo-Direct (AFD)

3. Topics of Discussion Industrial HW System Layout Markets
How does it work
FAB’s
Typical Applications
Paybacks
Examples

4. Promote the System

5. Industrial Hot Water Markets
CHEMICAL
CONCRETE
FOOD
LABORATORY
REFINERY

6. Flo-Direct® Opportunities
Plant Sanitation
Laundries
Tanneries
Textile
Chemical Plant Washdown & Process
Boiler Make-up Water
Animal Slaughter & further processing
General Food Industry
Beverage Production
Concrete Plants
+25,000 gallons per day

7. What is it How does it operate

8. Efficient Hot Water Double “Pass” Unit Efficient Heat Transfer
Transfers heat through the heat tube and then as it rises to exhaust through Pall rings
Efficient Heat Transfer
Large temperature differential between the flame and the water
Pall rings produce a large surface for heat transfer
Condenses the water formed during combustion. Approximately 10% of the available heat is normally lost up the stack
Scale Resistant
Virtually “immune” to scale build-up. Heat is on the same side of the metal surface as the water

9. How does it operate?
Incoming Water

10. How does it operate?
Dispersion Nozzles

11. How does it operate?
Burner

12. How does it operate?
Flame Tube

13. How does it operate?
Heat Flow

14. How does it operate?
Heat Transfer

15. How does it operate?
Lower Chamber

16. How does it operate?
Exhaust

17. How does it operate?
Alarms

18. FAB’s

19. High-efficiency burner/blower for low carbon monoxide and nitrous oxide emissions. Able to meet stringent emission standards.
Low Exhaust temperatures typically between 50F and 90F allow for inexpensive CPVC or single-walled stainless for ducting materials.
Water pressure limit switch and high temperature switch shut down the unit for safety if water pressure fails or is accidentally shut off.
Electrical programmable logic controller (PLC) for building automation system compatibility. NEMA 4 (watertight) enclosure, modular components for easy service or replacement. Status lights for easy troubleshooting.
Modular fuel train using slide out components for ease of maintenance or replacement. CSA, UL and FM approved.
Stainless Steel Pall Rings
Stainless steel construction with a ten-year warranty on the structure and its internals.
Indexability of the top portion to the bottom allows for flexibility in rotating for easiest utility hookups. Allows for ease of internal inspection.
Level controls automatically control the transfer pump (included) which delivers heated water to application.
Small footprint because the burner is installed on top of the unit and not on the side. No side clearance required.

20. Efficient Hot Water Low Exhaust Temps Stack Cool to the Touch
10 Year Warranty
Structural
2 Year Warranty
Natural Gas or Propane
Controls
Small Footprint

21. 99.7% Efficient Hot Water No Loss out the Stack No Lost Condensate
No Idling
No Radiant Heat Loss

22. Efficient Hot Water Near Instantaneous
Direct contact of hot gases and cold water
Size ranges of 1MBtu – 15MBtu standard
Produces from 15GPM – 400GPM
Modular Systems 80MBtu+
Output Water Temperatures up to 185°F

23. Sales Advantages Higher Efficiencies
Same Efficiency Throughout Operation
Maintains Higher Water Quality
Lower C02 Emissions
Lower Maintenance
Scale Resistant

24. Global Water Quality Standards
NSF 5 – Food Grade
USFDA – The United States Food and Drug Administration, Code of Federal Regulations Bottled Water Standard: Chapter I, Title 21, Part 165, Subpart B, Section
EU-TRW – The European Union Directives(s) – Treated Waters: 98/83/EC
Peoples Republic of China Standards for Drinking Water: GB

25. Optimum Application > 25,000 gallons per day
Hot water Generated at atmospheric pressure
Hot water temperatures 60°F to 185°F
Hot water is expended and re-heating is not required

26. Flo-Direct® Does Not Fit Every Hot Water Need
It is not the best for “people washing”
A good initial evaluator is: Customer must use 25,000 Gallons of HW per day to see value
When water above 120°F is re-circulated back through the water heater the efficiency is lost because water normally condensed during combustion is now lost out the stack. Reduced efficiency and increased scaling are a byproduct.
In the correct applications there is………
No Better Way To Heat Water!

27. Flo-Direct Superior Design

28. The Flo-Direct Advantage
100%
Energy In
Steam
Boiler
64%
Energy Out
Flo-Direct
100%
Energy In
99.7%
Energy Out

29. Armstrong Flo Direct® Complete Thermal Exchange Gas Fired Water Heaters
No Loss Out The Stack
No Lost Condensate
No Idle Run Time
No Lost Radiant Heat
Hot Water On Demand
100% Energy In
Fuel In
99.7%+ Energy Out
Hot Water Out

30. Hot Water Production with a conventional Steam System
Energy Out
Optimal = 80%
Typical = 50%
100% Energy In
Boiler System
Boiler
Fuel In
Hot Water Out
Potential Boiler System Loss Metrics
Inherent Boiler Loss = 15%
Radiant Losses = 1%
Blowdown Losses = 2.5%
Steam Leaks = 3%
Trap Losses = 10%
Scale Losses = 5%
Heat Exchange Losses = 5%
Lost Condensate = 5%
Air Fuel Ratio Losses = 4%
Total 50%

31. Flo-Direct vs Steam Boiler for generating Hot Water
99.7%
50%-80%
Boiler

32. Boiler vs. Flo-Direct® Boiler Use
High
Use
Idle
Flo-Direct does not have “idling” periods. It is either on or off. When it is off it does not use any fuel.

33. Common boiler replacement scenarios…..
Freeing boiler availability for process applications

34. Common boiler replacement scenarios…..
Shutting down under utilized boilers

35. Hours per day continuous usage: 10
Cost Saving potential of a 7,000,000 BTU Flo-Direct® Water Heater over Boilers with Heat Exchangers:
Hours per day continuous usage: 10
Gallons per minute average usage: 112
Gallons per day consumed: ,200

36. Cost Saving potential of a 7,000,000 BTU Flo-Direct® Water Heater over Boilers with Heat Exchangers
Hours per day continuous usage 10 hours
Natural Gas cost per 1,000 cubic feet $3.50 p/1,000 cu.ft.
Days of operation per year days
Gallons per minute average usage 112
Temperature of heated water 150°F
Temperature of incoming water 40°F
Temperature change (degrees delta) 110°F
Boiler efficiency 80%
System efficiency 80%
Resulting Boiler/System efficiency 64% (when new)
Flo-Direct Heater Efficiency % (or more)

37. Energy & Environmental Savings Potential
Example: 67,200 Gallons per day
At a 100% conversion efficiency the cost would be $216.16
Flo-Direct at 99.7% efficiency would cost $216.81
A boiler at 64% efficiency would cost $336.74
A daily savings of $ x 260 days = $31, Savings per year!
Emissions Savings
1,047,726 pounds of CO2 saved yearly
Grants for lowering fuel usage and pollutants available in some areas

38. $48,215.69 Fuel Costs (from previous) $31,350.28 Chemicals $4,800.00
Additional Annual Savings of Flo-Direct® Water Heaters Over Boilers (If the AFD can eliminate them completely)
Fuel Costs (from previous)
$31,350.28
Chemicals
$4,800.00
Inspections
$2,000.00
Idle and warm-up fuel (approx.)
$10,065.41
Total Yearly Savings
$48,215.69
Add cost of Boiler Operator if needed

39. Payback potential of Flo-Direct® Water Heaters Versus Using Steam Boilers to make Hot Water
Total Yearly Savings $ 48,215.69
Armstrong Flo-Direct $ 60,000.00
Installation $ 60,000.00
Total Cost $120,000.00
Payback Period Months

40. Examples

41. Flo-Direct® with storage tank and VFD

42. Multiple AFD Installation

43. Flo-Direct® with integral tank

44. Hot Water in a Box

45. Superpod

46. AFD 80,000 Concept

47. Coming Soon……

48. Online Resources

49. Armstrong University

50. Thank You