SuperFlow - Canetis

SuperFlow™

Data Sheet Outlining the Technical Solutions and

Product Opportunities for a High Performance

Domestic Hot Water System

Confidential Information of Canetis Technologies Limited – October 2017 2

Contents Overview ................................................................................................................................................. 3

Introduction ............................................................................................................................................ 4

Deployment Options ........................................................................................................................... 6

Existing Combi-Boiler Retrofit ......................................................................................................... 6

New Builds ...................................................................................................................................... 7

Larger Houses .................................................................................................................................. 8

Regulation Changes................................................................................................................................. 9

SuperFlow – “a new era in DHW performance” ................................................................................... 11

Stage 1 – Retrofit SuperFlow ............................................................................................................ 11

Test Results ................................................................................................................................... 14

In Summary ................................................................................................................................... 16

Further Work ................................................................................................................................. 16

Stage 2 - Optimised SuperFlow For Improved Efficiency .................................................................. 16

Stage 3 - Boiler Aware Integrated SuperFlow ................................................................................... 16


Overview The heating and hot water industry has for many years focussed attention of improved

heating efficiency while Domestic Hot Water (DHW) production has been driven more by

comfort levels normally expressed in litres per minute. However, improved building

insulation, tighter emission controls and emerging regulations aimed at addressing overall

systems efficiency, require innovative solutions that present new opportunities to increase

revenues of core product sales.

An innovative solution from Canetis Technologies Limited (Canetis) called SuperFlow is a

patented DHW technology that helps address both regulatory requirements and improves

performance and comfort levels for the consumer. SuperFlow provides a simple add-on to

improve DHW for both new and existing combination gas boilers, ranging from low cost

retrofit of any standard wall hung combination boiler through optimised accessories as well

as new-integrated core platforms required for emerging standards.

SuperFlow is unique in that it optimises the cold water temperature to a combination boiler

by providing a sustained, on-demand preheat function that works to address the negative

effect of seasonality thereby increasing the delivery of DHW to the boiler’s maximum

potential even during the coldest winter months. Consequently, SuperFlow reduces the

instantaneous gas required to deliver a standard temperature rise/litre per minute rate of

DHW or put another way, when comparing a standard 30kW combination boiler, for the

same instantaneous gas rate, SuperFlow will virtually double DHW output culminating in an

average increase of ~36% over a 10-minute period sufficient to deliver over 100 litres of

DHW, all from a pocket sized 25 litre thermal store that can recover to a primary flow

temperature setting in under two minutes.

SuperFlow provides a significant step forward in the direction of improved hot water

comfort while at the same time enabling lower heat input combination boilers to deliver

recognised levels of DHW with improved heating efficiency and in the UK improved SAP

scores. In addition, SuperFlow also creates new market opportunities for low cost passive

renewables, for example 12-volt photo voltaic solar that can be used as both preheat to the

gas boiler and as part of the SuperFlow strategy to help reduce electricity consumption for

household appliances that would otherwise use mains electricity to heat water e.g. washing

machines.


Introduction SuperFlow is a unique patented solution that addresses the problems associated with

combination boilers and electrical water heating appliances that heat domestic hot water

during the winter months.

In essence, Superflow works by selectively preheating the incoming cold water via a small

cylinder, called a temporal store, that can be heated from the boiler’s heating circuit, or an

immersion heater and/or an optional plug-in solar preheat kit.

Fig 1 - Typical UK heating and hot water interaction

Fig 1 shows the typical interaction between heating and hot water for a UK home and while

other EU countries may have different heating and hot water temperature ranges, most do

operate around a 9am to 5pm Monday through Friday work day. Therefore, it’s possible,

depending on levels of optimisation, to perform a balance between space heating and hot

water delivery to further improve overall efficiency. For example, a heating system that is

due to shut down may elect to recovery some heat energy from the heating system to the

SuperFlow store for the benefit of DHW or future space heating needs.

Currently, there are two capacities of SuperFlow cylinder available including a small 25 litre

under-sink store and mid-sized 50 litre vessel suitable for larger properties, that includes a

further feature of a second heat exchanger coil used to maintain a pumped hot water

circuit, reducing the time it takes to deliver hot water to remote points of use.

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The key objectives of SuperFlow can be described as:

• Improved efficiency

o Reduced hot water losses compared with traditional cylinder based options

o Lower heat input requirement for like for like DHW performance

o Pre-heat input water to 30°C optimises hot water generation

o SuperFlow operational running costs ~£1 per annum

▪ As heat loses 250Wh/day * 85% useful =0.0375Wh/day * 250

operational days = 9.3kwhs heat loss per annum ~£1e operational

costs. (Note: Operational costs would be negative given that the pre

heat originates from space heating with higher seasonal efficiency

transferred to DHW generation)

• Comfort

o 25 litre Super Flow store & 30kW combination boiler equivalent to 200 litre

G3 unvented cylinder

o Two-minute recovery time.

• Savings

o Lower gas consumption and CO2 emissions

o SuperFlow has a smaller equipment footprint, when compared to the likes of

a G3 unvented cylinder, with equivalent hot water output capability

o Lower initial purchase price and installation costs when compared to a G3

unvented cylinder – a few hundred pounds vs >£2.5k

o Lower water bills through reduction in lukewarm water rejection


Deployment Options

Existing Combi-Boiler Retrofit SuperFlow can easily be retrofitted to any existing make, model or brand of combi boiler

Fig 2 - Retrofit SuperFlow, where boiler primary flow passes through the store, requires no controls or

electricity supply.


New Builds

SuperFlow is ideal for new builds saving the developer space and cost whilst improving SAP

scores

Fig 3 – 50 litre SuperFlow configuration for new build project designed as low loss header


Larger Houses SuperFlow can also be configured for larger, multi-bathroom, houses to provide a hot water return.

Fig 4 - Multi SuperFlow configuration for large house project including secondary return

Figs. 2, 3 & 4 represent varying installation design options based on either the 25 or 50 litre

stores. Alternative store designs and capacities are available including polystyrene

atmospheric open vent and grey water heat recovery.


Regulation Changes The UK Government is now embarking on a new era of heating and hot water efficiency

with the imminent announcement of Boiler Plus. Commencing in Q2 2018, Boiler plus sets

new mandated efficiency standards for boiler installations across both new build and the

replacement market. Additionally, Minimum Energy Efficiency Standards (MEES) relating to

landlord responsibilities for the minimum efficiency of residential let property captures both

private and social housing within the scope of this policy.

Boiler Plus requires that every new boiler installed must be installed with one of four

product options.

Passive Flue Gas Heat Recovery (PFGHR) aka “Super Condensing”

Product Cost SAP Benefit Total SAP Comments

GasSaver £400 - £500 17% 17% DER benefit & consumer saving of £100 to £200 per annum

SuperFlow £400 - £500 4% 21% Addn. DER benefit & increased consumer DHW comfort

Solar PV (SuperFlow top-up)

£250 - £500 1.5% 22.5% Addn. DER benefit – developers save between £1k to £10 per new home

Weather Compensation


Weather Comp

£50 - £100 1.7% 1.7% No real payback

Load Compensation


Load Comp £100 - £250 0.5% 0.5% No real payback

Smart Controls


Smart Home System

£250 - £1000 0.5% 0.5% No real payback

N.B. Dwelling Emission Rate (DER) SAP savings for Canetis are normally cumulative and %

savings are house type dependent.


When adding GasSaver to SAP calculations, SAP removes the benefit of Weather

Compensation as GasSaver negates the need for additional controls due to super

condensing efficiency and heat recovery capability.

Weather Compensation, Load Compensation and Smart Home Systems are already

identified by the Government as life style products that only offer energy savings when

consumers are engaged in their operation. However, GasSaver & SuperFlow are recognised

for their improved energy efficiency as they are passive devices requiring no user

intervention.

Fig 5 below highlights SAP benefits for Canetis GasSaver & SuperFlow in SAP for various

wooden frame house types. Savings vary depending on many factors including post code,

orientation and method of construction. Typically, GasSaver scores highest for smaller new

build homes whilst a GasSaver & SuperFlow combination scores best for larger multi-

bathroom properties.

Fig 5 - Worked SAP calculation benefits for GasSaver & SuperFlow solutions.


SuperFlow – “a new era in DHW performance” This documents highlights the opportunities relating to SuperFlow; GasSaver is discussed

separately, however, GasSaver and SuperFlow are mutually beneficial, forming a central

strategy of the Canetis Home Energy Centre.

The SuperFlow solution recognises a number of new product concepts that aim to build

increased revenue potential through improved customer satisfaction and UK SAP benefits.

These product opportunities are time-lined as specific staged goals:

• Stage 1 - Retrofit SuperFlow solution for existing wall hung combination boilers

• Stage 2 - Optimised solution for improved efficiency of SuperFlow enabled boilers

• Stage 3 - Boiler aware integrated SuperFlow for new product platforms and

submission to EN standards

The goals outlined above are framed by overriding project and individual product objectives.

Objectives are defined as:

• Initial product offering based on ‘low tech, high impact’ retrofit solution for existing

Vaillant and non-Vaillant wall hung combination boilers.

• Initial product should be single skill two-hour installation.

• Low cost, improved cost benefit through simplicity, non-user intervention operation

• SuperFlow optimization through extended product sales into boiler replacement

market. Optimization to include, timed operation, installation design options and

variable SuperFlow store capacities

• Full boiler aware integration with extended energy management and delivery

options

• New store designs and future product concepts including plastic atmospheric stores

selecting primary or grey water storage mediums.

Stage 1 – Retrofit SuperFlow The SuperFlow Stage 1 product is based on the understanding that there are over 15 million

existing wall hung combination boilers in the UK. Traditional combination boilers are

popular with home owners due to their compact dimensions and dependable hot water

delivery. However, hot water output is substantially reduced during the winter months due

to the cooling of the incoming cold water supply.


Fig 6 - Temperature seasonality curve of cold water overlaid by SuperFlow delivery temperature

The above graph shows the range of cold water temperature and how the active SuperFlow

preheat substantially benefits the winter period.

Stage 1 SuperFlow consists of a kitchen cupboard sized store of approximately 25 litres

known as a temporal store. It is proposed that the store be sited near to the boiler and

plumbed directly into the primary flow before being circulated to the heating circuit.

Alternatively, and optional three port valve may be used in conjunction with a time clock to

enable selective heating of the store. However, given the small capacity and location of the

store, it is thought that a heat loss of 250Whs per day would result in a heat loss of ~£1 per

year. Any heat loss should be considered in light of the reduced gas consumption during hot

water production, improved hot water delivery and reduced water consumption through

the reduction in lukewarm water rejection, estimated at over £65 per year for a family

home.

The existing SuperFlow 25 litre store has been tested and found to deliver a range of

performance depending on the temperature of the primary heating circuit. It is estimated

that the mean primary heating water temperature is ~70 degree Centigrade. Tests show

that when heated to a temperature of 80 degrees Centigrade the store is able to deliver

over 100 litres of preheated water benefit. This delivery of preheated water would virtually

double the useful winter heat to water capability of existing wall hung combination boilers

e.g. the Worcester Junior 24kW.


Fig 7 - SuperFlow hydraulic principle of operation

UK homes traditionally have baths that require ~75 litres of hot water. Therefore, during

the winter months it will be necessary to reduce the flow rate of a traditional combination

gas boiler in order to produce sufficient hot water temperature. Whereas a SuperFlow

equipped boiler would maintain maximum flow rate for the same hot water requirement.

For example, filling a bath requires hot water at ~50 degrees Centigrade. During the winter

months the cold water supply might be only 5 degrees centigrade, a Worcester junior boiler

capable of 10 litres per minute at a 30 degree centigrade temperature rise will only produce

water at 35 degrees Centigrade. In order for the boiler to achieve 50 degrees Centigrade

then the flow rate will have to be reduced to approximately 5 litres per minute as a 15

degrees’ centigrade short fall on temperature is half of the boiler’s output capability.

Therefore, it will take more than 15 minutes to fill a bath.

Superflow changes the user’s experience as the store preheats the incoming supply to an

optimum temperature ~30 degrees centigrade. As a consequence of the preheat the boiler

can operate at its full 10 litres per minute flow rate and still achieve the target temperature

of 50 degrees centigrade to fill the bath in 7 minutes, or half the time.


Fig 8 - SuperFlow benefits for a range of primary temperatures

The Fig 8 chart above shows an extrapolation of the preheat to water benefit of the store

compared with primary flow temperature from the boiler. It is normal for boilers in the UK

to operate in the temperature region of between 60 and 80 degrees centigrade and often

with a primary flow of 80 degrees centigrade.

Test Results

It is recognised that the existing 25 litre temporal store is unable to give up all its heat

energy to water. This is thought to be due to the vertical thermocline stratification of heat

separation zones caused by the continual high volume flow rates associated with 100 litre

draw off requirements. However, this stratification does not affect 75 litre baths, shorter

tapings or shower rates. Also, after each hot water draw-off, the heating circuit recharges

the store in under two minutes. This means that for an average family with a 75 litre bath

fill or standard 8 litres per minute shower rate, they would never fully deplete the store.


Fig 9 25 litre SuperFlow test at 8 litres per minutes

Following SuperFlow tests Fig 9 above shows the output graph for an 8 litre per minute

graph for DHW at 60 degrees centigrade. The key to the graph shows:

• V_dhw is the flow rate of DHW from 10 to 60 degrees centigrade

• P_dhw, superflow (KW) is the heat input benefit of the SuperFlow store

• P_dhw, Boiler (KW) is the heat input of the boiler during the test

• P_dhw, Total (KW) is the combine Superflow and boiler heat input in (KW

The test demonstrates that –

1. For the first 2 minutes, and 16 litres of water, 60% of the heat to water was derived

from the SuperFlow store.

2. Over the first 5 minutes, and 40 litres of water, 50% of the heat to water was

derived from the SuperFlow store.

3. For the first 7 minutes SuperFlow provided an average of heat to water benefit of

11.2kW equivalent to 45% of the total heat input. The boiler heat input averaged

13.3kW.

Overall the test shows that SuperFlow raises the maximum flow rate for the boiler from 10

litres per minute to 14.5 litres per minute.


In Summary

Stage 1 “Retrofit SuperFlow” is a unique hot water product solution that addresses both

seasonality and dynamic demand for hot water production. SuperFlow 25 can be easily

installed into an existing combination boiler’s heating and hot water circuit, typically taking

less than two hours to install.

In addition to the combination boiler’s cold water pre-heat benefits, the temporal store may

be equipped with a 12volt solar PV top-up pre-heat while the increased water temperature

from the store may be used to preheat the cold water supply to washing machines or

dishwashers that would otherwise use more expensive electricity to heat water.

Further Work

The 25 litre temporal store has been designed around the needs of a UK family with a

combination boiler, however, it is thought that some additional R&D input may be able to

improve the heat transfer capability that might further reduce the size of the store from 25

litres to 15 litres?

Stage 2 - Optimised SuperFlow For Improved Efficiency SuperFlow optimisation options include smart load and weather compensation that

recognises the concept of a home energy store where additional energy, for example when

weather compensation lowers primary temperature, over temperature primary circuits may

be diverted to warm the store. Additionally, load compensation may benefit from carry

over primary heated water from one day to the next thereby reducing the energy required

to either reheat the home from cold or for the betterment of DHW supply.

Another Canetis technology, the patented Kelvin Energy Recovery System (KERS) extends

the operational concept of SuperFlow to include a Passive Heat Recovery Store (PHRS)

operates as a store and forward or use function and includes primary temperature

modulation and pump over-run functions as a trigger for managing residual heated water.

A key advantage for SuperFlow as the basis for optimisation in the home stems from the

fact that this is low and possibly lower technology using existing materials and methods of

construction in a simple engineer system model.

One objective for the system will be, unlike existing controls that are essentially life style

choices, an optimised SuperFlow and KERS enabled Home Energy Centre provides the basis

for passive non-intervention heat management that could be recognised in UK building

regulations.

Stage 3 - Boiler Aware Integrated SuperFlow The objective here is to integrate SuperFlow into new boiler and product platforms to

provide additional ease of installation and user benefits and also, over time, to enable the

submission of SuperFlow technology into EN Standards.

The background to this strategy and thinking is as follows -


Europe is on an historic trajectory for the electrification of heating and transportation,

however, with the emergence over the past few years of Liquid Natural Gas (LNG) is

reshaping the global economic model. LNG is a cheap and clean fuel that could be used to

extend our time line for the development of affordable, infinite energy. Today, this is not

possible and as of now European consumers are paying an ever-increasing price for their

essential heating and hot water needs. This upward cost of energy feeds directly into cost

of living and political stability. Therefore, it can only be a matter of time before regulations

reconsider the carbon saving statements of an historical policy and engage with LNG.

One thing we do know is that the impending changes to ErP will require boilers to be

labelled in accordance with other forms of heating technologies. Therefore, it will be

absolutely necessary for the boiler industry to reformulate their efficiency statements to

include broader system and economic efficiency including resource management.

To meet this future demand, boiler manufacturers will be required to produce a new super

condensing combination boiler that includes an optimised SuperFlow, KERS and strategy in

the form of the Canetis Home Energy System. Given that ErP changes are scheduled for

2021 then the boiler industry already needs to be moving along this trajectory.

However, in order for new innovations in core gas boiler products, it will be necessary to

align the emergence of test standards that recognise the benefits of system’s thinking to

include upstream economic and resource benefits.

SuperFlow - Canetis

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