Armstrong Flo-Direct (AFD)

ARMSTRONG FLO-DIRECT
(AFD)
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Topics of Discussion
• Industrial HW System Layout
• Markets
• How does it work
• FAB’s
• Typical Applications
• Paybacks
• Examples
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Promote the System
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Industrial Hot Water Markets
CHEMICAL CONCRETE
FOOD LABORATORY REFINERY
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Flo-Direct ® Opportunities
• Plant Sanitation • Boiler Make-up Water
• Laundries • Animal Slaughter &
• Tanneries further processing
• Textile • General Food Industry
• Chemical Plant • Beverage Production

Washdown & Process • Concrete Plants
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WHAT IS IT
HOW DOES IT OPERATE
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Efficient Hot Water
• Double “Pass” Unit
– 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
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How does it operate?
• Incoming Water
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• Dispersion Nozzles
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• Burner
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• Flame Tube
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• Heat Flow
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• Heat Transfer
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• Lower Chamber
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• Exhaust
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• Alarms
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FAB’S
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High-efficiency burner/blower for low
carbon monoxide and nitrous oxide Low Exhaust temperatures typically
emissions. Able to meet stringent between 50F and 90F allow for
emission standards. 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 Modular fuel train using slide out
easy troubleshooting. 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
Small footprint because the burner is
transfer pump (included) which delivers
installed on top of the unit and not on the
heated water to application.
side. No side clearance required.
Efficient Hot Water
Stack Cool to the

Touch
Structural
Controls
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Efficient Hot Water
99.7%
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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
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Sales Advantages
• Higher Efficiencies
• Same Efficiency Throughout
Operation
• Maintains Higher Water Quality
• Lower C02 Emissions
• Lower Maintenance
• Scale Resistant
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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 165.110
• EU-TRW – The European Union Directives(s) –
Treated Waters: 98/83/EC
• Peoples Republic of China Standards for
Drinking Water: GB5749-2006
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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
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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!
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Flo-Direct Superior Design
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The Flo-Direct Advantage
100% Steam
Boiler
64%
Energy In Energy Out
100% Flo-Direct 99.7%

Energy In Energy Out
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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
99.7%+ Energy Out

Fuel In
Hot Water Out
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H ot W a t e r Pr oduc tion w it h a c onve nt i onal
St e a m Sys t e m
Energy Out
100% Energy In Optimal = 80%
Boiler
Boiler Typical = 50%
System
Fuel In Hot Water Out
Potential Boiler System Loss Metrics
• Inherent Boiler Loss= 15% • Scale Losses = 5%
• Radiant Losses = 1% • Heat Exchange Losses = 5%
• Blowdown Losses = 2.5% • Lost Condensate = 5%
• Air Fuel Ratio Losses = 4%
• Steam Leaks = 3%
• Trap Losses = 10%
Total 50%
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Flo-Direct vs Steam Boiler for generating
Hot Water
99.7%
50%-80%
Boiler
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Boiler vs. Flo-Direct ®
Boiler Use
High
High High
Use
Use Use
Idle Idle Idle
Flo-Direct does not have “idling” periods. It is either on or off.

When it is off it does not use any fuel.
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Common boiler replacement scenarios…..
• Freeing boiler availability for process applications
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Common boiler replacement scenarios…..
• Shutting down under utilized boilers
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C os t Sa vi ng pot e ntia l of a 7 , 0 0 0,00 0 B TU Fl o - D irec t ®
W a t e r H e a t e r ove r B oi l e rs w ith H e a t Ex c ha ngers :
– Hours per day continuous usage:

10
– Gallons per minute average usage:
112
– Gallons per day consumed:
67,200
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C os t Sa vi ng pot e ntia l of a 7 , 0 0 0,00 0 B TU Fl o - D irec t ®
W a t e r H e a t e r ove r B oi l e rs w ith H e a t Ex c ha ngers
1. Hours per day continuous usage 10 hours

2. Natural Gas cost per 1,000 cubic feet $3.50 p/1,000 cu.ft.
3. Days of operation per year 260 days
4. Gallons per minute average usage 112
5. Temperature of heated water 150°F
6. Temperature of incoming water 40°F
7. Temperature change (degrees delta) 110°F
8. Boiler efficiency 80%
9. System efficiency 80%
Resulting Boiler/System efficiency 64% (when new)
Flo-Direct Heater Efficiency 99.7% (or more)
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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 $120.58 x 260 days = $31,350.28 Savings per
year!
Emissions Savings
• 1,047,726 pounds of CO2 saved yearly
• Grants for lowering fuel usage and pollutants available in some areas
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Additional Annual Savings of Flo -Direct ®
Water Heaters Over Boilers
( I f t he AFD c a n e l i m inat e t he m c om pl etely)
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

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Payback potential of Flo -Direct ® Water Heaters
Versus Using Steam Boilers to make Hot Water
Total Yearly Savings $ 48,215.69
Armstrong Flo-Direct 7000 $ 60,000.00
Installation $ 60,000.00
Total Cost $120,000.00
Payback Period 30 Months
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EXAMPLES
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Flo-Direct®
with storage
tank and
VFD
Multiple AFD Installation
Flo-Direct®
with
integral
tank
Hot Water in a Box
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Superpod
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AFD 80,000 Concept
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Coming Soon……
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Online Resources
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Armstrong University
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THANK YOU
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Armstrong provides intelligent system
solutions that improve utility performance,
lower energy consumption, and reduce
environmental emissions while providing an
enjoyable experience.
North America • Latin America • India • Europe
Middle East • Africa • China • Pacific Rim
ARMSTRONGINTERNATIONAL.COM

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ARMSTRONG FLO-DIRECT

FOOD LABORATORY REFINERY

• Textile • General Food Industry

• Chemical Plant • Beverage Production

Electrical programmable logic controller

Stainless Steel Pall Rings

Stainless steel construction with a ten-year

Stack Cool to the

• Modular Systems 80MBtu+

• It is not the best for “people washing”

• In the correct applications there is………

100% Flo-Direct 99.7%

• No Loss Out The Stack

99.7%+ Energy Out

Hot Water Out

Idle Idle Idle

Flo-Direct does not have “idling” periods. It is either on or off.

• Freeing boiler availability for process applications

• Shutting down under utilized boilers

– Hours per day continuous usage:

1. Hours per day continuous usage 10 hours

Fuel Costs (from previous) $31,350.28

Idle and warm-up fuel (approx.) $10,065.41

Total Yearly Savings $48,215.69

Add cost of Boiler Operator if needed

Total Yearly Savings $ 48,215.69

Armstrong Flo-Direct 7000 $ 60,000.00

Total Cost $120,000.00

Payback Period 30 Months

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