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www.process-heating.com | September 2012 | Volume 19, Number 9
Focus
Pocus
Infrared heaters can be shaped to direct heat
right where it is needed. Target manufacturers
with the capabilities you need using our
Equipment Overview on Infrared.
Periodical Class
13 Increase Boiler Efficiency and Heat Recovery
15 How to Cut Oven Operating Costs
Heat Treating Equipment
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© COPYRIGHT 2012 OMEGA ENGINEERING, INC. ALL RIGHTS RESERVED
Integrated Energy Delivery® Systems
Industrial Heating Solutions for Product Manufacturers
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RADPLANE® Infrared Heaters
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Process Development & Testing
Direct Assistance: Richard Hoffmann, Director of Sales • Email: [email protected]
www.glenro.com • 1-888-GLENRO1
September 2012
Volume 19 • Number 9
www.process-heating.com
WEB EXCLUSIVES:
READ MORE AT WWW.PROCESS-HEATING.COM
■ Maintenance Programs
page
page
13
21
Features
13
Used in conjunction with a heat-tracing system, an advanced control
system centralizes operations, allowing a user to control and vary the
heating cable output to achieve the desired temperature.
A company that develops systems to destroy industrial VOCs has
introduced what it says is the first non-destructive catalytic activity
tester for used catalysts.
Boilers
As boilers age, they can become less efficient, causing an increase in fuel costs.
The main cause of energy inefficiency is system heat loss. Here are several
ways to reclaim the heat loss in an effort to reduce facility operating costs.
Ovens
How to Cut Oven Operating Costs
By selecting the most energy efficient options and features for your oven,
you can reduce your energy use and operating costs considerably.
18
■ Control and Monitoring and Heat Tracing System
■ Test Catalysts for Re-Using or Recycling
Tips to Increase Efficiency and
Heat Recovery in a Boiler System
15
Among other maintenance tasks, certain procedures will help ensure
higher oven efficiencies.
UPDATED DAILY
■ New Products
■ Industry News
ALWAYS ONLINE
■ Archives
■ Calendar of Events
■ Drying Files columns
■ Energy Notes column
■ Equipment Overviews
■ Heating Highlights
■ Digital Editions
■ Buyers Guide
■ Archived Webinars
Check out our redesigned site with more frequent updates and web exclusives!
NETWORK WITH PROCESS HEATING!
■ Quick links point the way:
www.process-heating.com/connect
Chillers
Compressor Cycling Affects Laser Performance
Proper chiller sizing and selection are critical to obtaining optimum laser
performance. The size of the refrigeration system depends upon the heat
load produced by the laser when it is operated for long periods of time at
its maximum average power.
21
Heat Tracing
5 Tips for Preparing Your Heat Tracing for Winter Now
Now is the ideal time to prepare your pipelines for the cold weather ahead
and ensure you have an integrated, maintained pipe-freeze-protection
system in place.
24
Equipment Overview: Infrared Heaters
Fine Focus
Infrared heaters can be shaped to direct heat right where it is needed.
Target manufacturers with the capabilities you need using our Equipment
Overview on Infrared Heaters.
Columns & Departments
6
8
12
26
Editor’s Page
Inner Workings
Calendar
Advertiser Index
28 Product Highlights
29 Classified Directory
30 Places & Faces
■ Go Mobile
Use your smart phone to read Process Heating,
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About the Cover
A semi-cylindrical heater panel
from Radiant Energy Systems Inc.
(www.radiantenergy.com) consists
of 18 T4 lamps to heat a 62" wide
web around a 12" dia. roll. The short
wavelength lamps are controlled by
an optical pyrometer. Due to their
fast response, the emitters from the
Hawthorne, N.J.-based heater maker
are well suited for this application.
To learn more about infrared heaters,
turn to page 24.
PROCESS HEATING (ISSN 1077-5870) is published 12 times annually, monthly, by BNP Media, 2401 W. Big Beaver Rd., Suite 700, Troy, MI 48084-3333. Telephone: (248) 362-3700, Fax: (248) 362-0317. No charge for
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postage); all other countries: $170.00 (int’l mail) payable in U.S. funds. Printed in the U.S.A. Copyright 2012, by BNP Media. All rights reserved. The contents of this publication may not be reproduced in whole or in part without
the consent of the publisher. The publisher is not responsible for product claims and representations. Periodicals Postage Paid at Troy, MI and at additional mailing offices. POSTMASTER: Send address changes to: PROCESS
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Send old address label along with new address to PROCESS HEATING, P.O. Box 2146, Skokie, IL 60076. For single copies or back issues: contact Ann Kalb at (248) 244-6499 or [email protected].
www.process-heating.com • S e p t e m b e r 2 0 1 2
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5
By Linda Becker
Commentary
Designing in Safety
Eliminate or Reduce Hazards
The safest systems are those that eliminate hazards, of course, but
in the process industries, heat and pressure are often a part of the
manufacturing equation. To maximize plant safety, it is important
to regularly evaluate processes and products to see whether another
product, method or even temperature can deliver effective results more
safety. An online video that explains some real-life chemical processing
accidents and how applying the principles of inherent safety could have
prevented them is a great place to start reviewing your own process.
The video, produced by the U.S. Chemical Safety Board,
highlights the four main components of inherently safer design,
first identified by the National Academy of Sciences. Deceptively
simple, the four principal steps — substitute, minimize, moderate
and simplify — define criteria by which any processing facility can
evaluate potential hazards and incorporate inherently safer manufacturing practices. The CSB video describes the concepts:
• Substitute: replacing one material with another that is less hazardous.
• Minimize: reducing the amount of hazardous material in the
process.
• Moderate: using less hazardous process conditions such as lower
pressures or temperatures.
• Simplify: designing processes to be less complicated, and therefore less prone to failure.
“Inherently Safer: The Future of Risk Reduction” uses recent
chemical industry incidents to illustrate how applying inherent
safety principles increase safety. One example cited is the Kleen
Energy explosion which occurred in February 2010. Following the
event, CSB learned that the cause of the accident — purging piping
with natural gas to clear it of debris that could damage the turbines
— was a common practice in the power industry. Yet inherently
safety gases, including compressed air, are just as effective for purging the piping. In this case, change came quickly and with little
resistance from industry to adopting a safer practice.
Take a look around your facility. Are there hazards that the principles of inherent safety could help you mitigate? It needn’t take an
accident to adopt safer practices.
Linda Becker, Associate Publisher and Editor, [email protected]
International design experience...
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S e p t e m b e r 2 0 1 2 • Process Heating
Inner Workings
fired industrial process ovens
or furnaces.
Presented by Pittsburgh-based Bloom
Engineering on September 25 through
27 in Milwaukee, topics include:
Eastman Chemical
Acquires Solutia
Eastman Chemical has bought Solutia
Inc., a maker of heat transfer fluids
and other chemicals based in St. Louis.
Eastman, Kingsport, Tenn., acquired
Solutia for $4.8 billion.
With the acquisition, Eastman has
made structural and reporting changes,
resulting in five reporting segments:
• Specialty Fluids and Intermediates
consists of the specialty fluids product
lines from Solutia’s former Technical
Specialties segment and Eastman’s
oxo and acetyl intermediates product
lines of its former PCI segment.
• Additives and Functional Products
consists of the rubber materials
product lines from Solutia’s former
Technical Specialties segment and
the specialty polymers and solvents
product lines of Eastman’s former
Coatings, Adhesives, Specialty
Polymers and Inks (CASPI) segment.
• Adhesives and Plasticizers consists
of the plasticizer product lines of
Eastman’s former Performance
Chemicals and Intermediates
segment, and the adhesives product
lines formerly in its CASPI segment.
• Advanced Materials consists of
Eastman’s former Specialty Plastics
segment and Solutia’s former
Performance Films and Advanced
Interlayers segments.
• Fibers, which continues to consist
of the acetate tow, acetate yarn and
acetyl product lines.
Solutia’s Photovoltaics business will
be managed as a developing business
initiative and reported as “other” sales
and operating earnings (loss).
The acquisition is expected to expand
Eastman’s geographic reach and
product portfolio, especially in emerging
markets, according to the company.
Bloom Presents
Combustion Webinar
Learn combustion fundamentals at
a seminar designed for employees
responsible for the operation, design,
selection and maintenance of fuel-
GAS BURNERS
• Metal Fiber Burners, Including....
Atmospheric, Premix, Infrared and Blue Flame
• Tubular Shape or Flat Surface Burners
• Any Diameter or Dimension
• Burner Size up to 50,000,000 BTU/Hr.
MICRON FIBER-TECH
230 Springview Commerce Dr., Debary, FL 32713
Tel: 386-668-7895 • Fax: 386-668-7462
E-mail: [email protected] • www.mft-co.com
8
|
•
•
•
•
•
•
•
Fundamentals of combustion.
Industrial burners.
Radiant tube burners.
Ratio control burner turndown.
Fans and blowers.
Burner selection and system sizing.
Combustion safety to meet NFPA 85
and 86.
• Combustion systems with O2
enrichment.
• Heat transfer mechanisms.
• Heat balance.
More details about the $550 seminar
are at www.bloomeng.com.
Steam Systems Maker
Taps Social Media
Industrial product manufacturers are
learning to use social media to build
their customer base.
To stay on top of a growing trend that
will link it more deeply to its customers,
Spirax Sarco Inc. in Blythewood, S.C.,
has launched its first social media
campaign. Embracing Twitter, YouTube
and Pinterest, Spirax plans to keep
followers up to date with steam-system
management news and energy-saving
ideas. The company began by tweeting
technical tips and training information.
Once Spirax’s Twitter account reaches
1,000 followers, the company will give
away an iPad3 to one person. To sign up,
go to www.twitter.com/spiraxsarco_usa.
“We are rapidly moving ahead in the
game of social media by creating viral
campaigns and creating new customer
relations opportunities but not
dropping traditional marketing efforts,”
says Stephen Gow, marketing director.
The firm’s YouTube channel, located at
www.youtube.com/user/spiraxsarcousa,
includes a growing video library to
introduce products and technical
information. On Pinterest, visitors can
see the latest Spirax products by going
to www.pinterest.com and typing in
Spirax Sarco in the search box.
Au g u s t 2 0 1 2 • Process Heating
PH09124MFT.indd 1
8/22/12 4:27 PM
Inner Workings
Combustion
Flue Gas
Analyzers
• Industrial, Commercial,
& Residential use
• Easily replaceable gas
sensors are long life and
low maintenance
Left: Chemical Coaters Association International board member
Larry Melgary, president of Northern Coatings & Chemical
in Menominee, Mich., congratulates Bob Shipley, a chemical
technician at Briggs & Stratton, Milwaukee, on receiving the
User of the Year Award from CCAI’s Wisconsin Chapter. Right:
Bruce Bryan, director of sales at Chicago-based Mighty Hook,
has earned the Chemical Coaters Association International’s
2012 James F. Wright Lifetime Achievement Award. Bryan, a
CCAI past president, is a board member.
• Simultaneously analyze
up to 4 gases
• Upgradeable internal
flash memory
• Up to 10 selectable
fuel types
• Rechargeable batteries
and built-in printer
Seminar Covers Infrared Basics, Applications
The IRED (infrared) division of the Industrial Heating
Equipment Association will present a one-day seminar,
the “Ins and Outs of IR and IR Applications,” as part of the
Finishing Technologies Conference at FabTech 2012 on
www.palmerwahl.com
(800) 421-2853 [email protected]
y
Specif
Aitk en Process Modules
Aitken offers a variety
of infra-red metal sheath heaters
for virtually any drying application. They
feature heavy-duty elements designed for continuous operation at ambient temperatures up to 350 o F.
They afford high shock resistance - both physical and thermal and there are no ceramic parts to deteriorate or break. Most units can
be shipped within 24 hours. Visit our website at www.aitkenproducts.com.
1-800-569-9341
www.process-heating.com • S e p t e m b e r 2 0 1 2
|
9
Inner Workings
November 12 in Las Vegas.
The seminar will review infrared
basics, including an explanation of the
technology, how it is produced and
what its characteristics are. Attendees
also will learn about infrared
equipment and hear a discussion of
infrared applications, showcasing how
infrared can be used in today’s industrial environment.
For more details and to register for the seminar, go to
www.ihea.org.
ELECTRIC HEATERS, CUSTOMIZED & STOCK
Hotwatt has maintained leadership
in manufacturing resistance
heating elements for over 60
years. Products include cartridge,
air process, immersion, strip and
ﬁnned strip, tubular and ﬁnned
tubular, band, crankcase, foil, ﬂexible
glasrope and ceramic heaters. We
are a quality supplier to OEM,
Industrial, Medical, Commercial,
Packaging, Instrumentation, Aviation,
Transportation and Military ﬁelds.
The size, sheath, terminations and
ratings can be adapted to your
heating requirements.
Hotwatt, Inc.
(978) 777-0070;
FAX: (978) 774-2409
e-mail: [email protected]
www.hotwatt.com
For over 50 years, we have provided Electrical Safety Equipment for the
Industry. For complete info, contact us at [email protected].
Visit our website at www.protectioncontrolsinc.com
10
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S e p t e m b e r 2 0 1 2 • Process Heating
Register Now for Coating Show
Coating 2012, an industrial coating event dedicated entirely
to liquid and powder coatings, is open for registration.
Held October 9 through 11 in St. Louis, the trade show and
conference provides an opportunity for networking among
coating professionals.
The event offers attendees the following:
• Opportunities to advance skills and technical knowledge.
• Meetings with leading manufacturers, distributers,
suppliers and contractors.
• Technical conference.
• Central U.S. location.
• Introduction of new product technologies.
• Auction with opportunity to purchase coatings-related
products and services at low prices.
For more information and to register, go www.coating-show.com.
Sensors, Controllers Catalog
Configured for Smart Phones, Tablets
Watlow, a St. Louis-based manufacturer of complete thermal
systems, has introduced its new sensors and controllers
catalog in multiple formats.
The guide includes product descriptions, specifications,
features, benefits, applications, line drawings and photos of the
Inner Workings
company’s full line of temperature sensors, wire,
cable, temperature controllers, power controllers and
supporting software.
Divided into two sections, the catalog first lists Watlow’s
sensors, wire and cable products, followed by its temperature,
process and power controllers, and supporting software
listings. Users have a choice of format: print, downloadable
PDF at www.watlow.com, CD or electronic flip book for use
on smart phones and tablets.
for the combustion of natural gas, avoiding the associated
greenhouse gas emissions of CO2, nitrogen oxides (NOX) and
methane, the company says.
“We see this as the next step forward in wider acceptance
of CGT technology,” says Edward Spink, TurboSonic CEO. “Due
to the similarity of this particleboard process and emissions
to the oriented-strand board [OSB] process, we believe this
will lead to the successful introduction of CGT into the large
OSB market.”For more information on CGT technology, go to
www.turbosonic.com/products/cgt.
Treated Dryer Exhaust VOCs Meet EPA Rules
A clean-air technology system installation has been
tested and confirmed to be in compliance with the U.S.
Environmental Protection Agency’s air pollution control
regulations for plywood and composite wood products,
according to the system’s maker.
TurboSonic Technologies Inc., Waterloo, Ont., says the
installation, which treated the combined exhaust gases
from a particleboard press and dryer to reduce VOC
(formaldehyde and methanol) emissions, is the third one at
Arauco-USA’s Moncure, N.C., wood-panel production facility.
Other installations, which treated exhaust gases from a
medium-density fiberboard dryer and press, previously were
determined to meet applicable regulations, TurboSonic says.
The manufacturers’ CGT technology eliminates the need
• Short & Medium Wavelength Infrared Emitter Quartz Lamps
• Designed & Engineered To Your Speciﬁcations
• Advanced Heat Analysis And Proﬁling With Thermal Imaging Technology
• On-site Technical Visits For Heat Analysis And Engineering Support
• Unsurpassed Service & Customer Support
• 100% Product Guarantee
PH07124Emitted.indd 1
CPM Wolverine Proctor LLC
251 Gibraltar Road
Horsham, PA 19044
Phone: 215.443.5200 Fax: 215.443.5206
Email: [email protected]
www.cpmwolverineproctor.com
6/25/12 2:04 PM
CPM Wolverine Proctor LTD
3 Langlands Avenue
Kelvin South Business Park
East Kilbride
Glasgow, UK G75 0YG
Tel: 44 (0) 1355.575350
Fax: 44 (0) 1355.575351
www.wolverineproctor.co.uk
Email: [email protected]
www.process-heating.com • S e p t e m b e r 2 0 1 2
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11
Calendar of Events
September
19-22 — Association of Water
Technologies (AWT) Annual Convention
and Exposition, Palm Springs, Calif. Call
(301) 740-1421 or visit www.awt.org.
17-18 — Combustion Technology
Seminar and Exhibition, Cleveland.
Hosted by Industrial Heating
Equipment Association (IHEA).
Call (859) 356-1575 or visit
www.ihea.org.
23-25 — SPE Thermoforming
Conference, Grand Rapids, Mich.
Hosted by Society of Plastics Engineers,
Thermoforming Div. Call (706) 235-9298
or visit thermoformingdivision.com.
24-25 — Thermal Oxidizers Seminar,
Tulsa, Okla. Hosted by John Zink Co.
LLC. Call (918) 234-5710 or visit
www.johnzink.com.
24-27 — International Pump Users
Symposium, George R. Brown
Convention Center, Houston. Hosted by
Turbolab, Texas A&M University. Call (979)
845-7417 or visit turbolab.tamu.edu.
Did you know
that 90% of heat
transfer fluid
breakdowns
are caused by
equipment issues?
25-27 — AHR Expo-Mexico 2012,
Mon-terrey, NL, Mexico. Hosted by
co-sponsors ASHRAE and AHRI.
Call (203) 221-9232 or visit
www.ahrexpomexico.com.
26-28 — Process Flare Seminar, Tulsa, Okla.
Hosted by John Zink Co. LLC. Call (918)
234-5710 or visit www.johnzink.com.
Listing and temperature range chart for all Paratherm heat transfer fluids.
October
1-2 — Process Burner Fundamentals
Seminar, Tulsa, Okla. Hosted by John
Zink Co. LLC. Call (918) 234-5710 or visit
www.johnzink.com.
If you just check your hot-oil on a regular
basis you could practically eliminate unplanned
shutdown or loss of production. The easy way
to do this is by conducting a Fluid Analysis.
Because Fluid Analysis isn’t just to check
your fluid, it’s to test your system.
When we test your fluid (we suggest
annually or more frequently for demanding
service) the values we get from boiling range,
viscosity, and acidity tell us what’s going on in
there. Better yet, together with a one-to-one
system review with you, those same test
results can help pinpoint emerging issues with
oxidation, over-heating, or possible mismatches
in those interrelated components that could
lead to a downtime-causing problem.
This can help you keep the system up when
it’s supposed to be up, and know in advance if
any corrections are needed for when you do
have scheduled downtime. Your system runs
better, your fluid last longer, and your process
earns its keep.
Make your
system more
profitable, more
sustainable.
Services
Fluid Analysis
Fluid Maintenance
Products
Paratherm
Paratherm
Paratherm
Paratherm
Paratherm
CR® HTF
MR® HTF
LR™ HTF
HR™ HTF
HE® HTF
|
S e p t e m b e r 2 0 1 2 • Process Heating
1-4 — Boiler Operator (Level I) Training
Seminar, Garden City, Kansas. Hosted
by Kansas Industrial Technical School.
Call (620) 271-0037 or visit
www.boilerlicense.com.
Training
Troubleshooting
Consulting
Paratherm
Paratherm
Paratherm
Paratherm
Paratherm
Paratherm
NF® HTF
OR® HTF
GLT™ HTF
SC® Cleaner
LC™ Cleaner
AC™ Cleaner
2-3 — Furnaces North America 2012,
Renaissance Hotel and Convention
Center, Nashville, Tenn. Hosted by Metal
Treating Institute. Call (904) 249-0448 or
visit www.furnacesnorthamerica.com.
HEAT TRANSFER FLUIDS
31 Portland Road
West Conshohocken PA 19428 USA
800-222-3611
610-941-4900 • Fax: 610-941-9191
www.fluido-termico.com
[email protected]
See the sampling process in a 1-minute video at www.paratherm.com/fluid-analysis
12
1-3 —National Coil Coaters Association
(NCCA) Fall Technical Meeting and
Trade Show, Marriot Union Station,
St. Louis. Call (216) 241-7333 or visit
www.coilcoating.org.
®
®
4-5 — Interphex Puerto Rico, Puerto
Rico Convention Center, San Juan.
Hosted by International Society for
Pharmaceutical Engineering (ISPE).
Call (888) 334-8704 or visit
www.interphexpuertorico.com.
Boilers
Tips to Increase Efficiency
and Heat Recovery
in a Boiler System
Use these 10 tips to
evaluate your process
boiler and understand
how to maximize its
performance.
By Dominic Kasten,
Cleaver-Brooks
A
s boilers age, they can become
less efficient, causing an increase
in fuel costs. The main cause of
energy inefficiency is system heat loss. Here
are several ways to reclaim the heat loss in
an effort to reduce facility operating costs.
Maintain,
1 Maintain,
Maintain
Keep up with annual boiler maintenance.
Maintaining a boiler according to manufacturer recommendations is the simplest
way to ensure it will continue to run
efficiently.
Proper Water
2 Treatment
Check that the boiler system water is treated properly. Particulates clog up internal
boiler tubes, and over time the system loses
its heat transfer ability. In most applications, a deaerator is a good solution. It can
increase the water temperature to 227°F
(108°C) and remove a lot of the particulates from the water.
Install a High3 Turndown
Burner
Increasing the burner turndown rate will
increase energy savings and reduce maintenance. Energy savings increase when on/
off cycles are reduced. Each on/off cycle
is followed by a purge cycle. During a
purge cycle, a large volume of air passes
through the boiler, resulting in heat being
blown out of the stack. Installing a highBlow down the water column on a steam
boiler daily to keep it and the piping connections free from sediment or sludge.
www.process-heating.com • S e p t e m b e r 2 0 1 2
|
13
Boilers
turndown burner enables a boiler to consistently run at its most efficient point.
and the second stage is condensing, so
the system can heat two sources of water.
Adding a condensing economizer increases energy efficiency between 4 percent
and 8 percent.
Variable-Speed
4 Add
Drive Controls
Installing variable-speed drives (VSDs) on
boiler feed or deaerator pumps allows an
operator to fine-tune the system to run at
optimal conditions while saving energy.
This is because VSDs enable a motor
to operate only at the speed needed at a
given moment.
Recover and Repurpose
9 Heat
from Blowdown
A blowdown heat recovery unit is
the most effective method of purging
destructive solids from any steam boiler
system. The unit transfers heat energy
normally lost during continuous blowdown, transferring it to the cold makeup
water. The payback in fuel savings for a
blowdown heat recovery unit is typically
less than a year.
Another way to recover heat from
blowdown is a flash economizer. A flash
economizer uses the surface blowdown
to heat up the makeup water. It recovers
blowdown energy in the form of flash
steam (latent heat) and blowdown (sensible heat). By capturing both sensible
and latent heat, a flash economizer is able
to recover more heat than the blowdown
heat recovery unit. Payback for a flash
economizer often is less than a year.
5Incorporate
Parallel Positioning
Adding parallel positioning to a boiler
enables it to run at its most capable
efficiency point. Parallel positioning uses
dedicated actuators for the fuel and air
valves. Burners that incorporate parallel
positioning are able to maintain excess air
levels more precisely.
6 Include
O Trim
2
Another way to maintain peak efficiency
is to add an oxygen sensor/transmitter in
the exhaust gas. The sensor/transmitter
continuously senses oxygen content and
provides a signal to the controller that
trims the air damper and/or fuel valve,
maintaining the originally commissioned
oxygen concentration under varying conditions. This minimizes excess air while
optimizing the air-to-fuel ratio.
7 Integrate
Lead/Lag
Lead/lag sequences the operation of multiple boilers, matching system load. Lead/
lag enables boilers to operate in sync with
fluctuating steam loads, reducing the possibility of process failure and needless
boiler cycling.
an
8 Incorporate
Economizer
Another way to improve energy efficiency is to incorporate heat recovery into a
boiler system. The right type of equipment for a boiler system depends upon
several factors, including boiler type,
fuel used, stack material and operating
conditions.
14
|
S e p t e m b e r 2 0 1 2 • Process Heating
Adding an economizer to an existing
boiler system can increase efficiency up
to 8 percent.
Standard Economizer. Economizers
transfer energy from the boiler exhaust
gas to the boiler feedwater in the form of
sensible heat. Sensible heat is created by the
transfer of the heat energy of the exhaust
gas to boiler feedwater.
An economizer captures and redirects
sensible heat from the hot flue gas that
normally goes up the boiler stack. This
sensible heat increases the temperature
of boiler feedwater or makeup water. On
average, adding a standard economizer
increases boiler system efficiency by 3 percent to 5 percent.
Condensing Economizer. A condensing
economizer captures both sensible and
latent energy from the flue gases leaving
the boiler. Two types of condensing economizers are available: a standard one-stage
condensing economizer, or a two-stage
condensing economizer. In the two-stage
system, the first stage is noncondensing
Exchangers to
10 Use
Preheat Inlet Water
Water-to-steam or water-to-water U-tube
heat exchangers can be added to preheat
a boiler feedwater system or deaerator.
These heat exchangers operate similar to
a blowdown heat recovery unit. U-tube
heat exchangers can be used just about
anywhere to transfer heat between a hot
fluid and a cold fluid.
Payback calculations can help companies predict the annual cost savings for
making certain energy-efficient upgrades.
Some boiler manufacturers offer tools such
as software programs that can help you
calculate the potential savings. PH
Dominic Kasten is a sales/application engineer
in the Packaged Water Systems Group handling
the Heat Recovery product lines for CleaverBrooks, Milwaukee, a manufacturer of complete
boiler room solutions. For more information
from Cleaver-Brooks, call (800) 250-5883 or
visit www.cleaverbrooks.com.
Ovens
Put your oven into idle mode whenever
there are pauses in production.
commonly one to five years, and rebates
often are available from local utilities to
offset the initial investment.
Consider
4 Humidity
Control
How to Cut Oven
Operating Costs
By Mike Grande,
Infratrol Manufacturing Corp.
B
y selecting the most energy efficient options and features for your
oven, you can reduce your energy
use and operating costs considerably.
1
Look for EnergySaving Mode
For an electric oven, consider a heating
system that has an energy-saver mode.
Functioning much like a clothes dryer in
your home or overdrive for an automobile transmission, the energy-saver mode
allows you to run your oven using less
electricity for everyday use while still having more power available when needed.
Using a selector switch or PLC input, the
heater circuits are only partially energized
during energy-saver mode. This decreases
your peak demand charge and can provide
savings on your energy bill.
Your
2 Minimize
Exhaust Rate
In most industrial ovens, an exhaust fan
is required to remove solvent vapors,
Follow these 10 tips
to increase the energy
efficiency of your
oven or dryer.
moisture or combustion byproducts.
Exhaust fans allow adjustment of the
volume of air removed from the oven
using either a manual damper or variable-frequency drive.
It is critical that your exhaust fan be
adjusted to the minimum setting necessary
for the process. Too often, exhaust fans
are not adjusted properly, wasting large
amounts of energy and money.
a Heat
3 Add
Recovery System
Oven exhaust air carries a great deal of
heat energy. A heat recovery system may
be able to recover heat from exhaust air
and return it to the oven. A plate- or
tube-style heat exchanger is used to transfer heat from the hot exhaust air to the
incoming factory air. Payback periods are
When drying very wet product, consider
adding a humidity control system to vary
the exhaust rate of your oven or dryer.
A humidity control system continuously senses the humidity level in the oven
and uses closed-loop control to reduce
the oven exhaust rate to the minimum
necessary to achieve the desired product
dryness. The systems are especially valuable in dryers that process many different
materials with varying moisture levels or
with intermittent loading.
Monitor Lower
5 Explosive
Limit (LEL)
Also commonly known as a solvent monitor, the LEL monitor senses the concentration of flammable solvent vapors inside
the oven and sounds an alarm before it
reaches a dangerous level. National Fire
Protection Agency (NFPA) code allows
oven exhaust volume to be reduced by
approximately 50 percent if you use an
LEL monitor, which can reduce your
dryer’s energy use and operating cost
dramatically.
An additional advantage is safety: the
LEL monitor will shut off the oven heat
source if the vapor concentration becomes
too high, preventing fire or explosion.
Install Thicker
6 Insulation
A portion of the heat generated inside
an oven is continuously lost through the
insulated walls. This lost heat consumes
energy. By using thicker insulation, this
loss can be reduced and your oven will
operate more efficiently.
When purchasing a new oven, specifying just an additional 2" of insulation can
save thousands of dollars in energy costs
over the life of the equipment. The good
news is that the cost of this feature is very
reasonable.
www.process-heating.com • S e p t e m b e r 2 0 1 2
|
15
Ovens
An oven with an energy-saver mode
decreases your peak demand charge and
can provide savings on your energy bill.
Cost Reduction Using Energy-Saving Mode
$3,500
$3,000
$37,382
Typical Annual
Cost
$2,500
$2,000
Savings Per Year: $4,752*
$32,630
Annual Cost With
Energy-Saving
Mode
can operate at its optimum horsepower
rating and achieve maximum efficiency.
As the price of variable-frequency drives
has dropped in recent years, this feature
has become more attractive.
$1,500
Use the
9 Idle
Mode
$1,000
$500
$0
*Calculated based on demand charges for 2,064 hours per year; $0.06 per kilowatt hour;
$11 per kilowatt demand charge; 180 kW normal; 144 kW energy-saving mode.
If you have an older existing oven, it
can benefit from additional insulation
as well. It is common for older ovens
to have areas where the insulation has
settled or broken down. This is indicated
by hot areas on the oven exterior. These
areas should be repaired to maintain the
oven’s efficiency.
hard after the oven reaches temperature.
A variable-frequency drive can be used to
power the recirculation fan and ramp up
its speed (rpm) while the oven heats up,
matching the motor horsepower with the
fan requirements. In this way, the motor
Put your oven into idle mode whenever
there are pauses in production for tooling
changes or operator rest breaks. During
idle mode, the oven temperature is temporarily reduced to a preset temperature,
so it uses less energy. Ask for this feature
when purchasing a new oven, or consider
adding it to an existing unit. To avoid
accidentally restarting production while
in idle mode, use a flashing light or beacon to signify when the oven is idling.
However, do not use idle mode for long
periods such as overnight. You will save
Seal
7 Properly
Oven Openings
For conveyor ovens, it is critical to properly seal the area where the conveyor and
parts enter and exit the heating chamber.
High temperature curtains, powered air
seals or unheated vestibules should be
used to retain the heat. Even a small leak
wastes significant energy.
On batch ovens, be sure door gaskets are
in good condition and seal tightly.
a Variable-Speed
8 Add
Recirculation Fan
Heated air becomes lighter, so an oven’s
recirculation fan does not have to work as
WEB EXCLUSIVE
Maintenance Programs
Among other maintenance tasks,
certain procedures will help ensure
higher oven efficiencies.
READ MORE @ WWW.PROCESS-HEATING.COM
16
|
S e p t e m b e r 2 0 1 2 • Process Heating
High temperature curtains such as those shown, powered air seals or unheated vestibules
should be used to retain the heat.
Use A Heat Exchanger To Recover
Heat From The Exhaust Air Stream
Incoming Process
Heat
Exchanger
Ovens
more energy by shutting the oven off and
restarting it eight hours later.
Maintain
10Properly
Your Equipment
Oven Exhaust Air
Maintaining your oven equipment properly cannot be overemphasized. Properly
maintaining it — or failing to maintain it — will significantly impact your
energy costs.
To increase efficiency, maintenance programs should ensure the burner is adjusted
properly, filters are kept clean and recirculation and combustion blowers are properly maintained. Your oven does not have
to be an energy hog. Follow these steps and
“go green” for both for the environment
and your pocketbook. PH
Oven or Dryer
*Calculated based on demand charges for 2,064 hours per year; $0.06 per kilowatt hour;
$11 per kilowatt demand charge; 180 kW normal; 144 kW energy-saving mode.
A heat recovery system uses a heat exchanger to recover heat from exhaust air and
return it to the oven.
Mike Grande is the vice president of sales with
Infratrol Manufacturing Corp., New Berlin,
Wis., a manufacturer of ovens. To learn more
from Infratrol, call (262) 797-8140 or visit
www.infratrol.com.
THERMAL FLUID CHOICES AHEAD
CAUTION
NEXT EXIT
MULTITHERM
SLUDGE BUILD-UP
HIGH ENERGY COSTS
THE RIGHT CHOICE
MultiTherm’s Family of Thermal Fluids Will Meet Your Needs.
Contact Us so MultiTherm can help you make the right choice. We’ll review your system’s fluid
needs — one step at a time. Then, we’ll choose the right product so your system runs more
efficiently…for longer periods of time…with less down time.
Let MultiTherm Help Increase Your Productivity
Call Today!
1-800-339-7549
www.multitherm.com
Direct: 610-408-8361 • Fax: 610-408-8365 • Email: [email protected]
www.process-heating.com • S e p t e m b e r 2 0 1 2
|
17
Chillers
Compressor Cycling
Affects Laser Performance
By Rob Van Sumeren, Otpi Temp
R
ecirculating liquid cooling systems
are used in many of today’s
commercially available lasers to
efficiently remove waste heat and avoid
overheating critical components. Although
numerous heat transfer fluids are used as
coolants for laser applications, water is by far
the most common coolant used. If the system
is designed properly, a recirculating water
system provides an efficient, reliable means of
cooling high-power laser systems.
Many types of recirculating cooling
systems or chillers are used to circulate the
fluid. For most laser applications, however, a
closed-circuit refrigerated cooling unit is used
to maintain proper coolant temperature.
The size of the refrigeration system depends
upon the heat load produced by the laser
when it is operated for long periods of
time at its maximum average power. Proper
chiller sizing and selection are critical to
obtaining optimum laser performance and
long-term reliability.
While many refrigerated recirculating
water chiller designs are offered, not all water
chillers provide the same performance.
Many may use control methods that do
not provide for widely varying loads or
ensure good temperature stability.
Proper chiller sizing
and selection are
critical to obtaining
optimum laser
performance.
Chillers with an automatic zero-tofull-load capacity control eliminate
compressor cycling.
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S e p t e m b e r 2 0 1 2 • Process Heating
Chillers
To and
From
Process
Air-Cooled Chiller/Heater
Pressure Actuated
Water Bypass Valve
Reservoir
Float
Switch
Chiller
Evaporator
Temperature
Controller
Expansion Valve
Set for 8 to 12°F
SuperHeat
Heater
Thermocouple
Pump
Liquid Injection Valves Set to read
60 to 68°F at Suction Line
Cooling
Solenoid Valve
Sight
Glass
Hot Gas
Bypass Valve
Set for: 26 psi
(R-134A)
Mixing
Loop
Low
Pressure
Switch
Service
Compressor
Valve
50-55 psi Suction, R-134A, 65F LWT
Will Vary Based on LWT and When
Solenoid Valve Cycles
High
Pressure
Switch
Discharge Pressure
140-220 psi (R-134A)
(Varies with Ambient
Temperature)
Condenser
To understand the differences in water
chiller technology, it is helpful to first
understand why coolant temperature
control is important and how, in general
terms, it can affect laser operation.
Temperature Variation
and Laser Performance
Coolant temperature is a critical factor
in the proper operation of solid-state
lasers. Higher temperatures can result in
lower laser efficiency, so generally it is
desirable to operate the system at the
lowest temperature that is practical. If
the temperature is reduced to or below
the dewpoint, however, condensation may
begin to form on some laser components
that are exposed to the atmosphere.
If the laser-rod ends are cooled to the
dewpoint, for example, condensation can
form there. If the system is started, the
laser beam can burn off the condensation
layer — and damage the surfaces in
the process. Therefore, solid-state laser
systems should never be operated with
coolant temperatures low enough to result
in condensation. Because the dewpoint
depends on ambient temperature and
relative humidity, each application must
be analyzed to determine a safe operating
temperature based on the conditions to
which the laser is exposed.
Receiver
Service
Valve
Condenser Cooling
Medium (Air or Water)
Some process water chillers have refrigeration circuitry that provides zero-to-full-load
capacity control without cycling the compressor. Chillers also can provide temperature
stability to ±0.1°C.
Filter
Dryer
Legend:
- Process Supply Water
- Process Return Water
- Refrigeration High Pressure
- Refrigeration Low Pressure
an important factor in chillers designed
for lasers. Laser-diode devices must be
controlled at a specific temperature even
in applications with the potential for wide
ambient temperature ranges. Failure to
maintain a stable temperature can result
in volatility of the laser diode’s output
wavelength. The output wavelength of
a diode typically shifts with operating
temperature at a rate of approximately
0.33 nm/°C. In these lasers, the absorption
When the chiller is not operating at its
full capacity, it is necessary to offload the
excess capacity to ensure proper operation.
Moisture condensation also is a problem
for industrial carbon dioxide lasers, which
often have separate, or secondary, cooling
circuits designed specifically to cool the
optics. Usually, these circuits are maintained
at higher temperatures than the primary
circuit; that is, they are designed to operate
above the ambient dewpoint.
Coolant temperature stability also is
bandwidth of the gain medium normally
is about 2 to 4 nm, so temperature
regulation of the pump diodes to ensure
a stable power output from the laser head
is essential. Temperature changes in the
laser head can result in laser output power
drift, frequency drift in single-frequency
operation and drift in the output beam
direction (beam pointing).
www.process-heating.com • S e p t e m b e r 2 0 1 2
|
19
Chillers
Liquid cooling systems can be used to remove heat from lasers and avoid overheating
of critical laser components.
Selecting a Refrigerated
Chiller for Lasers
When selecting a water chiller for a laser
application, several factors should be
considered. The most important is cooling
capacity.
Typically, laser manufacturers will
provide cooling water specifications that
indicate a certain minimum cooling
capacity required to properly cool the
laser under full power conditions. It is
important to note, however, that lasers
do not always operate at the maximum
output power. Frequently, lasers are sold
to an integrator or end-use operator
that may be using the lasers for several
applications. The laser may often be
operated at much less than full time
(low-duty cycle). As a result, the average
output power will be much less than the
maximum design output. If the duty
cycle falls below 50 percent of the chiller’s
cooling capacity, it can lead to control
problems. To eliminate control problems,
the chiller must provide capacity control
over the full cooling range of the chiller.
Traditional refrigerated recirculating
chiller systems have a fixed design cooling
capacity. When the chiller is not operating
at its full capacity, it is necessary to offload
20
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S e p t e m b e r 2 0 1 2 • Process Heating
the excess capacity to ensure proper
operation. If the excess capacity is not
reduced, it can prevent system stability
and possibly cause damage. To reduce
capacity within the refrigeration system,
a hot gas bypass usually is incorporated
within the refrigeration circuit.
Although there are design variations
for hot gas bypass systems, the goal of
reducing system capacity is the same. The
hot gas bypass diverts some of the system’s
mass flow of refrigerant before it can be
used effectively in the condensing and
evaporation processes within the system.
The hot gas system is used when the
actual process load falls below the design
cooling capacity of the chiller.
This method for capacity control
generally works out satisfactorily until the
cooling load falls below approximately
50 percent of the design capacity of the
chiller. At this point, the hot gas bypass
quantity is so large that it can affect
the returning gas temperatures for the
refrigeration compressor. The refrigeration
system’s compressor can become heated
to levels exceeding the compressor
manufacturer’s recommendations. Elevated
return-gas temperatures cause compressor
overheating and can lead to premature
compressor failure and shortened life.
Consequently, some manufacturers will
cycle the compressor on and off when the
loads fall below this 50 percent threshold.
Frequent compressor cycling, however,
can cause increased wear and tear on
the system, temperature instability and
premature component failures. Excessive
compressor cycling (or short cycling)
can cause lubrication problems within
the refrigeration system. Because a
refrigeration compressor is bathed in oil,
it will naturally circulate oil throughout
the system. Constant cycling can prevent
proper oil circulation and cause the
compressor to progressively pump oil
from the compressor’s oil reservoir so that
the entire oil charge is lost from the
crankcase, starving the components of
proper lubrication.
A second source of compressor damage
can result from liquid refrigerant entering
the compressor due to lack of cooling
load or improper system design. Methods
such as control timers can be incorporated
to prevent the system from cycling too
frequently. Usually, however, the result is
poor system temperature control.
Advanced Refrigeration
Control Technology
As a result of advances in process chiller
controls, portable water chillers that
provide zero-to-full-load capacity are
available. Chillers like these offer several
advantages, including the ability to operate
multiple lasers or processes on one water
chiller. The zero-to-full-load capacity
control allows one or more lasers to be
operated simultaneously or separately, as
needed, without sacrificing temperature
control or stability. Some of these chillers
can also be equipped with heaters to help
bring the process fluid to a temperature
above the dewpoint, minimizing the
possibility of condensation. PH
Rob Van Sumeren is western regional sales
manager with Opti Temp, Traverse City, Mich.,
a manufacturer of chillers and temperature
control systems. For more information, call
(231) 946-2931 or visit www.optitemp.com.
Heat Tracing
5 Tips for Preparing Your
Heat Tracing for Winter Now
W
ith summer still lingering,
freezing temperatures and your
heat-tracing system may not
be top of mind. But perhaps they should
be: now is the ideal time to prepare your
pipelines for the cold weather ahead and
ensure you have an integrated, maintained
pipe-freeze-protection system in place.
One good way to make sure pipelines
are maintained throughout the summer
and protected in the winter is to install
an advanced control monitoring system.
Installing the right system for your pipelines is an integral step in improving process control.
While there are several devices —
thermostats, electric distribution panels,
and control and monitoring systems, for
instance — that can be installed to help
maintain the temperature of heat-traced
Control monitoring systems improve
process control and reap benefits.
By Eugene Ho and Chris Thibodeau, Tyco Thermal Controls
pipelines, it is important to think about
the long term when deciding on a system.
A basic thermostat may seem like an
attractive option due to low upfront costs,
but consider what would happen if you
were not alerted to a pipeline freeze and
suffered a serious shutdown. Although a
control and monitoring system has higher
upfront costs, it can offer process benefits
and cost savings over time.
Used in conjunction with a heat-tracing system, an advanced control system
centralizes operations, allowing a user to
control and vary the heating cable output
to achieve the desired temperature. An
added monitoring feature provides realtime feedback on the status of the heattraced system, which helps deliver data for
scheduling predictive maintenance and
alerts you if the system is malfunctioning.
Many control and monitoring systems
An advanced control and monitoring system can be accessed remotely, allowing
one central operator to view the entire
freeze-protection-management system.
www.process-heating.com • S e p t e m b e r 2 0 1 2
|
21
Heat Tracing
Consider selecting a provider that
designs and supplies each of the individual components needed for pipefreeze-protection applications and
control and monitoring systems to
ensure seamless integration.
include an auto-cycle feature that turns
on the heat-tracing system at preset intervals year-round. This helps ensure that
your system is still functioning properly
throughout the warmer months.
Once winter hits, the monitoring system continues to keep the user updated
so the plant is not hit with an unexpected
pipeline freeze or burst. The early alarm
reporting allows you to begin troubleshooting and remedying an issue before
it is serious enough to cause a complete
shutdown.
If you decide to install a control and
monitoring system in your facility, consider the following five tips for using the
system to improve process control.
Ambient
Sensing
RTD
Cable Tray
Power
Distribution
Panel
Transformer
End Seal
Power
Connection
Heating Cable
Insulation
1
Check the System
Status and the
Starting Temperature
Glass Tape
In general, the application temperature
ranges are grouped in three categories:
• Freeze protection, which applies to
applications that focus on keeping fluids
above 32°F (0°C).
• Broad temperature maintenance, which
applies to applications where the process
temperature must be controlled within
a moderate range, generally for viscosity
control to keep process fluids flowing.
• Narrow temperature maintenance,
which applies to applications with fluids
that must maintain a tight temperature
band to prevent fluid degradation.
It is important to make sure you know
the product’s temperature range. Some
fluids are sensitive to temperature fluctuations, and you need to be aware of their
requirements.
Your
2 Find
Design Current
Review the heat trace design and identify
how much current the design should use,
allowing you to see if the control and
22
|
S e p t e m b e r 2 0 1 2 • Process Heating
monitoring system is operating correctly.
Most electronic controllers allow the user
to select alarm levels that will monitor
the system and determine if there is a
discrepancy. Understanding the operating
current could allow you to prevent any
current trips that could potentially shut
down your process.
Define
3 Your
Needs
What applications are you looking to control? Do you need to control and monitor
your freeze-protection application, or are
you more concerned with temperature
control? In addition to asking yourself
that question, it is also important to consider the type of circuits that will work
best for your system. Individual circuits
have a one-to-one ratio of controllers
to circuits while group circuits provide
multiple circuits that are controlled by an
individual device.
Also, think about where you would like
to set up. A local control system is a good
choice if there is an individual circuit in
close proximity to the heat-trace power
connection. For large plants or when working in a remote location, a remote control
system is a better option.
Decide What Control
4Methods
and Monitoring
Are Needed
There are a number of considerations
depending on your needs and requirements. When it comes to the control system, an ambient sensing control option is
simple to install and requires low maintenance for a single thermostat, but its control usually is limited to freeze-protection
applications. A self-regulating control
option has high reliability, low installation costs and is best for freeze protection
and broad temperature maintenance, but
it relies on the performance of the heating
cables and has high energy costs compared to other methods. A third option
is a line sensing control, which has low
energy use, centralized control settings
Heat Tracing
A local control system is a good choice if there is an individual
circuit in close proximity to the heat-trace power connection. For
large plants or when working in a remote location, a remote control system is a better option.
and is well suited for narrow temperature
maintenance to prevent fluid degradation.
However, it has higher installation costs
and maintenance demands.
Once you select the right control system
for your installation, it is time to take
a look at what applications need to be
monitored. If the system only needs to
monitor the integrity of the heating cable
without monitoring system performance,
continuity monitoring is a good option. By
contrast, ground-fault monitoring is best
used for freeze-protection applications and
noncritical process maintenance. There are
also monitoring options that provide feedback on the heat-tracing system’s temperature and current.
of Everything as
5 anThink
Integrated System
Look for a provider that designs and supplies each of the individual components
needed for pipe-freeze-protection applications and control and monitoring systems to
ensure seamless integration. An integrated
approach includes selecting the appropriate heat-tracing cables and designing
a customized control and monitoring
system as well as providing engineering
design services, site services, installation
and maintenance. The ability to combine
products with post-installation services
allows the company to create a turnkey
solution that results in an efficient heat
management system.
Do not wait until winter to prepare your
pipelines for the cold weather. Considering
these five tips will help you plan ahead
and decide on a control monitoring system to improve process control for your
integrated heat management system. PH
Eugene Ho is a marketing manager and Chris
Thibodeau is a product manager with Tyco
Thermal Controls, Houston, Texas, a manufacturer of heat tracing system. To learn more
from Tyco, call (800) 545-6258 or visit
www.tycothermal.com.
WE KNOW ELECTRICITY
Questions about SCR
power control systems?
We can help.
•
•
•
•
•
Fusing
Cooling
Heatsink Design
Voltage protection
Application assistance
For more than 40 years we have been
designing and building SCR controls for
hundreds of thousands of users like you.
For answers to your solid state control questions
Call 1-800-331-1345
Box 70 Scott Depot,
WV 25560-0070
Fax: 304-757-7305
[email protected]
www.payneng.com
www.process-heating.com • S e p t e m b e r 2 0 1 2
|
23
Equipment Overview
Infrared Heaters
Infrared heaters are used to transfer heat
through a process or to a product via radiation. Our Equipment Overview on Infrared
Heaters, an apples-to-apples comparison of
the capabilities of a range of radiant heater
makers, will help you narrow the field of
potential suppliers to those that can satisfy
your process needs. Find the type of heater
you want and run down the column to see
which manufacturers supply it.
You also can conduct your search online
at www.process-heating.com. The online version lets you select multiple headings across
all of the categories and narrows the results
after each selection automatically. In addition,
WAVELENGTH
HEATER TYPE
You also can conduct your
supplier search online!
GAS FIRED
MANUFACTURING
PROCESS
ELECTRICALLY POWERED
Click on Equipment Overview,
then on infrared heaters.
Companies
Aitken Products Inc.
www.aitkenproducts.com
Emitted Energy
gy Corp.
www.emittedenergy.com
Glenro Inc.
www.glenro.com
Hix Corp.
www.ovens-dryers.com
Omega Engineering Inc.
www.omega.com
Tempco Electric Heater Corp.
www.tempco.com
Wisconsin Oven
www.wisoven.com
Catalytic
Ceramic Fiberboard
Ceramic Element
Ceramic Tile
Porous Metal Fiber Matrix
Porous Ceramic Fiber Matrix
Ceramic Element
Ceramic Generator
Coiled Metal Sheath
Halogen Lamp
Metal Ribbon
Panel Type
Quartz Tube
Radiant Tube
Radiant Wall
Sinuated Wire
Long Wave
Medium Wave
Short Wave
Annealing
Baking
Bonding
Cooking
Curing
Dehydrating
Drying
Embossing
Evaporating
www.process-heating.com
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Abutec LLC
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BBC (Black Body) Industries Inc.
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Heatcon Inc.
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Mor Electric Heating
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Osram Sylvania, Process Heating Div.
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Process Technology
Process Thermal Dynamics
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Manufacturers listed in this Equipment Overview responded to a special mailing by Process Heating and do not necessarily represent the entire infrared heater market. For contact
information or to be included in future listings, contact Linda Becker at (262) 564-0074; fax (248) 502-1001; e-mail [email protected].
Companies with in front of their names have an advertisement in this issue.
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Higuchi Inc. USA
24
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General Thermal Corp.
Intek Corp.
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Despatch Industries
Fostoria Process Equipment Div.
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Chromalox
David Weisman LLC
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Blasdel Enterprises
Casso-Solar Technologies LLC
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BGK Finishing Systems
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S e p t e m b e r 2 0 1 2 • Process Heating
hyperlinks will take you directly to manufacturers’ web sites.
To contact a specific manufacturer, click on the company name in the search results and use the contact
information shown in the lower right corner of the online
Equipment Overview.
Extruding
Fusing
Heat Setting
Heat Shrinking
Laminating
Pre-Drying
Pre-Heating
Soldering
Sterilizing
Tempering
Thermoforming
Other
Chemicals/Petrochemicals
Electronics
Ethanol/Biodiesel
Finishing
Food
Packaging/Printing
Paper/Pulp/Converting
Pharmaceuticals
Plastics/Rubber
INDUSTRIES SERVED
Does your company manufacture/market aftermarket
supplies/services for your infrared heaters?
MANUFACTURING
PROCESS
3++XEEHOOLQGG
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• Yes
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704-643-7299
www.process-heating.com • S e p t e m b e r 2 0 1 2
|
25
Equipment Overview
Infrared Heaters
WAVELENGTH
HEATER TYPE
You also can conduct your
supplier search online!
GAS FIRED
MANUFACTURING
PROCESS
ELECTRICALLY POWERED
Click on Equipment Overview,
then on infrared heaters.
Companies
Catalytic
Ceramic Fiberboard
Ceramic Element
Ceramic Tile
Porous Metal Fiber Matrix
Porous Ceramic Fiber Matrix
Ceramic Element
Ceramic Generator
Coiled Metal Sheath
Halogen Lamp
Metal Ribbon
Panel Type
Quartz Tube
Radiant Tube
Radiant Wall
Sinuated Wire
Long Wave
Medium Wave
Short Wave
Annealing
Baking
Bonding
Cooking
Curing
Dehydrating
Drying
Embossing
Evaporating
www.process-heating.com
Radiant Energy Systems Inc.
• •
Research Inc./Precision Control Systems Inc.
Scott Can Industries Ltd.
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Soneko USA Inc.
•
Technic Inc.
Thermal Engineering Corp.
•
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Trimac Industrial Systems LLC
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Vulcan Catalytic
•
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Watlow
•
Advertising Index
Zircar Refractory Composites Inc.
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Company
Phone
Website
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ACS Group/Sterling
262-641-8610
www.sterlco.com
www.aitkenproducts.com
9
Aitken Products Inc.
440-466-5711
11
CPM Wolverine Proctor
215-443-5200
www.cpmwolverineproctor.com
11
Emitted Energy Corp.
513-752-9999
www.emittedenergy.com
www.glenro.com
4
Glenro Inc.
888-453-6761
2
Heatec
423-821-5200
www.heatec.com
32
Heatec
423-821-5200
www.heatec.com
27
Hix Corp.
(620) 231-8568
www.ovens-dryers.com
10
Hotwatt
978-777-0070
www.hotwatt.com
25
Hubbell Electric Heater Co.
203-378-2659
www.hubbellheaters.com
6
Karl Dungs Inc.
732-582-1744
www.dungs.com/usa
8
Micron Fiber-Tech
386-668-7895
www.mft-co.com
17
MultiTherm
610-408-8361
www.multitherm.com
3
Omega Engineering Inc.
203-359-7815
www.omega.com
www.palmerwahl.com
9
Palmer Wahl
828-658-3131
12
Paratherm Corp.
610-941-4900
www.paratherm.com
27
Parker Boiler Co.
323-727-9800
www.parkerboiler.com
www.payneng.com
23
Payne Controls
304-757-7353
10
Protection Controls
847-674-7676
www.protectioncontrolsinc.com
25
Qmax Industries
704-643-7299
www.qmaxindustries.com
7
Volcanic Heater
330-823-0770
www.volcanic-heater.com
31
Wisconsin Oven
262-642-3938
www.wisoven.com
23
Wyssmont
201-947-4600
www.wyssmont.com
S e p t e m b e r 2 0 1 2 • Process Heating
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Trent Inc.
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Solar Products Inc.
26
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Red-Ray Mfg. Co. Inc.
•
Extruding
Fusing
Heat Setting
Heat Shrinking
Laminating
Pre-Drying
Pre-Heating
Soldering
Sterilizing
Tempering
Thermoforming
Other
Chemicals/Petrochemicals
Electronics
Ethanol/Biodiesel
Finishing
Food
Packaging/Printing
Paper/Pulp/Converting
Pharmaceuticals
Plastics/Rubber
Does your company manufacture/market aftermarket
supplies/services for your infrared heaters?
• • • • • • •
• • • •
Yes
• • • • • •
Yes
MANUFACTURING
PROCESS
•
INDUSTRIES SERVED
• •
• •
•
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It’s Time for You to...
-
Save Money Improve Efﬁciency Reduce Operating Costs Lower Utility Bills
-
It’s Time for Your New...
-
Thermal Fluid Heater Steam Boiler Medium Temp Process Heaters
Heating Medium: Thermal Fluids
Temp Range: 350° - 650°F
BTUs: 126,000 - 6,250,000
------
Available with:
Expansion Tanks with Level Controls
Distribution/Air Separation Tanks
Air-Cooled 650° Pumps
Custom Skid Mounts
Steam Boilers:
NEVER A COMPROMISE
FOR QUALITY OR SAFETY
Parker Boiler Co.
5930 Bandini Blvd.
Los Angeles, CA 90040
(323) 727-9800
Fax: (323) 722-2848
[email protected]
www.parkerboiler.com
15 to 250 PSI
HP: 1.5 to 150 HP
Available with:
Feed Systems or DA Tanks
Blow Off Tanks
Softeners
Chemical Feed Systems
Custom Skid Mounts
Medium Temp
Process Heaters
Temp Range: 130° - 400°F
BTUs: 300,000 - 6,800,000
Hot Water or Glycol
---
All Units Available with:
Expansion Tanks with Level Controls
Distribution/Air Separation Tanks
Air-Cooled 400° Pumps
Custom Skid Mounts
Natural Gas, #2 Oil, Propane,
Combination Fired, Low NOx,
or Bio Fuel Firing
All Parker Boilers Use a
Flexible Staggered Tube
Design with 8 to 10 Pass Flow
with a 25-Year Guarantee
Against Thermal Shock.
www.process-heating.com • S e p t e m b e r 2 0 1 2
|
27
Product Highlights
Wondering where to find products beneficial to your process? This department provides a number of new
products each month and allows you to easily request more information. Simply call those companies in
which you are interested, or visit those companies’ web sites using the published web addresses.
Thermal Processor
Turbo Dryer offers precise temperature control
and uniformity in each zone. The all-metal dryer
does not abrade the material to form dust; does
not form crusts and lumps; and operates with little operator attention. Its energy-efficient design
produces uniform product and eliminates hot
spots that overheat the product. Maximum temperature is 1,200°F (650°C).
Wyssmont • (201) 947-4600 • www.wyssmont.com
High Temperature, High Efficiency Fans
Fan for accelerated-temperature
applications in ovens, kilns and
dryers is recommended for installations where hot airstreams need
to be circulated or exhausted at
temperatures up to 1,000°F (538°C).
Because larger oven systems
require more capacity, Design 70
includes wheel sizes to 60", capable of moving 156,000 cfm.
Chicago Blower Corp. • (630) 858-2600
www.chicagoblower.com
in batch and continuous designs (overhead trolley, chain-onedge and belt conveyors) with standard temperature ratings
of 500, 650, 800, 1000, 1,250 and 1,400°F (260, 343, 427, 538
377 and 700°C). They can be heated by gas (direct or indirect
fired), electricity and steam.
Wisconsin Oven Corp. • (262) 642-3938 • www.wisoven.com
Y-Type Strainer
Fig 36HP is rated to ASME Class 600 standards. The stainless
steel Y-type strainer is designed to protect equipment from
pipeline debris such as scale, rust, jointing compound, weld
metal and other solids in flowing liquids or gases. The line
has a large screen area providing high Cv and low pressure
drop, reducing the frequency of blowdown for cleaning. The
strainer is capped, drilled and tapped to enable a blowdown
valve to be fitted to drain and clean the screen in service.
Spirax Sarco Inc.
(800) 883-4411 • www.spiraxsarco.com/us
Screw Plug Immersion Heaters
Series FW1200 is NSF/ANSI Standard 50 certified and offered in
vertical or horizontal configurations. It has two pump sizes, ductile
iron construction (bronze impeller), capacities to 2,800 gal/min
(636 m3/hr), heads to 155' (47 m), working pressures to 125 psig
(862 kPa) and pumping temperatures to 250°F (121°C).
Met-Global Pump Solutions-Dean Pump
(215) 723-8155 • www.mp-gps.com
Screw plug immersion heaters are offered in sheath
materials such as steel,
copper and Incoloy 840.
The standard heaters are
designed at 60 W/in2, 500
watts to 18 kW, and 120 V/
single-phase to 480 V/threephase. The threaded fittings ease tank insertion and removal.
Tubular heater elements are brazed or welded to NPT fittings
to ease mounting.
Durex Industries • (847) 639-5600 • www.durexindustries.com
Benchtop Temperature Controller
Cabinet Oven
Contained all in one enclosure,
the thermoelectric module,
benchtop temperature controller can be plugged into the wall
as a self-contained temperature
control system with its own
power supply. Model 5R6-900
also can be used universally, which allows the user to access
the device wherever they are located. As a solid-state MOSFET
bidirectional compact benchtop unit, it also is capable of
loading currents up to 10 A.
Oven Industries Inc. • (877) 766-6836 • www.ovenind.com
No. 858 is currently used at a
customer’s facility for annealing
plastics. Workspace dimensions
of the 850°F (454°C) electrically
heated oven measure 20 x 20 x 20",
and 10 kW are installed in Incoloysheathed tubular elements. A 600
cfm, 0.5-hp recirculating blower
provides horizontal airflow to the
workload. It has 6" insulated walls and Type 430 stainless
steel interior, all-welded construction plus explosion-venting
latches on the heavy-duty door. Controls include a digital
programming and recording temperature controller, manual
reset excess temperature controller with separate contactors,
and recirculating blower airflow safety switch.
Grieve Corp. • (847) 546-8225 • www.grievecorp.com
Vertical/Horizontal Water Pumps
Batch and Conveyor Ovens
Dryers, ovens and furnaces are suited for use in a range of
applications and industries. Heating equipment is designed
28
|
S e p t e m b e r 2 0 1 2 • Process Heating
PH Classifieds
Send advertising copy to:
Process Heating/Attn. Becky McClelland
Phone: (412) 306-4355 • Fax: (248) 502-1076
E-mail: [email protected]
Display Classified Rates:
1X $100 • 3X $95 • 6X $90 • 9X $85 • 12X $80
Equipment for Sale
CAN-ENG FURNACES INTERNATIONAL LTD.
z
z
Rebuilds z Retrofits z Combustion Controls z
Control Panels z Thermal Profiling z Ovens z Burners z Elements z
t: 905-356-1327
f: 905-356-1817
e: [email protected]
www.can-eng.com
Contact: JOE SALIBA (ext:2058) z KIM IAMARINO (ext:2037) z ANNA ROLFE (ext:2056)
YOUR BEST
SOURCE FOR ELECTRIC
HEATING ELEMENTS
128 Maple Street,
Danvers, Massachusetts, 01923-2096
Tel # (978) 777-0070
Fax# (978) 774-2409
[email protected]
www.hotwatt.com
YOUR AD HERE:
For $30 we will post &
link your print ad on
www.process-heating.com
Contact Becky McClelland
to reserve your classified
advertising space for 2012!
PRINT/ONLINE PACKAGES ARE AVAILABLE.
Phone: 412-306-4355 • Fax: 248-502-1076
Email: [email protected]
www.process-heating.com/buyersguide • S e p t e m b e r 2 0 1 2
| 29
®
Places & Faces
Telford, Pa.-based Met-Pro Global
Pump Solutions added an online
calculator to allow users to quickly
estimate the total lifecycle cost for
one or more pumps. Users input process and facility-specific data, and the
calculator generates an analysis. Visit
http://bit.ly/MOZiRI to try it.
Manufacturers and Technology
Association’s board of directors.
Eraser Co. Inc., Syracuse, N.Y., a manufacturer of wire, cable and tube process
equipment, launched a new website
at www.eraser.com. Features of the
SUBSCRIPTIONS
Contact Customer Service at (847) 763-9534; fax (847) 763-9538
or e-mail [email protected]. To subscribe or submit an address
change via the web, visit www.process-heating.com and click on
subscribe. Via mail, send your old address label along with your
new address to Process Heating, PO BOX 2146, Skokie, IL 60076.
PUBLISHING STAFF
Senior Group Publisher, Manufacturing Group
TOM ESPOSITO • (610) 436-4220 ext. 8530
Publisher • ANNE ARMEL
(847) 405-4043 • [email protected]
Associate Publisher and Editor • LINDA BECKER
(847) 405-4020 • [email protected]
Contributing Editor • JOY LEPREE ANDERSON
(856) 582-9554 • [email protected]
Bruce Bryan, director of sales at
Chicago-based Mighty Hook, has
earned the Chemical Coaters
Association International’s
2012 James F. Wright Lifetime
Achievement Award. Bryan, a CCAI
Art Director • COURTNEY FATHERS
(248) 244-1292 • [email protected]
Production Manager • BETH MCCLELLAND
(412) 306-4354 • [email protected]
Reprint Sales • JILL DEVRIES
(248) 244-1726 • [email protected]
E-Media Sales • SUSAN HEINAUER
(412) 306-4352 • [email protected]
past president, is a board member.
Classifieds • BECKY MCCLELLAND
(412) 306-4355 • [email protected]
From its humble beginnings as a
two-man sales and service operation designing and installing control
systems for industrial equipment,
Pyromation Inc., Fort Wayne, Ind.,
has grown and endured to celebrate
50 years in the temperature sensor business. Dick Wilson and Bill
Lewis founded Pyromation in 1962
and worked in the region, selling
and servicing controls for industrial
ovens and other equipment. Pete
Wilson, son of co-founder Dick
Wilson, transitioned to president
and owner of the company in 1992,
and led Pyromation’s growth in both
domestic and international sales.
Pyromation has marked the anniversary year with celebratory events,
including a ribbon-cutting ceremony
for a 15,000 ft2 facility expansion.
Lewco, Sandusky, Ohio, has appointed Scott Parish purchasing manager.
Can-Eng Furnaces International
Ltd., Niagara Falls, Ont., has made
the following appointments: Alan
Van Geyn, vice chairman; Michael
Klauck, president; and Gregory
Stanley, sales manager for North
America, steel products.
Pamela Kan, president of BishopWisecarver Corp., Pittsburg, Calif.,
has been appointed chair of the
Sacramento-based California
30
|
S e p t e m b e r 2 0 1 2 • Process Heating
Publishing Director, Manufacturing and Gaming Groups
JOHN R. SCHREI • (248) 786-1637
EDITORIAL OFFICE
155 N. Pfingsten Road, Suite 205, Deerfield, IL 60015
(847) 405-4000 • FAX (248) 502-1001
ADVERTISING SALES
NORTH AMERICA • Anne Armel • Publisher
155 N. Pfingsten Road, Suite 205 • Deerfield, IL 60015
(847) 405-4043 • FAX (248) 786-1441 • [email protected]
site includes an RSS feed, blog, testimonials, insert wizard, product videos,
detailed images of products, and links
to product operating manuals. Planned
enhancements include live chat, online
ordering and an interactive catalog.
EUROPE • Carolyn Eychenne • European Sales Representative
7 rue de Maurepas • 78000 Versailles France
tel/fax: 011 33 1 30 21 15 62 • [email protected]
CORPORATE STAFF
BNP Media Corporate Office • (248) 244-6400
BNP CUSTOM MEDIA GROUP
CHRISTOPHER WILSON
(248) 244-8264 • [email protected]
SINGLE COPY SALES
ANN KALB • (248) 244-6499 • [email protected]
John Piazza was
LIST RENTAL
appointed senior
vice president
of the Process
KEVIN COLLOPY • Sr. Account Manager
(402) 836-6265 • [email protected]
Technology
Division of Alfa
Laval Inc., Richmond,
AUDIENCE DEVELOPMENT
Piazza
Va. Piazza will lead
sales and marketing efforts for the
energy, environment, food, life science
and process industry segments for
Alfa Laval in the United States.
SHAWN MILLER • ACCOUNT MANAGER
(402) 836-6269 • [email protected]
Audience Development Specialist • CHRISTINA ROTH
Multimedia Specialist • MAGGIE LEE
Corporate Audience Audit Manager • CATHERINE M. RONAN
GET MORE ONLINE
Search and read our archives. Every article and column
published in Process Heating since 1998 is available online!
•
•
•
•
•
Rockwell Automation Safety
Automation Forum, planned for
November 6 at the Pennsylvania
Convention Center in Philadelphia, will
include presentations on best practices and how safety programs can
improve business performance. For
more information from Milwaukeebased Rockwell Automation, visit
www.safetyautomationforum.com.
•
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