www.process-heating.com | January 2011 | Volume 18, Number 1
A Steamy Situation Using boilers in process heating applications delivers benefits.
Periodical Class
18 Heat Transfer Fluid Guide 24 Preventive Maintenance Plan 33 Manufacturing Spotlights
These heaters will be fully assembled and checked at our factory before delivery.
Get a complete heater package Need a new heater? Get a complete heater package from Heatec. A complete package eliminates hassles, saves you time and saves you money. Our package includes design, manufacturing, factory assembly, on-site setup and startup. We also offer maintenance contracts and provide free phone support. Heaters have many components from a variety of manufacturers. It’s always best to mate these components with the heater and adjust them before the heater is shipped to you. This eliminates most compatibility problems. Our goal is that setup of our heater at your plant will be trouble free, without undue rework. Most setups should only require re-assembly of parts dismantled
for shipping, plus connection of electrical power and piping. Complete factory assembly eliminates last-minute fieldwork that can cause startup delays. It also eliminates buck passing if things don’t go right. Moreover, if a problem develops later, you won’t have to wrangle with a variety of component suppliers to fix it. So, when you buy a new heater, always choose a manufacturer that provides a complete package. Heatec has this capability, which sets us apart from others. Call today and let us answer any questions you have about our heater packages.
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SU CCE S S At Clear Seas Research we develop customized research solutions to identify:
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January 2011 Volume 18 • Number 1
www.process-heating.com WEB EXCLUSIVES: READ MORE AT WWW.PROCESS-HEATING.COM Q Steam Tips Here are a few ways to handle condensation and scale in boilers.
page
page
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Features 18
Equipment Overview: Heat Transfer Fluids Selecting the heat transfer fluid is the most important decision to make in specifying a system because the fluid’s properties have to be matched to the process requirements, and the equipment has to be matched to the fluid properties. Use our Equipment Overview to learn more about a fluid’s properties and narrow the field.
Ovens Before you take the plunge and make a commitment, make sure you understand what preventive maintenance (PM) is and its potential results. With a bit of planning, preventive maintenance can help you improve efficiency and profitability.
Q Midwestern Town Saves Time, Money and Energy with Wastewater Upgrade Peru Utilities needed to upgrade its two wastewater treatment facilities to reduce operations costs and expand capacity.
UPDATED DAILY Q New Products
Q Industry News
Q Archives Q Calendar of Events Q Drying Files columns
Q Energy Notes column Q Equipment Overviews Q Heating Highlights
Q Digital Editions Q Buyers Guide Q Archived Webinars
Check out our redesigned site with more frequent updates and web exclusives!
Heat Exchangers Meeting Mandates
31
A preventive maintenance program can provide benefits above and beyond what you might expect to see, including an improved company image and more satisfied employees.
ALWAYS ONLINE
A Real Resolution
28
The DOE estimates that boilers account for 35 percent of the energy consumed in this country, which is why the agency launched an initiative in 2000 with a number of development partners to create a model for a Super Boiler that would increase efficiency of boilers and reduce dependence on imported oil.
Q Preventive Maintenance: Bonus Points
Heat Transfer Fluid Guide
24
Q Turning Up the Heat for Better Efficiency
Q Go Mobile
Replacing an aging, energy-guzzling boiler with a Super Boiler — the ultra high efficiency boiler developed in part by the U.S. Department of Energy (DOE) — is not the only way to make progress toward meeting the agency’s aggressive goals for increasing boiler efficiency and reducing emissions. By retrofitting older boilers with flue gas condensing heat exchangers, it is possible to turn old boilers green.
Use your smart phone to read Process Heating, wherever you are! Simply visit http://gettag.mobi/ with your phone’s browser to install the Microsoft Tag app. Then, point your phone’s camera at the tag below to be taken to our current issue online — instantly.
Steam Heating
The reader works on most current smart and advancedd ffeature phones, h includi l d ing Windows Mobile (5.5 and above), iPhone, Blackberry, Symbian and J2ME.
A Steamy Situation Powered by an electric boiler, steam cleaning is effective at “melting away” grease and oils and removing soils and dirt from heavy equipment and process parts.
33
Heat Processing Focus Manufacturing Spotlight Enlighten yourself on the latest heat processing technology with this special section of products, tips and application ideas.
Columns & Departments 8 10 16 47
Editor’s Page Inner Workings Calendar Products
About the Cover Ajax Boiler Inc., Santa Ana, Calif., designs and manufactures boilers and water-heating equipment, including high-efficiency, condensing boilers for process water heating applications. To learn more about boilers, see page 31.
52 Classified Directory 53 Advertiser Index 54 Places & Faces
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 subscriptions to qualified individuals. Annual rate for subscriptions to nonqualified individuals in the U.S.A.: $115.00 USD. Annual rate for subscriptions to nonqualified individuals in Canada: $149.00 USD (includes GST & postage); all other countries: $165.00 (int’l mail) payable in U.S. funds. Printed in the U.S.A. Copyright 2011, 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 HEATING, P.O. Box 2146, Skokie, IL 60076. Canada Post: Publications Mail Agreement #40612608. GST account: 131263923. Send returns (Canada) to Pitney Bowes, P.O. Box 25542, London, ON, N6C 6B2. Change of address: 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 • J a n u a r y 2 0 1 1
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By Linda Becker
Commentary Prepared or Not, the Cold Weather Is Here
9 Heat Tracing Tips Some process equipment needs special attention in winter to ensure freeze protection or maintain proper flow. Because the heating equipment —heat tracing, for example — may not be needed during the warmer months, it can be overlooked until it’s time to use it. Did you find yourself in this situation? If so, here are nine tips from Tyco Thermal Controls, Menlo Park, Calif., to help maintain your electric heat tracing. 1. Maintain — and update — installation and maintenance records. Complete documentation will allow you to verify completed system tests, original electrical values and performance changes. 2. Check heat tracing components. Damaged components can result in water ingress, corrosion, or the loosening of electrical connections. 3. Check your insulation. Insulation plays a critical role in the overall heat tracing system. Also, perform an insulation resistance test on all heat tracing circuits. 4. Check your power distribution panel and secondary wire and conduit. Visually inspect the conduit distribution system for openings in the conduit, damaged or missing components, or low-point drains.
5. Test all ground-fault breakers according to the manufacturers’ instructions. 6. Check your thermostat or control system. They allow you to run automatic tests and capture alarm and fault information, which is useful if troubleshooting your heat tracing system becomes necessary. 7. Energize each heat trace circuit to ensure that no short circuits or ground faults exist and that RTDs are functioning properly. 8. Stock critical spare components and cable. If your system still fails after all your checks, stocking spare components and cable will allow for timely repairs or replacements. 9. Don’t wait until winter to check your electric heat tracing system! Or if you have, don’t skip maintenance checks just because you “don’t have the time now.” Happy heating in the New Year.
Linda Becker, Associate Publisher and Editor,
[email protected]
One tough test. One clear winner. CALFLO AF. TM
Results from Severe Oxidative Stability Test.
A specialty heat transfer fluid competitor No flow, remains completely stuck in tube.
A world leader in industrial lubricants
CALFLO AF
Flows, but severe build-up of deposits remains in tube.
Flows easily, stays cleaner longer.
CALFLO AF delivers longer fluid life and better equipment protection. And more savings to you. We put CALFLO AF and leading competitors to the test in a challenging Severe Oxidative Stability Test and the results are clear. CALFLO AF provides better oxidative stability for longer fluid life and enhanced equipment protection. That means more savings in operations and maintenance costs. And less worry. Test CALFLO AF, or another product in our line of CALFLO heat transfer fluids, in your operation. And see the results for yourself.
Visit www.calflo.com for the clear facts. Petro-Canada is a Suncor Energy business TM
Trademark of Suncor Energy Inc. Used under licence.
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J a n u a r y 2 0 1 1 • Process Heating
Inner Workings
20 Full-Tuition Scholarships Available for Manufacturing Workers
by Incoloy-sheathed, mineral-insulated rod elements located behind side duct sheets. Air is circulated by heavy-duty fan impellers on either side of the chambers.
The manufacturing industry needs a highly educated and competitive workforce. To help meet that demand, workers currently employed in U.S. manufacturing jobs have an opportunity to improve their skills with no-cost access to further education. The Manufacturing Institute of the Washington, D.C.-based National Association of Manufacturers and the University of Phoenix have come together to offer manufacturing employees full-tuition scholarships. Gaining advanced training can help manufacturing employees advance professionally and personally. Recipients can earn a degree at a University of Phoenix campus near his or her home or online. The 20 fulltuition scholarships will help workers hoping to complete their undergraduate or master’s degrees. The deadline for application is January 31, with a March 15 award date. Some of the criteria are:
General Mills is a well-known name to anyone who has gone to a grocery store or watched television commercials on a Saturday morning. But here is a lesser-known fact: the Lucky Charms cereal you or your kids dig into at breakfast soon may be made using a unique form of renewable energy. The company plans to deploy its first onsite biomass steam boiler in early 2011 at its milling plant in Fridley, Minn., where it produces oat flour for its signature cereals, including Lucky Charms. The boiler will burn the plant’s leftover oat hulls, the outer casing that is removed from the grain’s dense center. While the dense center begins process of becoming breakfast cereal, the hulls will be used as fuel to run the process.
• Applicants must be currently employed by a manufacturer in the United States. • Applicants residing in California, Florida, Indiana, Michigan, North
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J a n u a r y 2 0 1 1 • Process Heating
Carolina, Ohio, Texas or Washington will be given priority consideration. • Applicants must submit completed essays. • Applicants must submit two letters of recommendation. Additional eligibility requirements and the application form are online. To learn more, visit www.phoenix. edu, type in “manufacturing scholarship,” scroll to the heading “General Content” and click on “Manufacturing Institute Scholarship.”
PTFE Heated on Ovens’ Rotating Tables Greene, Tweed & Co., a maker of sealing materials headquartered in Kulpsville, Pa., has installed two high-specification Carbolite ovens to increase the capacity and consistency of the raw material sintering operation at its U.K. manufacturing facility. The company uses several proprietary polytetrafluoroethylene (PTFE) formulations for its products, which are molded in both tube and bar form in the facility before being sintered and then machined to custom designs. Carbolite, Hope Valley, U.K., supplied the ovens to join two existing 10-yearold units. The new ovens each have a maximum volumetric capacity of 61 ft3 (1.73 m3) and a maximum operating temperature of 797°F (425°C). According to Carbolite, temperature uniformity is guaranteed to be better than ±9°F (±5°C) but typically it is expected to be as good as ±5.4°F (±3°C). The tube and bar being processed stand on rotating tables, ensuring that heat is applied evenly to all the material. The tables, which are perforated to improve air circulation throughout the chamber, rotate approximately once every two minutes. Heating is provided
Lucky Charms Feed Boilers as Well as Kids
The new boiler will replace a naturalgas boiler, making the mill partially self-sustaining, in addition to cutting its carbon footprint by 21 percent by reducing carbon emissions. Because the hulls release the same carbon they absorbed from the atmosphere as plants, the process is essentially carbon neutral. The hulls have 80 percent of the energy of coal without the harmful effects on the environment. “General Mills is committed to reducing our environmental footprint in areas like water, solid waste, energy and greenhouse gas emissions,” says Gregg Stedronsky, General Mills vice president for engineering. “That’s good for the planet and good for our business.” Energy produced from burning the oat hulls will be enough to produce 90 percent of the steam needed for making oat flour and heating the
Inner Workings At Goodyear’s tire plant in Union City, Tenn., a steam boiler system assessment followed by a load management strategy saves the plant $875,000 a year.
Photo courtesy of Goodyear
Fridley plant, and that only takes 12 percent of the leftover hulls. General Mills’ remaining oat hulls are sold to the Koda facility, which is a partnership between the Shakopee Mdewakanton Sioux Community and Rahr Malting Co. This facility creates enough energy to power 30,000 homes in Shakopee, Minn. General Mills supplies about a third of the Koda facility’s fuel needs. The biomass boiler project will help the milling plant save more than $500,000 in natural gas costs every year.
Goodyear Analyzes Boiler, Saves Nearly $1 Million The Goodyear tire plant in Union City, Tenn., is saving energy, which helps keep the plant’s operating costs down. A Save Energy Now assessment from the U.S. Department of Energy in 2006 identified opportunities to improve the efficiency of the plant’s steam system. Working with a DOE energy expert, the company’s employees, including Dennis
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Burden, a Goodyear energy manager, learned how to analyze the plant’s steam system and identify areas of natural gas savings to improve efficiency. “The program helped bring together plant resources to implement findings
or assist in completing projects already in progress,” Burden says. “Energy savings go directly to the bottom line, helping the plant compete in this global market.” Goodyear implemented DOE recommendations that have helped the facility save $875,000 annually in energy costs. Employees optimized boiler operations and developed a load management strategy shortly after the assessment was completed. They also insulated the tire presses and plan to start recovering wasted heat in the near future. Additionally, results from the assessment were deemed applicable to several other Goodyear plants and are being shared with those facilities — 60 in total — at monthly energy conference calls.
Inner Workings
NEW FULL FEATURE
Revised Infrared Handbook on Sale The second edition of the “Infrared Process Heating for Industrial Applications Handbook” now is on sale through the Industrial Heating Equipment Association. The publication is produced by the Infrared Equipment Division of IHEA. The handbook provides a quick introduction to the many applications of infrared heating in industrial processes. Infrared heat processing first was developed in the 1930s for curing paint on automobile bodies. Since then, infrared has been used in hundreds of different applications such as curing metal finishes and protective coatings, fusing thermoset and thermoplastic powder coatings, forming molded plastics, bonding adhesives and metals, processing foods, and drying papers, inks and fabrics. The guide is $15 for IHEA or IRED members, and $20 for non-members. Order the handbook at www.ihea.org.
Manufacturing to Help Spur Lubricant Sales A Freedonia Group Study, “Lubricants to 2014,” notes that U.S. demand for lubricants will reverse recent declines, supported by increasing manufacturing output, a turnaround in motor vehicle production and an acceleration in the number of automobiles in use. Higher quality base stocks as well as syn-
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www.process-heating.com • J a n u a r y 2 0 1 1
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Inner Workings thetic types will increase their share of the market, according to the Cleveland research company. The study analyzes the 2.1 billion-gal U.S. lubricant industry, presenting historical demand data for the years 1999, 2004 and 2009, with forecasts for 2014 and 2019 by base oil, product (for example, engine oils, process oils, general industrial oils, transmission and hydraulic fluids, metalworking fluids) and market. The study also considers market environment factors, details industry structure, evaluates company market share and profiles 35 industry players, including Shell, Exxon Mobil and Chevron. The study can be purchased in print or a PDF format at www.freedoniagroup.com.
Dewater Paper Web Better, Cheaper Tests at the Voith Paper Technology Center in Heidenheim, Germany, and initial field tests at customer sites have
Protect finned tube coils from corrosive atmospheres with Heresite’s baked phenolic coating. It is the proven choice in processes around the world for service in corrosive fumes and salt atmospheres. For Shell and Tube Heat Exchangers, Heresite can provide protection with the licensed Saekaphen Si series. Typically used in heat exchangers, condensers
shown that using newly developed suction roll covers and felts can achieve increases in dry content of up to 1.5 percent without the need for large investment costs, says the manufacturer. The technology that Voith applied to the polyurethane roll covers leads to deeper and wider grooves, resulting in shortened flow paths for the extracted water, the company says. This increased capacity enables larger quantities of water to be removed quickly and efficiently. The increased water quantities and resulting increased dry content are made possible by the structurally engineered felt with optimized absorptive capacity. The structure enables the felt to bridge the open spaces created by the grooving, reducing the risk of marking the paper. According to the company, SolarMax, the combination of suction roll cover and felt, offers maximum dewatering of the paper web and thus the highest possible dry content.
and evaporators, tube bundles can be protected from many acids, salts, water and alkaline services. Heresite coatings reduce maintenance costs with less downtime and permit the use of less costly alloys to reduce capital costs. Learn the whole story on corrosion resistance by contacting your local Heresite representative. 822 South 14th Street, P.O. Box 250 Manitowoc, WI 54220 Phone: 920-684-6646 • 800-558-7747 Fax: 920-684-0110 www.heresite.com E-mail:
[email protected]
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Therminol TLC Total Lifecycle Care is a complete program of products and services from Solutia designed to keep your heat transfer system in top operating condition through its entire lifecycle. ©Solutia Inc. 2011. Therminol , TLC Total Lifecycle Care , Therminol logo, and Solutia and 5$',$1&(/2*2are trademarks of Solutia Inc., UHJLVWHUHGLQWKH86DQGLQRWKHUFRXQWULHV *Available only in North America.
Calendar of Events January 25-27 — Asphalt Product Maintenance Seminar, Lebanon, Pa. Hosted by Elster Hauck. Call (717) 272-3051 or visit www.hauckburner.com. 25-28 — Infrared Thermography Training Course (Level I), Phoenix.
Hosted by Infrared Training Center. Call (978) 901-8405 or visit www.infraredtraining.com. 26-28 — International Poultry Expo, Georgia World Convention Center, Atlanta. Hosted by U.S. Poultry & Egg Association. Call (770) 493-9401 or
visit www.internationalpoultryexpo sition.com. 31-February 2 — AHR Expo (held in conjunction with ASHRAE Winter Meeting), Las Vegas Convention Center, Las Vegas. Hosted by co-sponsors ASHRAE and ARI. Call (203) 221-9232 or visit www.ahrexpo.com.
February 1-4 — Infrared Thermography Training Course (Level I), Atlanta. Hosted by Infrared Training Center. Call (978) 9018405 or visit www.infraredtraining.com. 6-9 — Biodiesel Conference and Expo, Phoenix Convention Center, Phoenix. Call (800) 841-5849 or visit www.biodiesel.org. 6-10 — Cooling Technology Institute (CTI) Annual Meeting, Westin Riverwalk Hotel, San Antonio, Texas. Hosted by CTI. Call (281) 583-4087 or visit www.cti.org. 8-11 — Infrared Thermography Training Course (Level II), Nashville, Tenn. Hosted by Infrared Training Center. Call (978) 901-8405 or visit www.infraredtraining.com. 8-10 — Plastec West, Anaheim Convention Center, Anaheim, Calif. Hosted by Canon Communications. Call (310) 445-4200 or visit www.canon tradeshows.com/expo/plastecshows/. 14-17 — Boiler Operator (Level I) Training Seminar, Garden City, Kan. Hosted by Kansas Industrial Technical School. Call (620) 271-0037 or visit www.boilerlicense.com. 28-March 3 — Infrared Thermography Training Course (Level I), Boston. Hosted by Infrared Training Center. Call (978) 901-8405 or visit www.infraredtraining.com.
March 7-8 — Safety Standards Seminar for Industrial Ovens and Furnaces, Rosemont, Ill. Hosted by IHEA. Call (859) 356-1575 or visit www.ihea.org. 16
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J a n u a r y 2 0 1 1 • Process Heating
Did you know that 90% of heat transfer fluid breakdowns are caused by equipment issues? 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, overheating, 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 lasts longer, and your process earns its keep. The Immersion Engineering™ team of engineers can get deep into your process with you from the design stage, customizing maintenance plans, process expansions or, in cases where the Fluid Analysis and system review suggests it, just a good cleanout
of your system with one of Paratherm's three specialized system cleaners. Paratherm's nine heat transfer fluids are designed to cover a broad temperature range as well as a range of compatibility and performance criteria. The fluid chart below can give you a feel for their specifications, but to narrow it down to the right product for your application all it takes is a short conversation with one of Paratherm's sales engineers. Eliminate the downside risk and call Paratherm today or check us out on the web.
Immersion Engineering™
Services Fluid Analysis Fluid Maintenance Training Paratherm Paratherm Paratherm Paratherm Paratherm Paratherm
Troubleshooting Consulting
Products Paratherm Paratherm Paratherm Paratherm Paratherm Paratherm
CR® HTF MR® HTF MG™ HTF LR™ HTF HR™ HTF HE® HTF
NF® HTF OR® HTF GLT™ HTF SC® Cleaner LC™ Cleaner AC™ Cleaner
HEAT TRANSFER FLUIDS
4 Portland Road, • West Conshohocken PA 19428 USA
800-222-3611
610-941-4900 • Fax: 610-941-9191
[email protected]
www.paratherm.com
®
®
Listing and temperature range chart for all Paratherm heat transfer fluids.
Copyright© Paratherm Corporation 2011
Equipment Overview | Heat Transfer Fluids
W
hen choosing which heat transfer fluid to use for your process, data such as density, film coefficient, viscosity, pour point and thermal conductivity need to be taken into consideration. In Process Heating’s annual Equipment Overview on Heat Transfer Fluids, we have compiled all the data you need to
Viscosity** (ASTM D445, cSt @ 400˚F)
Viscosity** (ASTM D445, cSt @ 600˚F)
Thermal Conductivity** (BTU/hr-ft-˚F @ 400˚F)
Thermal Conductivity** (BTU/hr-ft-˚F @ 600˚F)
Specific Heat** (BTU/lb-˚F @ 400˚F)
693
-1
10%: 727 90%: 902
45.70
41.2
1.46
0.70
0.077
0.076
0.60
464
680
14
10%: 715 90%: 886
45.60
41.0
1.39
0.70
0.077
0.074
0.60
Duratherm 450
450
500
302
327
625
49
10%: 481 90%: 851
46.00
*
0.70
*
0.075
*
0.63
Density** (lb/ft3 @ 600˚F)
472
435
Density** (lb/ft3 @ 400˚F)
444
650
Distillation Range (ASTM D1160, ˚F)
Autoignition (ASTM E 659-78, ˚F)
670
600
Pour Point (ASTM D97, ˚F)
Firepoint (ASTM D92, ˚F)
630
Duratherm 600
Film, Maximum Temperature, ˚F
Duratherm 630
Company and Fluid Name
Bulk, Maximum Temperature, ˚F
Flashpoint (ASTM D92, ˚F)
You also can conduct your supplier search online! www.process-heating.com Click on Equipment Overview, then on heat transfer fluids.
choose a fluid that can take the heat — and move it to wherever you need it to go. You also can conduct your search online at www.process-heating.com. The online version includes advanced searching capabilities to make it even easier to find the fluid that is right for your process. You set the criteria
Duratherm Extended Life Fluids • www.heat-transfer-fluid.com
Duratherm FG (Food-Grade)
620
670
440
466
682
1
10%: 769 90%: 930
45.70
41.2
1.46
0.70
0.077
0.074
0.60
Duratherm HF (High FlashPoint)
640
680
530
582
830
15
10%:851 90%:1063
46.37
41.89
1.76
0.80
0.077
0.073
0.57
Duratherm S
650
690
615
636
818
-87
10%: 922 90%: 1255
54.90
51.8
8.47
3.37
0.055
0.042
0.47
Duratherm G
500
550
511
543
704
-40
10%: 694 90%: 957
52.07
*
2.32
*
0.080
*
0.55
Duratherm LT (Low Temperature)
600
640
329
370
675
-72
10%: 613 90%: 784
42.70
38.9
0.84
0.54
0.072
0.066
0.65
Duratherm XLT -50
350
400
210
240
*
-140
10%: 356 90%: 546
*
*
*
*
*
*
*
Duratherm XLT -120
150
200
120
140
*
-130
10%: 181 90%: 546
*
*
*
*
*
*
*
MultiTherm LLC • www.multitherm.com MultiTherm 503
500
550
310
335
*
-75
10%: 613 90%: 637
42
*
0.64
*
0.072
*
0.675
MultiTherm PG-1
600
640
340
385
*
-40
10%: 638 90%: 730
49.6
46.7
0.96
0.46
0.069
0.065
0.609
MultiTherm IG-4
600
650
440
500
*
0
10%: 760 90%: 930
46
40.2
1.5
0.67
0.07
0.065
0.667
MultiTherm FF-1 (flushing fluid)
600
630
330
345
650
-51
10%: 583 90%: 930
49.25
44.9
0.93
0.43
0.006
0.0611
0.63
MultiTherm OG-1
550
600
455
520
675
-44
10%: 704 90%: 904
47.6
44.2
1.5
0.7
0.076
0.074
0.605
MultiTherm IG-1
550
600
442
505
670
5
*
49.6
44.1
1.52
0.71
0.072
0.067
0.611
MultiTherm PSC
180
*
>350
*
*
50
*
*
*
150-200 @ 40°C, cSt
*
*
*
*
MultiTherm PSC Plus
550
*
>392
*
*
50
*
*
*
100 @ 40°C, cSt
*
*
*
*
Paratherm NF
*
650
340
355
*
-40
10%: 565A
49.7
46.8
1.2
0.49
0.07
0.06
0.61
Paratherm HE
600
*
465
480
*
10
10%: 730A
46.5
42.1
1.5
0.7
0.07
0.06
0.61
Paratherm Corp. • www.paratherm.com
Paratherm MR
550
600
330
365
*
<-50
10%: 600A
42.5
35.6
0.63
0.42
0.07
0.06
0.65
Paratherm LR
400
450
N/A
N/A
500
<-75
10%: 355A
39.1
*
0.34
*
0.08
*
0.65
Paratherm CR
*
400
N/A
N/A
430
<-184
10%: 290A
40.1
*
0.39
*
0.08
*
0.62
Paratherm MG
500
550
330
365
*
<-50
10%: 600A
42.5
*
0.63
*
0.07
*
0.65
Petro-Canada Lubricants • www.lubricants.petro-canada.ca Petro-Therm
599
617
437
473
666
0
10%: 709 90%: 880
46.8
42.4
1.37
0.69
0.077
0.074
0.6
Calflo AF
600
617
437
464
649
-44
10%: 689 90%: 887
46.8
42.5
1.41
0.72
0.077
0.073
0.6
Purity FG
620
650
459
480
669
0
10%: 721 90%: 892
46.8
42.5
1.44
0.73
0.074
0.07
0.6
Calflo HTF
620
650
448
473
666
0
10%: 705 90%: 889
46.8
42.4
1.46
0.73
0.077
0.074
0.6
Calflo LT
500
550
349
372
613
-81
10%: 604 90%: 734
43.4
38.8
0.82
0.51
0.072
0.067
0.65
Therminol 55
550
635
350
425
650
-65
10%: 644 90%: 734
46.5
41.1
0.964
0.453
0.0618
0.0542
0.612
Therminol 59
600
650
295
310
760
-90
*
52.2
46.2
0.551
0.313
0.06
0.0513
0.547
Therminol 62
620
670
340
385
765
-44
*
50.9
44.6
0.688
0.297
0.061
0.0528
0.565
Therminol 66
650
705
363
414
705
-25
10%: 658 90%: 738
55.1
49.7
0.935
0.477
0.0608
0.0535
0.528
Therminol 75
725
770
365
440
1000
170
*
59.3
53.6
0.853
0.386
0.0699
0.064
0.492
Therminol 72
716
752
270
289
1085
0
*
56.9
50.6
0.52
0.26
0.0678
0.06
0.49
Therminol VP-1
750
800
255
260
1150
54
*
56.8
50
0.421
0.257
0.0654
0.054
0.492
Solutia Inc. • www.therminol.com
Therminol VP-3
625
675
219
235
663
36
*
49.8
41.5
0.465
0.27
0.0538
0.0448
0.562
Therminol D-12
450
475
138
160
477
-148
10%: 374 90%: 400
38.1
*
0.308
*
0.044
*
0.684
Therminol LT
600
650
134
150
805
-103
*
43.8
34.8
0.266
0.19
0.0508
0.0374
0.588
Therminol XP
600
625
390
450
655
-20
10%: 630 90%: 780
47.3
42.3
1.06
0.497
0.0571
0.049
0.625
*Contact Manufacturer for Specifics | **Values provided for Density, Viscosity, Thermal Conductivity and Specific Heat were determined at 400°F and 600°F (204 and 316°C) unless otherwise indicated for a specific fluid | NR=Not Reported | AData is from a Gas Chromatograph (ASTM D2887). | BFor fired heaters. All other heat sources are 30°F higher | †Thermal Conductivity Liquid (mW/(m)(K) @ 25°C) | ‡Thermal Conductivity Vapor (m/W/(m)(K) @ 25°C)
18
|
J a n u a r y 2 0 1 1 • Process Heating
and let the search engine work for you. In addition, hyperlinks will take you directly to manufacturers’ web sites. If you would like a list of contact information for heat transfer fluid manufacturers listed in our Equipment Overview, Process Heating can help. Call or e-mail editor Linda Becker for the phone number, address and contact name of the companies in which you are interested: (847) 405-4020 or e-mail
[email protected].
No No
Reprocessed Fluid? No
•
Other
•
No
Synthetic
No
No
Silicone
EPA regulated
No
5
Petroleum
Fluid Meets NSF Criteria for Food Contact
5
0.06
Glycol
Thermal Expansion (average % per 100˚F)
0.06
0.68
Fluorocarbon
Vapor Pressure (psia @ 400˚F)
0.74
Aromatic
Specific Heat** (BTU/lb-˚F @ 600˚F)
BASE STOCK
*
2.11
5
No
No
•
0.69
0.06
5
Yes
No
•
No
0.66
0.03
5
*
*
•
No
0.51
0.18
4
No
No
*
0.34
5
No
No
0.72
1.02
5
No
No
*
*
*
No
No
•
*
*
*
No
No
•
No
•
No
•
No
•
0.5
5.4
No
No
0.13
4
Yes
No
•
0.788
0.02
5.4
Yes
No
•
*
0.74
*
4.5
Yes
No
•
*
0.7
0.06
5.6
No
No
•
*
0.705
0.05
5.4
No
No
•
*
•
A NEW REVOLUTION IN HEAT TRACE SYSTEMS
*
* 0.705
*
The old traditional way of installing a self-regulating heater system is being replaced with an innovative,
*
<0.01 psi @ 20°C
*
No
No
•
*
*
<0.01 psi @ 20°C
*
No
No
•
*
safe, and efficient system... T-Links by Heat Trace
0.7
0.2
3
Yes
No
•
No
Products. T-Links Pre-Terminated Heat Trace System
0.71
0.01
6
Yes
No
•
No
will revolutionize the way self-regulating heater
0.7
0.6
5
No
No
*
15
4
Yes
No
*
18
3
No
No
*
0.6
5
Yes
No
0.69
0.06
5.2
No
No
• •
No No No
• •
No
0.69
0.1
5
No
No
•
No
0.07
5.1
Yes
No
•
No
0.69
0.06
5.2
No
No
•
No
0.74
1.02
5.9
No
No
•
No
0.705
0.36
5.3
No
No
•
No
0.64
2.14
5.3
No
No
•
No
0.612
0.584
5.6
No
No
•
No
0.628
0.37
4.6
No
No
•
No
0.552
0.52
4.5
No
No
•
No
0.562
4.97
5.5
No
Yes
•
No
0.563
3.94
5.4
No
Yes
•
No
0.683
4.99
6.7
No
No
•
No
*
19.5
6.2
Yes
No
26.5
6
No
No
0.718
0.29
5
Yes
No
•
using the same reliable 2700 series type cables that have been used for over 30 years.
No
•
0.69
0.719
systems are viewed in the industry. Manufactured
No No
• •
No
Manufacturers listed in this Equipment Overview responded to a special mailing by Process Heating and do not necessarily represent the entire heat transfer fluid market. To be included in future listings, contact Linda Becker at (847) 4054020 or e-mail
[email protected].
www.process-heating.com • J a n u a r y 2 0 1 1 PH0111_Hea_vert.indd 1
|
19
12/21/10 2:19 PM
Specific Heat** (BTU/lb-˚F @ 400˚F)
1.1
*
0.07
*
0.61
47
0.46
0.29
0.064
0.056
0.53
Chem Group / Marlotherm N
600
640
385
410
626
-76
10%: 630 90%: 750
47
*
0.84
*
0.07
*
0.63
Chem Group / Marlotherm SH
662
716
421
475
842
-29
10%: 730 90%: 740
57
52
0.88
0.41
0.061
0.053
0.53
Chem Group / Marlotherm X
572
608
147
158
770
-130
10%: 355 90%: 365
44
*
0.29
*
0.048
*
0.61
Chem Group / Thermaflo 660
653
698
374
401
716
-27.4
10%: 650 90%: 670
55
50
0.89
0.42
0.061
0.059
0.51
Chem Group / Calflo HTF
620
650
439
462
687
5
10%: 738 90%: 932
46
41
2
0.73
0.077
0.074
0.6
Chem Group / Calflo AF
600
650
430
446
650
-44
10%: 693 90%: 900
45.8
40.8
2
0.73
0.077
0.073
0.6
Chem Group / Calflo FG
620
650
408
457
669
0
10%: 720 90%: 928
45
41
2
0.72
0.073
0.07
0.6
Chem Group / Calflo LT
500
617
343
372
613
-81
10%: 624 90%: 752
43
38
0.84
0.72
0.0725
0.07
0.65
Chemtherm 550
600
640
343
365
700
-50
10%: 609 90%: 867
48.7
44.3
1.14
0.61
0.0677
0.0629
0.615
Chemtherm 650
640
680
275
310
806
-4
10%: 516 90%: 519
52.5
46.5
0.43
0.25
0.0587
0.0503
0.504
Chemtherm 700
665
700
415
470
840
-30
10%: 690 90%: 720
56.2
51.4
0.85
0.47
0.0647
0.058
0.527
Thermalane 600
600
650
335
355
697
-45
10%: 622 90%: *
48.1
43.5
1.17
0.6
0.0678
0.0633
0.603
Thermalane 800
600
640
445
495
700
-80
10%: 753 90%: 850
43.2
38.6
1.17
0.67
0.76
0.0692
FluidGuard PG-USP (50% in water)
345
400
None
None
None
-67
*
66.6 @ 100°F
61.1@300°F
3.08 @ 100°F
0.56 @ 300°F 0.227 @ 300°F 0.217 @ 300°F
66.6 @ 100°F
Viscosity** (ASTM D445, cSt @ 600˚F)
*
53
Viscosity** (ASTM D445, cSt @ 400˚F)
45
10%: 532 90%: 540
Density** (lb/ft3 @ 600˚F)
10%: 650 90%: 880
-26
Density** (lb/ft3 @ 400˚F)
10
842
Distillation Range (ASTM D1160, ˚F)
617
295
Pour Point (ASTM D97, ˚F)
468
288
Autoignition (ASTM E 659-78, ˚F)
432
716
Firepoint (ASTM D92, ˚F)
617
680
Flashpoint (ASTM D92, ˚F)
572
Chem Group / Marlotherm LH
Film, Maximum Temperature, ˚F
Chem Group / Marlotherm FP
Company and Fluid Name
Bulk, Maximum Temperature, ˚F
Thermal Conductivity** (BTU/hr-ft-˚F @ 600˚F)
You also can conduct your supplier search online! www.process-heating.com Click on Equipment Overview, then on heat transfer fluids.
Thermal Conductivity** (BTU/hr-ft-˚F @ 400˚F)
Equipment Overview | Heat Transfer Fluids
Chem Group
Coastal Chemical
0.669 0.865@100°F
FluidGuard PG1 (50% in water)
350
400
None
None
None
-67
None
61.1@300°F
3.08 @ 100°F
0.56 @ 300°F 0.227 @ 300°F 0.217 @ 300°F
0.865@100°F
FluidGuard EG (50% in water)
300
350
None
None
None
*
*
64.2 @ 100°F 59.9 @ 300°F
2.29 @ 100°F
0.41 @ 300°F 0.230 @ 100°F 0.258 @ 300°F
0.826 @ 100°F
ThermGuard (50% in water)
320
370
None
None
None
-35
*
66.7 @ 100°F 61.3 @ 300 °F
2.29 @ 100°F
0.41 @ 300°F 0.230 @ 100°F 0.254 @ 300 °F
0.828 @ 100 °F
ThermGuard PG (50% in water)
360
410
None
None
None
-65
*
64.4 @ 100°F 60.1 @ 300 °F
3.08 @ 100°F
0.56 @ 300°F 0.227 @ 100°F 0.217 @ 300°F
0.867 @ 100°F
HITEC
1000
1100 None
None
None
290
*
120.6
115.5
3.85
1.53
0.35
0.35
0.373
HITEC XL
925
1000 None
None
None
240
*
129.6
124.3
18.62
3.7
0.3
0.3
0.353
Dowtherm A
750
800
236
245 “1,100”
54
*
56.4
49.3
0.42
0.24
0.063
0.053
0.5
Dowtherm G
670
720
256
262 “1,083” <40
*
56.5
51.1
0.63
0.32
0.061
0.053
0.52
Dowtherm J
600
650
136
140
788
<-120
*
44.1
35.5
0.33
0.29
0.052
0.038
0.6
Dowtherm Q
625
675
249
255
773
<-40
*
51.6
46.3
0.36
0.24
0.056
0.046
0.53
Dow Chemical Co
Dowtherm MX
625
675
329
*
788
-13
*
51.6
45.7
0.64
0.3
0.0598
0.0531
0.528
Dowtherm RP
660
710
381
*
725
<-5
*
56.1
50.8
0.86
0.46
0.062
0.054
0.52
Dowtherm T
550
600
370
410
707
<-40
*
46.6
41.8
0.965
0.49
0.054
0.04
0.6
Syltherm XLT
500
550
116
*
662
<-170
*
41.6
NR
0.36
0.27
0.038
NR
0.516
Syltherm HF
500
550
148
*
671
<-100
*
42.8
NR
0.44
0.3
0.035
NR
0.511
Syltherm 800
750
800
320
380
725
<-40
*
48.1
40.8
1.31
0.64
0.058
0.046
Dowfrost (50% in water)
250
300
None
None
None
<-60
*
64.52 @ 100°F 58.14 @ 300°F
0.032 @ 100°F
0.005 @ 300°F 0.214 @ 100°F 0.214 @ 300°F
0.861 @ 100°F
Dowfrost HD (50% in water)
325
375
None
None
None
<-60
*
65.32 @ 100°F 59.42 @300°F
0.032 @ 100°F
0.005 @ 300°F 0.214 @ 100°F 0.214 @ 300°F
0.830 @ 100°F
Dowtherm SR-1 (50% in water)
250
300
None
None
None
<-60
*
66.55 @ 100°F 61.05 @ 300°F
0.022 @ 100°F
0.004 @ 300°F 0.227 @ 100°F 0.239 @ 300°F
0.800 @ 100°F
Dowtherm 4000 (50% in water)
350
400
None
None
None
<-60
*
67.17 @ 100°F 61.80 @ 300°F
0.022 @ 100°F
0.004 @ 300°F 0.227 @ 100°F 0.239 @ 300°F
0.793 @ 100°F
Ucartherm (50% in water)
250
300
None
None
None
-60
*
66.56 @ 100 °F 61.06 @ 300 °F
0.022 @ 100 °F
0.004 @ 300°F 0.227 @ 100°F 0.239 @ 300°F
0.800 @ 100°F 0.45 @ 100°F
0.46
Dynalene Heat Transfer Fluids Dynalene MV
325
350
127
147
730
<-200
*
52.0 @ 100°F 46.6 @ 300°F
0.93 @ 100°F
0.29 @ 300°F
Dynalene HF
325
350
141
162
640
<-180
*
49.3 @ 100°F 44.5 @ 300°F
1.5 @ 100°F
0.38 @ 300°F 0.068 @ 100°F 0.057 @ 300°F
0.75 @ 100°F 0.58 @ 300°F
0.5 @ 100°F
Dynalene HC
425
450
None
None
None
<-60
*
82.0 @ 100°F 77.5 @ 300°F
1.67 @ 100°F
0.56 @ 300°F
0.79 @ 100°F
0.37 @ 300°F 0.227 @ 100°F 0.239 @ 300°F
0.3 @ 100°F
0.37 @ 300°F
Dynalene EG (50% in water)
250
300
None
None
None
-36
*
66.2 @ 100°F 61.8 @ 300°F
2.3 @ 100°F
Dynalene PG (50% in water)
250
300
None
None
None
-31
*
64.6 @ 100°F
*
3.1 @ 100°F
*
0.214 @ 100°F
*
0.861 @ 100°F
0.793 @ 100°F
Dynalene HFLO
325
350
140
161
640
<-180
*
46.8 @ 100°F
*
2.0 @ 100°F
*
0.062 @ 100°F
*
0.465 @ 100°F
Dynalene LO-170
400
425
>170
>190
>640 <-100
*
48.0 @ 100°F
*
5.0 @ 20°F
*
0.065 @ 68°F
*
0.45 @ 68°F
Dynalene LO-230
400
425
>230
>250
>640
<-60
*
49.8 @ 100°F
*
37.0 @ 32°F
*
0.085 @ 68°F
*
0.48 @ 68°F
Dynalene SF
600
644
355
>370
626
-76
*
47
42.4
0.54
0.32
0.07
0.064
0.63
Dynalene HT
660
716
392
456
842
-30
*
57
52
0.88
0.41
0.061
0.053
0.533
Safe-T-Therm (50% in water)
250
310
None
None
None
-60
*
65 @ 100°F
*
1.83 @ 100°F
*
0.22 @ 100°F
*
0.875 @ 100°F
Safe-T-Therm HD (50% in water)
315
370
None
None
None
-60
*
65 @ 100°F
*
1.85 @ 100°F
*
0.22 @ 100°F
*
0.875 @ 100°F
Wintrex (50% in water)
250
310
None
None
None
-70
*
67 @ 100°F
*
1.17 @ 100°F
*
0.23 @ 100°F
*
0.822 @ 100°F
Wintrex HD (50% in water)
245
400
None
None
None
-70
*
67 @ 100°F
*
1.19 @ 100°F
*
0.23 @ 100°F
*
0.822 @ 100°F
Houghton Chemical Corp.
*Contact Manufacturer for Specifics | **Values provided for Density, Viscosity, Thermal Conductivity and Specific Heat were determined at 400°F and 600°F (204 and 316°C) unless otherwise indicated for a specific fluid | NR=Not Reported | AData is from a Gas Chromatograph (ASTM D2887). | BFor fired heaters. All other heat sources are 30°F higher | †Thermal Conductivity Liquid (mW/(m)(K) @ 25°C) | ‡Thermal Conductivity Vapor (m/W/(m)(K) @ 25°C)
20
|
J a n u a r y 2 0 1 1 • Process Heating
FOUR SIMPLE STEPS TO FUEL COST SAVINGS THROUGH BASE STOCK
Specific Heat** (BTU/lb-˚F @ 600˚F)
Vapor Pressure (psia @ 400˚F)
Thermal Expansion (average % per 100˚F)
Fluid Meets NSF Criteria for Food Contact
EPA regulated
CATALYTIC INCINERATION
*
3.6
4
Yes
No
0.62
2.2
7
No
No
•
*
*
0.2
5
No
No
•
*
0.63
0.09
4
No
No
•
*
*
26
6
No
No
•
*
0.61
0.23
4.6
No
No
•
0.68
<0.39
5.6
No
No
•
*
0.69
0.2
5.6
No
No
•
*
0.688
<0.437
5.1
Yes
No
•
*
0.68
<4.2
5.8
No
No
•
*
0.711
0.34
4
No
No
0.593
3.745
4
No
No
•
0.62
0.2
4
No
No
•
0.698
0.3
4
No
No
0.748
0.073
5
No
No
0.951 @ 300°F
52.08 @ 300°F
3.5
No
No
•
*
0.951 @ 300°F
52.08 @ 300°F
3.5
No
No
•
*
0.920 @ 300°F
66.3 @ 300°F
3
No
Yes
•
*
0.923 @ 300°F
66.3 @ 300°F
3
No
Yes
•
*
0.955 @ 300°F
52.08 @ 300°F
3.5
No
No
•
0.373
*
2
No
Yes
•
*
0.344
*
2
No
Yes
•
*
0.58
4
5.2
No
Yes
•
* PH01114ConvProd.indd 1
0.62
1.9
5.2
No
Yes
•
*
0.72
25.3
5.6
No
Yes
•
*
0.61
2.9
6.2
No
Yes
•
*
0.614
0.51
5.7
No
No
•
*
0.6
0.27
3.9
No
Yes
•
*
0.68
0.17
4.7
No
Yes
•
*
Clean Effluent to Atmosphere
Reprocessed Fluid?
Other
Synthetic
Silicone
Petroleum
Glycol
Fluorocarbon
Aromatic
Hinged Gate
*
•
*
Auxiliary Catalytic Assembly
Optional Diverter Gate Assembly
Flow Direction Existing Thermal Oxidizer
Pollution Source
Catalyst Section w/Hinged Door
Extraction Fan
1. Install a Conversion Products Auxiliary Catalytic Assembly 2. Lower Your Thermal Oxidizer Temperature 3. Direct Lower Temperature Thermal Oxidizer Air to the Conversion Products Auxiliary Catalytic Assembly 4. Start Collecting Significant Fuel Cost Savings > Changeover time is measured in hours, not weeks > Typical fuel savings run over $20,000 per year Isn’t this worthwhile looking into?
* *
Conversion Products, Inc.
* •
Phone: (800) 503-4121 Fax: (510) 887-7894 E-mail:
[email protected] Web: conversionproductsinc.com
* *
•
*
NR
28
6
No
No
•
*
NR
12.9
6.2
No
No
•
*
0.51
15.1
5.6
No
No
•
0.963 @ 300°F
0.8 @ 100°F
3
Yes
No
•
*
0.950 @ 300°F
0.8 @ 100°F
3
No
No
•
*
0.903 @ 300°F
0.7 @ 100°F
3
No
Yes
•
*
0.898 @ 300°F
0.7 @ 100°F
3
No
Yes
•
*
0.903 @ 300°F
0.7 @ 100°F
3
No
Yes
•
*
0.59 @ 300°F
0.06 @ 100°F
5
No
No
0.62 @ 300°F
0.03 @ 100°F
5
No
No
•
0.86 @ 300°F
40 @ 300°F
2.5
No
No
•
0.898 @ 300°F
0.7 @ 100°F
3
No
Yes
• •
12/22/10 9:47 AM
*
*
•
* * * *
*
0.8 @ 100°F
3
No
No
*
0.03 @ 100°F
5
No
No
•
*
*
0.006 @ 100°F
5
No
No
•
*
*
0.19 @ 300°F
5
No
No
•
0.72
0.3
5
No
No
•
*
0.63
0.09
4
No
No
•
*
*
*
*
0.48 @ 100°F
2.1
Yes
No
•
*
0.48 @ 100°F
2.1
No
No
•
*
*
0.68 @ 100°F
1.8
No
Yes
•
*
*
0.68 @ 100°F
1.8
No
Yes
•
*
Manufacturers listed in this Equipment Overview responded to a special mailing by Process Heating and do not necessarily represent the entire heat transfer fluid market. To be included in future listings, contact Linda Becker at (847) 4054020 or e-mail
[email protected].
s &LUID 0ROCESS (EATING s s &LU UID 0ROCESS (EATIN UID NG s s $ESIGN, %NGINEER AND -ANUFACTURE s #ONTACT OUR %NGINEERING 3ALES TEAM DIRECTLY TEL s &AX INFO HUBBELLHEATERSCOM wwwHUBBELLHEATERSCOM
4(% %,%#42)# (%A4%2 #/-0ANY www.process-heating.com • J a n u a r y 2 0 1 1
|
21
Autoignition (ASTM E 659-78, ˚F)
Pour Point (ASTM D97, ˚F)
Distillation Range (ASTM D1160, ˚F)
Viscosity** (ASTM D445, cSt @ 400˚F)
Viscosity** (ASTM D445, cSt @ 600˚F)
350
None
None
None
<-60
*
65.8 @ 100°F 59.9 @ 300°F
2.3 @ 100°F
*
0.24 @ 100°F 0.24 @ 300°F
300
350
None
None
None
<-60
*
65.8 @ 100°F 59.9 @ 300°F
2.3 @ 100°F
*
0.24 @ 100°F 0.24 @ 300°F
0.84 @ 100°F
Jeffcool P150 (50% in water)
300
350
None
None
None
<-60
*
63.2 @ 100°F 57.6 @ 300°F
3.1 @ 100°F
*
0.22 @ 100°F 0.22 @ 300°F
0.88 @ 100°F
Jeffcool P150N (50% in water)
300
350
None
None
None
<-60
*
63.2 @ 100°F 57.6 @ 300°F
3.1 @ 100°F
*
0.22 @ 100°F 0.22 @ 300°F
0.88 @ 100°F
Jeffcool P200 (50% in water)
300
350
None
None
None
<-60
*
63.2 @ 100°F 57.6 @ 300°F
3.1 @ 100°F
*
0.22 @ 100°F 0.22 @ 300°F
0.88 @ 100°F
Intercool OP-100/50
250
400
None
None
None
<-60
*
67
61
1.8
0.39
0.23
0.24
<0.83
Intercool NFE/50
250
300
None
None
None
<-60
*
67
61
1.8
0.39
0.23
0.24
<0.83
Intercool P-300/50
275
325
None
None
None
<-60
*
64
59
3.2
0.34
0.22
0.21
<0.87
Intercool NFP/50
275
300
None
None
None
<-60
*
64
59
3.2
0.34
0.22
0.21
<0.87
Specific Heat** (BTU/lb-˚F @ 400˚F)
Firepoint (ASTM D92, ˚F)
Thermal Conductivity** (BTU/hr-ft-˚F @ 600˚F)
Flashpoint (ASTM D92, ˚F)
300
Jeffcool E100N (50% in water)
Density** (lb/ft3 @ 600˚F)
Film, Maximum Temperature, ˚F
Jeffcool E100 (50% in water)
Company and Fluid Name
Density** (lb/ft3 @ 400˚F)
Bulk, Maximum Temperature, ˚F
You also can conduct your supplier search online! www.process-heating.com Click on Equipment Overview, then on heat transfer fluids.
Thermal Conductivity** (BTU/hr-ft-˚F @ 400˚F)
Equipment Overview | Heat Transfer Fluids
Huntsman International 0.84 @ 100°F
Interstate Chemical Co. Inc.
Intercool P-323 (50% in water)
250
300
None
None
None
<-60
*
63.6
57.8
3.2
0.34
0.21
0.21
<0.85
Intercool Biogreen 50/50
275
400
None
None
None
<-60
*
64
63.2
1.4
0.34
0.22
0.2
<0.87
KostChill EG (50% in water)
250
300
None
None
None
<-60
*
65.5 @ 100°F
*
*
*
0.23 @ 100°F 0.237 @ 300°F
0.813 @ 100°F
KostChill EG HD (50% in water)
350
400
None
None
None
<-60
*
66.0 @ 100°F
*
*
*
0.23 @ 100°F 0.237 @ 300°F
0.813 @ 100°F
KostChill PG (50% in water)
250
300
None
None
None
<-60
*
64.5 @ 100°F
*
*
*
0.214 @ 100°F 0.214 @ 300°F
0.835 @ 100°F
KostChill PG HD 50% in water
325
375
None
None
None
<-60
*
65 @ 100°F
*
*
*
0.214 @ 100°F 0.214 @ 300°F
0.835 @ 100°F
KostChill PG FG (50% in water)
250
300
None
None
None
<-60
*
64.0 @ 100°F
*
*
*
0.214 @ 100°F 0.214 @ 300°F
0.835 @ 100°F
BioChill 13 (50% in water)
350
400
None
None
None
<-60
*
65.3 @ 100°F
*
*
*
0.22 @ 100°F 0.22 @ 300°F
0.805 @ 100°F
KostChill B20100 (50% in water)
350
400
None
None
None
<-60
*
66.5 @ 100°F
*
*
*
0.23 @ 100°F 0.237 @ 300°F
0.813 @ 100°F
Kost USA
Radco Industries Xceltherm MK1
750
800
255
265
1150
53.6
*
56.8
50
0.421
0.257
0.065
0.054
Xceltherm LV1
700
750
251
263
1120
45
*
56.78
50.99
0.44
0.26
0.065
0.054
0.492 0.5
Xceltherm HT
660
710
325
332
842
-50
*
56.64
57.25
1.05
0.55
0.065
0.058
0.547
Xceltherm XT
650
700
275
283
803
-40
*
53.95
48.96
0.44
0.26
0.061
0.051
0.543
Xceltherm 600
600
650
380
420
680
-4
*
46.18
41.97
0.798
0.375
0.07
0.065
0.627
Xceltherm 550
550
600
350
380
640
-9
*
48.67
NR
0.709
NR
0.73
NR
0.701
Xceltherm 500
500
550
325
350
625
-80
*
42.29
NR
0.709
NR
0.073
NR
0.701
Xceltherm 445FP
550
600
445
480
715
5
*
48.41
NR
1.48
NR
0.07
NR
0.672
Xceltherm 315
550
600
358
410
660
-61
10%: 642 90%: 738
46.5
41.1
0.96
0.45
0.0619
0.0542
0.612
700
725
460
535
760
-90
10%: 750 90%: 1000
43.1
37.9
1.6
0.8
0.121
0.117
0.665
Galden HT 55
*
*
None
None
None <-166
*
111.1 @ -40°F 101.8 @ 100°F
1.40 @ -40°F
0.38 @ 100°F 0.040 @ -40°F 0.037 @ 100°F
0.19 @ -40°F
Galden HT 70
*
*
None
None
None <-166
10%: 140 90%: 282
112.4 @ -40°F 103.0 @ 100°F
1.79 @ -40°F
0.43 @ 100°F 0.040 @ -40°F 0.037 @ 100°F
0.19 @ -40°F
Galden HT 90
*
*
None
None
None <-166
10%: 172 90%: *
113.36 @ -40°F 103.6 @ -40°F
3.12 @ 40°F
0.63 @ 100°F 0.040 @ -40°F 0.037 @ 100°F
0.19 @ -40°F
Galden HT 110
*
*
None
None
None
<-73
10%: 190 90%: 275
114.9 @ -40°F 104.9 @ 100°F
3.74 @ -40°F
0.64 @ 100°F 0.040 @ -40°F 0.087 @ 100°F
0.19 @ -40°F
Galden HT 135
*
*
None
None
None
<-73
10%: 257 90%: 293
116.4 @ -40°F 106.3 @ 100°F
6.32 @ -40°F
0.84 @ 100°F 0.040 @ -40°F 0.037 @ 100°F
0.19 @ -40°F
Galden HT 170
*
*
None
None
None
-130
10%: 302 90%: 401
108.6 @ 100°F 43.0 @ 300°F
1.40 @ 100°F
0.37 @ 300°F 0.037 @ 100°F 0.032 @ 300°F
0.24 @ 100°F
Galden HT 200
*
*
None
None
None
-121
10%: 363 90%: 414
109.9 @ 100°F 94.9 @ 300°F
1.81 @ 100°F
0.44 @ 300°F 0.037 @ 100°F 0.032 @ 300°F
0.24 @ 100°F
Galden HT 230
*
*
None
None
None
-107
10%: 410 90%: 482
111.7 @ 100°F 89.3 @ 400°F
3.10 @ 100°F
0.39 @ 400°F 0.037 @ 100°F 0.029 @ 400°F
0.24 @ 100°F
Galden HT 270
*
*
None
None
None
-87
*
114.1 @ 100°F 95.5 @ 400°F
7.98 @ 100°F
0.59 @ 400°F 0.037 @ 100°F 0.029 @ 400°F
0.24 @ 100°F
Protocol HT-50
350
400
None
None
None
<-60
*
*
*
*
*
0.24 @ 100°F
*
0.80 @ 100°F
Protocol LT-50
275
325
None
None
None
<-60
*
*
*
*
*
0.24 @ 100°F
*
0.80 @ 100°F
Protocol NT-50
325
375
None
None
None
<-60
*
*
*
*
*
0.22 @ 100°F
*
0.83 @ 100°F
Protocol FG-50
250
300
None
None
None
<-60
*
*
*
*
*
0.22 @ 100°F
*
0.86 @ 100°F
SubZero LLC-50
275
325
None
None
None
<-60
*
*
*
*
*
0.24 @ 100°F
*
0.80 @ 100°F
SubZero ELC-50
275
325
None
None
None
<-60
*
*
*
*
*
0.24 @ 100°F
*
0.80 @ 100°F
Perfluorohexane
*
*
None
*
*
-130
*
1.68 g/ml @ 77°F
*
0.4 cSt @ 77°F
*
57†
12.4‡
0.25 cal/g °C @ 77°F
Perfluorooctane
*
*
None
*
*
214
*
1.77 g/ml @ 77°F
*
0.8 cSt @ 77°F
*
64†
*
0.25 cal/g °C @ 77°F
Galden H200
*
*
None
*
*
-121
*
1.79 g/ml @ 77°F
*
2.4 cSt @ 77°F
*
70†
*
0.23 cal/g °C @ 77°F
Royal Purple Inc. Hytherm 707 Solvay Solexis
Thermal Fluid Technologies
TMC Industries Inc
Galden H110
*
*
None
*
*
<-166
*
1.71 g/ml @ 77°F
*
0.77 cSt @ 77°F
*
70†
*
0.23 cal/g °C @ 77°F
Galden HT170
*
*
None
*
*
-142
*
1.77 g/ml @ 77°F
*
1.8 cSt @ 77°F
*
70†
*
0.23 cal/g °C @ 77°F
Vertrel XF
*
*
None
*
*
-112
*
1.58 g/ml @ 77°F
*
*
0.67 cPs
*
*
*
*Contact Manufacturer for Specifics | **Values provided for Density, Viscosity, Thermal Conductivity and Specific Heat were determined at 400°F and 600°F (204 and 316°C) unless otherwise indicated for a specific fluid | NR=Not Reported | AData is from a Gas Chromatograph (ASTM D2887). | BFor fired heaters. All other heat sources are 30°F higher | †Thermal Conductivity Liquid (mW/(m)(K) @ 25°C) | ‡Thermal Conductivity Vapor (m/W/(m)(K) @ 25°C)
22
|
J a n u a r y 2 0 1 1 • Process Heating
The Process Heating Flanged Heater Advantage
No
0.96 @ 300°F
0.77 @ 100°F
3
No
No
•
No
0.96 @ 300°F
0.77 @ 100°F
3
No
No
•
No
0.96 @ 300°F
0.77 @ 100°F
3
Yes
No
•
No
<0.9
<0.5
3
No
Yes
*
No
<0.9
<0.5
3
No
Yes
*
No
<0.9
<0.7
3
No
No
*
No
<0.9
<0.7
3
No
No
*
No
<0.9
<0.8
3
Yes
No
*
<0.9
<0.8
3
No
No
0.90 @ 300°F
<0.9
3
*
Yes
•
No
0.90 @ 300°F
<0.9
3
*
Yes
•
No
0.95 @ 300°F
<0.9
3
*
*
•
No
0.95 @ 300°F
<0.9
3
*
*
•
No
0.95 @ 300°F
<0.9
3
Yes
*
•
No
0.905 @ 300°F
<0.9
3
*
*
•
No
0.91 @ 300°F
<0.9
3
*
Yes
•
No
0.563
3.95
5.3
No
Yes
•
No
0.572
3.76
5
No
No
•
No
0.647
0.0631
4.1
No
No
•
No
0.625
2.344
4.2
No
No
•
0.717
0.176
3.5
Yes
No
•
NR
1.404
5.2
No
No
•
NR
1.4043
5.2
Yes
No
NR
0.105
4
No
No
0.705
0.361
5.3
No
No
•
No
0.747
0.073
4.8
No
No
•
No
0.24 @ 100°F
7.43 @ 100°F
4
No
No
•
*
0.24 @ 100°F
4.84 @100°F
4
No
No
•
*
0.24 @ 100°F
1.78 @ 100°F
4
*
No
•
*
0.24 @ 100°F
0.48 @ 100°F
4
No
No
•
*
0.24 @ 100°F
0 @ 100°F
4
No
No
•
*
0.32 @ 300°F
6.1@ 300°F
4
No
No
•
*
0.32 @ 300 °F
2.4 @ 300°F
4
No
No
•
*
0.36 @ 400°F
0.80 @ 300°F
4
No
No
•
*
0.36 @ 400°F
0.21 @ 300°F
4
No
No
•
*
*
<1.0
3
No
Yes
•
*
*
<1.0
3
No
Yes
•
*
*
<1.0
*
No
No
•
*
*
<1.0
*
Yes
No
•
*
*
<1.0
*
No
Yes
•
*
*
<1.0
*
No
Yes
•
*
x
Reprocessed Fluid? No
•
Other
•
Yes
Synthetic
Yes
No
Silicone
EPA regulated
No
3
Petroleum
Fluid Meets NSF Criteria for Food Contact
3
0.71 @ 100°F
Glycol
Thermal Expansion (average % per 100˚F)
0.71 @ 100°F
0.90 @ 300°F
Fluorocarbon
Vapor Pressure (psia @ 400˚F)
0.90 @ 300°F
Aromatic
Specific Heat** (BTU/lb-˚F @ 600˚F)
BASE STOCK
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i>ÌiÀÊvi ELEMENTS #/.42/,3 UÊ ÜÊÜ>ÌÌÊ Ê `iÃÌÞÊi>ÌiÃÊ>ÌiÀ>Ê`>>}i UÊÛiÊÞi>ÀÊiiiÌÊÀi«>ViiÌÊÜ>ÀÀ>ÌÞ If a highly efficient flanged heater is in your future, please call, write or e-mail us. Or simply check out our web site for more information as well as a handy order and quote form.
No No
•
No
PROCESS HEATING COMPANY 0/ "OX s 3EATTLE 7! 0HONE s s &AX E MAIL INQUIRE PROCESSHEATINGCOM WWWPROCESSHEATINGCOM
PH12084Pro.indd 1
11/17/08 9:19:26 AM
No
No No •
No No
•
ARI Valves can take the heat… There’s no margin of error when it comes to reliability of the valves in your system. While you may not have to protect against lava flow, we can solve your problems up to 800˚F! ARI Valves are the choice of industrial professionals. Our quality assurance system is in accordance with DIN ISO 9001. You can trust our bellows-seal valves to perform under adverse conditions and never need to replace stem packing.
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232 mmHg @ 25°F
*
*
No
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Yes
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29 mmHg @ 25°F
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*
No
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Yes
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<1 mmHg @ 25°F
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*
No
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Yes
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17 mmHg @ 25°F
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*
No
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Yes
*
<1 mmHg @ 25°F
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*
No
•
Yes
0.27 cal/g °C
226 mmHg @ 25°F
*
*
No
•
Yes
ARI Valves are in Heat Transfer Service Around the Globe. So if you are responsible for the security and safety of your company’s system, make certain that ARI Valves are the choice. When things get hot, you should specify ARI Valves for Thermal Transfer Fluid Applications. ARI Valves…The Obvious Choice
ARI Valve Corporation Manufacturers listed in this Equipment Overview responded to a special mailing by Process Heating and do not necessarily represent the entire heat transfer fluid market. To be included in future listings, contact Linda Becker at (847) 4054020 or e-mail
[email protected].
1738 Sands Place, S.E. · Marietta, Georgia 30067 U.S.A. Fax: (770) 933-8846 · Phone: (770) 933-8845 www.arivalve.com
www.process-heating.com • J a n u a r y 2 0 1 1 PH04104ARI.indd 1
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3/26/10 2:13:40 PM
Real Resolution Ovens
By Jeff Kent, Wisconsin Oven
A H
appy New Year! I hope you don’t mind me asking, “What is your New Year’s resolution?”
You didn’t make one, or you need help coming up with one? If so, I recommend a business resolution that will help your company, your customers and – last but not least – you. The resolution is simple.
I, (Insert Your Name), resolve to review or develop a preventive maintenance program for the equipment I am responsible for at the place of my employment, and then execute the program for the benefit of my company, our customers and myself. Now, before you you take the plunge and make a commitment, make sure you understand what preventive maintenance (PM) is and its potential results. If you understand how a formalized PM program
Improve efficiency and profitability with a preventive maintenance program for your heating equipment. One of the main goals of preventive maintenance is to avert breakdowns and failures before they occur.
can reap benefits for your company, your customers and you, I am confident you will want to start this project right away.
What Is It? Simply put, preventive maintenance is a schedule of planned actions with the goal of preventing breakdowns and failures before they occur. PM tasks include visual inspections of moving components, scheduled cleanings and regular lubrication. Even if the equipment manufacturer did not provide a written program, you should not have much trouble establishing a preventive maintenance program. With a little effort, you will find numerous articles on how to maintain your equipment, what to maintain on your equipment, and when to perform maintenance. What sometimes gets overlooked is the “why”: why it is important to invest time and money in this area. Looking at the “why” will help those controlling the purse strings of your organization understand how the costs associated with an established preventive maintenance program can be compared with the longterm benefits and related savings. Much of the information in this article can be applied to any industrial equipment; however, the emphasis is on process heating equipment. Some of the long-term benefits of a preventive program include: • Improved system reliability with decreased downtime. • Better spare parts inventory management with decreased cost of replacement. • More consistent quality. • Improved energy efficiency and a safer work environment. • Higher customer satisfaction, retention and increased profitability. A closer look at each of these potential benefits will help show how PM results in long-term savings and payback.
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Ovens Adjusting the exhaust blower for the proper rate and making sure all filters are clean are two ways to reduce the energy consumption of your oven.
Improved System Reliability with Decreased Downtime. One of the main goals of preventive maintenance is to avert breakdowns and failures before they occur. Maintenance and inspections planned outside of normal work hours do not negatively impact production. However, unscheduled equipment breakdowns typically will result in substantial costs due to lost production time, late product deliveries to customers, and expedited services and parts expenses to get the equipment operational again.
Better Spare Parts Inventory Management with Decreased Cost of Replacement. Companies with established preventive maintenance programs can better anticipate what parts they need and when they will need them. Depending on the equipment and the products manufactured, you may still want to stock long-lead or critical components. However, most companies with an effective PM program eventually find that they do not need to keep nonessential components in stock.
Stocking less spare parts increases inventory turns and improves cash flow. Often, the routine inspections that are a part of an effective PM program uncover components that need to be replaced in the near future. For instance, the inspection can detect a motor that is beginning to vibrate a little more than usual, which can indicate the bearings might need to be replaced. If performance changes such as this are noticed early enough, the maintenance department can purchase the required components without paying expediting charges. As an added benefit, they often are then able to schedule maintenance during regularly scheduled work hours (no overtime costs). More Consistent Quality. Equipment that is operating optimally will provide more consistent and higher quality parts. Over time, the temperature accuracy of process ovens as well as the temperature
SCRs Need Heatsinks SCRs generate heat. Up to 2 watts/amp per phase. This heat must be dealt with or it will destroy your control. All Payne Engineering controls have integral heatsinks designed, tested, and proven at 50° C ambient to dissipate the damaging heat produced by semi conductors without fans or derating curves.
Only Payne Engineering controls have these exclusive “Silicon-Protection” features • 2ms semiconductor fuses • Vbo voltage protection • 50°C ambient heatsinks that ensure long, reliable, trouble-free service. Nearly 40 years of experience designing, building and applying trouble-free SCR controls.
Call 1-800-331-1345 for Complete SCRs Box 70 Scott Depot, WV 25560-0070 • Fax: 304-757-7305 E-mail:
[email protected] • www.payneng.com
PH06074Payne02Red.indd 1
www.process-heating.com • J5/21/07 a n u a r y9:58:46 2 0 1 1 AM | 25
Ovens Right: Preventive maintenance tasks include visually inspecting moving components, performing scheduled cleanings and lubricating moving and rotating parts. Below: Over time, the temperature accuracy and uniformity of industrial process ovens can deteriorate. Equipment that is operating optimally due to proper preventive maintenance will provide more consistent, higher quality parts.
uniformity throughout the work chamber can deteriorate. Parts not processed at the correct temperature may not meet the expectations or requirements of your cus-
tomers. Most often, part failures are not discovered with the very first part, so entire batches may need to be recalled or reinspected. This is costly and can permanently damage business relationships. Performing regular uniformity surveys will allow you to maintain control over your process and the quality of your parts. It will give your sales department the con-
SYSTEM DOWN!
fidence it needs to make the next big sale. Improved Energy Efficiency and a Safer Work Environment. Adjusting the exhaust blower for the proper rate, making sure all filters are clean, and checking to ensure that all gaskets are sealing properly are all huge energy savers. For instance, in a gasfired oven, a properly adjusted and cleaned burner can reduce gas consumption by as
MultiTherm’s Heat Transfer Fluids Keep All Systems
GO! Run your system more efficiently, for longer periods, with less down time. Make System Maintenance a Priority!
1-800-339-7549 www.multitherm.com 26
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J a n u a r y 2 0 1 1 • Process Heating
Ovens WEB EXCLUSIVE Bonus Points A preventive maintenance program can provide benefits above and beyond what you might expect to see, including an improved company image and more satisfied employees. READ MORE @ WWW.PROCESS-HEATING.COM
much as 5 to 15 percent when compared to a burner that has not been maintained. Depending on the application, an oven that is not cleaned can actually be a potential safety concern. A buildup of residual combustible materials released during the heat cycle can ignite, which is obviously something to avoid no matter the cost. Higher Customer Satisfaction, Retention and Increased Profitability. Effective preventive maintenance and attention to the above items helps keep current customers happy and helps improve profitability. It is well known that it costs more to find new customers than to retain current customers.
If you keep current customers happy, the sales department will have more time to secure new business at the proper sell price. Equipment that is well maintained will last longer and have a higher resale value.
Why You Should Act You can see from the items outlined how it will help your company and your customers, but how will it help you? If you are the person who takes the initiative to develop or dust off an existing preventive maintenance program, you will be recognized as an employee who cares about the company and has ideas on how to help the company and its customers. What a great item to bring up in your next performance review! In most companies, profitability directly impacts employee benefits. The more profitable a company is, the more money it has to be invested in facility improvements, new equipment and tools, better wage increases and larger profit sharing contributions. So not only will it benefit you, it
will benefit your coworkers as well. So now that you have a better understanding of how maintaining your equipment benefits all parties, do you have time to do this yourself? If not, contact the manufacturer of the equipment or another reputable oven manufacturer to see how they might be able to help you. If you consider your time and lack of expertise, you may be able to easily justify the expense of having an expert service technician visit your facility on a regular basis to train you or to help you maintain your equipment. Like any New Year’s resolution, now is the time to start. Don’t wait: Discuss this with your manager to obtain support and direction. Start putting together your preventive maintenance program today for a more profitable tomorrow. PH Jeff Kent is the executive vice president at Wisconsin Oven Corp., East Troy, Wis., a manufacturer of industrial process ovens. For more information, call (262) 642-3938 or visit www.wisoven.com.
PROVEN SOLUTIONS SINCE 1851 Struthers Wells, a division of TEi, stands the test of time by setting global standards of excellence in the design and manufacture of custom built Fired Heating Systems and Waste Heat Recovery Boilers. Our experienced engineers and dedicated project teams are committed to maintaining the legacy by continuing to provide proven solutions in all applications of fired heater technology to the Chemical, Petrochemical, Petroleum and Power industries. Struthers Wells is a division of Thermal Engineering International (USA) Inc. which is a Babcock Power Inc. company.
8833 N. Sam Houston Pkwy. West, Houston, TX 77064 TEL 281.664.8020 | FAX 832.237.8758 |
[email protected]
www.strutherswells.com
www.process-heating.com • J a n u a r y 2 0 1 1
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Heat Exchangers
Meeting Mandates By retrofitting older boilers with flue gas condensing heat exchangers, it is possible to turn old boilers green. By Richard Parrish
R
eplacing an aging, energy-guzzling boiler with a Super Boiler, the ultra high efficiency boiler developed in part by the U.S. Department of Energy (DOE), is not the only way to make progress toward meeting the agency’s aggressive goals for increasing boiler efficiency and reducing emissions. Other options seek to improve efficiency by utilizing existing technology — condensing heat exchangers — in previously unexpected ways. In fact, says one control system developer, any boiler or burner combination can be turned into a low NOX boiler by installing a different control strategy to operate the fan and the combustion control system. In this type of setup, the operation is based on an airto-fuel ratio instead of using a damper on a fixed speed fan. By circulating a small amount of flue gas in older boilers, it is possible to attain NOX emissions similar to those of low-NOX burners. “The easiest way to reduce greenhouse gases is to improve efficiency. So, by reducing the amount of fuel that is burned, it is possible to reduce carbon dioxide emissions and lower energy costs at the same time,” says Robert Benz, 28
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J a n u a r y 2 0 1 1 • Process Heating
A Super Boiler with a flue gas heat recovery system operates at 95 percent efficiency at Del Monte Foods in Modesto, Calif.
president of Benz Air Engineering in Las Vegas, which has developed such a system. The technology, a flue-gas condensing heat exchanger, uses a two-stage heat exchange design, recovering sensible heat without the waste associated with directcontact heat exchangers, says Benz. This allows the system to preheat makeup water to more than 220°F (104°C) while keeping stack temperatures at less than 110°F (43°C). To create the system, the company maintains the existing boiler and adds a different control system. Included in the retrofit is a condensing heat exchanger that is engineered for the specific application, taking into consideration the approach tempera-
ture, pressure drop and other variables. Many of the boilers used in industry today were designed 50 to 75 years ago to burn No. 6 diesel fuel, which produces high quantities of ash. As a result, heat exchangers were made with wide fin spacing, which reduced clogging of the fins and coils with ash and dirt, but the wide spacing also made the unit less efficient. Even as many of these older boilers were converted to burning lower cost natural gas, they kept the same, less efficient, design in heat exchangers. By using a condensing heat exchanger made with a stainless steel coil and fins set close together, the flue gas temperature can be brought down below the dewpoint
Heat Exchangers tomato processing plant, while the NOX and CO2 emissions were reduced 13 ppm and 2,380 tons per year, respectively.
Super Boiler Designs
Left: SunOpta Aseptic in Modesto, Calif., retrofitted a boiler with a flue control system to increase efficiency. Above: A stainless steel condensing heat exchanger typically is used in the boiler control system.
by extracting heat from the exhaust. The flue gas condensate collected with the dropout volume under the downstream coil is pumped back to the makeup water line coming out of the upstream coil, contributing up to 7 percent of the total makeup water flow to the boiler.
Pacific Coast Producers in Woodlands, Calif., a tomato processing plant with five high-pressure steam boilers, contacted Benz Air to retrofit one of the plant’s boilers with the boiler combustion control system. At Pacific Coast, the capacity of the watertube boiler — 100,000 lb/hr before the retrofit — increased to 150,000 lb/hr after the system was in place. Annual fuel savings were more than $400,000 for the
Wolverine Proctor, LLC
251 Gibraltar Road Horsham, PA 19044 Phone: 215.443.5200 Fax: 215.443.5206 Email:
[email protected] www.cpmwolverineproctor.com
PH02084CPM.indd 1
Following the success of the Pacific Coast Producers project, Benz Air knew it had a solution to many processors’ problems, but the company needed assistance with the development of a flue gas heat recovery system. Benz Air turned to Super Radiator Coils, a manufacturer of heat exchangers headquartered in Chaska, Minn., which has an experienced design engineering team focused on custom designs for heat exchanger applications. One of the first projects the two firms worked on together was a new Super Boiler that went online in 2007 at the Del Monte Foods plant in Modesto, Calif. The project involved an additional, condensing heat exchanger between the makeup water and the feedwater that would provide a reduction in the needed heat transfer of the condensing heat
CPM Wolverine Proctor LLC
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 • J a1/23/08 n u a r y 21:14:54 0 1 1 |PM2 9
Heat Exchangers An efficiency rate of 96 percent was achieved with a Super Boiler at Seneca Foods in Modesto, Calif.
WEB EXCLUSIVE Turning Up the Heat for Better Efficiency
where a 96 percent efficiency rate was achieved. NOX emissions were reduced to 5 ppm and CO2 emissions were reduced by 562 metric tons and the stack temperature was 97°F (36°C). Presently, California is the only state with a CO2 emissions mandate. However, metro areas in other states, including many along the upper East Cost, have mandates, most of which start by requiring all new boiler installations to maintain emissions below a certain level. Other state and local governments are currently considering such actions. PH
The DOE estimates that boilers account for 35 percent of the energy consumed in the United States. READ MORE @ WWW.PROCESS-HEATING.COM
exchanger. Again in this installation, the flue gas condensate is collected within the dropout volume under the downstream stainless coil and pumped back to the makeup water line coming out of the upstream coil. Capturing this condensate contributes up to 7 percent of the total makeup water flow to the boiler. In addition, capacity for preheating up to 50 gal/min of process or makeup water was added. The saturated flue gas at 110°F (43°C) still contains nearly 7 percent of the total energy input to the boiler. The additional flow capacity of the last coil
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increases efficiency to 95 percent. As a result, CO2 emissions were reduced by 1,171 metric tons per year. Subsequently, Benz Air designed a Super Boiler for Seneca Foods, also in Modesto,
Richard Parrish is a marketing communications consultant for Super Radiator Coils. For more information from Super Radiator Coils, call (952) 556-3330 or visit www.superradiatorcoils.com. For more information from Benz Air Engineering, call (702) 597-4805 or visit www.compunox.com.
Steam Heating
S
team cleaning is a process that uses steam (low moisture vapor) generated in a boiler via hoses, nozzles or other accessories to clean. Boilers heat tap water to high pressure to produce steam that can be applied to cleanable surfaces. The primary component of steam is heat, which is powerful enough to soften and break the physical bond between dirt or stains that stick to various surfaces. As a result, the broken grease, soil or other substances can be easily wiped off with a mop or towel. Steam is nearly 100 percent effective in cleaning surfaces faster and easier. With its extremely high temperature, it can thoroughly clean and, in many cases, sanitize or
Powered by an electric boiler, steam cleaning is effective at “melting away” grease and oils and removing soils and dirt from heavy equipment and process parts. By Miaomiao Liu, Reimers Electra Steam di i f surfaces f ih h introduction i d i disinfect without the of chemical solutions. The environmentally friendly cleaning process is widely used in: • Cleaning heavy equipment and process parts — as well as non-process applications such as automotive engines, restaurant equipment and laboratory cages — before maintenance and service. • Removing grease and oil from surfaces and hard-to-reach areas such as corners in the food processing industry. • Preparing and pretreating metal surfaces before phosphating, powder coating or painting.
Steam Cleaning vs. Pressure Washers Steam cleaners consume much less water than pressure washers. For example, some electric boilers use only 0.21 gal/min (12.6 gal/hr) of water. When comparing this to the 3.5 gal/min (210 gal/hr) of water that a 4,000 psi pressure washer uses, it equates to almost four 55-gal drums of waste or runoff. So, to achieve similar results on a cleaning job, steam cleaning uses less water than a pressure washer. Electric steam cleaning also produces less water and chemical runoff than presElectric steam cleaners can provide steam and cleaning solutions at 328°F (165°C).
h D i l i ih a sure washers. During cleaning with steam cleaner, if the chemical is not needed, the operator can close the valve on the chemical injection line. Once the valve is closed, only saturated steam is released by device to rinse and dry the surface. Steam is effective in cutting through grease or oil and usually does not leave any residue. By contrast, pressure washers can leave an oily residue on surfaces. Also, with a pressure washer, a whole rinsing process is required. In addition, an exhaust fan might be needed in the cleaned area, which incurs additional operating costs. Toweldrying — common in some pressurewash cleaning applications — can further delay the process. Electric steam cleaners utilize high temperature steam and a chemical mix — both typically at 328°F (165°C) — to dissolve grease, grime and oils. Such high temperatures are effective at “melting away” grease and oils and removing soils and dirt. It also dissolves cleaning agents better if chemicals are added to the process. High temperature steam can effectively clean dirt, soil and grease accumulated in hard-to-reach corners, creases and other difficult areas. It does not splash or generate excessive water runoff, unlike what can happen with a pressure washer. Cold-water pressure washers use high pressures — 4,000 psi — to push away the dirt and grime. www.process-heating.com • J a n u a r y 2 0 1 1
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Steam Heating
Using steam, or low moisture vapor, generated in a boiler can allow a processor to clean process parts and equipment with tools such as this steam wand.
WEB EXCLUSIVE Steam Tips Here are a few ways to handle condensation and scale in boilers. READ MORE @ WWW.PROCESS-HEATING.COM
To produce the steam needed for cleaning, in some applications, an electric boiler can be installed adjacent to an application so a separate boiler room is not required. This can provide operating savings. Multiple certifications and approvals ensure the electric steam boiler is safe to use. Electric steam boilers should
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be designed and constructed to Section I, Parts PMB and PEB of the ASME Boiler Code. They also should be inspected and registered by an inspector commissioned National Board of Boiler and Pressure Vessel Inspectors. Finally, other credentials to look for on the boiler include a cULus listing to UL Standard 834 and a
design compliant with ASME CSD-1 for Controls Safety Devices. PH Miaomiao Liu is a marketing analyst with Reimers Electra Steam, Clear Brook, Va., a manufacturer of electric boilers and steam generators. For more information, call (800) 872-7562 or visit www.reimersinc.com.
SPOTLIGHT ON PRODUCT APPLICATIONS High Flashpoint Fluids from Duratherm Keep Things Cooking Insurance companies, fire marshals and other regulators have recently begun mandating in some cases that heat transfer fluids be used below their flashpoints. While this certainly can add a measure of safety to a heat transfer system, it has often left manufacturers in a bind, forcing them to lower their operating temperatures, find a higher flashpoint fluid or cease operation altogether.
suitable fluid with a high enough flashpoint,” Maltby said. Duratherm not only had the correct fluid – they actually offered Atwood a choice of fluids with flashpoints that fit their needs. Following an extensive technical evaluation, it was determined that Duratherm G, one of the company’s high oxidation resilient fluids, would be best suited.
Duratherm Heat Transfer Fluids • • • • • •
-120°F to +650°F temp range Flashpoints as high as 615°F Non-Toxic, Non-Hazardous Open Bath Fluids to 500°F Food Grade Fluids, choice of two Dual-Cycle Heat/Cool Fluids
Duratherm System Cleaners • Clean systems while running production • Easily remove/dissolve sludge and carbon • Large system concentrates up to 600°F • Pre-blended cleaners and heat transfer fluids up to 550°F • Fast-acting ‘solvent’ type cleaners • Preventive maintenance to emergency downed system revivers Duratherm thermal fluid, which will operate its rendering process. This will enable Atwood to shut down its gas-fired thermal heater and eliminate the use of approximately 1,000,000 m3 of natural gas each year.
About Duratherm Extended Life Fluids Rendering systems at Atwood Pet Foods.
Atwood Pet Foods, one of Canada’s largest deadstock rendering operations, felt the effects of this firsthand in 2006. Ontario’s Technical Standards and Safety Authority (TSSA) mandated that their imported rendering batch cookers use fluid a full 50°F below its flash point. This meant the fluid needed a flashpoint above 500°F (260°C). Facing costly equipment retrofitting or replacement, Atwood’s Ken Maltby soon found out it wasn’t going to be easy to find a suitable high flashpoint thermal fluid. “I contacted just about all thermal fluid vendors I could find but it wasn’t until I called Duratherm that I found a
Michael Bates, Duratherm’s Technical Director said: “Having 3 fluids with flashpoints above 500°F – and one as high as 615°F – means we’re able to offer customers not just a high flashpoint fluid, but also one that satisfies other important criteria like system compatibility, suitability and oxidation or thermal stability.” Since 2006 Atwood has added three more cookers at its facility in Atwood, Ontario. The company is currently in the midst of its most challenging project, which will see it construct a gasification system to destroy the contaminated beef protein. It will capture the energy from the process to heat the
Duratherm manufactures out of an 80,000 sq. ft. facility in Jacksonville, Florida. The company has stocking points through the U.S. and Canada. Along with its complete line of 11 heat transfer fluids, Duratherm also offers a full line of heat transfer system cleaners.
Contact Duratherm (800) 446-4910
[email protected]; www.heat-transfer-fluid.com SEE OUR AD ON PAGE 55 www.process-heating.com • J a n u a r y 2 0 1 1
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SPOTLIGHT ON PRODUCT APPLICATIONS Heat Transfer Fluids that Are Efficient, Non-Hazardous and Non-Toxic MultiTherm fluids provide you with energy efficient, non-hazardous and non-toxic benefits that are recognized by such organizations as the USDA, FDA and NSF. These efficient fluids operate in a temperature range from 10˚F (-12˚C) to 600˚F (316˚C) and are offered as follows: • MultiTherm PG-1 is a high quality, thermally stable heat transfer fluid for use in closed-loop, liquid-phase systems, and is applicable to the chemical, food, plastics, die casting, rubber, film processing, oil and gas, laundry and electronics industries. The unique formula of MultiTherm PG-1 assures performance without the potential problems of many conventional fluids. • MultiTherm IG-4 is a high quality, durable heat transfer fluid used in closed-loop systems. Benefits include a very low pressure, excellent oxidation resistance, and a very high flashpoint of 440˚F (227˚C) [one of the highest of all heat transfer fluids]. MultiTherm IG-4
is applicable to the chemical, laundry, packaging, asphalt, particle board, food, glass, marine and adhesive industries. • MultiTherm 503 provides users with a non-toxic, non-hazardous alternative to synthetic-based heat transfer fluids used for heating and cooling in the same loop. Because of its low viscosity, heat loads can be achieved with lower flow rates, smaller heat exchangers and lower approach temperatures. Used in such industries as plastics, chemicasl, rubber, film processing, pharmaceutical and electronics. • MultiTherm OG-1 has been designed to prevent oxidative degradation and deposits in open- and closed-loop systems. MultiTherm OG-1 is designed for a maximum film temperature of 600˚F (316˚C) and a maximum system bulk temperature of 550˚F (288˚C). MultiTherm OG-1 offers a high flashpoint and a very low vapor pressure that is required in the R&D, chemicals, plastics, die casting,
adhesives and rubber industries. • MultiTherm IG-1 is a highly refined heat transfer fluid that has been designed to offer an economical alternative to competitively priced fluids for temperatures ranging from 150˚F (66˚C) to 550˚F (288˚C). MultiTherm IG-1 is used in such industries as asphalt, paper, particle board, die casting, plastics and roofing compounds (shingles). • MultiTherm FF-1 (flushing fluid) and MultiTherm PSC Plus (process system cleaner) are cleaning fluids designed for hot oil systems.
(800) 225-7440; (610) 408-8361 Direct
[email protected] www.multitherm.com/ph SEE OUR AD ON PAGE 26
Advanced Test Lab for Precise Heat Exchanger Testing The new, advanced on-site Test Lab at Super Radiator Coils is the first to test a wide variety of fluids circulating through a coil. The closed-loop wind tunnel provides wide variations in the temperature, humidity and air volume through coils. The purpose of the new lab is to test coil performance under the most demanding
and realistic conditions. The 15 ft. long custom-designed wind tunnel is connected to complex loop systems for pumping six fluids and steam through a coil. Each loop system has its own pump, flow meter, RTD sensors and other measurement instruments. The fluids are hot or cold water, glycol, oil, steam and most refrigerants in both evaporating and condensing modes. The new wind tunnel can test a coil configuration as large as 36 in. high x 36 in. wide x 75 in. deep (65 cu. ft.). The performance of larger coils can be verified by testing smaller versions or the components of a coil design.
A 50 HP blower fan in the wind tunnel varies air velocity from 50 to 3,000 fpm and produces an airflow rate from 400 – 8,000 cfm. The temperature can be set from 35 to 140° F and humidity levels regulated from 40 to 95%. The new lab has one steam boiler, six electric heaters and a chiller that can generate 800,000 BTUs per hour of heating and up to 60 tons of cooling.
[email protected] www.superradiatorcoils.com SEE OUR AD ON PAGE 49 34
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SPOTLIGHT ON PRODUCT APPLICATIONS Combustion Controls The Karl Dungs Inc. product offerings represent a wide range of gas-flow controls, shutoff valves, pressure reducing and ratio regulators, air- and gas-pressure switches, actuators and other burner equipment. Dungs products are suitable for industrial combustion gases, non-corrosive gases and air. These products, which comply with high safety requirements, are used in gas-firing systems throughout the world, and include:
• Valve-proving systems
• Dual modular valve combining two automatic shutoff valves in one compact housing
• Modular systems
• Dual modular valve with proof of closure
• Gas-flow controls and burner accessories.
• Gas-pressure switches • Air-pressure switches • Pressure regulators • Modulating control valves and motors
• Pre-piped valve trains
• Two-stage dual modular valves with gas/air ratio control or a servo pressure controller
For more information, go to www.dungs.com/usa or call (651) 792-8912.
• Single valves with or without proof of closure
SEE OUR AD ON PAGE 48
HeetSheet Tank and Vessel Heating Units HeetSheet units are plate-type heating units made of 20 or 26 gauge (0.91 or 0.45 mm) 304 stainless steel. The units are seam-welded to define a variety of parallel passageways for steam or other heat transfer fluids. HeetSheet units are applied to the external wall of a tank and may be installed on flat or curved surfaces. Crosscontamination may be a concern with internal steam heating coils and jacketed tanks, but not with HeetSheet units.
Each unit is pre-rolled to your specific diameter and includes welded inlet and outlet connections. A special non-hardening heat transfer compound is applied to enhance heat conduction through the tank wall and into the process being heated. The 26 gauge (0.45 mm) HeetSheet unit only weighs about 9.8 kg/m2 (2 lb/ft2) compared to almost 40 kg/m2 (8 lb/ft2) for a typical external plate-type-heating coil. The lightweight designs permit the installation
of HeetSheet units in minutes compared to hours for other methods. Product temperatures to 177°C (350°F) can be maintained with common applications that include heating phthalic anhydride, paraffin, syrup, sulfur, asphalt, “heavy ends” and many food products. For information on all Thermon heat tracing products and services, visit www.thermon.com. SEE OUR AD ON PAGE 30 www.process-heating.com • J a n u a r y 2 0 1 1
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SPOTLIGHT ON PRODUCT APPLICATIONS The Parker Design Process heating applications that require temperatures between 350°F and 650°F frequently can be serviced more dependably, efficiently, uniformly and safely with a thermal liquid system as opposed to a steam, water, electric or direct-fired system. Over the past 40 years, thermal liquid systems have been used in a wide variety of applications, from food processing to chemical plants to adhesive heating and particle-board pressing. A thermal liquid system consists of the heater, circulating pump and expan-
sion tank, and possibly a distribution tank, with properly sized piping to the heat utilizers. System distribution tanks for primary secondary pumping systems are common when heater flow-through cannot be guaranteed with one pump system. Correctly engineered, a thermal liquid system is extremely trouble free. Operating pressures are very low. Parker’s direct-fired heater for thermal liquids is an all-double-welded bent-steel liquid-tube design for continuous expan-
sion and contraction, which eliminates problems from rolled tubes, ferrell fits and retainer clips. All Parker tube bundles carry a 25 year guarantee against thermal shock. Parker Boiler (323) 727-9800
[email protected] www.parkerboiler.com SEE OUR AD ON PAGE 47
No Tools Required: Install T-Links in Minutes vs. Hours T-Links is a revolutionary self-regulating heat trace system, manufactured by Heat Trace Products, LLC of Leominster, Massachusetts. T-Links is manufactured using the same reliable 2700 series low temperature type cables that have been installed for 30 plus years with zero field failures. “T-Links Pre-Terminated Heat Trace System will revolutionize the way selfregulating heater systems are viewed in the industry,” said Deborah A. DiIorio, Vice President Sales & Marketing for HTP.
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The traditional way of installing a selfregulating heater system is being replaced with an innovative, safe and efficient system called T-Links. The T-Links PreTerminated Heat Trace System takes minutes vs. hours to install and no tools are required. Standard lengths available from 5 to 200 foot lengths. Factory connections are fail proof and water tight. Advantages of a T-Link Heat Trace System include: • Effortless T connections. • Best for High Maintenance applications. • Ability to step up or down the wattage when required on the same run. • Zero remnant scrap. • Available in 120V and 240V, 3, 5, 8 or 10 watts per foot. • Can be combined with conventional heat trace.
Heat Trace Products, LLC. 233 Florence Street, Leominster, MA 01453 Tel: 978-534-2810 Fax: 978-534-2819 www.rscc-heattrace.com SEE OUR AD ON PAGE 19
SPOTLIGHT ON PRODUCT APPLICATIONS Experts Guide Steam System Selection It takes more than a steam boiler to get the job done. In fact, it’s a challenge to engineer steam systems for process applications. While steam system design and engineering expertise in the United States appears to be on the decline, the need for turnkey engineered steam systems is not. Steam Generation systems require a wide range of support equipment, a feed set and a means to handle blow-down water. With all of the complexities needed to do the job right, process application clients are looking more and more to experts in the field of steam engineering when it comes to putting together the right system. Fulton has provided its clients with steam system engineering guidance throughout the complex process of selecting the right steam system for more than a decade. Because Fulton has the facilities and engineering experts to design very small systems, up to systems requiring several thousand pounds of steam output per hour, the Fulton team is ready to customize its wide range of products to meet any client’s individual needs. The Fulton team of engineers, technicians, and project managers has designed and
manufactured more than 2,000 engineered solutions for the process industry. These systems are used for both process humidification and heating applications, helping industries all over the world become more efficient and more effective. Fulton has the capability to supply all the steam ancillary support equipment, in addition to our full line of steam boilers. The engineered systems have UL-listed, ASME-certified, and CSD-1 code compliant equipment. Equipment may be supplied independently, or skid-mounted for plug-and-play orientation. The Fulton team knows this business is about much more than supplying equipment: it’s about providing service, too. For your next steam system application, let Fulton help take some of the challenge out of your job.
Fulton is a global manufacturer of steam, hydronic, and thermal fluid heat transfer systems with facilities in the United States, Great Britain, and China. Backed by more than 60 years of research, innovation and experience, Fulton is building on its tradition of improving life through heat transfer and energy management solutions.
Please visit us at www.fulton.com. SEE OUR AD ON PAGE 9 www.process-heating.com • J a n u a r y 2 0 1 1
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SPOTLIGHT ON PRODUCT APPLICATIONS Pumps Operate Up to 800°F Without Utility Cooling Many industrial processes require heating to accomplish a goal, such as melting or drying a product. A large percentage of systems use heat transfer fluid (hot oil) that is circulated by a pump. Special designs from Dickow Pump
allow operation at temperatures up to 800°F. These pumps ensure acceptable service life for bearings and mechanical seals without utility cooling. Dickow model NKLs mechanically sealed pumps use a metal bellows seal with
silicon carbide faces. The rotating bellows resists buildup of coke particles. Dickow model NCL sealed pumps use tandem seals with pumping ring and seal pot. Dickow model NMW is a magnetically coupled sealless design with 30 years of successful applications. Mechanical seals are eliminated, enhancing personnel safety and environmental protection. Maintenance outages and associated costs are reduced. Pump designs from Dickow offer: • Flows to 7000 gpm • Heads to 700 ft Hot water and boiler feed pumps also are available. Dickow Pump Co.
[email protected] www.dickow.com SEE OUR AD ON PAGE 16
Heat Recovery from Struthers Wells Struthers Wells has proudly supplied heat recovery equipment to many of the world’s leading Chemical, Petrochemical, Petroleum and Power producers by taking advantage of the hot gases generated by process reactions during production of many chemicals and processes such as: • • • • • • • • • • •
Ammonia Ethylene Methanol Hydrogen Sulfuric Acid Nitric Acid Sulfur Recovery Fluid Catalytic Cracking Flue Gas Cooling Reactor Effluent Cooling Incineration
Struthers Wells was one of the original founders of the Tubular Exchanger 38
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J a n u a r y 2 0 1 1 • Process Heating
Manufacturers Association (TEMA) and a charter member of the Heat Transfer Research Institute (HTRI). As such, Struthers Wells has available the most current and advanced technology for the design and manufacture of shell and tube heat exchangers. Furthermore, Struthers Wells is a major supplier of circulating thermal fluid systems, with about 1,000 installations over
the past 40 years. Our products are provided for every heat transfer fluid type available, ranging from mineral oils at lower temperatures, to synthetic fluids at elevated temperatures, to inorganic fluids such as molten salt and liquid metals for the highest temperature applications.
For more information, go to www.strutherswells.com. SEE OUR AD ON PAGE 27
SPOTLIGHT ON PRODUCT APPLICATIONS A “Cool” Combination Following two unplanned shutdowns due to heat transfer fluid leaks, one Brazilian chemical company made a change. Resitol Industria Química, a chemical company located in Santa Catarina in the southern part of Brazil, is a major producer of two products: crude tall oil (CTO) and crude sterol. The tall oil is extracted from byproducts of pulp and paper production. Crude sterol is contained in the tall oil, which after distillation is concentrated in tall oil pitch. To extract the crude sterol, Resitol has a unit of molecular distillation with high vacuum system. The chemical company uses a secondary coolant fluid to achieve -94°F (-70°C). The very low temperature is required to maximize separation efficiency while reducing product degradation that would occur if the separation were done at higher temperatures. The purified sterol is used in the pharmaceutical and food industry. All of Resitol’s products are exported to customers in the United States.
By using secondary coolant system technology rather than direct cooling, this process substantially reduces the amount of refrigerant charge in the main refrigeration loop. Because the use of traditional refrigerants is highly regulated and can be quite costly to own, operate, and maintain, this reduction in primary refrigerant benefits Resitol. Since 1991, Resitol used a siliconebased fluid as its secondary coolant fluid. In 2008, they experienced two major leaks from their heat transfer system. As a result of each of these unplanned failures, they were forced to shutdown production because the fluid supplier was not able to deliver enough fluid to replenish Resitol’s system in a timely manner. After the second incident, Resitol contacted the local Solutia team to help explore their options. Solutia’s Therminol heat transfer fluid experts in Brazil were immediately dispatched to meet with the Resitol engineers, review their system design and discuss their heat transfer fluid options. In October 2009, after in-depth consultation with Solutia, Resitol engineers decided to change their silicone-based fluid to Therminol LT synthetic heat transfer fluid due to the extensive technical services and logistical support offered by the local TLC Total Lifecycle Care team in Brazil. “Our local Solutia Therminol engineers provided us with comprehensive guidance for draining our old fluid, flushing the system and refilling with the new Therminol LT. They also provided on-site support as needed throughout the process until the system was started up. We have never received this level of expert support with our previous supplier. They also have local stock in case of emergencies,” says Charles Souza, maintenance and production manager for Resitol. Once the system reached stable operation, Mr. Souza notes, “Because of Solutia’s local support and outstanding services, I rest easier knowing that they will be here whenever I need.” Solutia developed its TLC Total Lifecycle Care Program to support Therminol heat
transfer fluid customers throughout their systems’ lifecycle. This comprehensive program includes no-cost services such as system design consultation, startup assistance, on-site training and sample analysis in addition to products such as heat transfer fluids and system flushing fluids. The program is supported by a team of technical industry experts in each global region. For more information from Solutia, call (800) 433-6997, e-mail
[email protected] or visit www.therminol.com. SEE OUR AD ON PAGE 15
www.process-heating.com • J a n u a r y 2 0 1 1
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SPOTLIGHT ON PRODUCT APPLICATIONS Customized Oven Handles 2,800 lbs of Components at 1 Time Precision Quincy Corp.’s model #HD5G-5-7TIFG is a customized Class ‘A’ oven derived from the company’s popular HD Series of industrial process ovens. This particular model weighs 6,000 lbs with exterior measurements of 120” W x 136” D x 165” H. The interior oven volume measures 560 sq. ft. and provides a maximum operating temperature of 450°F (232°C). The HD5G-5-7TIFG oven was custom ordered and outfitted to process and handle up to 2,800 lbs of various automotive door and hood components at a time. Cart guide tracks have been added to enable fast and easy removal of product.
All of Precision Quincy’s ovens meet or exceed NFPA-86, NFPA-70, OSHA and UL requirements, and are factory wired, tested and balanced before shipping to ensure quick, trouble-free start-ups.
Precision Quincy Corp. (815) 338-2675
[email protected] www.precisionquincy.com SEE OUR AD ON PAGE 32
SCR Power Controls Payne Engineering solid state power controls utilizing SCRs as the power devices are the perfect replacements for variable transformers, saturable core reactors, mercury relays and electromechanical contactors when used in almost all electric heating applications. We offer these controls in both zerofired (our 18DZ and 18EZ models) and
tor fuses and our own proprietary heat sinks. Control inputs are via the standard potentiometer that is provided with every unit or any of the optional analog input signals from 1 to 5 milliamps through 4 to 20 milliamps.
phase-angle fired (18D and 18E models) for single-phase and three-phase applications. The product range for these controls is 10 amps to 1200 amps, operating at 120 volts AC to 600 volts AC. All of these power controls are protected with integral “2 millisecond” semiconduc40
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J a n u a r y 2 0 1 1 • Process Heating
Payne Controls (800) 331-1045
[email protected] www.payneng.com SEE OUR AD ON PAGE 25
SPOTLIGHT ON PRODUCT APPLICATIONS OMEGASCOPE® Handheld Infrared Thermometer Goes Wireless Handheld infrared thermometers are very popular for making on the spot non-contact temperature measurements with little or no setup. These devices are completely selfcontained and require no additional wiring or signal processing, unlike thermocouples and RTDs. They are perfect for determining the temperature of objects that are too hot to touch, hazardous to approach, moving object, or just hard to reach. Choices are available that range from no frills models for the simplest applications to full-featured units, which can be indispensable in industrial, commercial, or scientific applications. The OMEGASCOPE® Wireless Handheld Infrared Thermometer Series represents the best-of-breed in this arena. Its low cost, unique built-in wireless capability, and patented dot or circle switchable laser sighting set it well apart from the competition. The numerous standard features such as adjustable Emissivity, the analog output, tripod mount, and large, backlit display also make it best-in-value.
Omegascope® Features For a product line that is loaded with useful features, the OMEGASCOPE® OS530E Series is an exceptionally economical choice and includes models starting at $295. The unit is rugged and looks it with a hefty,
high quality housing that is well-suited to a wide range of settings, including factory conditions where gentle handling is not the norm. There are even protective bumpers around the lens and the LCD display. When making a reading, squeeze or lock the trigger and aim the built-in laser sight at the measurement location. The laser sight has a feature that allows you to switch between a laser dot for general measurements and a circle which clearly indicates the target area. If a continuous laser beam poses a problem in your environment, the beam can even be set to flashing. In addition, a flashing laser draws more attention and consumes less power. An integral tripod mount and trigger lock permits the unit to be set in one place for long-term monitoring applications. The new wireless feature incorporated into the OMEGASCOPE® Series adds many of the capabilities of a more elaborate and complicated hard-wired temperature sensor installation. For instance, it allows you to monitor, record, or data log readings directly to a PC. This PC can be at hand or in a remote location such as a process control center.
When it comes to using the wireless feature, simplicity is the order of the day. Plug the inexpensive $35 flash drive sized receiver into a USB port on a desktop or laptop computer, install the included software, and you are good to go. As an added bonus, this software is compatible with many of Omega’s wireless thermocouples, RTDs, and humidity sensors. It can support up to 48 wireless devices, displayed 12 at a time, and can turn your PC into a multi-channel chart recorder and data logger. © COPYRIGHT 2011 OMEGA ENGINEERING, INC. ALL RIGHTS RESERVED. REPRODUCED WITH THE PERMISSION OF OMEGA ENGINEERING, INC., STAMFORD, CT 06907.
omega.com
™
®
www.omega.com SEE OUR AD ON PAGE 3 www.process-heating.com • J a n u a r y 2 0 1 1
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SPOTLIGHT ON PRODUCT APPLICATIONS Central Steam Heating Plant Relies on 2 Wood-Chip Fuel Boilers Chadron State College (CSC), Chadron, Nebraska, is now in its 14th year of firing its central steam heating plant with woodchip fuel from a local supplier. Fifteen years ago, CSC was heating its 20 buildings (approximately 1,100,000 square feet) with natural gas-fired boilers. When an engineering analysis indicated they could significantly reduce fuel costs by heating with wastewood, they installed two Hurst wood fuel boilers — 150 and 250 horsepower. The gas boilers were retained as backup. The milliondollar project was financed over a 10-year period, but paid out in seven. Concern about the high cost of electricity,
particularly for air-conditioning, led CSC to an evaluation of how the addition of co-generation might fit into the mix, and prompted their move to use biomass as a renewable source of energy. Their engineering study indicated that while generation of electricity was not economically desirable, the installation of absorption chillers, using surplus steam for power, would result in sizeable cost savings.
For more information on Hurst Boiler, go to www.hurstboiler.com. SEE OUR AD ON PAGE 13
Need Thermal Fluid Heaters... To find them, turn here: www.process-heating.com/buyersguide Locate the industrial equipment, components and services specifically used in applying, transferring, measuring, monitoring and controlling heat in the manufacturing operations that you need! • •
Search by Company Name or Product Category Downloadable Product Spec Sheets
• • •
Alpha Company Listings Live Web & Email Links Product Photos
2011 Buyers Guide Start your search today! • Watch for expanded - listings! www.process-heating.com/buyersguide 42
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SPOTLIGHT ON PRODUCT APPLICATIONS Batch Oven Cures Composites for Aircraft Manufacturing Wisconsin Oven designed and manufactured a gas fired batch oven to cure composite honeycomb material used in aircraft manufacturing. The curing oven has chamber dimensions of 12’0” wide x 28’0” long x 8’0” high and a maximum operating temperature of 500º F. The oven was designed with the capacity to heat the oven and 6,500 pound load of composite and steel fixtures from 70° to 400° F within one (1) hour and cool down to 150° F within 30 minutes. The composite curing oven is constructed with 6” thick tongue and groove panel
assemblies and 20 gauge aluminized steel interiors and ductwork. The heating system features a 3,000,000 BTU per hour high efficiency air heat burner including a motorized gas control valve, flame detector and flame relay with alarm horn. The recirculation system has a 50,000 CFM @ 40 HP blower, and utilizes combination airflow to maximize heating rates and temperature uniformity. The industrial batch oven is specifically designed with composite curing features for precise temperature and pressure control. The exhaust features motorized
dampers on both the fresh air inlet and the exhaust outlet for enhanced heating and cooling capabilities. Twenty-four (24) interior vacuum stubs were located throughout the oven. All of these composite curing features provide the customer with the ability to closely monitor part temperatures for a high quality cure. For more information on composite curing ovens visit our website at http://www.wisoven.com/composite.htm. The customer required a 35-point temperature uniformity of +/-5° F at 150° and 400° F. The oven has a UL certified NEMA 12 control enclosure with IEC style motor starters, push buttons, and pilot lights. The temperature for the oven is controlled by a Honeywell UDC 2500 programmable controller with autotune. The customer also added Wisconsin Oven’s energy efficient E-Pack™ oven upgrade to the composite curing oven, which includes thicker wall panels, higher efficient motors, a door limit switch, and a few other energy saving items that will reduce their operating costs. For further details on this equipment, or if you would like to work with us on another application, call Jim Lucas at (262) 6426010, or by email at
[email protected]. To request a quote for a composite curing oven please fill out our online questionnaire with your equipment specifications at http://www.wisoven.com/content/ batch-oven-request-quote. Visit Wisconsin Oven at www.wisoven.com.
Wisconsin Oven Corporation 2675 Main Street, PO Box 873 East Troy, WI 53120 USA (262)642-3938 phone (262)363-4018 fax
[email protected] http://www.wisoven.com/ SEE OUR AD ON PAGE 11 www.process-heating.com • J a n u a r y 2 0 1 1
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SPOTLIGHT ON PRODUCT APPLICATIONS If you operate a large heater for process heating, it may be possible to cut its fuel costs significantly. If the heater has a net thermal efficiency of 80 percent or less, it is wasting a lot of fuel. That is well below the efficiencies of heaters currently available. By changing to a heater with high thermal efficiency, it may be possible to achieve substantial savings over the course of a year. Obviously, the amount of savings depends on several variables such as the cost of fuel, the number of hours the heater operates, its heat load, etc. The first thing you need to determine is the net thermal efficiency of the heater you are using. To do that, simply measure the temperature of its exhaust gas. Then use the chart shown here to find its net thermal efficiency. Now examine the table shown. It is based on a heat load of 8 million Btu/hour and shows fuel usage for a wide range of thermal efficiencies. You can use the hourly usage shown to compare fuel usage of your heater with heaters that have thermal efficiencies from 87 to 92 percent. You can then calculate usage over a year using variables applicable to your operation. As an example, consider a facility with a heater that provides 8 million Btu/hour for a production process. Assume it has a heater with a thermal efficiency of 80 percent. If that heater operates only 50 percent of the time, it will burn 330,159 gallons of No. 2 fuel over the course of a year. At $3.90 a gallon that amounts to $1, 287,619 a year! A heater operating at 87 percent thermal efficiency could reduce that fuel usage from 330,159 gallons to 303,594 gallons. That would cut usage by 26,565 gallons and save you $103,604 dollars a year. And remember, this is for a single heater. If your heater has a lower thermal efficiency than the example cited, the savings would be even greater. And if the size of your heat output is more heat than our example, the savings would be greater yet. Reducing the amount of fuel you use not only saves you money: it also conserves 44
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J a n u a r y 2 0 1 1 • Process Heating
Stack Temperature (degrees F)
How to Cut Fuel Costs for Heating at Industrial Facilities 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92
1130 1100 1070 1039 1003 972 945 910 875 840 805 770 746 708 665 625 595 558 525 495 465 435 390 348
Stack Temperature vs.
Heater Efficiency
0
65
70
75
80
85
90
95
Net Heater Efficiency (%) Potential savings by upgrading your heater to one with a higher thermal ef¿ciency Usage Usage Usage Thermal Gal per year Gal per hour Gal per week Ef¿ciency (operating 50% of time) (24/7) (8 million Btu/hr) (%)
Cost per year (No. 2 Fuel at $3.90 gallon)
Savings per year by upgrade to 87% ef¿ciency
Savings per year by upgrade to 92% ef¿ciency
70
86.4
14,512
377,324
$1,471,565
$287,547
$351,896
71
85.2
14,308
372,010
$1,450,838
$266,821
$331,170
72
84.0
14,109
366,843
$1,430,688
$246,670
$311,019
73
82.8
13,916
361,818
$1,411,089
$227,072
$291,421
74
81.7
13,728
356,928
$1,392,021
$208,003
$272,352
75
80.6
13,545
352,169
$1,373,460
$189,443
$253,792
76
79.6
13,367
347,536
$1,355,388
$171,371
$235,720
77
78.5
13,193
343,022
$1,337,786
$153,769
$218,117
78
77.5
13,024
338,624
$1,320,635
$136,617
$200,966
79
76.5
12,859
334,338
$1,303,918
$119,901
$184,249
80
75.6
12,698
330,159
$1,287,619
$103,602
$167,950
81
74.7
12,542
326,083
$1,271,723
$87,705
$152,054
82
73.7
12,389
322,106
$1,256,214
$72,196
$136,545
83
72.9
12,239
318,225
$1,241,079
$57,061
$121,410
84
72.0
12,094
314,437
$1,226,304
$42,286
$106,635
85
71.1
11,951
310,738
$1,211,877
$27,859
$92,208
86
70.3
11,812
307,124
$1,197,785
$13,768
87
69.5
11,677
303,594
$1,184,018
$64,349
88
68.7
11,544
300,144
$1,170,563
$50,894
89
67.9
11,414
296,772
$1,157,410
$37,742
90
67.2
11,287
293,474
$1,144,550
$24,882
91
66.4
11,163
290,249
$1,131,973
$12,304
92
65.7
11,042
287,095
$1,119,669
$78,116
SPOTLIGHT ON PRODUCT APPLICATIONS About Net Thermal Efficiency
MOISTURE
STACK LOSS
HOT OIL HEATER
Eth = [ (Hinput – Hstack) /Hinput ] x 100 Where: Eth is percentage thermal efficiency (NET) Hinput is Heat input Btu/hour (NET) Hstack Stack loss Btu/hour
WALL LOSS
GROSS HEAT INPUT (HHV)
NET (LHV)
AVAILABLE
HEAT OUTPUT
TO HELICAL COIL
This 2-pass thermal fluid heater from Heatec achieves a thermal efficiency of 91.5 percent. Two external heat exchangers boost basic efficiency by capturing heat from the exhaust stack. One preheats combustion air. The other preheats thermal fluid.
energy. And that is one of the biggest concerns of our nation at this time. If you are concerned that your heater may be wasting a lot of fuel, consider having an on-site analysis. Heatec Inc. in Chattanooga, Tennessee, provides free onsite analysis of heaters at industrial facilities. The analysis will show possible savings you could expect by switching to a heater with higher thermal efficiency. Heatec offers thermal fluid heaters with basic thermal efficiencies of 87 to 89
Net thermal efficiency is defined as a measure of a heater’s usable heat input vs. its heat output. Thus, thermal efficiency indicates how much of the heat released actually ends up as usable output compared to the amount lost through the exhaust stack and walls. Consider a heater that runs on No. 2 fuel. The net amount of heat released by each gallon burned is usually about 132,200 Btu. This is the fuel’s low heating value (LHV), which is always lower than its high heating value (HHV) because some heat is lost through moisture and this is unavoidable. If its burner consumes 69.5 gallons an hour, the input or the net amount of heat released is 9.2 million Btu/hour. If the usable portion of that heat released is 8 million Btu/hour, the thermal efficiency would be 87 percent. The formula for calculating the net thermal efficiency of a thermal fluid heater is shown in the accompanying drawing, which also illustrates where the heat goes. But a simpler method of determining thermal efficiency with reasonable accuracy is to measure stack temperature and use the accompanying bar chart that shows efficiencies for various stack temperatures. Thermal efficiency and combustion efficiency should not be confused with each other. Thermal efficiency is affected by flux rate and many other details of a heater’s design. Combustion efficiency is affected mainly by the burner and combustion air.
percent. With optional heat exchangers, efficiencies range up to 92 percent. Heatec is a leading manufacturer of heaters for a variety of industries and has been in business since 1977. You can contact them by calling toll free (800) 235-5200. Heatec (800) 235-5200 www.heatec.com SEE OUR ADS ON PAGES 2 & 56
an Astec Industries Company
www.process-heating.com • J a n u a r y 2 0 1 1
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SPOTLIGHT ON PRODUCT APPLICATIONS A Free Sample ‘Tip Sheet’ from Paratherm: Lubricating Oils and Heat Transfer Oils: The Differences There is sometimes a fine line between the Thermal Oil and Lubricating Oil product lines marketed by oil companies. Both are slippery and transfer heat but beyond that they are formulated for very different functions. Certain terms and test results provided in product data sheets are more common to lube oils than heat transfer oils.
4 5
1
out of an expansion tank vent knows that water doesn’t typically remain inside a thermal fluid system for very long.
Viscosity Index – Most lube oils are formulated for as little change in the viscosity as possible whereas for heat transfer you want as much change as you can get. Viscosity Index, for heat transfer fluids, is much less useful to engineers than the actual viscosity at a given temperature.
2
SAE Grade/ISO Grade – General lube terms where the lower the number, the lower the viscosity. Used by manufacturers to distinguish between product grades. Works for car oil but again provides no usable data for heat transfer systems.
3
SUS (Saybolt Universal Seconds) – This is a viscosity unit that makes sense only for lubrication. Heat transfer oils use centistokes, centipoise or lbs/ft-hr for sizing pumps and heat exchangers. 46
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J a n u a r y 2 0 1 1 • Process Heating
Copper Corrosion – Copper is seldom used in heat transfer systems so why worry about corrosion?
Resistance to Water/Non-foaming/ Demulsibility – Only lube oils retain water long enough to cause system corrosion or foam. Anybody who has seen a geyser of thermal fluid coming
6
Conradson Carbon Residue / Ramsbottom Carbon Residue/ Carbon Residue (Micro Method) – While theoretically an indication of the tendency of an oil to form deposits, this test really measures the amount of inorganic additives left after pyrolysis destroys most of the carbon in the residue. So, look out for claims and properties that indicate that the product is not formulated exclusively for heat transfer. Check with Paratherm’s Immersion EngineeringTM specialists for specific technical data to find the HTF that best suits your application. Subscribe to Paratherm’s Tipsheet at www.Paratherm.com/tipsheets
4 Portland Road West Conshohocken, PA 19428 Phone: 610-941-4900 Toll Free in the USA and Canada: 800-222-3611 Fax: 610-941-9191
[email protected] www.paratherm SEE OUR AD ON PAGE 17
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.
Portable Infrared Heat Banks
less. Offered in three sizes, the recirculating box ovens are stainless steel lined and included integral power supplies. All units come complete with internal movable shelves. The 437°F (225°C) rated units include single setpoint temperature controllers with 99 min/99 hour timers. The 500°F rated unit has a programmable controller. The line also includes split- and solid-tube furnaces available in either ~2,000 or 2,200°F (~1,100 or 1,200°C) models. Thermcraft Inc. • (336) 784-4800 • www.thermcraftinc.com
Heat banks combine electric infrared heating with a modular, portable design to provide the flexibility needed in many finishing operations. The portable electric infrared units can be wheeled up to the product to provide water dryoff, boost of powders and wet coatings, or complete cures of paints and powders. Benefits include the ability to add or remove heat sections at specifically designed heating loads and infrared wavelengths that best conform to the product and application. Standard models are available at 208 through 600 V, single or three-phase. Fostoria Process Equipment Div., TPI Corp. (800) 495-4525 • www.fostoriaprocessequipment.com
Hot Air Knife Systems Systems can be custom configured with one or more hot air blowers, deflectors, air nozzles, and control options to blow up to 1,000°F (538°C) heated air at pressure up to 4.5 psi. Suitable for drying machined metal as well as cast or stamped parts, the combination of hot air and pressure allows faster conveyor line speeds. Available for new and retrofit applications, the hot air systems can fully dry metallic surfaces to prevent corrosion and prepare them for subsequent processes. Malcom Co. Inc. • (800) 289-7505 • www.malcomcompany.com
Laboratory Furnaces, Ovens and Control Systems The Express-Line includes 500°F (260°C) rated recirculating air box ovens available with a delivery time of two weeks or
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Thermal Fluid Heater Steam Boiler Medium Temp Process Heaters Heating Medium: Thermal Fluids Temp Range: 350° - 650°F BTUs: 126,000 - 6,250,000
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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
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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 • J a n u a r y 2 0 1 1
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Product Highlights Hybrid Temperature Controllers The UTAdvanced line combines exceptional PID control with embedded ladder sequence control, which supports 84 ladder commands and a range of analog and digital I/O points. Up to 500 ladder steps can be programmed and run together with the PID control. The PLC capability allows engineers using a temperature controller along with a mini- or microPLC in an application to obtain the same control functionality in one package. Features include full-text-scrolling configuration prompts, three configuration levels, user-defined function keys, user-settable default values for OEMs and multiple language support. Yokogawa • (800) 888-6400 • www.yokogawa.com/us
Digital Thermostat for Heat Trace System Control Model DTS provides temperature control, power switching, power connection and alarm indication for heat trace systems used in process temperature maintenance or freeze protection applications. The digital thermostat controller mounts directly to the pipe and houses the heating cable power connection. Pipe or
ambient temperature is monitored with a three-wire, 100 1 platinum RTD. The unit is programmable from -40 to 485°F (-40 to 252°C) standard. It provides digital indication of process setpoint, process temperature, high and low temperature alarm, and sensor failure alarm. Chromalox • (412) 967-3800 • www.chromalox.com
Zero-Side-Clearance, High-Capacity Steam Generator Designed with a compact footprint, Model LX-300 is UL listed for side-by-side installation without requiring clearance between units. A multiple installation of the modular boilers provides enhanced energy management via load-matching capability, primarily because they can be sequentially turned on or off in response to load fluctuations, as opposed to consuming energy while idling on standby. The low-volume design reduces thermal radiation from the boiler during operation, which allows for safe sideby-side boiler placement without requiring the clearance needed between conventional large-volume boilers. Miura Boiler • (888) 309-5574 • www.miuraboiler.com
Valve Proving Systems Experience Dungs valve proving system advantages! t*NQSPWFETBGFUZ t&OWJSPONFOUBMMZGSJFOEMZ t$PTUFGGFDUJWF t.FFUT/'1"1SPPGPG$MPTVSF SFRVJSFNFOUT 'PSBDPNQMJNFOUBSZ%7%GFBUVSJOH %VOHTWBMWFQSPWJOHTZTUFNTDPOUBDU POFPGPVSGSJFOEMZDVTUPNFSTFSWJDF SFQSFTFOUBUJWFT www.dungs.com/usa KARL DUNGS INC. 3890 Pheasant Ridge Drive NE Suite 150 Blaine, MN 55449 Office: (763) 582-1700 Fax: (763) 582-1799 Email:
[email protected] 48
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J a n u a r y 2 0 1 1 • Process Heating
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Product Highlights Heat Recovery System The advanced heat recovery system utilizes the Transport Membrane Condenser (TMC) technology, which is patented by the Gas Technology Institute (GTI) and exclusively licensed to the boiler manufacturer. Called Ultramizer by the exclusive licensee, the system recovers both sensible and latent heat as well as water from the exhaust stream to enhance boiler efficiency. It can be used on any clean fuel boiler to raise the efficiency to 95 percent while allowing the return of clean water to the system. Cannon Boiler Works Inc. (724) 335-8541 • www.cannonboilerworks.com
Evaporators AI Aircoil evaporators are designed specifically for efficient operation in liquid overfeed (pumped), direct-expansion (DX) or brine systems with any refrigerant, including ammonia, dioxide, halocarbons and glycols. Tubes are 0.625" OD and offered in stainless steel, aluminum or copper. The standard cabinet/casing material is corrosionresistant galvanized steel. Fans are individually compartmented with continuous tubesheets to permit fan cycling. Colmac Coil Manufacturing (800) 845-6778 www.colmaccoil.com
outlet ports. Because the bottom port on the valve is common, the valve can be used as a diverter or a selecting valve. It can be used to hook three instruments together as well as testing various gages and transmitters. Dwyer Instruments Inc. (800) 872-9141 • www.dwyer-inst.com
Ultra-Low NOX Burner The ECOjet offers ultra-low emissions with little or no flue gas recirculation. All aspects of the burner, from air entry to gas and oil nozzles to swirler, was strategically designed, developed and tested, according to the manufacturer. Ignition is achieved using a self-cleaning Chentronics’ direct-spark ignitor. The burst-mode ignition with flashing indicator allows the operator to observe the ignitor condition during operation and eliminates the need for an ignitor fuel train. Gas-electric ignitors also are available firing natural gas, propane, coke oven gas and other fuels. Hamworthy Peabody Combustion Inc. (203) 922-1199 • www.hamworthy-peabody.com
My Forecast:
Windy,Hot & Humid
3-Way Shutoff Valve Series A-5000 is constructed of solid gray PVC and has Buna-N seals and a rotating flag handle. The shutoff valve can withstand a maximum operating pressure of 125 psi (8.6 bar) and a maximum temperature of 140°F (60°C). The handle has 180° rotation and lies directly over the open port. When the handle is rotated 90° from either port, flow is shut off to both
Verifying the performance of advanced coil designs often involves testing with variances in air flow, temperature and humidity. We built an advanced on-site Test Lab that does it all, using steam, water, oil, glycol, refrigerants, and other fluids. It’s the super quality you expect from a leader. Not good enough? How about the fastest delivery in the business.
Dr. Jian Yu, Ph.D. Director of Product Development
And service that doesn’t quit.
Send us an email at:
Heat Transfer Specialists Since 1928 www.superradiatorcoils.com
[email protected] www.process-heating.com • J a n u a r y 2 0 1 1
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Product Highlights 550°F Shelf Oven No. 834 is an electrically heated 550°F(~288°C) shelf oven currently used for drying trays of ore samples. The unit has 4" insulated walls and a Type 430 stainless steel interior. A 1,000 cfm, 1-hp recirculating blower provides horizontal airflow to the workload, and 12 KW are installed in Nichrome wire heating elements. Stainless steel pans are held by three tiers of 17 shelf supports on a 3" vertical center. Controls include a digital indicating temperature controller, recirculating blower airflow safety switch and a manual reset excess temperature controller with separate contactors. Grieve Corp. • (847) 546-8225 • www.grievecorp.com
six basic models of plate heat exchangers, five counterflow models and one crossflow model. Munters • (800) 843-5360 • www.munters.us
Safety Relays The Allen-Bradley Guardmaster line of safety relays is intended to help machine builders and end-users simplify safety relay selection and reduce component inventory costs. Designed to meet global functional safety standards such as EN ISO 13849-1, the line includes seven basic units capable of supporting safety devices in common applications, including single- and multi-zone configurations. Rockwell Automation (978) 446-3284 • www.rockwellautomation.com
Plate Heat Exchangers
Hand-Held Loop Calibrator
The Z-Duct is suited for dusty or dirty applications and has integral online cleaning systems, drains and cleanout panels to ease maintenance. Doublewall-insulated construction is available for higher temperature applications with a maximum temperature of 400°F (204°C). The line includes
MultiCal 15 provides accuracy of ±0.02 percent of reading. The compact, hand-held loop calibrator measures DC voltage up to 55 V; simulates DC voltage up to 10 V; measures DC current up to 50 mA; simulates DC current up to 20 mA; measures frequency up to 50 KHz; and simulates frequency up to 10 KHz. It also is able to provide loop supply (24 V) for the transmitter. E Instruments International (215) 750-1212 • www.e-inst.com
Two Coils
are Better than One Designed with twin helical coils the General Combustion HYT Series heaters offer the highest efficiency available. The HYT is designed for high temperature applications and its small, compact package makes it the ideal choice for limited space environments and easy installation. The General Combustion HYT is suitable for use with a wide range of fuels and thermal fluids making it the most versatile and efficient heater available. For reliability you can trust and efficiency you can bank on... Call the experts at General Combustion.
HERE’S WHY . . . • • • • • • •
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Highest efficiency available Reduced operating costs Lower stack temperatures Compact construction for easy installation Safe, low-pressure operation No castable refractory Factory tested for optimum performance
J a n u a r y 2 0 1 1 • Process Heating
5201 N. Orange Blossom Trail, Orlando, FL 32810 • Phone (407)290-6000 • Fax (407) 578-0577
Pro-Environmental, Inc. Thermal and Catalytic Oxidizers for VOC/HAPS Control
Standard Features: • 98% - 99% DRE with 95% Heat Recovery • Low Operating Costs • Process Fan Motor with Variable Frequency Drive • PLC(Allen Bradley SLC-5/03) Controls with Touch-screen Display • Start-up Service • Modem for Remote Troubleshooting PTO-10000
Pro-Environmental is a full service company providing: • • • • •
Emissions source testing Construction management Spare parts Performance Testing Field service technicians for startup, maintenance and troubleshooting PTO-30000
Visit us online: www.pro-env.com • E-mail:
[email protected] Corporate Office: 10134 6th Street • Suite K • Rancho Cucamonga, CA 91730 • 909.989.3010 Made In America
Free Literature Protectofier Service Manual
Custom Electrical Control Panels
This comprehensive Service Manual covers all Protectofier combustion safeguard units. Information on installation, service guides, testing and trouble shooting as well as specifications, features and applications on single and multi-burner units.
Protection Controls Inc. www.protectioncontrolsinc.com
This publication illustrates our experience as a UL 508A Certified Panel Shop in designing and building custom electrical control panels. It also presents a user-friendly guide to selecting a temperature control based on the performance required. Tempco Electric Heater Corp., Ph: 800-323-6859. www.tempco.com
Process Heating Magazine
Immersion Heaters
ARI Valve ARI Valves are in service all around the globe in applications such as cars, ships, chemicals, food processing and heating technology. ARI also works where any fluid, liquid, gas or vapor needs to be isolated, secured or regulated. ARI Valve Corp., (800) 933-8845,
www.process-heating.com
Use Process Heating Co.’s low-watt density, dry-well style immersion heaters for temperature-sensitive products. They keep the sheath temperature decreased to reduce product damage and all but eliminate buildup on the sheath. Units allow servicing without draining the tank. www.processheating.com.
To request any of these free brochures, use the contact information in the literature item in which you are interested, or consult our ad index for the phone, fax, web and e-mail information.
www.arivalve.com. www.process-heating.com • J a n u a r y 2 0 1 1
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PH Classifieds
Display Classified Rates: 1X $100 • 3X $95 • 6X $90 • 9X $85 • 12X $80
Equipment for Sale Total Plant Solutions.
Send advertising copy to: Process Heating/Attn. Becky McClelland Phone: (412) 306-4355 • Fax: (248) 502-1076 E-mail:
[email protected]
CAN-ENG FURNACES INTERNATIONAL LTD.
Innovative. Trusted. Proven.
Peace of Mind.
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Control Panels z Thermal Profiling z Ovens z Burners z Elements z
t: 905-356-1327
Quality. Efficiency. Reliability.
Experience You Can Trust.
Rebuilds z Retrofits z Combustion Controls z
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)
SCR Leader. CataStak.™ Nationwide.
To l e a r n m o r e c a l l 2 8 1 - 9 1 3 - 7 7 5 6 or visit www.catastak.com
HEAT CLEANING OVENS PARTS AND SERVICE 1-888-648-7776 • 519-352-4550 www.guspro.com Low Emissions. High Efficiency.
Boilers | Gas Turbines | Heaters | Furnaces PH12104Guspro_class.indd 1
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Need Thermal Fluid Heaters... To find them, turn here: www.process-heating.com/buyersguide
CATALYTIC INFRARED HEATERS Locate the industrial equipment, components and services specifically PH12084XchangerClass.indd 11/24/08 11:34:24 AM New, “As Is”1 & Factory Refurbished used in applying, transferring, measuring, monitoring and controlling Discount Prices/Many Sizes Available
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Contact Becky McClelland to reserve 8:58:46 AM space12/19/07 for 2011! Phone: 412-306-4355 • Fax: 248-502-1076 Email:
[email protected]
PH01084AmerCatClass.indd 1 your classified advertising
52 | J a n u a r y 2 0 1 1 • Process Heating
heat in the manufacturing operations that you need! • Search by Company Name or Product Category • Downloadable Product Spec Sheets • Alpha Company Listings • Live Web & Email Links • Product Photos
2011 Buyers Guide Start your search today! Watch for expanded - listings! www.process-heating.com/buyersguide
The Plastics Industry’s Face-to-Face Resource for Project Acceleration on the West Coast February 8–10, 2011 Anaheim Convention Center Anaheim, CA Sponsored by:
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Advertising Index
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Page
Company
Phone
Fax
Web
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23 21 29 16 (38) 55 (33) 14 9 (37) 50 19 (36) 2, 56 (44-45) 14 21 13 (42) 48 (35) 12 26 (34) 6-7 3 (41) 17 (46) 47 25 (40) 8 32 (40) 51 23 13 15 (39) 27 (38) 49 (34) 30 (35) 11 (43)
ARI Valve Conversion Products Inc. CPM Wolverine Proctor Dickow Pump Duratherm Extended Life Fluids Epcon Industrial Systems Fulton Thermal Corp. General Combustion Heat Trace Products LLC Heatec Heresite Protective Coatings Hubbell Electric Heater Co. Hurst Boiler & Welding Co. Inc. Karl Dungs Inc. Maxitrol Co. MultiTherm LLC Nanmac Corp. Omega Engineering Inc. Paratherm Corp. Parker Boiler Co. Payne Controls Petro-Canada Lubricants Precision Quincy Corp. Pro-Environmental Process Heating Co. Protection Controls Solutia Struthers Wells, Division of TEI Super Radiator Coils Thermon Manufacturing Co. Wisconsin Oven
(800) 933-8845 (510) 887-7891 (215) 443-5200 (800) 880-4442 (800) 446-4910 (936) 273-3300 (315) 298-5121 (407) 290-6000 (978) 534-2810 (800) 235-5200 (800) 558-7747 (800) 647-3165 (229) 346-3545 (763) 582-1700 (248) 356-1400 (610) 408-8361 (508) 872-4811 (203) 359-1660 (800) 222-3611 (323) 727-9800 (800) 331-1345 (866) 335-3369 (815) 338-2675 (909) 989-3010 (206) 682-3414 (847) 674-7676 (314) 674-7187 (281) 664-8022 (800) 394-2645 (800) 820-4328 (262) 642-3938
(770) 933-8846 (510) 887-7894 (215) 443-5206 (770) 933-8846 (905) 984-6684 (936) 273-4600 (315) 298-5311 (407) 578-0577 (978) 534-2819 (423) 821-7673 (920) 684-0110 (203) 378-3593 (229) 346-3821 (763) 582-1799 (248) 356-0829 (610) 408-8365 (508) 879-5450 (203) 968-7192 (610) 941-9191 (323) 722-2848 (304) 757-7305 (905) 804-3619 (815) 338-2960 (909) 989-3011 (206) 682-1582 (847) 674-7009 (314) 674-7907 (832) 237-8758 (804) 379-2118 (512) 396-3627 (262) 363-4018
www.arivalve.com www.conversionproductsinc.com www.cpmwolverineproctor.com www.dickow.com www.heat-transfer-fluid.com www.epconlp.com www.fulton.com www.gencor.com www.rscc-heattrace.com www.heatec.com www.heresite.com www.hubbellheaters.com www.hurstboiler.com www.dungs.com/usa www.maxitrol.com www.multitherm.com www.nanmac.com www.omega.com www.paratherm.com www.parkerboiler.com www.payneng.com ww.lubricants.petro-canada.ca www.precisionquincy.com www.pro-env.com www.processheating.com www.protectioncontrolsinc.com www.therminol.com www.strutherswells.com www.superradiatorcoils.com www.thermon.com www.wisoven.com
[email protected] [email protected] [email protected] [email protected] [email protected] [email protected] [email protected] [email protected] [email protected] [email protected] [email protected] [email protected] [email protected] [email protected] [email protected] [email protected] [email protected] [email protected] [email protected] [email protected] [email protected] [email protected] [email protected] [email protected] [email protected] [email protected] [email protected] [email protected] [email protected] [email protected] [email protected]
Note: Companies with a page number in parentheses have a Manufacturing Spotlight on the ( ) page.
www.process-heating.com • J a n u a r y 2 0 1 1
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®
Places & Faces Charlotte-based SPX Corp. held a ground-breaking ceremony to mark the start of construction of its 53-acre China manufacturing campus, which is being built in the FOHO Economic Development Zone in Shanghai. The planned campus represents a $40 million investment by SPX over the next three years to support the company’s business expansion in China and facilitate product localization efforts serving both China and global markets.
CEC Combustion Services Group, Cleveland, has redesigned www.combustionsafety.com with an improved user interface and navigation. Features include expanded content, video capabilities and answers to many of CEC’s most commonly asked questions.
Conair, Cranberry Township, Pa. Peter Armbruster, formerly a regional vice president of sales for Novatec, will manage Conair activities Armbruster in the Midwest and Northeast as well as Canada. John Heinrikson, formerly the director PET North America for Piovan/Una-Dyn, will oversee sales in the north-central region and the Southeast.
Swep, Landskrona, Sweden, introduced its T-Reg heat exchanger, which is used in the plastic molding industry as a single-phase water-to-water heat exchanger combined with an electrical heater. The device uses parts of a temperature control unit (TCU) and combines them into a compact brazed unit. For more information, visit www.t-reg.net. Alfa Laval, Lund, Sweden, has
Imbert Corp., Niles, Ill., joined the network of sales representatives for Colville, Wash.-based Colmac Coil Manufacturing. Imbert can help customers in north central Illinois, northwestern Indiana, southeastern Iowa and southeastern Wisconsin select and specify plate-fin heating and cooling coils, dry coolers, and aircooled condensers. A 74-page reference guide from ABB, Cary, N.C., serves as a primer for selecting and applying electromagnetic flowmeters. The guide includes topics such as principles of operation, construction, magnetic fields, maintenance, transmitters, installation and calibration. To request the guide, send an e-mail to instrumentation@ us.abb.com or call (800) 922-2475. Two experienced plastics industry sales executives were named to new regional sales manager positions for 54
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received a more than $7 million order for its Packinox heat exchangers to be used in a refinery in India, scheduled for 2011. The heat exchangers will be used in a catalytic process to remove sulphur from refined diesel.
PUBLISHING STAFF Senior Group Publisher, Manufacturing Group TOM ESPOSITO • (610) 436-4220 ext. 8530 Group Publisher • DOUG GLENN (412) 306-4351 •
[email protected] Publisher • ANNE ARMEL (847) 405-4043 •
[email protected] Associate Publisher and Editor • LINDA BECKER (630) 694-4332 •
[email protected] Contributing Editor • JOY LEPREE ANDERSON (856) 582-9554 •
[email protected] 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] Classifieds • BECKY MCCLELLAND (412) 306-4355 •
[email protected] 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 • Sean Meaney • National Sales Manager 530 Humiston Drive • Bay Village, OH 44140 (440) 895-0919 • FAX (248) 502-1051 •
[email protected] NORTH AMERICA • Anne Armel • Publisher 155 N. Pfingsten Road, Suite 205 • Deerfield, IL 60015 (847) 405-4043 • FAX (248) 786-1441 •
[email protected] EUROPE • Carolyn Eychenne • European Sales Representative 7 rue de Maurepas • 78000 Versailles France tel/fax: 011 33 1 30 21 15 62 •
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CORPORATE STAFF BNP Media Corporate Office • (248) 244-6400
SINGLE COPY SALES ANN KALB • (248) 244-6499 •
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POSTAL LIST RENTAL ROBERT LISKA • (800) 223-2194 x726
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E-MAIL LIST RENTAL SHAWN KINGSTON • (800) 409-4443 x828
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AUDIENCE DEVELOPMENT
BASF, Iselin, N.J., agreed to acquire the styrene catalysts business of CRI/ Criterion, a wholly owned subsidiary of Houston-based Shell. CRI/Criterion manufactures chemical catalysts used in the dehydrogenation of ethylbenzene to styrene, a vital ingredient in the making of plastics, rubber and resins.
Petrobras, Sao Paulo, has selected St. Louis-based Emerson Process Management to provide process automation technologies and services for the petrochemical complex of Rio de Janeiro (Comperj) in Brazil. As main automation contractor for Comperj, Emerson will deliver engineering services and technologies for process automation and systems integration of the refining unit, selected utilities and offsite operations.
Audience Development Coordinator • HAYAT ALI-GHONEIM Corporate Fulfillment Manager • MEGAN NEEL Corporate Audience Audit Manager • CATHERINE M. RONAN
SUBSCRIPTIONS Contact Customer Service at Tel. (847) 763-9534 or Fax (847) 763-9538 or e-mail
[email protected]. Via Web: to subscribe or submit an address change, 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.
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Got Maintenance? Plant operators are finding out the advantages of having their heaters serviced by Heatec on a regular basis. There are important benefits of having a contract for our service technicians to do preventative maintenance once or twice a year. An important benefit is safety. Our technicians make sure all limit devices are working properly. Insurance companies usually prefer that specialists, such as Heatec technicians, perform services related to safety. Fuel savings is another important benefit that results from maintenance that includes tuning the burner. Moreover, preventative maintenance usually eliminates unexpected heater
shutdowns at times that interrupt production. Preventative maintenance can usually be done without adversely affecting production schedules. Another benefit is usually a reduction in costs for each service call. This results from lower travel expenses when our technicians can make service calls at other plants in the same area. Moreover, many of our technicians reside in diverse locations that reduce travel to plant sites. Call today to find out what kind of service contract would work best for you.
HEATEC
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