Process Heating January 2012

www.process-heating.com | January 2012 | Volume 19, Number 1

Ensuring compliance with tthe EPA’s new boiler rules requires a new mindset.

Periodical Class

20 Compare Heat Transfer Fluid Specs 26 Selecting and Specifying an Oven

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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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January 2012 Volume 19 • Number 1

www.process-heating.com WEB EXCLUSIVES: READ MORE AT WWW.PROCESS-HEATING.COM Q Online Compliance Assistance

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Features 18

The plate test helps users accurately assess the maximum sheath temperature of mineral insulated heat tracing cables. Are you familiar with this tool?

Equipment Overview: Heat Transfer Fluids Heat Transfer Fluid Guide 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.

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Q What Not to Do When Specifying an Oven As an over builder, we find there are three general categories of customers: the clueless messenger, the overprepared messenger, and an educated buyer. Oven buyers will get the best result by putting the educated buyer in direct contact with the oven manufacturer.

Q Sheath Impacts Design

Heat Tracing A Proper Assessment

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One manufacturer has set up an educational website to make it easier for facility managers to understand and comply with the EPA’s new rules for boilers.

Ovens

Before making electric heat tracing design decisions, engineers should confirm with their cable manufacturers that the sheath temperature data provided for their cables is the result of using the plate test.

UPDATED DAILY Q New Products Q Archives Q Calendar of Events Q Drying Files columns

Quick links point the way: www.process-heating.com/connect Q Go Mobile

Heat Exchangers Increasing Heat Transfer Efficiencies Adding economizers to existing boilers can help heat processing operations get the most out of every BTU they buy. Is it time to look at improving energy efficiency at your facility?

Boilers A Whole New (Boiler) Ballgame In 2011, the EPA enacted the Area Source Rule, making it mandatory for many commercial, institutional and manufacturing facilities to monitor fuel usage on a monthly basis and conduct biennial tuneups. Some facilities also are required to conduct a one-time energy assessment, and others must regularly meet emissions limits. Ensuring compliance with the EPA’s new boiler rules requires a new mindset.

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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 6 10 17 47

Editor’s Page Inner Workings Calendar Free Literature

Q Digital Editions Q Buyers Guide Q Archived Webinars

NETWORK WITH PROCESS HEATING!

Having a good idea of what you are looking for in an oven is the best way to get what you need.

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Q Energy Notes column Q Equipment Overviews Q Heating Highlights

Check out our redesigned site with more frequent updates and web exclusives!

Selecting & Specifying an Oven

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Q Industry News

ALWAYS ONLINE

48 49 49 50

Classified Directory Advertiser Index Subscription Form Places & Faces

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. The reader works on most current smart and advancedd ffeature phones, includh i l d ing Windows Mobile (5.5 and above), iPhone, Blackberry, Symbian and J2ME.

About the Cover A large corn oil and ethanol producer uses four boilers from Precision Boilers LLC (www.precisionboilers.com) to base load the plant at more than 400,000 lb/hr of steam during nine months of the year. In the hottest summer months, says the Morristown, Tenn.-maker of boilers and steam generators, the ethanol producer typically runs 50 percent of the time based on electric rates due to high summer heat and air-conditioner loading at the utility. For more information about boilers, turn to page 31.

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 2012, by BNP Media. All rights reserved. The contents of this publication may not be reproduced in whole or in part without the consent of the publisher. The publisher is not responsible for product claims and representations. Periodicals Postage Paid at Troy, MI and at additional mailing offices. POSTMASTER: Send address changes to: PROCESS 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 2

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New Ways to Handle Old Business

By Linda Becker

Commentary

Gimme Gadgets If you get the chance, tune in to the History Channel’s 101 Gadgets that Changed the World, a program the network compiled in conjunction with the editors of Popular Mechanics. It’s a fascinating look at history in all new ways. For instance, the show suggests that the audio cassette tape was instrumental in the fall of the Shah of Iran in 1979, and that wristwatches helped make it possible for the Allied troops to be successful on D-Day. Certainly, obvious game-changers such as the iPod, the calculator and the personal computer made the list. Still others, like the wristwatch, surprised me, though their influence on history is made clear on the show. Among the top 10 are the light bulb, the alarm clock, the rotary phone and portable air-conditioning, and even a cursory thought about your work day makes clear how different life would be without them. At the top of the list — the gadget that most changed the world — was a smartphone. As a device that combines so many other gamechanging gadgets — the personal computer, the Internet, radio, the telephone, Wi-Fi, and a calculator, to name a few — a smartphone is certainly useful. Yet I was unconvinced until two key points were asserted. First, as anyone who has ever owned one can attest, once you adjust to having a smartphone at your disposal, it’s almost impossible to live

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without one. Second, the smartphone will continue to be a gadget that changes lives because it has created an app-driven world. Now, it is no longer necessary to buy a dedicated device or even a full, multi-function computer program. Instead, “There’s an app for that!” Whether you want to play a game, listen to music, create music, share files — you name it — there is likely an app already offered for most smartphone platforms. Do you have a smartphone? Do you use it for work? There are some apps that can help. For instance Munters AB, Kista, Sweden, has released PsychroApp, a psychrometric calculation tool that allows users to determine the thermodynamic properties of air on an iPhone or iPod Touch. App developers also have begun to introduce engineering tools for smartphones. Check out some of those currently offered in iTunes or the Android market, such as HeatXchanger, Steam, Gas Rating Calculator, Building Engineer’s Formulator or Gas Rate & Heat Input Calculator. Each costs $0.99 or more, but if after a careful review you decided to buy, you can put an effective tool in your pocket.

Linda Becker, Associate Publisher and Editor, [email protected]

Inner Workings

Gasifiers Reduce Fossil-Fuel Use A biomass energy equipment company has the ability to produce renewable electricity from scrap wood chips using a clean thermo-chemical process. PHG Energy, LaVergne, Tenn., developed the process — called gasification — to produce a fuel much like natural gas, and then processed and purified that gas so it can be used to run a 1 MW Caterpillar generator. A successful implementation of the technology was installed and recently demonstrated at a Boral Bricks Inc. plant in Gleason, Tenn.

Gasification equipment from PHG fires brick kiln burners during a demonstration of the technology at Boral Bricks.

“We have trialed our gasification equipment producing fuel gas to fire large brick kilns here in Gleason as well as at two other manufacturing facilities in Georgia and Alabama,” says Tom Stanzione, PHG president. “We have more than 40,000 hours of successful gas production from waste biomass products on these gasifiers.” Boral uses six PH-8 downdraft gasifiers that convert wood chips to producer gas. The gas is piped directly into brick kiln burners for firing, with 2 percent biochar residue. According to PHG’s website, the gasification equipment uses wood chips with 25 percent moisture content. Feedstock input capacity is 48 tons/day and the producer gas output capacity is 24 million BTU/hr. “This ongoing application of our gas generation system has been focused on accomplishing just what we did today, cleaning and cooling the fuel gas 10

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J a n u a r y 2 0 1 2 • Process Heating

in order to generate power directly in a reciprocating engine generating set and putting that renewable power on the grid,” Stanzione says. PHG’s gasification equipment can utilize many biomass feedstocks such as wood chips or foresting wastes, and it can take advantage of recycled waste materials from industrial and manufacturing operations. “Our new generation of gasification equipment is truly industrial-grade,” Stanzione says. “It brings our customers the ability to reduce their use of fossil fuels, thereby their carbon footprint, and perhaps more importantly cut their fuel costs by 50 percent or better.” The project to produce electricity has been supported over the past year through collaborative contributions and funding from the U.S. Department of Energy as part of the ARES Program, which includes Caterpillar Inc., Peoria, Ill., and Boral Bricks, headquartered in Roswell, Ga. PHG notes that Boral’s Gleason site has realized the following benefits: • Fuel Cost Savings. The project uses $2 million BTU producer gas from dry $30/ton wood chips vs. $8 million BTU natural gas cost. • Reduced Reliance on Fossil Fuels. There is a projected 65 percent reduction in natural gas use. • Good Capitalization. With quality feedstock, projected payback is less than four years through fuel cost savings. For more information, go to www.phgenergy.com.

Thermcraft, Electrotherm Partner Two makers of heat processing equipment have formed a joint partnership to better serve their North American customers. Thermcraft Inc., Winson-Salem, N.C., a manufacturer of ovens and furnaces, and Electrotherm Industry, Migdal HaEmek, Israel, will work together to

provide products and services for industrial heat processing. Thermcraft manufactures thermal processing equipment such as laboratory and production furnaces, recirculating ovens, vacuum formed ceramic fiber heaters, cast heaters, heater coils, air heaters, ovens, kilns and diffusion heaters. Electrotherm Industry designs, develops, manufactures and markets precision forging and heat treatment furnaces for the aerospace, medical and energy industries. Electrotherm focuses on developing systems that meet stringent precision process requirements, NADCAP quality standards and AMS-2750D. As a part of the partnership, Scott Miller will join the team as sales manager in the United States. Working from an office in St. Louis, Miller can be reached by at (314) 726-4743 or via e-mail at [email protected].

Tweeting Combustion Alerts Anyone working with combustion equipment now can receive via Twitter information on important safety and risk events occurring throughout the world. CEC Combustion Safety, Cleveland, offers the service to keep those people involved with boilers, ovens, furnaces, thermal oxidizers and fuel delivery systems, including natural gas pipelines, fully informed when incidents happen, even those occurring outside the United States. If you want to know when there is a plant explosion, boiler blowup or factory fire, sign up for CEC’s service. Knowing details about an event can help you avoid the same fate. According to CEC, besides end-users of combustion equipment, the following groups could benefit from the service: insurance industry risk managers, environmental health and safety managers, corporate executives and plant personnel. CEC also will tweet important equipment-related issues such as safety recalls and warnings about potential problems related to gas valves, pressure switches, flame safety devices and other critical safety components. To subscribe, visit twitter.com and enter “CombustSafety” in the “Find People” search area. Those that do not already have an account can create one

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. Our Fluid Services Program 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.

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Inner Workings at no charge. CEC notes that it will tweet as it becomes aware of publicly released and important events. After getting a Twitter account, type “CombustSafety” to visit the company’s Twitter feed page, and then click on “follow” to receive CEC’s tweets in your Twitter feed. You also can view @CombustSafety on Twitter with a mobile device.

Facility Expansion Completed A $10.5 million facility expansion at Fulton provides efficiencies that are already allowing for increased response to customer demands, according to company officials. While introducing the recently completed project, Mark Hilton, Fulton’s vice president of manufacturing, noted, “The new facility will also provide the opportunity to expand Fulton’s product lines.” At the Pulaski, N.Y.-based facility, the expansion’s manufacturing space is already fully functioning; office space transitions have begun and are

expected to be complete in the first quarter of 2012. According to the company, an additional $3.5 million will be spent to complete project interior and equipment needs. All told, the project is expected to provide: • 10,000 ft2 of new research and development space. • 82,000 ft2 of new manufacturing space. • 20,000 ft2 of additional office space. • 70 tons of additional lifting capacity at Pulaski, N.Y., headquarters. Guests will be encouraged to visit and see firsthand the innovative technologies employed for heating and cooling, lighting and customized energy

recovery. Some of them include: • Heating. The heating system for the office space uses a 12-zone in-floor radiant hydronic system that can be heated using waste heat from the manufacturing processes or the factory’s research and development facilities. • Cooling. The office space is divided up into 43 zones with a chilled beam system mounted in the ceilings to efficiently distribute cooling to the building occupants. Cooling towers are incorporated to manage the energy balance of the overall system. For example, when waste heat exceeds the energy required by the system, excess energy can be rejected to the cooling towers. The system

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Inner Workings

Gas Burner Products

also has the potential to utilize gas absorption heat pumps and retention ponds as an energy source. The expansion also provided an opportunity for Fulton’s affiliate, Synex Controls, to integrate a custom energymanagement system to centralize and manage the facility’s heating, cooling, fresh air, humidification and lighting. Video and project background can be viewed online at www.fulton.com.

• • • • •

e-Distributor Gets Dow Glycol Fluids

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Dow Chemical Co., Midland, Mich., has expanded its relationship with ChemPoint.com, an e-distributor of fine and specialty chemicals, to include Dowfrost and Dowtherm glycol-based heat transfer fluids. ChemPoint will provide marketing, sales, order fulfillment and expanded technical support for customers in the food, beverage, radiant, geothermal, pharmaceutical and HVAC industries in the United States. Contact ChemPoint at www.chempoint.com.

Oxidizers Recover Energy Regenerative thermal oxidizers are abatement systems for volatile organic compounds and hazardous air pollutants. Regenerative thermal oxidizers from Catalytic Products

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Inner Workings International, Lake Zurich, Ill., use a ceramic heat exchange media for high thermal efficiency, and the exhaust temperature is 75 to 100°F (41 to 55°C) higher than the inlet temperature. In ambient temperature applications, there is not a lot of heat left over in the regenerative thermal oxidizer’s stack to allow for efficient secondary heating. According to CPI, it has developed a system that can affect the oxidizer’s thermal efficiency, raising the stack temperature to provide efficient heating. In certain applications, says the company, energy derived from VOCs is sufficient to offset the lower efficiency, and the net result is savings that otherwise might have been lost up the stack. The most common form of energy recovery is hot air delivered back to the process. Other options include heating, makeup air, hot water or other heating fluids. For more information about air pollution control and energy conservation from CPI, visit www.cpilink.com.

Metso Signs 2 Boiler Installation Contracts Biomass boilers from Metso, Helsinki, are scheduled for installation in two diverse applications. A biomass-fired steam boiler equipped with Metso’s DNA automation system will be installed in 2013 at Helsinki-based Valio Ltd.’s Lapinlahti, Finland, milk-production facility. The other biomass-fired boiler will be installed at a pulp and paper mill owned by Arkhangelsk, headquartered in Novodvinsk, Russia. The boiler plant destined for the milk-production facility will generate the steam and heat needed by the processing plant. The plant will be fueled by wood chips and peat. Wood chips are expected to be used at 100 percent eventually, but in the initial stage, they will account for 50 to 60 percent of the fuel mix, with a gradual increase, according to Metso. “Valio is investing in the development

The boiler plant destined for the milkproduction facility will generate the steam and heat needed by the processing plant.

of its energy-generation structure and in the recovery of waste energy streams, with the goal of improving energy efficiency, achieving lower emissions and increasing its use of domestic fuels,” says Esa Mäkipelto, Valio’s technical manager. The annual operation of the new plant will be around 8,500 hr and its process steam output will total approximately 140 GWh/a. The boiler is based on Hybex bubbling fluidized-bed combustion technology, patented by Metso, that allows the use of a range of fuels.

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J a n u a r y 2 0 1 2 • Process Heating

Inner Workings The boiler output is 20 MWth and that of the auxiliary boiler, also included in the delivery, is 12.4 MWth. The pulp and paper mill’s bubbling fluidized-bed biomass-fired boiler has a completion date of 2014. It will replace an existing power boiler and is expected to increase the mill’s energy independence and cut electricity costs. Bark and sludge will be used as fuel in the boiler, which has a capacity of 60 MWth. By replacing old coal boilers with a new biomass boiler, the Arkhangelsk mill will obtain an additional amount of steam and electricity.

EDL Adds Shopping Cart to Site An online shopping cart has been added to Danville, Va.-based EDL Inc.’s website. Now visitors can purchase temperature-related products with payments processed through EDL’s secure site using all major credit cards or a PayPal account.

Also on the site, visitors can download a temperature product catalog or request a hard copy; read product details; learn about the calibration laboratory and service; or sign up for eNews bulletins. See the site at www.edl-inc.com.

Study Outlines Promising Powder Coating Markets A new powder coating study based on surveys and interviews with U.S. companies has identified 21 market segments that spell opportunity for powder coaters. “Project Expand,” commissioned by the Powder Coating Institute in The Woodlands, Texas, and conducted by Chemmark Consulting Group Inc., Southern Pines, N.C., indicates that the segments carry a total potential value of more than $4 billion. Of the 21 segments that hold the most promise, five are within the markets that powder coatings currently serve, four are adjacent to the typical or

current areas, and 12 are in markets not previously penetrated by conventional powder coating systems. The 142-page report is available as a CD or hard copy. Cost depends on the type of PCI membership the purchaser has, but the report also is being sold to nonmembers. To order the study, go to www.powdercoating.org and click on the “Project Expand” logo.

Sizing Software for Valve Module Gets New Features As a part of its product sizing and selection software library, Spirax Sarco, Blythewood, S.C., has released Phase 1 of its pressure-reducing valve. The addition to the sizing software allows directacting products to be selected. Sizing charts no longer are necessary because the visual product-range selection option allows viewing of full product descriptions and code numbers. Users can access the software at http://prs.spiraxsarco.com.

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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.

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Calendar of Events January 23-25 — AHR Expo (held in conjunction with ASHRAE Winter Meeting), McCormick Place, Chicago. Hosted by co-sponsors ASHRAE and ARI. Call (203) 221-9232 or visit www.ahrexpo.com. 24-26 — International Poultry Expo, Georgia World Convention Center, Atlanta, Georgia. Hosted by U.S. Poultry & Egg Association. Call (770) 493-9401 www.internationalpoultryexposition.com. 24-26 — Elster Hauck Asphalt Product Maintenance Seminar, Customer Technical Center, Hauck Manufacturing Co.. Lebanon, Pa. Other dates available. Call (717) 272-3051 or visit www.hauckburner.com.

Exhibition, Las Vegas. Hosted by Water Quality Association. Call (630) 505-0160 or visit www.wqa-aquatech.com. 11-15 — Pittcon Conference and Expo, Orange County Convention Center, Orlando, Fla. Hosted by Pittsburgh Conference on Analytical Chemistry and

Applied Spectroscopy Inc. (Pittcon). Call (412) 825-3220 or visit www.pittcon.org. 13-15 — Composites Manufacturing Conference, Phoenix Marriott Mesa, Mesa, Ariz. Hosted by Society of Manufacturing Engineers. Call (800) 7334763 or visit www.sme.org/composites.

Lower production costs for snack expansion. AeroExpanderTM provides continuous hot air expansion of pelleted snack products with exceptional texture and appearance. Unmatched uniformity with 100% pellet expansion is achievable on a wide variety of products. Develop the industry’s next better-for-you snack with Buhler Aeroglide.

February 5-8 — Biodiesel Conference and Expo, Orlando, Fla. Call (800) 841-5849 or visit www.biodiesel.org.

Buhler Aeroglide 100 Aeroglide Drive, Cary NC 27511 USA Tel +1 919 851 2000, Fax +1 919 851 6029 [email protected], www.buhlergroup.com/aeroexpander

5-9 — Cooling Technology Institute (CTI) Annual Meeting, Hilton Hotel, Houston. Call (281) 583-4087 or visit www.cti.org. 8-13 — Hydraulic Institute Annual Meeting, Renaissance Vinoy, St. Petersburg, Fla. Call (973) 267-9700 or visit www.pumps.org. 14-16 — Plastec West, Anaheim Convention Center, Anaheim, Calif. Hosted by Canon Communications. Call (310) 445-4200 or visit www.canontradeshows.com/expo/plastecshows/. 28-March 1 — IPC APEX Expo, Convention Center, San Diego. Call (847) 615-7100 or visit www.ipc.org.

March 6-7 — Safety Standards Seminar for Industrial Ovens and Furnaces, Hilton Garden Inn O’Hare, Rosemont (Chicago), Ill. Hosted by Industrial Heating Equipment Association (IHEA). Call (859) 356-1575 or visit www.ihea.org.

Innovations for a better world.

6-9 — Aquatech USA Conference and www.process-heating.com • J a n u a r y 2 0 1 2

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Heat Tracing

A Proper Assessment By Blair McGrath and Sudhir Thorat, Tyco Thermal Controls

E

ngineers have many considerations when designing a heat tracing installation, especially if the area where it is located is defined as a hazardous location — a location where flammable gases may be present. It is vital that engineers assess all their equipment and ensure that it is up to code to protect the safety of personnel, the installation and its equipment. For example, an electric heat tracing cable can be accurately tested — provided that accurate assessment methods are used — to ensure the maximum sheath tem-

• Required temperature to maintain the fluid in the pipes. • Ambient temperature where the tracing system will be installed. • Heat loss from the fluid to ambient. • Maximum pipe temperature to which the heating cable will be exposed.

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• Autoignition temperature of the hazardous gases that may be present in the area.

Heat Trace Panel (May Include Circuit Breakers, Controllers and Alarms)

The plate test helps users accurately assess the maximum sheath temperature of mineralinsulated heat tracing cables. Are you familiar with this method? perature attained by the cable will not be so high as to cause harm to the installation through autoignition of hazardous gases present in the area. An electric heat tracing system may be used in an installation’s pipe system to compensate for heat losses and to maintain a minimum temperature. This often is important to ensure the proper viscosity of the process fluid in the pipe, or to prevent water or steam lines from freezing. Prior to designing and installing an electric heat tracing system, an engineer must carefully evaluate the application the system is serving. Important items to check include:

In applications where the heating cables will be installed in hazardous areas, there are additional design inputs that need to be considered, including the:

Transformer

Lighted End Seal

Remote Configuration and Monitoring Insulation Systems RTD Temperature Measurement Separate Wiring Run to Panel (Shown) Power Connection Heating Cable

An electric heat tracing system can be used in an installation’s pipe system to compensate for heat losses and to maintain a minimum temperature. This often is important to ensure the proper viscosity of the process fluid in the pipe, or to prevent water or steam lines from freezing. Prior to designing and installing an electric heat tracing system, an engineer must carefully evaluate the application the system is serving.

Solid Conductors

Magnesium Oxide Insulation

Seamless Metal Sheath

• Area temperature rating of the physical location of the installation. • Highest sheath temperature that the heating cable will reach during operation. The sheath temperature — the temperature of the outermost heat trace cable jacket — must not exceed the area temperature rating and is an extremely important part of electric heat tracing system design. Suppliers of heat tracing cables are required to predict the maximum sheath temperature that the cable will reach. However, given the varied methods used to measure and predict maximum sheath temperatures of mineral-insulated (MI) heating cables, there is confusion in the industry about the best approach. Two common methods have been evaluated and identified in IEEE 515, Standard for the Testing, Design, Installation, and Maintenance of Electrical Resistance Trace Heating for Industrial Applications. IEEE 515 requires that manufacturers verify their ability to predict sheath temperatures using either the pipe test or the plate test.

Benefits of the Plate Test vs. the Pipe Test Many pipe and plate experiments were performed to determine the maximum sheath temperature of various mineral-insulated cables from the same manufacturer, ranging in size from 0.12 to 0.43" (3 to 11 mm). Pipe Test. The pipe test consists of a 2" dia., L-shaped pipe sculpture with a valve located along the horizontal section and various flanges located along the length of the pipe. The heating cable is installed on the surface of the pipe according to the manufacturer’s instructions. Thermocouples are located at anticipated hot spots and attached to the heating cable

There is some confusion in the industry as to the best approach to measure and predict maximum sheath temperatures of mineral-insulated heating cable (shown in a cutaway view).

sheath, with another thermocouple located on the pipe itself in close proximity to the thermocouple on the heating cable sheath. After several of these thermocouple pairs are located along the length of the pipe, the entire assembly is insulated with 2" fiberglass insulation. The heating cable is energized at the required wattage and the pipe temperature is allowed to stabilize. After stabilization, the heating cable sheath temperature is recorded from all thermocouples, and the highest recorded temperature is the maximum sheath temperature of the cable at the given operating conditions. With the pipe test, it was difficult to obtain reproducible temperatures, and the hottest spot on the pipe varied from test to test and pipe to pipe. After reviewing the variations in the results, it was concluded that the pipe test was not a suitable method for consistently and accurately determining the maximum cable sheath temperature. Considering the implications for hazardous areas where a fire or explosion may occur, it is critical to have accurate sheath temperatures. Plate Test. The plate test uses a metal plate that is air cooled, electrically heated and well insulated. In the procedure, the cable is laid on the plate over a trough to simulate a common field condition where the heating cable is not in direct contact with the pipe. Thermocouples are located on the cable sheath at the center of the trough to measure the sheath temperature and also on the plate itself to measure the plate temperature. The plate temperature is monitored and controlled by the heating and cooling channels throughout the test. The assembly is insulated on all sides and on the top and bottom. After many trials, it was determined that the plate test produced more accurate and repeatable results with several benefits. It provides a simple, consistent method to

Heat Tracing install the cable and removes the installerrelated variability from the test. The cable sample simply is placed on the plate over a predetermined location and clamped down, without any bending or manipulation of the cable required. The trough depth of ~0.20" (5 mm) between the cable and the plate is highly controlled, represents the worst case condition, and is not dependent on the technique of the installer. In the authors’ opinion, the plate test proved to be a more repeatable, cost effective and reliable method of predicting maximum sheath temperature and ensuring the intent of the industry standards is met. In conclusion, engineers can rest assured that most heat tracing equipment manufacturers take a conservative approach to prevent hazards. For instance, the area temperature ratings and the temperature at which a fire can occur often are intentionally understated by the industry to build precaution into electrical installation designs. Additionally, even if the maximum temperatures are reached, the required insulation and cladding around the heating cables offer another layer of protection. The plate test has proven effective in predicting maximum sheath temperatures for mineral-insulated cable in an accurate and repeatable manner. Adoption of the plate test within industry standards as the single acceptable test method is the most logical next step to ensure consistency across the industry. PH Blair McGrath and Sudhir Thorat are product managers with Tyco Thermal Controls, Menlo Park, Calif. For more information from the manufacturer of heat tracing, call (800) 5456258 or visit www.tycothermal.com.

WEB EXCLUSIVE Sheath Impacts Design Before making electric heat tracing design decisions, engineers should confirm with their cable manufacturers that the sheath temperature data provided for their cables are the results of using the plate test. READ MORE @ WWW.PROCESS-HEATING.COM

www.process-heating.com • J a n u a r y 2 0 1 2

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19

Equipment Overview | Heat Transfer Fluids

W

Thermal Conductivity** (BTU/hr-ft-˚F @ 600˚F)

* *

* *

* *

0.46 0.67 0.43 0.7 0.71

*

0.072 0.069 0.07 0.006 0.076 0.072

0.065 0.065 0.0611 0.074 0.067

*

0.675 0.609 0.667 0.63 0.605 0.611

* *

* *

* *

* *

0.78 1 1.5 0.95 0.63 0.34 0.39

0.41 0.22 0.7 0.43 0.42

0.061 0.06 0.07 0.06 0.07 0.08 0.08

0.053 0.05 0.06 0.051 0.06

0.56 0.67 0.61 0.61 0.65 0.65 0.62

42.4 42.5 42.5 42.4 38.8

1.37 1.41 1.44 1.46 0.82

0.7 0.7 0.7 0.7 0.51

0.077 0.077 0.074 0.077 0.072

0.074 0.073 0.07 0.074 0.067

0.6 0.6 0.6 0.6 0.65

*

1.1 0.46 0.84 0.88 0.29 0.89 2 2 2 0.84

*

0.07 0.064 0.07 0.061 0.048 0.061 0.077 0.077 0.073 0.0725

*

0.61 0.53 0.63 0.53 0.61 0.51 0.6 0.6 0.6 0.65

42 49.6 46 49.25 47.6 49.6

46.7 40.2 44.9 44.2 44.1

*

* *

* *

0.64 0.96 1.5 0.93 1.5 1.52 150-200 @ 40°C, cSt 100 @ 40°C, cSt

10%: 600FA 10%: 565A 10%: 730A 10%: 650A 10%: 600A 10%: 355A 10%: 290A

51 47 47 47 43 39.1 40.1

46 43 42 42 41

41.2 41.1

-75 -40 0 -51 -44 5 50 50

10%: 613 90%: 637 10%: 638 90%: 730 10%: 760 90%: 930 10%: 583 90%: 930 10%: 704 90%: 904

430

n/a n/a n/a n/a n/a n/a n/a

Firepoint (ASTM D92, ˚F)

Autoignition (ASTM E 659-78, ˚F)

Density** (lb/ft3 @ 600˚F)

* *

Density** (lb/ft3 @ 400˚F)

* *

Distillation Range (ASTM D1160, ˚F)

* *

Pour Point (ASTM D97, ˚F)

38.9

45.70 45.63 46.00 45.70 46.38 54.94 52.07 42.70

670 650 490 670 690 690 550 630 390 180

444 435 302 440 530 615 511 329 210 120

472 464 327 466 582 636 543 370 240 140

693 680 625 682 740 818 704 675

500 600 600 600 550 550 180 550

550 640 650 630 600 600

310 340 440 330 455 442 >350 >392

335 385 500 345 520 505

* * * 650 675 670

* *

* *

650 600 600 550 550 400

700 650

Specific Heat** (BTU/lb-˚F @ 400˚F)

Thermal Conductivity** (BTU/hr-ft-˚F @ 400˚F)

* *

Viscosity** (ASTM D445, cSt @ 600˚F)

0.066

0.60 0.60 0.63 0.60 0.57 0.47 0.55 0.65

Viscosity** (ASTM D445, cSt @ 400˚F)

0.074 0.074

0.54

0.077 0.077 0.075 0.077 0.077 0.054 0.080 0.072

0.73 0.71

10%: 727 90%: 902 10%: 715 90%: 886 10%: 481 90%: 851 10%: 769 90%: 930 10%:769 90%:930 10%: 922 90%: 1255 10%: 694 90%: 957 10%: 613 90%: 784 10%: 356 90%: 546 10%: 181 90%: 546

630 600 450 620 640 650 500 600 350 150

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

1.46 1.39 0.70 1.46 1.76 8.47 2.32 0.84

-1 14 -49 1 15 -87 -40 -72 -70 -130

Flashpoint (ASTM D92, ˚F)

Company and Fluid Name

Film, Maximum Temperature, ˚F

You also can conduct your supplier search online! www.process-heating.com Click on Equipment Overview, then on heat transfer fluids.

Bulk, Maximum Temperature, ˚F

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

Duratherm Extended Life Fluids • www.heat-transfer-fluid.com Duratherm 630 Duratherm 600 Duratherm 450 Duratherm FG (Food-Grade) Duratherm HF (High FlashPoint) Duratherm S Duratherm G Duratherm LT (Low Temperature) Duratherm XLT -50 Duratherm XLT -120

MultiTherm LLC • www.multitherm.com MultiTherm 503 MultiTherm PG-1 MultiTherm IG-4 MultiTherm FF-1 (flushing fluid) MultiTherm OG-1 MultiTherm IG-1 MultiTherm PSC MultiTherm PSC Plus

Paratherm Corp. • www.paratherm.com Paratherm HR Paratherm NF Paratherm HE Paratherm GLT Paratherm MR Paratherm LR Paratherm CR

Petro-Canada • www.calflo.com Petro-Therm Calflo AF Purity FG Calflo HTF Calflo LT

* *

* *

600 600 450 400

330 340 465 360 330 N/A N/A

599 600 619 619 550

617 617 650 650 550

437 437 459 448 349

473 464 480 473 372

666 649 669 666 613

0 -44 0 0 -81

10%: 709 90%: 880 10%: 689 90%: 887 10%: 721 90%: 892 10%: 705 90%: 889 10%: 604 90%: 734

46.8 46.8 46.8 46.8 43.4

572 680 600 662 572 653 620 600 620 500

617 716 640 716 608 698 650 650 650 617

432 288 385 421 147 374 439 430 408 343

468 295 410 475 158 401 462 446 457 372

617 842 626 842 770 716 687 650 669 613

10 -26 -76 -29 -130 -27.4 5 -44 0 -81

10%: 650 90%: 880 10%: 532 90%: 540 10%: 630 90%: 750 10%: 730 90%: 740 10%: 355 90%: 365 10%: 650 90%: 670 10%: 738 90%: 932 10%: 693 90%: 900 10%: 720 90%: 928 10%: 624 90%: 752

45 53 47 57 44 55 46 45.8 45 43

*

*

>780F

* * *

* * * * 500

*

41.2 41.89 51.82

*

* *

*

0.73 0.81 3.37

*

* *

*

0.074 0.073 0.042

*

* *

Chem Group Chem Group / Marlotherm FP Chem Group / Marlotherm LH Chem Group / Marlotherm N Chem Group / Marlotherm SH Chem Group / Marlotherm X Chem Group / Thermaflo 660 Chem Group / Calflo HTF Chem Group / Calflo AF Chem Group / Calflo FG Chem Group / Calflo LT

47

*

52

*

50 41 40.8 41 38

0.29

*

0.41

*

0.42 0.73 0.73 0.72 0.72

0.056

*

0.053

*

0.059 0.074 0.073 0.07 0.07

*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

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J a n u a r y 2 0 1 2 • 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].

* * 0.62 0.81 0.71 0.69 0.7

*

0.06 0.05 <0.01 psi @ 20°C <0.01 psi @ 20°C

* *

No Yes Yes Yes No No No No

No No No No No No No No

0.49 0.4 0.01 0.4 0.6 15 18

5.5 5.5 6 5.5 4.4 4 3

No Yes Yes No Yes Yes No

No No No No No No No

0.69 0.69 0.69 0.69 0.74

0.06 0.1 0.07 0.06 1.02

5.2 5 5.1 5.2 5.9

No No Yes No No

No No No No No

*

3.6 2.2 0.2 0.09 26 0.23 <0.39 0.2 <0.437 <4.2

4 7 5 4 6 4.6 5.6 5.6 5.1 5.8

Yes No No No No No No No Yes No

No No No No No No No No No No

* *

0.62

*

0.63

*

0.61 0.68 0.69 0.688 0.68

Reprocessed Fluid?

Other

Synthetic

5.4 4 5.4 4.5 5.6 5.4

No No No No No

Silicone

0.5 0.13 0.02

• • • • •

*

No No No No No

Petroleum

*

0.705 0.788 0.74 0.7 0.705

*

Glycol

* *

No No No No

Fluorocarbon

* *

No No No Yes

Aromatic

* *

*

0.69 0.66 0.51

EPA regulated

5 5 5 5 5 4 5 5

0.74 0.68

Fluid Meets NSF Criteria for Food Contact

Thermal Expansion (average % per 100˚F)

* 0.72

0.07 0.06 1.83 0.06 0.03 0.02 0.34 1.02

Specific Heat** (BTU/lb-˚F @ 600˚F)

Vapor Pressure (psia @ 400˚F)

BASE STOCK

No No No No No No No No

• • • • • • • • • • • • • •

No No No

• • • • • • • • • • • • • • • • • • • • •

* * * * * * * *

*

No No No 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. 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 2 PH04104ARI.indd 1

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21

3/26/10 2:13:40 PM

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) 0.615 0.504 0.527 0.603 0.669 0.865@100°F 0.865@100°F 0.826 @ 100°F 0.828 @ 100 °F 0.867 @ 100°F 0.373 0.353

* * * * * * * * * * * * * * *

56.4 49.3 56.5 51.1 44.1 35.5 51.6 46.3 51.6 45.7 56.1 50.8 46.6 41.8 41.6 NR 42.8 NR 48.1 40.8 64.52 @ 100°F 58.14 @ 300°F 65.32 @ 100°F 59.42 @300°F 66.55 @ 100°F 61.05 @ 300°F 67.17 @ 100°F 61.80 @ 300°F 66.56 @ 100 °F 61.06 @ 300 °F

0.42 0.63 0.33 0.36 0.64 0.86 0.965 0.36 0.44 1.31 0.032 @ 100°F 0.032 @ 100°F 0.022 @ 100°F 0.022 @ 100°F 0.022 @ 100 °F

0.24 0.32 0.29 0.24 0.3 0.46 0.49 0.27 0.3 0.64 0.005 @ 300°F 0.005 @ 300°F 0.004 @ 300°F 0.004 @ 300°F 0.004 @ 300°F

0.063 0.061 0.052 0.056 0.0598 0.062 0.054 0.038 0.035 0.058 0.214 @ 100°F 0.214 @ 100°F 0.227 @ 100°F 0.227 @ 100°F 0.227 @ 100°F

0.053 0.053 0.038 0.046 0.0531 0.054 0.04 NR NR 0.046 0.214 @ 300°F 0.214 @ 300°F 0.239 @ 300°F 0.239 @ 300°F 0.239 @ 300°F

0.5 0.52 0.6 0.53 0.528 0.52 0.6 0.516 0.511 0.46 0.861 @ 100°F 0.830 @ 100°F 0.800 @ 100°F 0.793 @ 100°F 0.800 @ 100°F

730 <-200 None <-60 None -36 None -31 640 <-180 >640 <-100 >640 <-60 626 -76 842 -30 <-85 464 266

* * * * * * * * * * * *

52.0 @ 100°F 46.6 @ 300°F 82.0 @ 100°F 77.5 @ 300°F 66.2 @ 100°F 61.8 @ 300°F 64.6 @ 100°F 46.8 @ 100°F 48.0 @ 100°F 49.8 @ 100°F 47 42.4 57 52 48.5 110.5 @ 572 F 116.25@572 F

0.93 @ 100°F 1.67 @ 100°F 2.3 @ 100°F 3.1 @ 100°F 2.0 @ 100°F 5.0 @ 20°F 37.0 @ 32°F 0.54 0.88 0.222 2.32 @572F 2.1 @572 G

0.29 @ 300°F 0.75 @ 100°F 0.58 @ 300°F 0.56 @ 300°F 0.3 @ 100°F 0.37 @ 300°F 0.37 @ 300°F 0.227 @ 100°F 0.239 @ 300°F 0.214 @ 100°F 0.062 @ 100°F 0.065 @ 68°F 0.085 @ 68°F 0.32 0.07 0.064 0.41 0.061 0.053 .0713 0.271 @ 572 F 0.241 @527 F

0.45 @ 100°F 0.79 @ 100°F 0.793 @ 100°F 0.861 @ 100°F 0.465 @ 100°F 0.45 @ 68°F 0.48 @ 68°F 0.63 0.533 0.387 0.363 @ 572 F 0.353 @ 572 F

None None None None

None None None None

-60 -60 -70 -70

* * * *

65 @ 100°F 65 @ 100°F 67 @ 100°F 67 @ 100°F

* * * *

1.83 @ 100°F 1.85 @ 100°F 1.17 @ 100°F 1.19 @ 100°F

* * * *

0.22 @ 100°F 0.22 @ 100°F 0.23 @ 100°F 0.23 @ 100°F

* * * *

0.875 @ 100°F 0.875 @ 100°F 0.822 @ 100°F 0.822 @ 100°F

None None None None None

None None None None None

None None None None None

<-60 <-60 <-60 <-60 <-60

* * * * *

65.8 @ 100°F 65.8 @ 100°F 63.2 @ 100°F 63.2 @ 100°F 63.2 @ 100°F

59.9 @ 300°F 59.9 @ 300°F 57.6 @ 300°F 57.6 @ 300°F 57.6 @ 300°F

2.3 @ 100°F 2.3 @ 100°F 3.1 @ 100°F 3.1 @ 100°F 3.1 @ 100°F

* * * * *

0.24 @ 100°F 0.24 @ 100°F 0.22 @ 100°F 0.22 @ 100°F 0.22 @ 100°F

0.24 @ 300°F 0.24 @ 300°F 0.22 @ 300°F 0.22 @ 300°F 0.22 @ 300°F

0.84 @ 100°F 0.84 @ 100°F 0.88 @ 100°F 0.88 @ 100°F 0.88 @ 100°F

None None None None None None

None None None None None None

None None None None None None

<-60 <-60 <-60 <-60 <-60 <-60

* * * * * *

67 67 64 64 63.6 64

61 61 59 59 57.8 63.2

1.8 1.8 3.2 3.2 3.2 1.4

0.39 0.39 0.34 0.34 0.34 0.34

0.23 0.23 0.22 0.22 0.21 0.22

0.24 0.24 0.21 0.21 0.21 0.2

<0.83 <0.83 <0.87 <0.87 <0.85 <0.87

365 310 470 355 495 None None None None None None None

700 806 840 697 700 None None None None None None None

750 670 600 625 625 660 550 500 500 750 250 325 250 350 250

800 720 650 675 675 710 600 550 550 800 300 375 300 400 300

236 256 136 249 329 381 370 116 148 320 None None None None None

245 262 140 255

1,100 54 1,083 <40 788 <-120 773 <-40 788 -13 725 <-5 707 <-40 662 <-170 671 <-100 725 <-40 None <-60 None <-60 None <-60 None <-60 None -60

325 425 250 250 325 400 400 600 660 550 1050 933

350 450 300 300 350 425 425 644 716

127 None None None 140 >170 >230 355 392 600 None None

147 None None None 161 >190 >250 >370 456

250 315 250 245

310 370 310 400

None None None None

300 300 300 300 300

350 350 350 350 350

250 250 275 275 250 275

400 300 325 300 300 400

Density** (lb/ft3 @ 400˚F)

343 275 415 335 445 None None None None None None None

Pour Point (ASTM D97, ˚F)

640 680 700 650 640 400 400 350 370 410 1100 1000

Density** (lb/ft3 @ 600˚F)

0.0629 0.0503 0.058 0.0633 0.0692 0.217 @ 300°F 0.217 @ 300°F 0.258 @ 300°F 0.254 @ 300 °F 0.217 @ 300°F 0.35 0.3

600 640 665 600 600 345 350 300 320 360 1000 925

Distillation Range (ASTM D1160, ˚F)

0.0677 0.0587 0.0647 0.0678 0.76 0.227 @ 300°F 0.227 @ 300°F 0.230 @ 100°F 0.230 @ 100°F 0.227 @ 100°F 0.35 0.3

Autoignition (ASTM E 659-78, ˚F)

0.61 0.25 0.47 0.6 0.67 0.56 @ 300°F 0.56 @ 300°F 0.41 @ 300°F 0.41 @ 300°F 0.56 @ 300°F 1.53 3.7

Firepoint (ASTM D92, ˚F)

1.14 0.43 0.85 1.17 1.17 3.08 @ 100°F 3.08 @ 100°F 2.29 @ 100°F 2.29 @ 100°F 3.08 @ 100°F 3.85 18.62

Flashpoint (ASTM D92, ˚F)

48.7 44.3 52.5 46.5 56.2 51.4 48.1 43.5 43.2 38.6 66.6 @ 100°F 61.1@300°F 66.6 @ 100°F 61.1@300°F 64.2 @ 100°F 59.9 @ 300°F 66.7 @ 100°F 61.3 @ 300 °F 64.4 @ 100°F 60.1 @ 300 °F 120.6 115.5 129.6 124.3

Film, Maximum Temperature, ˚F

Company and Fluid Name

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.

Viscosity** (ASTM D445, cSt @ 400˚F)

Equipment Overview | Heat Transfer Fluids

Coastal Chemical Chemtherm 550 Chemtherm 650 Chemtherm 700 Thermalane 600 Thermalane 800 FluidGuard PG-USP (50% in water) FluidGuard PG1 (50% in water) FluidGuard EG (50% in water) ThermGuard (50% in water) ThermGuard PG (50% in water) HITEC HITEC XL

-50 -4 -30 -45 -80 -67 -67

10%: 609 90%: 867 10%: 516 90%: 519 10%: 690 90%: 720 10%: 622 90%: 10%: 753 90%: 850

*

* * * * *

-35 -65 290 240

Dow Chemical Co Dowtherm A Dowtherm G Dowtherm J Dowtherm Q Dowtherm MX Dowtherm RP Dowtherm T Syltherm XLT Syltherm HF Syltherm 800 Dowfrost (50% in water) Dowfrost HD (50% in water) Dowtherm SR-1 (50% in water) Dowtherm 4000 (50% in water) Ucartherm (50% in water)

* *

410

* *

380 None None None None None

Dynalene Heat Transfer Fluids Dynalene MV Dynalene HC Dynalene EG (50% in water) Dynalene PG (50% in water) Dynalene HF-LO Dynalene LO-170 Dynalene LO-230 Dynalene SF Dynalene HT Dynalene 600 Dynalene MS-1 Dynalene MS-2

Houghton Chemical Corp. Safe-T-Therm (50% in water) Safe-T-Therm HD (50% in water) Wintrex (50% in water) Wintrex HD (50% in water)

* * *

* * *

* * *

Huntsman International Jeffcool E100 (50% in water) Jeffcool E100N (50% in water) Jeffcool P150 (50% in water) Jeffcool P150N (50% in water) Jeffcool P200 (50% in water)

Interstate Chemical Co. Inc. Intercool OP-100/50 Intercool NFE/50 Intercool P-300/50 Intercool NFP/50 Intercool P-323 (50% in water) Intercool Biogreen 50/50

*

*

None

* * * * * * *

* * * *

* * * *

* * *

* * *

*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

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J a n u a r y 2 0 1 2 • Process Heating

THE ONLY THING WARMER THAN A TRENT OVEN IS THE PRAISE IT RECEIVES

* * *

* * *

* * *

No No No No No No No No No No No No

No No Yes No No No No No No No No No

* * * *

0.48 @ 100°F 0.48 @ 100°F 0.68 @ 100°F 0.68 @ 100°F

2.1 2.1 1.8 1.8

Yes No No No

No No Yes Yes

• • • •

* * * *

0.90 @ 300°F 0.90 @ 300°F 0.96 @ 300°F 0.96 @ 300°F 0.96 @ 300°F

0.71 @ 100°F 0.71 @ 100°F 0.77 @ 100°F 0.77 @ 100°F 0.77 @ 100°F

3 3 3 3 3

No No No No Yes

Yes Yes No No No

• • • • •

No No No No No

<0.9 <0.9 <0.9 <0.9 <0.9 <0.9

<0.5 <0.5 <0.7 <0.7 <0.8 <0.8

3 3 3 3 3 3

No No No No Yes No

Yes Yes No No No No

* * * * 0.72

• • • • • • • • • • •

• • • • •

• • • • • • • • • • •

• • • • •

We understand your need for reliable performance and increased efficiency. That’s why we design our ovens to outlast and outperform your expectations. For a custom or standard design and the ability to heat up to 1400°F, call us today.

* * * * * * * * * * * * * * * * * * * * * * * *Untitled-2 * * *

• • •

•

Reprocessed Fluid?

5 2.5 3 3 5 5 5 5 4

•

0.63

0.06 @ 100°F 40 @ 300°F 0.7 @ 100°F 0.8 @ 100°F 0.03 @ 100°F 0.006 @ 100°F 0.19 @ 300°F 0.3 0.09

0.59 @ 300°F 0.86 @ 300°F 0.898 @ 300°F

Other

• • • • • • •

Synthetic

Yes Yes Yes Yes No Yes Yes No No No No No Yes Yes Yes

Silicone

No No No No No No No No No No Yes No No No No

Petroleum

5.2 5.2 5.6 6.2 5.7 3.9 4.7 6 6.2 5.6 3 3 3 3 3

0.58 0.62 0.72 0.61 0.614 0.6 0.68 NR NR 0.51 0.963 @ 300°F 0.950 @ 300°F 0.903 @ 300°F 0.898 @ 300°F 0.903 @ 300°F

* *

Glycol

4 1.9 25.3 2.9 0.51 0.27 0.17 28 12.9 15.1 0.8 @ 100°F 0.8 @ 100°F 0.7 @ 100°F 0.7 @ 100°F 0.7 @ 100°F

0.34 3.745 0.2 0.3 0.073 52.08 @ 300°F 52.08 @ 300°F 66.3 @ 300°F 66.3 @ 300°F 52.08 @ 300°F

Fluorocarbon

EPA regulated No No No No No No No Yes Yes No Yes Yes

0.711 0.593 0.62 0.698 0.748 0.951 @ 300°F 0.951 @ 300°F 0.920 @ 300°F 0.923 @ 300°F 0.955 @ 300°F 0.373 0.344

Aromatic

Fluid Meets NSF Criteria for Food Contact No No No No No No No No No No No No

Vapor Pressure (psia @ 400˚F)

4 4 4 4 5 3.5 3.5 3 3 3.5 2 2

Specific Heat** (BTU/lb-˚F @ 600˚F)

Thermal Expansion (average % per 100˚F)

BASE STOCK

* * * * * * * * * * * *

We carry a full line of ovens, furnaces, heating elements and melters.

www.trentheat.com 201 Leverington Avenue, Philadelphia, PA Phone (800) 544 TRENT s Fax (215) 482-9389

MADE IN USA

1

12/14/11 2:04 PM

3++XEEHOOLQGG

No No No 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 2

|

23

Firepoint (ASTM D92, ˚F)

Autoignition (ASTM E 659-78, ˚F)

Pour Point (ASTM D97, ˚F)

Density** (lb/ft3 @ 400˚F)

Density** (lb/ft3 @ 600˚F)

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)

250 350 250 325 250 350 250 325

300 400 300 375 300 400 300 375

None None None None None None None None

None None None None None None None None

None None None None None None None None

<-60 <-60 <-60 <-60 <-60 <-60 <-60 <-60

* * * * * * * *

65.5 @ 100°F 66.0 @ 100°F 64.5 @ 100°F 65 @ 100°F 64.0 @ 100°F 65.3 @ 100°F 64.0 @ 100°F 65 @ 100°F

* * * * * * * *

* * * * * * * *

* * * * * * * *

0.23 @ 100°F 0.23 @ 100°F 0.214 @ 100°F 0.214 @ 100°F 0.214 @ 100°F 0.22 @ 100°F 0.214 @ 100°F 0.214 @ 100°F

0.237 @ 300°F 0.237 @ 300°F 0.214 @ 300°F 0.214 @ 300°F 0.214 @ 300°F 0.22 @ 300°F 0.214 @ 300°F 0.214 @ 300°F

0.813 @ 100°F 0.813 @ 100°F 0.835 @ 100°F 0.835 @ 100°F 0.835 @ 100°F 0.805 @ 100°F 0.835 @ 100°F 0.835 @ 100°F

750 700 660 650 600 550 500 550 550

800 750 710 700 650 600 550 600 600

255 251 325 275 380 350 325 445 358

265 263 332 283 420 380 350 480 410

1150 1120 842 803 680 640 625 715 660

53.6 45 -50 -40 -4 -9 -80 5 -61

* * * * * * * * 10%: 642 90%: 738

56.8 56.78 56.64 53.95 46.18 48.67 42.29 48.41 46.5

50 50.99 57.25 48.96 41.97 NR NR NR 41.1

0.421 0.44 1.05 0.44 0.798 0.709 0.709 1.48 0.96

0.257 0.26 0.55 0.26 0.375 NR NR NR 0.45

0.065 0.065 0.065 0.061 0.07 0.73 0.073 0.07 0.0619

0.054 0.054 0.058 0.051 0.065 NR NR NR 0.0542

0.492 0.5 0.547 0.543 0.627 0.701 0.701 0.672 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

550 600 620 650 725 715 750 625 450 600 600

635 650 670 705 770 750 800 675 475 650 625

350 295 340 363 365 270 255 219 147 134 390

425 310 385 414 440 290 260 235 175 150 450

650 760 765 705 1000 1085 1150 663 477 805 655

-65 -90 -44 -25 170 0 54 36 -148 -103 -20

10%: 644 90%: 734

46.5 52.2 50.9 55.1 59.3 56.9 56.8 49.8 38.1 43.8 47.3

41.1 46.2 44.6 49.7 53.6 50.6 50 41.5

0.453 0.313 0.297 0.477 0.386 0.26 0.257 0.27 0.19 0.497

0.0618 0.06 0.061 0.0608 0.0699 0.0678 0.0654 0.0538 0.044 0.0508 0.0571

0.0542 0.0513 0.0528 0.0535 0.064 0.06 0.054 0.0448

34.8 42.3

0.964 0.551 0.688 0.935 0.853 0.52 0.421 0.465 0.308 0.266 1.06

0.0374 0.049

0.612 0.547 0.565 0.528 0.492 0.49 0.492 0.562 0.684 0.588 0.625

* * * * * * * * *

* * * * * * * * *

None None None None None None None None None

None None None None None None None None None

None <-166 None <-166 None <-166 None <-73 None <-73 None -130 None -121 None -107 None -87

111.1 @ -40°F 112.4 @ -40°F 113.36 @ -40°F 114.9 @ -40°F 116.4 @ -40°F 108.6 @ 100°F 109.9 @ 100°F 111.7 @ 100°F 114.1 @ 100°F

101.8 @ 100°F 103.0 @ 100°F 103.6 @ -40°F 104.9 @ 100°F 106.3 @ 100°F 43.0 @ 300°F 94.9 @ 300°F 89.3 @ 400°F 95.5 @ 400°F

1.40 @ -40°F 1.79 @ -40°F 3.12 @ 40°F 3.74 @ -40°F 6.32 @ -40°F 1.40 @ 100°F 1.81 @ 100°F 3.10 @ 100°F 7.98 @ 100°F

0.38 @ 100°F 0.43 @ 100°F 0.63 @ 100°F 0.64 @ 100°F 0.84 @ 100°F 0.37 @ 300°F 0.44 @ 300°F 0.39 @ 400°F 0.59 @ 400°F

0.040 @ -40°F 0.040 @ -40°F 0.040 @ -40°F 0.040 @ -40°F 0.040 @ -40°F 0.037 @ 100°F 0.037 @ 100°F 0.037 @ 100°F 0.037 @ 100°F

0.037 @ 100°F 0.037 @ 100°F 0.037 @ 100°F 0.087 @ 100°F 0.037 @ 100°F 0.032 @ 300°F 0.032 @ 300°F 0.029 @ 400°F 0.029 @ 400°F

0.19 @ -40°F 0.19 @ -40°F 0.19 @ -40°F 0.19 @ -40°F 0.19 @ -40°F 0.24 @ 100°F 0.24 @ 100°F 0.24 @ 100°F 0.24 @ 100°F

350 275 325 250 275 275

400 325 375 300 325 325

None None None None None None

None None None None None None

None None None None None None

<-60 <-60 <-60 <-60 <-60 <-60

* * * * * *

* * * * * *

* * * * * *

* * * * * *

* * * * * *

0.24 @ 100°F 0.24 @ 100°F 0.22 @ 100°F 0.22 @ 100°F 0.24 @ 100°F 0.24 @ 100°F

* * * * * *

0.80 @ 100°F 0.80 @ 100°F 0.83 @ 100°F 0.86 @ 100°F 0.80 @ 100°F 0.80 @ 100°F

* * * * * *

* * * * * *

None None None None None None

* * * * * *

* * * * * *

-130 214 -121 <-166 -142 -112

* * * * * *

1.68 g/ml @ 77°F 1.77 g/ml @ 77°F 1.79 g/ml @ 77°F 1.71 g/ml @ 77°F 1.77 g/ml @ 77°F 1.58 g/ml @ 77°F

* * * * * *

0.4 cSt @ 77°F 0.8 cSt @ 77°F 2.4 cSt @ 77°F 0.77 cSt @ 77°F 1.8 cSt @ 77°F

* * * * * 0.67 cPs

57† 64† 70† 70† 70†

12.4‡

0.25 cal/g °C @ 77°F 0.25 cal/g °C @ 77°F 0.23 cal/g °C @ 77°F 0.23 cal/g °C @ 77°F 0.23 cal/g °C @ 77°F

Distillation Range (ASTM D1160, ˚F)

Flashpoint (ASTM D92, ˚F)

Company and Fluid Name

Film, Maximum Temperature, ˚F

You also can conduct your supplier search online! www.process-heating.com Click on Equipment Overview, then on heat transfer fluids.

Bulk, Maximum Temperature, ˚F

Equipment Overview | Heat Transfer Fluids

Kost USA KostChill EG (50% in water) KostChill EG HD (50% in water) KostChill PG (50% in water) KostChill PG HD (50% in water) KostChill PG FG (50% in water) BioChill 13 (50% in water) BioChill PG FG (50% in water) BioChill PG HD (50% in water)

Radco Industries Xceltherm MK1 Xceltherm LV1 Xceltherm HT Xceltherm XT Xceltherm 600 Xceltherm 550 Xceltherm 500 Xceltherm 445FP Xceltherm 315

Royal Purple Inc. Hytherm 707

Solutia Inc. Therminol 55 Therminol 59 Therminol 62 Therminol 66 Therminol 75 Therminol 72 Therminol VP-1 Therminol VP-3 Therminol D-12 Therminol LT Therminol XP

* * 10%: 658 90%: 738 * * * * 10%: 374 90%: 400 *

10%: 630 90%: 780

*

*

*

Solvay Solexis Galden HT 55 Galden HT 70 Galden HT 90 Galden HT 110 Galden HT 135 Galden HT 170 Galden HT 200 Galden HT 230 Galden HT 270

Thermal Fluid Technologies Protocol HT-50 Protocol LT-50 Protocol NT-50 Protocol FG-50 SubZero LLC-50 SubZero ELC-50

TMC Industries Inc Perfluorohexane Perfluorooctane Galden H200 Galden H110 Galden HT170 Vertrel XF

*

10%: 140 90%: 282 10%: 172 90%: 10%: 190 90%: 275 10%: 257 90%: 293 10%: 302 90%: 401 10%: 363 90%: 414 10%: 410 90%: 482

*

*

*

*

* * * * *

*

*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)

24

|

J a n u a r y 2 0 1 2 • Process Heating

NEW FULL FEATURE

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

BASE STOCK

0.90 @ 300°F 0.90 @ 300°F 0.95 @ 300°F 0.95 @ 300°F 0.95 @ 300°F 0.905 @ 300°F 0.95 @ 300°F 0.95 @ 300°F

<0.9 <0.9 <0.9 <0.9 <0.9 <0.9 <0.9 <0.9

3 3 3 3 3 3 3 3

* Yes * Yes * * * * Yes * * * Yes * * *

0.563 0.572 0.647 0.625 0.717 NR NR NR 0.705

3.95 3.76 0.0631 2.344 0.176 1.404 1.4043 0.105 0.361

5.3 5 4.1 4.2 3.5 5.2 5.2 4 5.3

No No No No Yes No Yes No No

Yes No No No No No No No No

0.747

0.073

4.8

No

No

0.705 0.64 0.612 0.628 0.552 0.562 0.563 0.683 0.719 0.718

0.36 2.14 0.584 0.37 0.52 4.97 3.94 4.99 19.5 26.5 0.29

5.3 5.3 5.6 4.6 4.5 5.5 5.4 6.7 6.2 6 5

No No No No No No No No Yes No Yes

No No No No No Yes Yes No No No No

0.24 @ 100°F 0.24 @ 100°F 0.24 @ 100°F 0.24 @ 100°F 0.24 @ 100°F 0.32 @ 300°F 0.32 @ 300 °F 0.36 @ 400°F 0.36 @ 400°F

7.43 @ 100°F 4.84 @100°F 1.78 @ 100°F 0.48 @ 100°F 0 @ 100°F 6.1@ 300°F 2.4 @ 300°F 0.80 @ 300°F 0.21 @ 300°F

4 4 4 4 4 4 4 4 4

No No No No No No No No

No No No No No No No No No

* * * * * *

<1.0 <1.0 <1.0 <1.0 <1.0 <1.0

3 3

No No No Yes No No

Yes Yes No No Yes Yes

* * * * * 0.27 cal/g °C

232 mmHg @ 25°F 29 mmHg @ 25°F <1 mmHg @ 25°F 17 mmHg @ 25°F <1 mmHg @ 25°F 226 mmHg @ 25°F

* * * * * *

No No No No No No

COMBUSTION SAFEGUARD

* * * * * * * * * *

*

• • • • • • • •

Reprocessed Fluid?

Full Feature Combustion Safeguard including: r


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• • • •

•

No No No No No No No No No

•

No

• • • •

• • • • • • • • • • • • • • • • • • • •

No No No No No No No No No No No

* * * * * * * * * • • • • • •

• • • • • •

Monitor and control burners in new, replacement or retrofit applications. Designed to reach new levels of operating control and safety.

No

•

*

Other

Synthetic

Silicone

Petroleum

Glycol

Fluorocarbon

Aromatic

EPA regulated

FORM 6642FF

* * * * * * Yes Yes Yes Yes Yes Yes

'PS
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7317 N. LAWNDALE AVE. r P.O. BOX 287 r SKOKIE, IL 60076-0287 (847) 674-7676 r CHICAGO: (773) 763-3110 r FAX: (847) 674-7009

Heaters Failing? PHCo has a Solution

These tubular heaters are clearly NOT what you want. It often results in a total and costly shutdown since replacement is usually the only solution. Contrast that to PHCo’s low watt density drywell electric heater and there’s no comparison. Not only does is not damage material or cause build up, it is longer lasting and if there is an element failure, the internal heating element can be replaced without draining the system. So, if you need to keep material at specific temperatures and are looking for a new or replacement system, be sure to contact us. These patented ETL listed elements might just be your answer to the above question. After all, we’ve been manufacturing them since 1947 with incredible success.

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].

PROCESS HEATING COMPANY P.O. Box 84585 Seattle, Washington 98124-5885 Ph: 206/682-3414 • Fax: 206/682-1582 www.processheating.com email: [email protected]

Since 1947 www.process-heating.com • J a n u a r y 2 0 1 2

PH10114ProHeatCo.indd 1

|

25

9/22/11 9:58 AM

Ovens

&

Selecting Specifying an

Oven

Having a good idea of what you are looking for in an oven is the best way to get what you need. By Ken Klein, Engineered Production Systems

O

ven building can be a challenging enterprise, especially where large industrial ovens are concerned. Small laboratory units or other small standard catalog ovens are relatively easy to help a customer select and specify — unless the customer’s requirements are completely misinterpreted. For larger units that must be designed specifically for the application, customers with clear, comprehensive requirements are the easiest to understand, respond to and provide the right type of oven. To help you become one of those customers, here is what you should be thinking about when you talk to prospective oven vendors. Airflow. In real estate, the three primary considerations are location, location and location. For a large forced convection oven, the primary considerations — as I see it — are airflow, airflow and airflow. That sounds very basic, doesn’t it? But airflow determines a number of things, including how efficiently you will heat your load, how fast you will recover after a door-open condition if you will be taking

26

|

J a n u a r y 2 0 1 2 • Process Heating

parts in and out, and the temperature uniformity you can expect to achieve. Adequate airflow is necessary to heat your product effectively. Before entertaining quotes, consider how you think it would be best to heat your product, and anything that would impede airflow through the oven. I have chatted with prospective customers who are entertaining quotes from other builders for horizontal-in-from-the-side,

This car-bottom style, direct gas-fired, stress relief furnace is designed to heat large weldments.

vertical-return-to-the-ceiling airflow patterns — when it turns out their load would block vertical airflow. Or a customer could get a quote for an oven with horizontal side-to-side airflow, yet during the heating process they will stand large panels on end that will block the flow. Give some thought up front to what you plan to heat, and how that may affect airflow, and save yourself a lot of nightmares downstream. Rate of Rise. How fast do you want to get to temperature? It is one thing to say you want to get there in 45 minutes or so if you are heating a load that does not weigh much. Heating up a 40,000 lb weldment is another story. Be realistic. Depending on the weight and nature of your load, the air temperature may get there way before the core of your product. Uniformity. What temperature uniformity do you need? If the customer does not specify a certain level of temperature uniformity, oven builders assume it is not critical enough that they may need to modify the normal design. Yet if uniformity is important, be realistic about what is really required for the process — please don’t tell the oven builder you need ±2°F temperature gradient in an oven you could move your family into. Aside from being difficult to achieve, it may make your oven unnecessarily more expensive than it has to be. Many spec writers confuse uniformity with accuracy.

Ovens • Accuracy refers to the capability of a control instrument to achieve the temperature desired, and to have the temperature at the instrument’s sensor location be stable and repeatable to within a certain tolerance. • Uniformity is largely a function of airflow. If the airflow is managed properly, the air temperature uniformity throughout the chamber will be tight, assuming the airflow is not blocked completely with the load. Most builders will state the zone in the oven in which uniformity can be expected — for example, to within what distance of the walls, ceiling and floor the uniformity will be achieved. This defines the “uniform zone.” Your builder should be up front with you in advising that. If the builder tests the uniformity before the oven leaves the shop, the builder will state that all uniformity statements and certifications apply to an empty oven at steady-state conditions. One more thing about uniformity: Where you measure temperature influences how uniform your readings are. For example, if you specify ±10°F (±5.5°C) at 300°F (149°C), can you expect the readings taken during a survey to be 290 to 310°F (143 to 154°C) throughout the uniform zone? Only

The more complex the operating parameters are, the better the case can be made for a PLC. This continuous oven is used to cure solar panels.

if you have physically located the sensor (the control thermocouple) at a point that represents the mean of all the temperature readings in the chamber. Control. Ahh…the biggest challenge for the spec writer. Pretty simple rules though: The simpler your operation, the simpler the controls should be. Take examples from one extreme to another. Suppose you are leaving the temperature in the unit at one point all day, and taking

your parts in and out several times a shift. A single setpoint controller, teamed with a door switch that shuts down the heat and circulation when the door is opened for loading and unloading, will serve the purpose. At the other end of the spectrum is an application where you need to ramp the temperature up and down at a controlled rate, acquire data from vacuum transducers and part thermocouples, and make that data available to your computer system for archiving and print out. Often, this type of application requires a graphical human-machine interface (HMI) and a PLC. In between these two extremes are the programmable controllers, which will allow the heating cycle to run automatically, ramping up, holding, cooling down and shutting off. PLC. The PLC itself is a control component that many spec writers either forget about, take for granted or have some foggy notion that lies in between. In the early years, all actions — turning on the heaters, turning them off in the event of an alarm condition, processing an alarm condition, or turning on an exhaust blower to cool the unit — were handled with relays. A large system could have a No matter what type of oven you buy, it is important to have clear and comprehensive specifications so the oven can effectively serve your application. www.process-heating.com • J a n u a r y 2 0 1 2

|

27

Ovens You will not find a PLC in a small laboratory oven or even in many small industrial units where the operating logic is simple. The more complex the operating parameters are, the better the case can be made for a PLC. Gas or Electric. One final consideration is whether the unit should be heated by gas or electricity. A sensible way to make the decision is to determine the expected power usage during the average operating day and use the local utility rates to compare costs. Another way to make the decision is by the size of the unit. On a smaller unit, electricity may be the way to go to avoid what could be a more expensive gas system that will require more maintenance. At the other end of the scale are the very large units, where the cost of the gas system will pale in comparison to the very expensive components (relays, breakers, SCRs, wire sizes, etc.) that would be needed for a unit with a lot of electrical power. Once you have given some thought to the system you need, you can contact some

daunting array of relays, usually marked in some manner that could tie them to the unit’s schematic, and they were an electrician’s nightmare. The poor fellow could spend hours with his meter trying to trace a problem and find the relay that was at fault. Then along came the PLC, a black box that took the place of all those relays. The box could be programmed with what was referred to as ladder logic. On one side of the ladder — which essentially was what a PLC program schematic looked like — was a vertical line, which represented the inputs. The line on the opposite side represented the outputs. The rungs in between the two lines were the transmitters between the inputs and outputs. So, it could be set up so that the a number of inputs — for example, power switch on and limits satisfied — had to be on before the “rung” would tell the output to be active. This output could allow the heaters to be energized, the blowers to come on, and other oven functions.

-

-

It’s Time for You to...

WEB EXCLUSIVE What Not to Do When Specifying an Oven As an over builder, we find there are three general categories of customers: the clueless messenger, the overprepared messenger, and an educated buyer. Which one will you be? READ MORE @ WWW.PROCESS-HEATING.COM

oven vendors confident that you will buy enough — but not too much — oven to handle your process effectively and even leave you some room for growth. PH Ken Klein is the president of Engineered Production Systems, a division of Engineered Product Sales Corp., Orange, Calif. For more information from EPS, call (714) 532-2742 or visit www.epsovens.com.

-

Save Money Improve Efficiency Reduce Operating Costs Lower Utility Bills

-

It’s Time for Your New...

-

Thermal Fluid Heater Steam Boiler Medium Temp Process Heaters Heating Medium: Thermal Fluids Temp Range: 350° - 650°F BTUs: 126,000 - 6,250,000

------

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Parker Boiler Co. 5930 Bandini Blvd. Los Angeles, CA 90040 (323) 727-9800 Fax: (323) 722-2848 [email protected] www.parkerboiler.com 28

|

J a n u a r y 2 0 1 2 • Process Heating

15 to 250 PSI HP: 1.5 to 150 HP

Available with: Feed Systems or DA Tanks Blow Off Tanks Softeners Chemical Feed Systems Custom Skid Mounts

Medium Temp Process Heaters Temp Range: 130° - 400°F BTUs: 300,000 - 6,800,000 Hot Water or Glycol

---

All Units Available with: Expansion Tanks with Level Controls Distribution/Air Separation Tanks Air-Cooled 400° Pumps Custom Skid Mounts Natural Gas, #2 Oil, Propane, Combination Fired, Low NOx, or Bio Fuel Firing

All Parker Boilers Use a Flexible Staggered Tube Design with 8 to 10 Pass Flow with a 25-Year Guarantee Against Thermal Shock.

Heat Exchangers

Increasing

Heat Transfer Efficiencies By Ken Kaye, Super Radiator Coils

I

ndustrial and commercial boilers are one of the largest categories of equipment in this country — and one that needs to become more efficient and use less energy. They consume a whopping 37 percent of our energy, according to a May 2010 report from the International Energy Agency (IEA), an autonomous organization, headquartered in Paris, that provides research and energy development programs to 28 member countries. The IEA also reports that 76 percent of the boilers are more than 30 years old, and about 50 percent have been converted to gas. Other industry experts say many boilers still in use date back to the 1960s and earlier. Even though conversion to natural gas has helped to make these aging boilers run cleaner and more efficiently, more must be done.

Adding economizers to existing boilers can help heat processing operators get the most out of every BTU they buy. Is it time to look at improving energy efficiency at your facility? For instance, the installed base of industrial and commercial boilers can be made to operate even more efficiently by retrofitting them with better economizers and advanced control systems. Simply stated, an economizer is a heat exchanger coil that uses exhaust gases from the boiler to preheat the incoming cold water before it is fed to the boiler itself, thereby reducing energy consumption. Unfortunately, many of those aging boilers use standard economizers that were appropriate when the equipment burned high sulfur, thick No. 6 diesel oil. However, standard economizers are not all that efficient. They were built with large-diameter tubes — so water temperatures would never

reach less than 270°F (132°C) — to minimize condensation that creates sulfuric acid when mixed with sulfur dioxide from burning diesel fuel. They also needed large fin spacing to ease cleaning that was needed to prevent clogging from ash. In addition, standard economizers weigh in at 25,000 to 30,000 lb and stand 6' tall or more.

Smaller But Mighty Today’s more efficient economizer heat exchangers use smaller-diameter tubes, small and tightly spaced fins, lighter weight (coming in around 4,000 lb) and an overall smaller size (14" high). Because the economizers take up take up less space, older boilers can be retrofit with new economizers without moving walls or raising roofs. Economizers like these are a critical part of advanced control systems such as those designed for boilers by Benz Air Engineering. The control system makes the boilers more energy efficient, lowers operating costs and reduces emissions, often without the prolonged downtime and expense of replacing the old burner. In recent years, these kinds of modifications have significantly improved boiler operations for several major California food processors, including Del Monte Foods, Pacific Coast Producers and Seneca Foods. (For more on Seneca Two stainless steel heat exchanger coils are used in the economizers for the boiler upgrades at Enwave’s district heating plant in Toronto. The horizontal manifold in front, with its input/output pipes, distributes water through the tubes and cooling fins behind the manifold. www.process-heating.com • J a n u a r y 2 0 1 2

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Heat Exchangers to less than 3 ppm and CO2 was reduced by an estimated 2,000 metric tons.

Quenching Another Hot Problem

Workers install ductwork and pipes for the housing to contain the economizer, condensing coils and other components above one of the eight boilers at the Enwave plant.

Foods, see “Meeting Mandates,” Process Heating, January 2011, or search for it on www.process-heating.com.) These same technologies also were used last year to upgrade eight massive boilers in a district heating plant operated by Enwave Energy Corp. in Toronto. Each boiler measures 45 by 12 by 14' and weighs about 65 tons. All employ a watertube design and have steam-generating capacity of 100,000 lb/hr at 390°F (199°C) and 200 psig. Combustion temperature of the

flame inside the firebox is about 2,200°F (1,204°C) and flue gas leaving the boilers is 450 to 550°F (232 to 288°C). Two of the boilers that were recommissioned in February showed a remarkable 79 to 96 percent increase in combustion efficiency. This correlates to an increased boiler output from 100,000 to 120,000 lb/hr and saves 11.5 billion BTUs per boiler, if operated for a full 170-day heating season. The exhaust temperature from the boilers was reduced from 550 to 95°F (228 to 35°C) with no pre-cooling, and the plume from the plant’s 300' stack completely disappeared. Early results also showed NOX emissions fell from 130 ppm

A round coil is used in a vacuum at G-M Enterprises to rapidly quench heat from the unit and the products inside. The closeup view shows the 90 fins/ft that enables the furnace to cool down quickly. 30

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At another installation, an unusual, customdesigned round heat exchanger coil was used. Designed with 90 cooling fins/ft rather than the standard 50 cooling fins/ft, the exchanger was a breakthrough for G-M Enterprises, which manufactures high-tech vacuum furnaces at its plant in Corona, Calif. The furnaces are used by companies that produce cell phone cases, eyeglass hinges, parts for the aerospace industry and other products, all from powdered exotic metals such as titanium, columbium and super alloys. Vacuum furnaces do not use oxygen because heating metals in a vacuum maintains the purity of the metal and prevents oxidation and imperfections. Instead, heat is transmitted to the metals by injecting an inert gas such as nitrogen, argon, helium or hydrogen into the chamber. Inert gases do not interact with powdered or solid metals. The round coil fits inside the heating chamber of the company’s vacuum furnaces, which resemble a horizontal cylinder about the size of a large pickup truck. The furnace heats up to 3,000°F (1,649°C), followed by rapid super cooling, called “super quenching.” During quenching, water is forced through the round coil at 150 to 600 gal/min to rapidly cool down the oven and the products inside faster than conventional coils mounted outside the oven. The process, called sintering, causes powdered metal to form a coherent mass and harden without melting. Also, quenching is done in an energy-efficient, closed-loop system. As the brief case histories demonstrate, economizers can help processors reuse what would otherwise be waste heat. Capturing this waste heat allows processors to squeeze as much out of every BTU they buy and run processes that are optimized for energy efficiency. PH Ken Kaye is sales and engineering manager for Super Radiator Coils, Phoenix. To learn more about coils and economizers from Super Radiator Coils, call (800) 899-2645 or visit www.superradiatorcoils.com.

Boilers

A

W E N E WHOL

By Paul Welch Goggins, Cleaver-Brooks

I

n 2011, the EPA enacted the Area Source Rule, making it mandatory for many commercial, institutional and manufacturing facilities to monitor fuel usage on a monthly basis and conduct biennial tuneups. Some facilities also are required to conduct a one-time energy assessment, and others must regularly meet emissions limits. The new rule applies to any area source facility, which includes the majority of facilities in the United States. An area source facility is one that emits less than 10 tons per year of any single air toxic and 25 tons or more per year of any combination of air toxics. A comprehensive list of the regulated air toxics can be found on the EPA website at www.epa.gov. Methods for calculating a facility’s emissions are detailed in the “Preferred and Alternative Methods for Estimating Air Emissions from Boilers” guide, also available on the EPA site. When the EPA proposed the Area Source Rule, the agency also proposed the Major Source Rule (also known as Boiler MACT or BMACT), designed to reduce boiler and process heater emissions at large sources of air toxics. Currently, the EPA is reconsidering parts of the Major Source and Area Source Rules. While it is carrying

Ensuring compliance with the EPA’s new boiler rules requires a new mindset. out the formal reconsideration process, the Area Source Rule is in effect. However, the Major Source Rule is delayed while the EPA reconsiders reconsiders it.

cess gas, landfill gas, coal-derived gas, refinery gas, hydrogen or biogas, not combined with any solid fuels. To maintain status as a gas-fired boiler, periodic burning of a liquid fuel cannot exceed a combined total of 48 hours during any calendar year. Boiler size, as it relates to the Area Source Rule, is expressed in terms of rated design heat input capacity and is measured in million British thermal units per hour, or MMBTU/hr. Boilers that are larger or equal to 10 MMBTU/hr input have different requirements than those that are smaller. The age of a boiler also is a factor in determining compliance requirements. A boiler is considered an existing source if construction or reconstruction began on or before June 4, 2010. A boiler is considered a new source if: construction or reconstruction began after June 4, 2010, and the applicability criteria was met when construction started; or, the boiler switched from firing natural gas fuel to a solid fossil fuel, biomass, or liquid fuel after June 4, 2010.

Factors that Determine Compliance Requirements Compliance requirements for the Area Source Rule — many of which take effect in 2012 — vary depending upon the type of fuel burned, the size of the boiler and its age. All area sources can be classified as one of the following fuel subcategories: • Biomass. Any boiler that burns at least 15 percent biomass on an annual heat input basis. • Coal. Any boiler that burns any solid fossil fuel and no more than 15 percent biomass on an annual heat input basis. • Oil. Any boiler that burns any liquid fuel and is not in either the biomass or coal subcategories. • Gas-Fired. Any boiler that burns gaseous fuels, including natural gas, proIntegrated boiler room controls can facilitate fuel monitoring and reporting and provide good payback in terms of energy savings. www.process-heating.com • J a n u a r y 2 0 1 2

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Boilers

Under the Area Source Rule, facilities must monitor fuel usage on a monthly basis and conduct biennial tuneups.

Meeting Compliance Requirements Under the new Area Source Rule, facilities must meter and record their fuel usage monthly. Fortunately, several products are available to help facilities monitor fuel usage. For instance, sophisticated control and monitoring systems work with an advanced supervisory control and data acquisition (SCADA) computer system to control a boiler’s room balance while gathering continuous, real-time data. If an integrated boiler room control is not the best solution for your facility, another option to consider is a standalone transmitter that provides pertinent boiler information to a PC or server within a facility’s existing network. One particular system can monitor up to three fuels per boiler. There also are monitoring systems avail32

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able that collect fuel usage on boiler systems that are not equipped with intelligent controls. For example, one model gathers data for up to two fuels per boiler, utilizing a transmitter to send the information to a PC or facility network server.

Conducting Boiler Tuneups Another requirement of the EPA rules is a boiler tuneup, which must be conducted for all biomass- and oil-fired boilers as well as for new and existing coal-fired area source boilers with a heat input capacity of less than 10 MMBTU/hr. For existing boilers, the first tuneup should be completed by March 21, 2012, and for new sources, the tuneup was to be done by May 20, 2011, or upon startup of the boiler, whichever is later. Subsequent tuneups are required every other year.

For the initial tuneup, the following steps are necessary: • Inspect the burner and clean or replace any components, as necessary. • Adjust the burner as necessary to optimize the flame pattern. • Inspect the air-to-fuel ratio control system to ensure it is calibrated and functioning properly. • Optimize emissions of carbon monoxide (CO) consistent with manufacturer’s specifications, if available. • Measure CO and O2 levels in exhaust before and after tuneup. • Record the type and amount of fuel used for previous 12 months (the effective date of the rule was May 20, 2011, so the first tuneup will have less than 12 months of reporting).

Boilers WEB EXCLUSIVE Online Compliance Assistance One manufacturer has set up an educational website to make it easier for facility managers to understand and comply with the EPA’s new rules for boilers. READ MORE @ WWW.PROCESS-HEATING.COM

• Submit a signed statement indicating that a boiler tuneup was completed. The same steps are required for subsequent tuneups. The compliance certificates should be kept at the facility and submitted upon request.

• Visual inspection of the boiler system. • An evaluation of operating characteristics of the facility. • An inventory of major systems consuming energy away from affected boiler(s). • A review of architectural and engineering plans, facility operation and maintenance. • A list of major energy conservation measures. • A list of energy savings potential. • A report detailing ways to improve efficiency. A facility must keep the results of the energy assessment on site for submission when requested.

Meeting Emissions Limits Arranging an Energy Assessment For large, existing biomass-, oil- and coalfired boilers, a one-time energy assessment is required under the Area Source Rule. The assessment must be performed by a qualified energy assessor and should include:

Under the Area Source Rule, large, coalfired boilers must meet emissions limits for CO and mercury (Hg). Existing sources have until May 21, 2014, to comply, but new sources (built or rebuilt after June 4, 2010) were required to meet the stated emissions limits by May 20, 2011. New

sources also must meet the emissions limits for particulate matter (PM). Oil- and biomass-fired boilers built prior to June 4, 2010, do not have to meet emissions limits, but those built after that date must have met particulate matter emissions limits by May 20, 2011, or upon startup. Facilities that are now required to meet stricter emissions limit requirements have several options to help meet the requirements or avoid applicability altogether. Among the options are burner conversions that can increase fuel efficiency and decrease emissions, fuel-train conversions that can help minimize or eliminate the use of oil, or a boiler replacement, which can maximize performance while minimizing emissions. PH Paul Welch Goggins is director of marketing communications and development for CleaverBrooks. The Thomasville, Ga.-based company can be reached at (800) 250-5883 or www.cleaverbrooks.com.

Spend less time searching for information and more time using it www.process-heating.com/buyersguide

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SPOTLIGHT ON PRODUCT APPLICATIONS AeroExpander Delivers Optimal Flavor, Efficiency in Snack Production Food processors are reconsidering their use of hot oil to expand snack pellets as the demand for healthy foods in the U.S. and other countries continues to grow. Expanding pellets in oil makes snacks taste and feel good in the mouth, but it also loads them with a lot of fat – up to 30 percent by weight. It’s possible to minimize oil content by using hot air to expand pellets. One challenge, however, is getting air-popped snacks to have the same flavor and mouth feel as those expanded in oil. Another is getting the same 100 percent expansion efficiency. Bühler Aeroglide in Raleigh, N.C., has developed the AeroExpander, which can do both. The units are available in 300 kg/hr,

600 kg/hr and 1,200 kg/hr capacities. The secret is in how the company managed to combine two of its core technologies – rapid heating and precision conveying. On the heating side, the unit uses dual-plenum airflow for even distribution of heated air across the processing bed and even pressure to the air nozzles. The system delivers thermal energy heat hot and fast enough to cause moisture inside the pellets to become steam, which causes them to expand. Like oil, hot air completely surrounds each and every pellet. Meanwhile, Bühler Aeroglide’s proprietary conveyor system provides highly accurate control of retention time. Total expansion reduces pellet waste and saves money, as does not having to use oil. Savings can reach up to $380,000 per year with the 1,200 kg/hr model. While oil is AeroExpander installation in Mexico for the production of better-for-you pelleted snack products.

not needed to expand the pellets, a small amount is usually added afterwards to provide the desired mouth feel and taste to the finished product.

Bühler Aeroglide Bühler Aeroglide (919) 851-2000. [email protected] www.aeroglide.com SEE OUR AD ON PAGE 17

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 6 34

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SPOTLIGHT ON PRODUCT APPLICATIONS Maximize Fluid Life with Careful Starts and Stops Regardless of system design, size or heat source, there are a few basic procedures that should be followed when starting up or shutting down your heat transfer system. Following these procedures will help maximize the life of your fluid by reducing incidents of thermal degradation.

System Start-Up A fluid at room temperature may have a viscosity higher than 100 cSt. If the system is outdoors and the ambient temperature is below 32˚F (0˚C), the viscosity could be as high as 1000 cSt, or higher. While a fluid can usually be pumped at these viscosities, it’s not yet ready for full heat. Both small electric and larger, gasfired heaters could apply heat during startup at the full rate even though the fluid is not yet prepared to take it. The fluid will be too thick to allow for efficient, turbulent flow and if a heater is allowed to fully fire during these periods it will most likely overheat and thermally degrade the fluid. The fluid is basically moving too slow through the heater under these conditions. It may not always be possible to completely avoid this situation but there are a few measures that can be taken which can help mitigate the damage to your fluid. Typically electrically heated systems will have a controller start-up option that will allow for slower, easier starts. Gas fired boilers will have a similar low fire start option. In either case, your equipment manufacturer should be able offer some guidance. If your system doesn’t have these features, slowly increase the temperature by 20°F to 30°F increments to allow for steady, even heating without overheating and thermally degrading the fluid. Consult your equipment manufacturer for help with these features.

System Shutdown When shutting your system down a few basic steps will help ensure that your thermal fluid isn’t damaged by overheating. During normal operation, your heat source will be cycling either on and off or from a low fire to a high fire in order to maintain your set point temperature. Keep in mind too that within a short period of time the boiler tubes or electric element’s chamber will become nearly as hot as the heat source itself. Therefore, it’s important to remember that your heater is actually hotter than your output temperature and if the flow is stopped, there’s a good chance it will quickly apply more heat than the fluid can handle. If a system is shut down without allowing the heat source and adjacent areas to cool before the fluid stops flowing, it can become trapped and subsequently ‘burn’ or thermally degrade. For this reason it’s important when shutting down any system to allow the fluid to cool below 250˚F (121˚C) before turning the pumps off. Using a heat exchanger or leaving your heater blower running will help speed up this cooling process.

About Duratherm Extended Life Fluid Duratherm Heat Transfer Fluids • • • • • •

-120°F to +650°F temp range Flashpoints as high as 615°F Non-Toxic, Non-Hazardous Open Bath Fluids Food Grade Fluids Heat/Cool Fluids

Duratherm System Cleaners • Clean systems while running production • Easily dissolve sludge and carbon • Large system concentrates • Pre-blended cleaners and heat transfer fluids up to 550°F • Fast-acting ‘solvent’ type cleaners

Contact Duratherm (800) 446-4910 [email protected] www.heat-transfer-fluid.com SEE OUR AD ON PAGE 51 www.process-heating.com • J a n u a r y 2 0 1 2

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SPOTLIGHT ON PRODUCT APPLICATIONS Class A Oven Handles Up to 2,800 lbs at a Time up to 2,800 lbs at a time of various automotive door and hood components. Cart-guide tracks have been added to enable safe, 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 startups.

Precision Quincy’s model No. HD5G5-7TIFG is a customized Class A oven derived from its 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 ft² and provides a maximum operating temperature of 450°F (232°C). The HD5G-5-7TIFG was custom ordered and outfitted to process and handle

Precision Quincy Corp. (815) 338-2675 [email protected] www.precisionquincy.com SEE OUR AD ON PAGE 12

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 36

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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 13

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 4 www.process-heating.com • J a n u a r y 2 0 1 2

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SPOTLIGHT ON PRODUCT APPLICATIONS Ovens, Ovens and More Ovens Thermal Product Solutions, known for its high quality ovens, manufactures industrial ovens and environmental test chambers for just about any application. Here’s a sample of what’s available: • Class 100, ISO 5 sterilizing oven is a heavy duty, fully-welded structural steel frame unit for a large pharmaceutical customer. These units are cGMP-compliant with a flush front with a host of standard features including side walls and loading tracks, HEPA filters to ensure class 100 environment, and 100% continuously heliarc-welded interior chamber seams to eliminate contamination. • Custom safety conveyor for industrial ovens are used for processes that involve solvents or combustible material where a potential explosion or fire hazard could occur. Perfect for an NFPA 86 Class A oven, as required by OSHA, the conveyor can be used to dry plastic or glass panels that will be vertically hung. The Class A oven conveyor keeps flammable vapor concentration at safe levels and provides adequate ventilation.

plastics and pharmaceuticals that require a high vacuum. The oven provides condensation-free drying in a homogenous vacuum environment with an ultimate vacuum value of 8 mm/hg. The unit dries materials using high or low temperatures, ranging from ambient to 200°C. The ZKG can also be used in applications that do not require a vacuum. • Tenney T2 temperature/humidity chamber features a non-sparking interior, intrinsic barrier and redundant over-temperature protection. The chamber design also considers requirements for OSHA, NEC, and ASME Code for Unfired Pressure Vessels. The Tenney T2 chambers have a compact design while maximizing available workspace. The temperature ranges between -70°C to 100°C while the humidity range is 20% relative humidity to 96% relative humidity.

Blue M 146 Series

cesses and testing requirements. ASTM D5423 specifies evaluation methods using a forced air mechanical convection oven to test thermal endurance of electrical insulating materials. Thermal Product Solutions, a division of SPX Corp., is a global leader in the design and manufacture of industrial ovens, environmental simulation, heat treating, photovoltaic and pharmaceutical equipment.

• Tenney ZKG thermal vacuum oven is ideal for drying chemicals, electronics, Thermal Product Solutions (800) 586-2473 www.thermalproductsolutions.com SEE OUR AD ON PAGE 15

Tenney T2 temperature/humidity chamber

Tenney ZKG thermal vacuum oven 38

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• Blue M 146 Series mechanical convection oven is ideal for a range of industrial oven applications, including ASTM D5423 testing, epoxy curing, moisture drying, UL testing, aging of electronic components and devices, and other pro-

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 objects, 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 2

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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-

Combustion Safeguards Protection Controls Inc. offers this comprehensive Service Manual covering all PROTECTOFIER combustion safeguard units. It provides important and valuable information on installation, service guides, testing and troubleshooting, as well as specifications, features and application on Protection Controls' single and multi-burner units.

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 28

GET CONNECTED www.process-heating.com/connect

Protection Controls, Inc. P.O. Box 287, Skokie, IL 60076 Tel: 847-674-7676 • Fax: 847-674-7009 [email protected] www.protectioncontrolsinc.com SEE OUR AD ON PAGE 25 40

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J a n u a r y 2 0 1 2 • Process Heating

Stay connected to the best source of useful on-the-job information in heat processing.

SPOTLIGHT ON PRODUCT APPLICATIONS Ovens and Furnaces for Every Industry, Every Application 2 Ovens: Truck-Loading Clean Room, Combo Airflow Jumbo Walk-In The truck-loading unit No. 1010 is an electrically-heated 500°F (260°C) cleanroom oven from Grieve currently used for curing plastic mesh at a customer’s facility. Workspace in this oven comprises two chambers, each 34" W x 54" D x 72" H. 80 kW are installed in Incoloy-sheathed tubular elements to heat the workspace, while a 10,000 CFM, 7½ HP recirculating blower provides horizontal airflow to a common central duct system. This Grieve clean-room oven features 4" thick insulated walls, Type 304 2B finish stainless steel interior with continuously back-welded seams, stainless steel exterior with #4 brushed finish, 24" x 24" x 6" thick HEPA fresh air filter with 2” pre-filter, thus no internal filtration is needed. Shelf trucks with supports on 2" centers, as well as a transfer dolly with oven-to-dolly latch and dolly-to-truck latch, also are provided with this unit for easier load handling. No. 1010 includes a digital programming temperature controller, 10" dia circular chart recorder and SCR power controller onboard.

The truck-loading No. 1010 is an electrically-heated 500°F (260°C) cleanroom oven from Grieve currently used for curing plastic mesh at a customer’s facility. The two chambers measure 34” W x 54” D x 72” H each, and 80 kW are installed in Incoloy-sheathed tubular elements to heat the workspace, while a 10,000 CFM, 7½ HP recirculating blower provides horizontal airflow to a common central duct system.

The No. 999 is an electrically-heated 350°F (176°C) jumbo combination walk-in oven currently used for curing composite parts. Workspace dimensions are 10’ W x 40’ D x 8’ H, and 160 kW are installed in Incoloy-sheathed tubular elements to heat the unit, while two 20 HP recirculating blowers with total 49,500 CFM capacity provide combination airflow to the load.

Also from Grieve, the No. 999 is an electrically-heated, 350°F (176°C) jumbo combination walk-in oven being used for curing composite parts at the customer’s plant. Workspace dimensions measure 10' W x 40' D x 8' H, and 160 kW are installed in Incoloy-sheathed tubular elements to heat the unit, while two 20 HP recirculating blowers with total 49,500 CFM capacity provide combination airflow to the load. The oven features 4" insulated walls throughout, removable top-mounted heat chamber (shown removed in photo), aluminized steel interior and exterior, front and rear double doors with air-operated opening-assist plus an 8" x 10" double pane Pyrex window in each door, 1/4" thick plate floor and four interior oven lights. The unit was split into six sections for installation clearance at the customer’s factory. No. 999 is equipped with all safety equipment for handling flammable solvents, including explosion-venting door hardware, 2,600 CFM powered forced exhauster and motorized dampers on intake and exhaust for accelerated cooling. The unit is built to NEMA 12 electrical standards.

Controls on this Grieve jumbo combination walk-in oven include a digital programming temperature controller, strip chart recorder, SCR power controller and 10 digital countdown timers.

Grieve Corp. [email protected] www.grievecorp.com SEE OUR AD ON PAGE 7

www.process-heating.com • J a n u a r y 2 0 1 2

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41

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 14

Spend less time searching for information and more time using it www.process-heating.com/buyersguide

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BROWSE Get the free mobile app at

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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.

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 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 11 www.process-heating.com • J a n u a r y 2 0 1 2

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43

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 2 • 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 & 52

an Astec Industries Company

www.process-heating.com • J a n u a r y 2 0 1 2

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45

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.

Indexing Oven Cures Coatings Gas-fired, three-lane oven with an indexing cart drive system is used for curing coatings on parts for wind turbines. The parts are a mix of steel and alloy with the largest weighing 300 lb. The industrial oven has a production rate of 40 carts per hour. The customer required a 25-point temperature uniformity of ±15°F (8°C) at 140°F (±60°C). A flash-off section utilizing a tubeaxial blower removes solvents that are released during the curing process. The recirculation system utilizes adjustable louvers, direct-drive blowers and a combination airflow design to maximize heating rates and temperature uniformity of the product. Wisconsin Oven • (262) 642-3938 • www.wisoven.com

ume air supply and exhaust fan for moisture removal. A set of removable filters for the recirculating air maximizes clean airflow and eases maintenance. The dryer is capable of producing up to 2,400 lb of extruded snack products per hour. Lanly Co. • (216) 731-1115 • www.lanly.com

500°F Rotary Hearth Oven No. 816 is used for preheating and curing powder coatings onto electric motor parts. Workspace dimensions on 500°F (260°C) gas-fired, rotary hearth oven measure 54 x 54 x 72", and 350,000 BTU/hr are installed in a modulating gas burner. A 4,200-cfm, 3-hp recirculating blower provides horizontal airflow to the workload. Grieve Corp. • (847) 546-8225 www.grievecorp.com

Wireless Cellular Controller Model T925 connects to remote equipment through cellular networks, eliminating the need for hardwired connections. It allows end users, machine and skid builder OEMs, RTU and SCADA OEMs, security monitoring system OEMs and other firms to monitor and control the automation and monitoring systems through the cellular network at sites thousands of miles away. Typical applications include pipelines, pump stations and electrical substations. Xenon Inc. • (866) 571-8595 • www.xenoninc.com

Oxygen Probe The revamped design of the Endura AZ20 offers an increased choice of probe lengths compared to previous probes from the company and models suited for high temperature applications up to 1,472°F (800°C). Manufactured using a ceramic-to-steel bonding process, the probe offers improved resistance to thermal stresses and shocks compared to a conventional brazed design, says the company. ABB Instrumentation (215) 674-6580 • www.abb.com/instrumentation

Wireless Data Recorder Intended for Type J, K, S and T thermocouples, Model TR-505TC can measure and record temperatures from -326 to 2,372°F (-199 to 1,300°C). It has 15 recording intervals from 1 second to 60 minutes and a capacity to store 16,000 readings. Additional features include a large LCD display, IP64 water resistance and battery life up to 4 years. TandD Corp. • (518) 669-9227 www.tandd.com

Large-Capacity Steam Generator Model FC-OSSG design includes an elevated steam drum with large water holding capacity that manages load swings and ensures high-steam quality (99.5 percent). The forcedcirculation oil sands steam generator has water-cooled membrane furnace walls with minimal refractory. Engineers have designed the boiler with the correct water/steam circulation ratio to ensure a proper two-phase flow with all internal surfaces sufficiently water wetted. The product is scalable to 500,000 lb/hr and achieves a 10:1 turndown. Cleaver-Brooks • (800) 250-5883 • www.cleaverbrooks.com

Snack Food Dryers Model 2500 includes a 50" wide, balanced-mesh-weave type 304 stainless steel conveyor belt. The dryer utilizes a natural gas burner with top-down, high vol46

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J a n u a r y 2 0 1 2 • Process Heating

Event Recording, Alarm Annunciation System Model Y-Plant Alert offers alarm event sequence-of-event recording and annunciator functions. Alarm events are time stamped with one millisecond resolution. Features

Product Highlights

WE KNOW ELECTRICITY

include plug-and-play installation with minimal to no wiring changes required; event storage in a SQL database format that eases report generation, including customized reports; and security of buffering alarm events in the high speed I/O system in case of PC failure. Yokogawa Corp. of America (800) 888-6400 • www.yokogawa.com/us

Gas Calibration Kit Model GCK-200CO-2000CO2 provides a reliable flow of carbon monoxide and carbon dioxide to calibrate the company’s gas sensing transmitters. Every kit includes a span gas of 200 ppm carbon monoxide and 2,000 ppm of carbon dioxide; a reference gas of 99.99 percent nitrogen; a 0.5 liters/min flow regulator and tubing. For convenient transportation, each gas calibration kit is packaged in a hard carrying case. A certificate of analysis and material safety data sheets are included for both gas cylinders. Dwyer Instruments Inc. (800) 872-9141 • www.dwyer-inst.com

Free Literature

Questions about SCR power control systems? We can help. • • • • •

Fusing Cooling Heatsink Design Voltage protection Application assistance

For more than 40 years we have been designing and building SCR controls for hundreds of thousands of users like you. For answers to your solid state control questions

Call 1-800-331-1345 Box 70 Scott Depot, WV 25560-0070 Fax: 304-757-7305 [email protected] www.payneng.com

ARI Valve

Ovens and Furnaces

Metal Fiber Burners

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.arivalve.com.

The Grieve Corporation offers its recently expanded 100-page, full-color catalog of ovens and furnaces. New equipment, new market applications and an increased factory-trained sales representative network are all highlighted in this catalog from Grieve, a leader in ovens and furnaces since 1949. Ph: 847-546-8225. Fax: 847-546-9210. www.grievecorp.com

Micron Fiber-Tech produces metal fiber burners to custom demands in all shapes whether cylindrical, rectangular, concave, etc. Specializing in low NOx performance, our burners boast exceptional reliability, including hydrogen gas. www.mft-co.com

New Catalog of Solid State Controls

Immersion Heaters

Protectofier Service Manual

Use Process Heating Co.’s low-watt density, dry-well style immersion heaters for temperaturesensitive 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.

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

Short form catalog describes the most complete line of solid state motor and power controls with ratings to 1,200 amps, 600 volts. Single phase and three phase, zero-fired and phase angle controls, relays, motor soft-starters, reversing starters, and contactors are all available. Payne Engineering. 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.

Industrial Heating Solutions This brochure provides a unique overview of many kinds of industrial heating solutions, demonstrating that there is a wide range of applications where electrical heat can not only meet manufacturers’ needs, but provide uniform and cost-effective solutions to production challenges. PH: 800-544-TRENT. Trent. Website: www.trentheat.com www.process-heating.com • J a n u a r y 2 0 1 2

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47

PH Classifieds

Display Classified Rates: 1X $100 • 3X $95 • 6X $90 • 9X $85 • 12X $80

Equipment for Sale

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. z

z

Rebuilds z Retrofits z Combustion Controls z

Control Panels z Thermal Profiling z Ovens z Burners z Elements z

t: 905-356-1327

f: 905-356-1817

e: [email protected]

www.can-eng.com

Contact: JOE SALIBA (ext:2058) z KIM IAMARINO (ext:2037) z ANNA ROLFE (ext:2056)

HEAT EXCHANGERS ▼

Liquid Cooled

The Next Generation

Air Cooled FOR

▼

PROCESS HEAT

GASES & LIQUIDS!

Talk Directly with Design Engineers! LHS Air Heater

Blower Cooling

Vent Condensing

Built-in thermocouple with digital temperature readout

Upgrade your LE to a Next Generation LHS air heater today www.leisterusa.com Toll-free: (855) Leister [email protected]

(952) 933-2559 [email protected]

GET CONNECTED www.process-heating.com/connect

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Company

Phone

21

ARI Valve

17

Buhler Aeroglide

51

0109SUB Jan-1201SUB

Fax

Web

E-Mail

770-933-8845

770-933-8846

www.arivalve.com

[email protected]

919-851-2000

919-851-6029

www.aeroglide.com

[email protected]

Duratherm Extended Life Fluids

800-446-4910

905-984-6684

www.heat-transfer-fluid.com

[email protected]

8

Fulton Thermal Corp.

315-298-7182

315-298-5311

www.fulton.com

[email protected]

9

Fulton Thermal Corp.

315-298-7182

315-298-5311

www.fulton.com

[email protected]

7

Grieve Corp.

847-546-8225

847-546-9210

www.grievecorp.com

[email protected]

21

Grieve Corp.

847-546-8225

847-546-9210

www.grievecorp.com

[email protected]

2

Heatec

423-821-5200

423-821-7673

www.heatec.com

[email protected]

52

Heatec

423-821-5200

423-821-7673

www.heatec.com

[email protected]

23

Hubbell Electric Heater Co.

203-378-2659

203-378-3593

www.hubbellheaters.com

[email protected]

14

Karl Dungs Inc.

732-582-1744

763-582-1799

www.dungs.com/usa

[email protected]

13

Micron Fiber-Tech

386-668-7895

386-668-7462

www.mft-co.com

[email protected]

13

MultiTherm

610-408-8361

610-408-8365

www.multitherm.com

[email protected]

3

Omega Engineering Inc.

203-359-7815

203-968-7192

www.omega.com

[email protected]

11

Paratherm Corp.

610-941-4900

610-941-9191

www.paratherm.com

[email protected]

28

Parker Boiler Co.

323-727-9800

323-722-2848

www.parkerboiler.com

[email protected]

47

Payne Controls

304-757-7353

304-757-7305

www.payneng.com

[email protected]

16

Petro-Canada Lubricants

905-804-3631

905-804-3619

http://calflo.com/family.htm

[email protected]

12

Precision Quincy Corp.

815-338-2675

815-338-2960

www.precisionquincy.com

[email protected]

25

Process Heating Co.

206-682-3414

206-682-1582

www.processheating.com

[email protected]

25

Protection Controls

847-674-7676

847-674-7009

www.protectioncontrolsinc.com

[email protected]

6

Super Radiator Coils

804-378-1367

804-379-2118

www.superradiatorcoils.com

[email protected]

15

TPS-Gruenberg

570-538-7200

570-538-7380

www.thermalproductsolutions.com

[email protected]

23

Trent Inc.

215-482-5000

215-482-9389

www.trentheat.com

[email protected]

4

Wisconsin Oven

262-642-3938

262-363-4018

www.wisoven.com

[email protected]

12/18/08 12:05:59 PM

www.process-heating.com • J a n u a r y 2 0 1 2

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Places & Faces Yokogawa Corporation of America, Newnan, Ga., released a new Sensor Wiring Guide that includes all sensors and analyzers designed and supported by Yokogawa across its liquid measurement product line. The guide can found on its analytical home page or via http://bit.ly/rI5wYL.

Marsh Bellofram Group acquired the product line assets of King Engineering Corp. Inc., Ann Arbor, Mich., a manufacturer of liquid level measurement and inventory tank gauging systems, including related air-filtration components. King Engineering manufacturing operations have been moved to Marsh Bellofram global corporate headquarters in Newell, W.V.

John J. Ghirardelli was appointed to the board of directors for Paul Mueller Co., Springfield, Mo.

Spirax Sarco, Blythewood, S.C., a provider of steam solutions to industry, received both platinum and gold marketing communications awards for best overall digital magazine from the International Association of

Marketing and Communication Professionals, Arlington, Texas. The company received the Platinum MarCom Award for Steam News, its digital magazine, and the Gold MarCom Award for its trade advertisements promoting the electronic publication. Winners were selected from more than 200 categories in seven forms of media and communication efforts. Tracy Britt is the company’s marketing communication coordinator.

Kason Corp., Milburn, N.J., launched a new website at www.kason.com to show its vibratory bed products such as dryers, coolers and moisturizers.

Ghirardelli joins the board effective January 1, 2012, to fill seat vacated by William R. Patterson, who retired.

Sam Directo, the owner of Directrik Inc., Mississauga, Ontario, was named best sales representative by DDI Heat Exchangers, Hollywood, Fla.

Carlos Cabrera, president and CEO of National Institute of Low Carbon and Clean Energy, Beijing, joined the board of directors at the Gas Technology Institute, Des Plaines, Ill.

Among Directo’s accomplishments was winning an order for an additional two heat exchangers sales in the Niagara region, to the city of Welland.

ABB, Zurich, a power and automation Cleaver Brooks, Lincoln, Neb., established a help desk to help companies navigate the new EPA rules for boilers. Visitors to cleaverbrooks.com/epa can follow a simple three-step process to determine the right category for each of their boilers and learn more about the associated compliance requirements.

BASF Automotive Refinish, Southfield, Mich., named Vitor Margaronis marketing director for BASF Coatings, North America. 50

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J a n u a r y 2 0 1 2 • Process Heating

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technology group, won a more than $15 million order to supply integrated automation and power equipment and related engineering and commissioning services to JK Paper Ltd., Delhi, for its expansion project at JK Paper Mills, in Rayagada, India.

AUDIENCE DEVELOPMENT

The Portland, Ore., Beaver Bag Plant of International Paper, headquartered in Memphis, is celebrating its 50th anniversary of producing environmentally friendly paper bags. “Our bags are a great environmental choice as they are recyclable, reusable and produced using renewable resources,” says Ron Gale, plant general manager.

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Audience Development Specialist • CHRISTINA ROTH Multimedia Specialist • MAGGIE LEE Corporate Audience Audit Manager • CATHERINE M. RONAN

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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.

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