Process Heating November 2011

www.process-heating.com | November 2011 | Volume 18, Number 11

On the

SPOT Wh th constructed Whether t t d iinto t assemblies bli or used d as bare devices, temperature sensors play an essential role in many processes. Use our Equipment Overview to find manufacturers of these essential tools.

Periodical Class

16 Recovering Waste Heat 21 Temperature Measurement Strategies

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.

HEATEC

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INDIRECT AIR HEATERS

F O R S P R AY D R Y I N G

Engineered to meet the demanding requirements of the dairy industry, ER Indirect Air Heaters deliver clean, ccontaminant-free indirect heat for spray drying processes. The robust construction and all welded heat exchanger T provide the performance and durability you need for p ttrouble-free operation. Plus, they are compact, with a ssmaller footprint than competing heaters. For over 20 yyears, we’ve been helping customers improve their drying processes with ER Indirect Air Heaters. d

For more information visit: www.eclipsenet.com/erheaters/

Industrial Grade

Gasification Commercially Proven. Reduces Emissions. Scalable To Your Project. Available Now. Our technology can lower your price of fuel up to 50 percent PHG’s new generation of downdraft gasification equipment solves financial and environmental problems by providing a steady supply of clean burning fuel gas. This energy can be converted from waste material that would otherwise have been landfilled…or from renewable biomass sources. Find out more…and contact us for an initial benefit analysis and to discuss feedstock options:

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November 2011 Volume 18 • Number 11

www.process-heating.com WEB EXCLUSIVES: READ MORE AT WWW.PROCESS-HEATING.COM Q Waste Heat Recovery System Considerations

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Q Best Practices for Infrared Temperature Measurement

Thermal Fluid Heaters More Than Meets the Eye

16

To get the best noncontact measurements, follow these guidelines.

UPDATED DAILY

When heating millions of gallons of liquid asphalt, a complete thermal fluid heater package is essential.

Q New Products

Heat Recovery

Q Archives Q Calendar of Events Q Drying Files columns

A Key Issue Energy recovery as related to energy optimization is one of the key issues of our times. This involves both optimizing efficiency and ensuring environmental protection by reducing CO2 emissions. However, the key to success in this application is the ability to accommodate partial- or full-load operation in a harsh environment.

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Q Upgraded Software Provides Up-to-Date Features The controls manufacturer helped design of a software tool that allows dryer users to update the equipment from a website.

Features 14

In terms of return on investment, the waste heat flow stream needs to have a certain temperature and volume to justify the installation of a waste heat recovery system.

Q Industry News

ALWAYS ONLINE Q Energy Notes column Q Equipment Overviews Q Heating Highlights

Q Digital Editions Q Buyers Guide Q Archived Webinars

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

NETWORK WITH PROCESS HEATING! Quick links on www.process-heating.com/connect point the way.

Process Controls Time for an Upgrade The automation system for one company’s continuous flow dryers was redesigned to help farmers handle wetter grains, and the revamped controls, combined with tailored dryer design, result in effective grain drying.

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Temperature Sensors Temperature Measurement Strategies Understanding infrared thermometers and using them properly in industrial applications goes a long way toward improving the process and product.

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Equipment Overview: Temperature Sensors On the Spot Whether constructed into assemblies or used as bare devices, temperature sensors play an essential role in many processes. Use our Equipment Overview to find manufacturers of these essential tools.

Columns & Departments 6 Editor’s Page 8 Inner Workings 13 Calendar

26 Advertiser Index 28 Classified Directory 30 Places & Faces

Q Go Mobile 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 At times, a bare sensor is a good choice for measuring process temperatures. At others, temperature transmitters, thermowells and other devices are used with the sensor to provide more complete, stable and reliable control. For one application, Ametek Test & Calibration Instruments (www.ametekcalibration.com), Allerød, Denmark, prepared an array of temperature sensors in assembly with a built in two-wire transmitter (red), shown here without the protective lid mounted. For more information about temperature sensors, turn to page 24.

PROCESS HEATING (ISSN 1077-5870) is published 12 times annually, monthly, by BNP Media, 2401 W. Big Beaver Rd., Suite 700, Troy, MI 48084-3333. Telephone: (248) 362-3700, Fax: (248) 362-0317. No charge for subscriptions to qualified individuals. Annual rate for subscriptions to nonqualified individuals in the U.S.A.: $115.00 USD. Annual rate for subscriptions to nonqualified individuals in Canada: $149.00 USD (includes GST & postage); all other countries: $165.00 (int’l mail) payable in U.S. funds. Printed in the U.S.A. Copyright 2011, by BNP Media. All rights reserved. The contents of this publication may not be reproduced in whole or in part without the consent of the publisher. The publisher is not responsible for product claims and representations. Periodicals Postage Paid at Troy, MI and at additional mailing offices. POSTMASTER: Send address changes to: PROCESS HEATING, P.O. Box 2146, Skokie, IL 60076. Canada Post: Publications Mail Agreement #40612608. GST account: 131263923. Send returns (Canada) to Pitney Bowes, P.O. Box 25542, London, ON, N6C 6B2. Change of address: Send old address label along with new address to PROCESS HEATING, P.O. Box 2146, Skokie, IL 60076. For single copies or back issues: contact Ann Kalb at (248) 244-6499 or [email protected].

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By Linda Becker

Commentary Incentives Abound to Encourage Less Energy Use

Tools for Success Every state in the nation has a website that allows consumers to find out whether the state is holding some money for them. For instance, in my home state of Wisconsin, I searched the database and found that a typographical error in my address meant a rebate I had filed for long ago had been turned into the state’s unclaimed property department. Getting the money back is fairly easy — I only need to request, fill out and return some forms, and the money should be on its way to me. And for $50, I think it’s well worth the effort. But it got me thinking about rebates and the incentive they provide to encourage us to act. There may be money out there waiting for you to find it — and not only as a consumer. Corporations can gain access to rebates and incentives. • The Database of State Incentives for Renewables and Efficiency is funded by the U.S. Department of Energy and is an ongoing project of the North Carolina Solar Center and the Interstate Renewable Energy Council. At www.dsireusa.org, you can search for local, state, federal and utility incentives that promote renewable energy and energy efficiency. Many of the offers

pertain to manufacturing companies. On the website, users will find menu items like frequently asked questions, a glossary, search by state using a map of the United States, and even ways to customize the directory to shorten your search time. • Companies interested in combined heat and power (CHP) systems and biomass/biogas projects may qualify for federal and state incentives. According to http://www.epa.gov/chp/funding/ funding.html, CHP and biomass/biogas funding opportunities include financial incentives such as grants, tax incentives and low-interest loans as well as and tradable allowances. Also, don’t forget to look for regional and state incentives as well. For instance, the Southeast Energy Efficiency Alliance promotes energy efficiency in the Southeastern region of the United States. Check out its incentives database at www.seealliance.org/database.php.

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

SCRs Need Heatsinks SCRs generate heat. Up to 2 watts/amp per phase. This heat must be dealt with or it will destroy your control. All Payne Engineering controls have integral heatsinks designed, tested, and proven at 50° C ambient to dissipate the damaging heat produced by semi conductors without fans or derating curves.

Only Payne Engineering controls have these exclusive “Silicon-Protection” features • 2ms semiconductor fuses • Vbo voltage protection • 50°C ambient heatsinks that ensure long, reliable, trouble-free service. Nearly 40 years of experience designing, building and applying trouble-free SCR controls.

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

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Inner Workings

Single-End Tubular Heaters Control Mercury Emissions A maker of smoke-stack sampling equipment for power and process industries needed some help meeting the U.S. Environmental and Protection Agency’s rules. Under the Clean Air Act, the EPA requires all coal-fired electric generating plants to monitor and report mercury emissions from their stacks. Coal-fired plants are the single largest source of mercury emissions in the country. To

meet the requirements, accurate measurement devices are a necessity. The amount of monitoring needed at a particular source plant is a function of its current output levels. In some cases, high levels of mercury emissions require continuous monitoring. Accurate measurement is most critically affected by one thing: the amount of moisture content in the gas. It is imperative to keep the sampling draw on the stack gas above the dewpoint to prevent condensation and measurement variance. NIST–traceable calibration standards from the National Institute of Standards and Technology are used for maximum accuracy, and readings are taken based on a dry-standard cubicmeter basis for the gas sample. A power plant specified single-end

tubular heaters from Pittsburgh-based Chromalox to keep the stack-probe gas temperature sampling tube dry and the measurement error-free. The design also extended probe life by protecting against corrosion that could be caused by condensation. For continuous monitoring operation environments, using heaters like those from Chromalox could make the difference between the ability to ratify compliance data without interruption and having a gap in data recording that could result in costly fines to the site owner. For more information on Chromalox heat and control products, go to www.chromalox.com.

Digital Magazine Focuses on Steam Use Steam News, a digital magazine, provides plant managers with editorial, steam tips and training opportunities to help improve plant production. Promoting sustainability and energy

THERMAL FLUID HEATERS Proven Solutions Since 1851

Stuthers Wells, a division of TEi, stands the test of time by setting global standards of excellence in the design and manufacture of custom built Fired Heating Systems and Waste Heat Recovery Boilers. With a size range of 3 mmBtu/hr to more than 120 mmBtu/hr and thermal fluid applications of Dowtherm®, Therminol®, Syltherm®, Molten Salt, Liquid Metals and more, our experienced engineers and dedicated project teams helped fabricate over 2,500 plus process-fired heaters and 1,000 direct-fired HTF heaters. We are committed to maintaining the legacy by continuing to provide proven solutions in all applications of fired heater technology to the Chemical, Petrochemical, Petroleum and Power industries.

Struthers Wells is a division of Thermal Engineering International (USA) Inc. which is a Babcock Power Inc. company.

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8825 N. Sam Houston Pkwy. West, Houston, TX 77064 TEL 281.664.8020 | FAX 832.237.8758 | [email protected]

www.StruthersWells.com

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Gas Burner Products • • • • •

Tubular burner Gas IR burner Hydrogen burner Ribbon burner Box burner

Heat: 9-50,000,000Btu/H Single digit NOx emission Premix Atmospheric IR. Metal fiber matrix Made in USA

Inner Workings efficiency, the electronic magazine from Spirax Sarco, Blythewood, S.C., comes out quarterly, offering plant managers, engineers in manufacturing industries, and facility and operations professionals practical information they can use in their jobs. According to Spirax Sarco, the goal is to provide readers with information and solutions to make informed decisions relating to the needs of their steam system facility. Articles in Steam News will focus on industry topics, and the digital magazine will product information. It also will include information about promotions and company news at Spirax Sarco. The company says “we guarantee that the material presented will attract serious reader attention.” To subscribe to the nocost publication, visit www.spiraxsarco.com/us.

Unusual Annealing, Aging Oven Built

230 Springview, Commerce Dr. S100, Debary, FL 32713 Tel: 386-668-7895 • www.mft-co.com

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Despatch Industries, Minneapolis, received an order for an aluminum annealing and aging oven system from a large supplier of commercial airplane assemblies and components. In addition to the oven, the customer also has ordered a custom process control package and a data monitoring and recording system. The equipment will heat treat aluminum parts for increased strength and ductility. The oven has a pass-through design with swing doors, side-mounted heater boxes and a 12 x 12 x 14' chamber. The 10:02 AM oven’s airflow configuration is “vertical down” with temperature uniformity specification of ±9°F (±5°C). Despatch also is providing several additional components to the oven system, including a custom process control package, trucks and rails and a jib crane at the front and back of the oven to load and unload parts from the truck. “Despatch has a long history of providing critical heat processing equipment to commercial aerospace component suppliers,” says Rolf Kragseth, Despatch applications engineer.

4' Dryer Replaces 56' Unit

Problems can’t hide from the

Wahl Heat Spy! Searching for clues not visible to the naked eye? Uncover them with the New Wahl Heat Spy Thermal Imager. The first camera upgradeable with up to 15 configurations after purchase, it is the most advanced weapon in its class to help eliminate the threat of energy loss and equipment downtime. Visit wahlheatspy.com to investigate today! CAUTION

CAUTION

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Phone: (800) 421-2853 Email:[email protected]

The current generation HTI Spectra HE ultra drying system from Heat Technologies Inc., Atlanta, has been installed at a customer plant to dry heavy water- and solvent-based coatings. The approximately 4' long system fully replaced the customer’s existing 56' dryer. Yet, at the same coating and adhesive coverage, and for water-based applications, the Spectra HE provided the required drying without use of external heaters, says the manufacturer. Average operating temperature of the hot air delivered by the system is lower by about 50 to 70°F (28 to 39°C) than the hot air delivered by the existing system. For more information on HTI drying systems, go to www.heattechnologiesinc.com.

Website Redesigned for 61st Anniversary Bishop-Wisecarver Corp., Pittsburg, Calif., has launched its new website to celebrate the company’s 61st anniversary. The

Inner Workings manufacturer of the DualVee guide wheel used in motion technology redesigned its website to provide more detailed product information organized in tabbed sections, richer photography, embedded videos, social media, digital catalogs for web view before download, site search and improved part search. Customers now can search by specific part numbers or drop-down menus of product categories with descriptions. In the weeks to follow, the company will apply the new design to its Spanish and Chinese websites to create one online experience for all users. Other additions will include enhanced customer participation and interactive product support. Check out the redesign at www.bwc.com. For live news and updates, follow Bishop-Wisecarver at twitter.com/bwcnews.

Emerson to Automate Arthritis Drug Plant Hanwha Chemical, Seoul, has selected Emerson Process Management, Austin, Texas, to supply and commission its DeltaV digital automation system for a pharmaceutical production facility in Osong Bio-technology Technopolis, Chungcheongbuk-do, Korea. Known as the Eagle Project, the facility will manufacture Hanwha’s biosimilar rheumatoid arthritis drug HD203. The DeltaV system will play a key role in automating the facility’s biotechnology process and support the compliance requirements for FDA approval. Project completion is planned for 2012.

Flexible Temperature Sensor Saves Time and Money WATCH the WORM Temperature Sensor Technology Demo!

www.miinet.com/theworm Universal WORM Sensor Installs in Minutes. Replace your temperature sensors without disassembling your thermowell! Unlike straight sensors, the innovative WORM flexible sensor bends and slides right into a thermowell without having to remove the transmitter enclosure or assembly components. • Trims to fit any thermowell length up to 36 inches (longer lengths available). • Ideal for hockey-puck, connection head, and dual-sided enclosures. • Popular RTD and thermocouple sensor types. • Delivers faster response time than straight sensors.

www.miinet.com www.process-heating.com • N ove m b e r 2 0 1 1 Moore Industries_ProcessHeating_hlfpg_vert_11-2010_REV2.indd 1

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Inner Workings

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The 2,900-I/O Eagle Project will consolidate its plant process using an integrated system of Emerson’s DeltaV S-Series, AMS Suite asset management software, and audit/change control functionality that supports validation requirements. Emerson will provide a total of 34 electronic marshalling panels, 10 operator workstations installed in the clean room process areas, five manager workstations and five server stations. The server stations will be used for the process historical data collection, alarm management, complete batch control and diagnosis of the engineering and control systems. According to Emerson, electronic marshalling will not only reduce site construction time and cost, but also provide a complete solution for future I/O expansion and plant management because it can be installed in the proximity of devices in the process area and provide the ultimate in flexibility, allowing users to choose I/O type on a channel-by-channel basis. Emerson’s AMS Suite asset management software will be used during installation of measurement and control devices to help reduce costs and improve device start-up efficiency. The Hanwha Chemical pharmaceutical production facility in Korea will use a Emerson Process Management digital automation system.

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Calendar of Events December 13-15 — Power-Gen International, Convention Center, Las Vegas. Call (918) 831-9160 or visit www.power-gen.com.

January 2012 23-25 — AHR Expo, McCormick Place, North and South Halls, Chicago. Held in conjunction with ASHRAE Winter Meeting. Call (203) 221-9232 or visit www.ahrexpo.com. 24-26 — International Poultry Expo, Georgia World Convention Center, Atlanta. Hosted by U.S. Poultry & Egg Association. Call (770) 493-9401 or visit www.internationalpoultryexposition.com.

February 5-8 — Biodiesel Conference and Expo, Orlando, Fla. Call (800) 841-5849 or visit www.biodiesel.org. 5-9 — Cooling Technology Institute (CTI) Annual Meeting, Hilton Hotel, Houston. Call (281) 583-4087 or visit www.cti.org.

Applied Spectroscopy Inc. (Pittcon). Call (412) 825-3220 or visit www.pittcon.org.

16-19 — SNAXPO, Sheraton Downtown, Phoenix. Hosted by Snack Food Association. Call (800) 628-1334 or visit www.snaxpo.com.

13-15 — Composites Manufacturing, Phoenix Marriott Mesa, Mesa, Aria. Hosted by Society of Manufacturing Engineers. Call (800) 733-4763 or visit www.sme.org/composites.

20-22 — Fabtech Canada, Congress Centre, Toronto. Call (800) 733-4763 or visit www.fabtechcanada.ca.

Did you know that 90% of heat transfer fluid breakdowns are caused by equipment issues? Listing and temperature range chart for all Paratherm heat transfer fluids.

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. Hosted by IPC – Association Connecting Electronics Industries. Call (847) 6157100 or visit www.ipc.org.

March 6-9 — Aquatech USA Conference and 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

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.

Immersion Engineering™™

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Thermal Fluid Heaters When heating millions of gallons of liquid asphalt, a complete thermal fluid heater package is essential.

W

hen Construction Resources Management, a company that provides design, materials and construction for the heavy and highway construction industry, first acquired its Milwaukee Terminal site in 1988, only one very small heater was being used to heat a single small tank. There were several tanks on site; however, they were all deteriorating and had to be torn down so new ones could be constructed. Although the terminal was in sad disrepair, the advantageous geographical location — with access by rail and barge for the transportation of liquid asphalt — tipped the scales for the Waukesha, Wis.-based captive service provider in favor of purchasing the site despite its condition. As a part of improving the site, new 140' pilings were installed for support for the new tanks, and load-bearing tests were performed to verify stability. The construction and renovation took place over a seven-year period and, in 1995, all the tanks on site were new, which dictated the need for new heating equipment. Glenn Elliott, CRM’s asphalt plant and tank farm manager, began the equipment

More Than Meets the Eye selection process with the assistance of John Schwalenberg from Heat and Power Products Inc., Fulton Thermal Corp.’s local representative. “I had originally been looking at other equipment, but when I was introduced to the Fulton product, I liked the total package aspect,” says Elliott. Elliot also was swayed by the product’s heavy-duty construction, precise tempera-

Above: Thermal fluid heaters brought a tank farm heating in Milwaukee back to life for Construction Resources Management. Left: Two pumping stations with fully insulated piping feed the heated thermal oil to the tanks and approximately 4,000' of loading lines. 14

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N ove m b e r 2 0 1 1 • Process Heating

ture control via a modulation package, and the fact that the equipment is made in America, which means obtaining replacement parts would not be an issue. “I also liked the down-fired heater design since it is actually better for the thermal oil,” says Elliott. The first equipment selected included: • A 6 million BTU/hr design thermal fluid heater. • A thermal fluid circulating pump. • Deaerator cold seal tank with autovent and expansion tank. • A 150 hp horizontal SteamPac unfired steam generator, return tank, blowdown separator and chemical feed system.

Thermal Fluid Heaters

Above: The modulation system maintains the different temperatures within the piping and storage tanks. Right: The Milwaukee terminal has 14 storage tanks, and of the nine largest tanks, seven hold 3 million gallons of liquid asphalt and two hold 2 million gallons.

The generator produces steam off the hot oil, and the steam is used to heat the coils under the railroad cars, clean the railroad cars and provide a full backup via relatively simple piping, should anything happen to the heaters in the building. The unit also can be set up at a major highway construction site, or it can be used as a backup to any of CRM’s other tank farms, which are located in Waukesha, Green Bay, Wis., and Gladstone, Mich. CRM’s Green Bay Terminal also runs with Fulton equipment. It has a 10 million BTU/hr heater, modulation package and a Fulton SteamPac unfired steam generator within the system, which provides steam when needed. Between 1995 and 2001, two 10 million BTU/hr thermal fluid heaters were purchased. These skid-mounted packaged heaters are piped together with two skid-mounted pumping stations containing a custom deaerator system and temperature modulation control system. The system is a split system. Either of the

heaters and the pumping station can heat the entire terminal, or the heaters can be split up for each to run its own half of the tank complex. The outdoor expansion tank has nitrogen blanketing, which keeps the thermal fluid from oxidizing.

The Process The liquid asphalt comes in via barge and rail. A polymer is added to the liquid asphalt to give it elasticity. Although used in Europe for some time, this procedure is relative new to United States, having only gained wide use within the last 10 years. Most of the interstates in Wisconsin use the modified, more elastic asphalt due to its increased durability. The modulation package maintains different temperatures for the piping and the storage tanks: Pipes are maintained at 320 to 335°F (160 to 168°C) and the storage tanks from 275 to 350°F (135 to 177°C), using thermal fluid supply temperatures ranging from 450 to 550°F

An expansion and overflow tank is a necessity in a closed-loop system.

(232 to 288°C). This temperature control is extremely important because without modulation, the lines could hydraulically pressurize the valves, creating a hazardous situation as well as a costly mess to clean up. Elliot explains, “For the past year, one of the Fulton heaters has been operating 24/7 without any problems, while the other unit remains on stand by as a backup. “The recently tested thermal fluid is just as clear today as it was the day it was installed.” He adds that he is glad price was not his first consideration when purchasing the equipment. “You spend up front so you don’t have headaches in the future,” he says. “The proof is in the condition of the units, longevity of use and the condition of the thermal oil.” PH To learn more about thermal fluid heaters from Fulton Thermal Corp., Pulaski, N.Y., call (315) 298-5121 or visit www.fulton.com. www.process-heating.com • N ove m b e r 2 0 1 1

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15

Heat Recovery

Recovering waste heat can help protect the environment and reduce production costs. By Oliver Krapp, Siemens Industry

E

nergy recovery as related to energy optimization is one of the key issues of our times. This involves both optimizing efficiency and ensuring environmental protection by reducing CO2 emissions. For instance, the glass production process — similar to many other continuous heated processes — creates tremendous amounts of waste heat that are too valuable to simply be released through a stack. To efficiently use this waste heat, steam turbines are used in some plants to convert it into electricity via waste heat boilers. However, the key to

success in this application is the ability to accommodate partial- or full-load operation in a harsh environment. The product being manufactured is always the focal point of any operation, which is why the waste heat recovery system must not have any negative impact on the production process. Reliability and uptime of the waste heat recovery system typically are more important than the peak amount of energy recovered. Finding the right compromise between rugged design and highest theoretical efficiency will result

in a system recovering the most energy over the plant’s life cycle. The waste heat recovery system consists of these core components: • • • • •

Heat recovery boiler. Steam turbine with generator. Condenser. Auxiliary systems. Piping.

In order to recover the most heat, the waste heat recovery system boiler should be installed between the furnace and the electrostatic precipitator (ESP), exposing the boiler to the furnace’s contaminated flue gas. Particles that could clog up the boiler and the composition of the flue gas are factors that should be considered during the boiler design. The temperature drop in the boiler, which is recoverable energy, is limited by the

A Key Issue

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N ove m b e r 2 0 1 1 • Process Heating

Heat Recovery Right: Reliability and uptime of the waste heat recovery system typically are more important than the peak amount of energy recovered. Finding the right compromise between rugged design and highest theoretical efficiency will result in a system recovering the most energy over the plant’s life cycle. Opposite: The main purpose of the turbine is to drive the generator converting steam to electricity.

input temperature (oven or furnace’s output temperature) as well as the minimum temperature allowed to be passed on to the ESP and, finally, to the stack. Most production processes provide a changing flow stream of waste heat that can vary from 50 to 100 percent (partial- to full-load operation) — a range the boiler must handle. The turbine is the second core component and the heart of the system. Its main purpose is to drive the generator converting steam to electricity. One of the turbine’s important characteristics is flexible construction. This flexibility ensures that a proven standard product can be used in a range of applications without customizing on a plant-by-plant basis. Customizations typically lead to higher initial and maintenance costs. Another important aspect is the turbine’s high efficiency from partial- to fullload operation. For instance, in the glass industry, the volume of the extracted air from the glass production process increases over the furnace’s lifetime. In other industries, the amount of available waste heat can vary based on the quantity and type of product being produced. The turbine must be capable of processing the corresponding changing steam volume with a load range from 50 to 100 percent, ideally without impacting the turbine’s efficiency. In practice, it is beneficial to have a twin turbine with one high-pressure stage and one low-pressure stage, driving the same generator via a gear box. This approach can increase the efficiency and the energy that can be recovered, and steam can be tapped between the two stages for process heating or space/building purposes. A two-stage system can qualify as a com-

Get a Helping Hand with CHP In the United States, federal incentives for developing CHP projects can be given. The prerequisites to qualify for a tax credit can be found online at www.epa.gov/chp/incentives/index.html.

bined heat and power (CHP) system and provide specific advantages. Because high temperatures and pressures are involved in the waste heat recovery system steam cycle, the monitoring and control system needs to be carried out as a fail-safe system (safety integrity level [SIL] classification) with the capability to be integrated into the overall control system, typically a distributed control system (DCS). This allows the waste heat recovery system to be monitored and controlled from both the central control room and on-site from a local operating station. If a manufacturing execution system (MES) is involved, key performance indicators like energy consumption and energy recovery can be tracked at any given time and contribute to the overall plant efficiency.

Return on Investment More than 90 percent efficiency can be achieved if the steam is used not only for generating electricity but also for other processes via CHP units, as well as for heating water or for air-conditioning with absorption-type refrigerating systems. Up to 60 percent of the electrical energy used in some manufacturing plants such as glass processing can be covered with the electricity generated in the waste heat recovery system. Depending on the infrastructure, the heat energy also can be fed back into the municipal district heating grid or supplied to nearby companies. This shows that

many factors must be considered that go beyond the confines of the site, and that is the reason why full installation, from working out the overall concept all the way to implementation, can take two to three years. Many experienced specialists must pool their knowledge and the system must be designed as a whole, always keeping the manufacturing process, and any negative consequences, in mind. The break-even point for a waste heat recovery system can vary. For instance, at a medium-sized float-glass plant, it is typically just a few years, depending on the design of the overall plant, the production volume and local energy prices. The fees paid for electricity and heat fed into municipal utility grids, subventions for CHP plants, bonus payments for renewable energy, and rebates on mineral oil taxes can help attain return on investment sooner. PH Oliver Krapp is a solar industry consultant with the Industry Automation Division of Siemens Industry, Alpharetta, Ga. He can be reached at [email protected] or (215) 260-4533. For more information from Siemens, visit www.siemens.com.

WEB EXCLUSIVE Waste Heat Recovery System Considerations In terms of return on investment, the waste heat flow stream needs to have a certain temperature and volume to justify the installation of a waste heat recovery system. READ MORE @ WWW.PROCESS-HEATING.COM

www.process-heating.com • N ove m b e r 2 0 1 1

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17

Process Controls

Time for an

Upgrade O

ver the years, farms and the equipment for harvesting crops have both dramatically increased in scale. To keep up with the added work, farmers have started harvesting earlier, which usually results in wetter grain. Consequently, farmers need larger grain dryers and upgraded automation systems to improve performance. The automation system for one company’s continuous flow dryers was redesigned to help farmers han-

dle these wetter grains, and the revamped controls, combined with tailored dryer design, result in effective grain drying.

Dryer Operation The continuous flow dryers can dry grain with moisture level as high as 35 percent. Typically, the ideal moisture content of the grain exiting the dryer is 15 percent, but grain that will be stored for long periods of time requires lower moisture content. The

An automation technology upgrade allowed one grain dryer manufacturer to improve product quality and throughput while increasing uptime. By Matt Koch, Sukup Manufacturing Co.

operator decides what the actual moisture content should be and adjusts the setpoint accordingly. Surprisingly, the ideal moisture content for different grains such as corn, wheat, barley, sunflowers and canola is nearly the same, plus or minus a few percent. For the continuous flow grain dryers, the grain enters through the top and is distributed across the wet holding bin by an auger. The grain travels through 24" vertical grain columns at a rate set by four metering rolls. The length of the dryer determines its rated capacity. The grain columns are arranged so they surround the heating chamber, or plenum. Two metering rolls run the dryer length through each of the grain columns, and propane or natural gas heaters are located on one end. Two metering rolls are used in each dryer column to ensure even drying, and this allows the dryer to pull the grain down the columns at different speeds. Specifically, the rolls pull the inner and hotter layer of grain down the column faster than the outer and cooler layer. A variable-frequency drive (VFD) varies metering roll speeds depending on the moisture content of the discharged grain. This process produces consistent moisture content, minimizes damage and maintains higher test weights and overall quality. The VFD also allows slower metering roll operation, needed for drying wetter grain. A sensor located in the discharge tube monitors the moisture content of the grain exiting the dryer. This sensor signal is fed to the PLC, which uses a tuned PID loop

The power box contains the PLC and most of the automation components. The power box includes a through-panel Ethernet connection for the HMI, which allows users to mount the HMI wherever they choose. 18

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N ove m b e r 2 0 1 1 • Process Heating

Process Controls A split-plenum dryer is capable of full-heat drying or heat/cool drying when discharged grain must be near ambient temperature.

to control the speed of the VFD that runs the metering rolls. Controlling the metering roll speed based on grain moisture rather than temperature provides accuracy in the drying process and produces better moisture consistency. The grain-drying process requires forced air and heat, with the speed of the fan fixed at 1,750 rpm in most cases. The fan speed is fixed because providing consistent airflow across the grain is essential to the fundamentals of dryer operation. The fan speed is constant, but the rate at which the grain travels through the drying columns varies depending on the grain moisture sensed at the dryer’s discharge. Grain dries faster with higher heat, but it can be scorched and damaged by excessive heat. Therefore, RTDs sense plenum temperature and feed this signal to analog inputs at the PLC. Tuned PID loops are

employed to control the temperature to within ±3°F (±1.6°C) of setpoint by sending analog output signals from the PLC to electronic-modulating valves that control gas flow to the heaters. A flame detection/flame safeguarding safety system is used on the gas burners that heat the plenums. If the flame goes out, the sensor feeds the signal back to a heater board. The heater board alarms the PLC, which then suspends dryer operation by closing the gas supply solenoid valves.

SYSTEM DOWN!

The dryers can be used in either continuous flow or batch mode. Sometimes, the grain moisture content is so high that using the continuous flow mode at its slowest speed is still too fast. In these cases, the batch mode can be used, essentially holding the grain in the dryer for a fixed period of time. In the batch drying mode, the PLC calculates the total time the grain was in the dryer, and then records the average discharge moisture. If needed, the PLC can then automatically make proportional corrections to the next batch’s drying time.

Inside the Dryer Controls The touch-screen dryer automation system, manufactured by Phoenix Contact, Harrisburg, Pa., has an operator interface display with user-friendly menus, remote operation via Ethernet and built-in data collection. A PLC with various I/O modules was chosen, and the PLC communicates with the touch-screen HMI via Ethernet.

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19

Process Controls The control system’s HMI can be located up to 200' from the dryer. It connects to the PLC, which is located in the power box on the grain dryer, via Ethernet.

A switch-mode 24 VDC power supply, terminal blocks and through-panel Ethernet couplers Phoenix Contact also are used. Optional GSM functionality is offered so users can keep an eye on dryer operation from any cell phone. This allows notifications to be automatically sent via text message when the dryer enters a fault condition or needs to be restarted. Users of the system also can send text message queries to the dryer to get status and relevant data. The HMI displays data from the PLC via an Ethernet connection while the DIN rail-mounted PLC controls the operation and safety of the entire dryer. Relevant dryer

information is available on the various HMI screens, and advanced users can use this data to spot ways to improve drying operations. Datalogging is managed by the HMI. The PLC generates one-minute running averages and sends them to the HMI via the Ethernet link. The HMI records the information on a USB drive in a Microsoft Excel-friendly format. Various I/O configurations are used depending on dryer size and desired functionality. Safety circuits, emergency stop circuits and assorted sensors are connected to discrete inputs at the PLC. Digital PLC outputs provide signals to energize relays, motor starters and other components. The PLC-based automation system was designed to eliminate the need to monitor the dryers around the clock as well as to increase productivity and efficiency. The automation system also is able to mini-

Two Coils

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mize large swings in the temperature and moisture content of the discharged grain. Providing all of these features required a carefully designed automation system, not only in terms of the selected hardware, but also with respect to coding and programming of the entire system. PH Matt Koch is an electrical engineer at the Sukup Manufacturing Co., Sheffield, Iowa. To learn more about the company’s grain dryers, call (641) 892-4222 or visit www.sukup.com. To learn more about PLC-based controls from Phoenix Contact, call (717) 944-1300 or visit www.phoenixcontact.com.

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Temperature Sensors

I

n a short time, hand-held infrared thermometers have gone from exotic to commonplace. Portable and convenient, they are useful for troubleshooting and checking both product quality and process quality. Following some best practices for process heating applications can help users get the most from these temperature measurement tools. In general, there are three ways to use any kind of infrared, noncontact thermometer: • Measuring the Temperature at a Spot. This type of measurement is used to measure and track temperature at a single

spot. It is useful for trending the temperature of an object or comparing a measurement to a specification. A thermometer with high repeatability helps ensure consistency for this kind of measurement. • Comparing the Temperature of Two Spots. This type of measurement might be used to check the functioning of a steam trap by measuring the temperature of the inlet and outlet. No change indicates the trap has failed open. A large change indicates the trap has failed closed.

• Scanning an Object and Detecting Changes within a Continuous Area. This capability allows the user to find hot or cold spots on housings, panels and structures. For example, one can check the heat sink of air-cooled transformers for cool tubes that indicate a restricted flow or a lack of flow. Infrared thermometry can be used for process monitoring, plant predictive and preventive maintenance, electrical applica-

Understanding infrared thermometers and using them properly in industrial applications goes a long way toward improving the process and product. By Ted Lund, Fluke Corp. tions, quality assurance and other applications. Where calibration is a matter of concern, infrared thermometers are available with an NIST calibration certificate.

Applications and Features

Temperature Measurement

Strategies

Infrared noncontact thermometers have proven useful in many process applications. Electrical Maintenance. Check for heat buildup created by loose connectors. Troubleshoot problems in battery banks and power panel terminations, ballasts, switchgear and fuse connections. Identify hot spots in the output filters on DC battery connections. Equipment Maintenance. Check moving parts and housings in motors and gear boxes for hot spots. Temperature change can indicate developing problems in many types of equipment, from ovens and boilers to freezers. Routine temperature audits of generators and their bearings can prevent expensive repairs. Measure Temperature of Process or Product. Monitor process lines. Check

An infrared thermometer and probe are used to monitor the fluid temperature of a soap bath solution used in the cleaning of raw wheels before the first primer process at Helios Coatings. www.process-heating.com • N ove m b e r 2 0 1 1

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Temperature Sensors

D:S = 30:1 at Focal Point

0.9" at 12"

S

1.2" at 36"

2.5" at 60"

D

the temperature of different products on production lines. These can vary from rubber tires to plastic, from concrete to chocolate bars. Building Controls. Although not a process use, a noncontact infrared thermometer also can be used to monitor HVAC/R components for quick energy audits and room balancing in a short time. An infrared thermometer with a 60:1 distance-tospot ratio makes elevated vents and returns more accessible. The following infrared measurement capabilities are particularly useful for measuring and tracking key indicators in industrial facilities. High Optical Resolution. Industrial process technicians want their infrared thermometers to provide accurate temperature readings at some distance as well as close up. For example, it is not unusual for them to log the temperatures of connections inside an open electrical panel one minute and then want to take the temperature of a conveyor drive motor 20' above the floor the next minute. The optical systems of all infrared thermometers collect infrared energy from a circular area or “spot,” which is illuminated by an infrared beam. (The infrared spot is for aiming purposes only, and not a part of the actual measurement process.) The farther from the instrument one gets, the larger the spot that is measured. The optical resolution of an instrument is defined by the ratio of the distance from the instrument to the object, compared to the size of the spot as its focal point. This is commonly known as distance-to-spot, or A worker monitors the surface temperature of a wheel that just had a primer coat applied in the spray booth in Helios Coatings research lab. 22

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N ove m b e r 2 0 1 1 • Process Heating

The size of the temperature measurement area, or “spot,” increases with distance. Infrared thermometers with a higher distance-to-spot ratio (D:S) can take accurate measurements at a greater distances.

D:S = 50:1 at Focal Point

0.8" at 12"

S

0.7" at 36"

1.7" at 60"

D

D:S, ratio. For other distances, this ratio is a useful approximation. Some entry level-instruments have a relatively low D:S ratio of 6:1 or 8:1. Better infrared thermometers for process uses have greater distance-to-spot ratios, going as high 60:1. For instance, with a 6:1 ratio, the user must be 6" from the target to measure a 1" spot. With a 60:1 ratio, you can measure the same 1" spot from a distance of approximately 5'. By contrast, from 5' away, the entry-level instrument would be measuring a spot 7.5 to 10" in diameter. Optical resolution is important in infrared thermometry. In order to get a good reading, the target must be larger than the spot size and ideally should be twice as large. For example, from the floor, a technician might not be able to record the temperature of a conveyor motor described using an instrument with a 8:1 D:S ratio. However, a 60:1 resolution would get the job done. High optical resolution is also important when working closer up because it allows precise measurement of smaller targets from a safe distance.

Good Laser Sighting. Accurate aiming is critically important. Better quality infrared thermometers may have lasers that appear brighter to the human eye while maintaining the same safety rating as lasers that are not as bright. This makes accurate sighting easier in a range of lighting conditions and distances. Wide Temperature Range. Process technicians must measure a range of temperatures. They may have to track the temperatures of refrigerated products one day and the temperature of baked goods emerging from the oven the next. In some manufacturing environments, production personnel use handheld infrared thermometers to monitor very hot products such as hot steel or plastic. Make sure that the infrared thermometer you plan to use has sufficient measurement range for the job. High quality infrared thermometers can measure from -25 to 1,600°F (-30 to 900°C). Adjustable Emissivity. Infrared thermometers calculate the surface temperature of an object using the amount of energy emitted by the object, and the efficiency with which the surface material of that object is known to emit that energy — its emissivity. Because the emissivity of most organic materials and painted or oxidized surfaces is about 0.95, many infrared thermometers use this value for all temperature calculations. However, some materials such

Temperature Sensors An infrared thermometer is used check the exit temperature of wheels after a metal primer coating is cured in a UV oven.

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Best Practices for Infrared Temperature Measurement

instruments. This feature makes readings more accurate, and it, like the high temperature range, allows these units to be used in process quality assurance. Some units offer selectable emissivity settings for common materials. High Measuring Speed. A thermometer that records readings quickly will record accurate readings even in situations where target temperatures are changing rapidly. Short response times of infrared thermometers mean that serious problems can be diagnosed even when temperatures are changing rapidly or require fast scanning. Furthermore, it is not necessary to shut down equipment to take a reading. Some infrared thermometers may have response times as fast as a quarter of a second. Datalogging. Some infrared thermometers may enable the user to record many data points that can later be downloaded and analyzed with software for logging,

as concrete and metals are poor emitters, so using an emissivity setting of 0.95 in calculating surface temperatures of these objects does not give an accurate result. Some infrared thermometers enable the user to adjust the emissivity setting of the

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graphing and analyzing temperature. This feature can save a lot of time and minimize transcription errors as well. Other useful features include a lighted display makes it easier to view results in poorly lit areas. Also, high temperature alarm warnings call attention to temperatures that exceed a specified threshold. Alarms that are both audible and visible are more effective even in loud environments. PH Ted Lund is the infrared thermometers product manager with Fluke Corp., Everett, Wash. For more information, call (425) 347-6100 or visit www.fluke.com.

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Equipment Overview

Temperature Sensors

From thermal imagers to contact temperature sensors, find suppliers that can help you get a sense of your process. Temperature sensors are a critical part of any process control scheme. To keep your oven, dryer, chiller, heater or other heat processing equipment within your process

process or remote-reading using noncontact infrared sensing — allow you to know exactly what’s going on in your process. Whether you need a linescanner, imager,

specifications, you need to know what temperature the process is at now, and how far away it is from where you want it to be. Temperature sensors — located in the

THERMOMETERS

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

Exergen Corp.

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www.exergen.com

Thermal Imagers

Optical Pyrometers

Multi-Wavelength

Single Wavelength

Dual Wavelength

Ratio

Remote Recording

Printing

Datalogging

Computer Interface

Voltage

Current

Thermocouple

Emissivity, Fixed

Emissivity, Automatic

Emissivity, Adjustable

Liquid-in-Glass

Fiber Optic

Digital (Hand-Held)

Bimetal

Companies

INFRARED OUTPUTS

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Moore Industries Inc. www.miinet.com

Palmer Wahl www.palmerwahl.com Advanced Thermal Products Ametek Test & Calibration Instruments Applied Sensor Technologies ARi Industries Ashcroft Inc. Athena Controls Inc. Brighton Electronics Inc. Burns Engineering Inc. CCPI Chino Works America Inc. Chromalox Cole-Palmer Comark Instruments DeltaTrak Inc. Dickson Co. Duratherm Processing Systems Inc. Durex Industries Dwyer Instruments Inc. E Instruments Group Electronic Development Labs Inc. Eustis Co. Inc. Extech Instruments Fluke Corp. Furnace Parts LLC GeoCorp Inc. GIC Thermodynamics Harrop Industries Inc. Heaters Controls & Sensors Heraeus Sensor Technology USA Honeywell Infrared Cameras Inc. Invensys Eurotherm Ircon Inc. JMS Southeast Inc. LumaSense Technologies Minco Nanmac Corp. Omega Engineering Inc. Oven Industries

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Manufacturers listed in this Equipment Overview responded to a special mailing by Process Heating and do not necessarily represent the entire industrial process temperature sensors market. To be included in future listings, contact Linda Becker at (847) 405-4020 or e-mail [email protected]. 24

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Programmable

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TEMP TRANSMITTERS

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THERMISTORS

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Plastic Machinery Style

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THERMOCOUPLES

Averaging

Element: Wire Wound

Element: Thin Film

Element: Platinum, JIS

Element: Platinum, DIN

Element: Nickel-Ion

Element: Nickel

Element: Copper

Thermal Line Scanners

RTDs

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searching capabilities: You set the criteria and let the search engine work for you. In addition, hyperlinks will take you directly to some manufacturers’ web sites.

You also can conduct your search online at www.process-heating.com. The online version of our Equipment Overview on Temperature Sensors includes advanced

infrared point sensor, thermocouples, RTDs, thermistors or thermometers, this chart will allow you to quickly identify the suppliers that offer the equipment you want.

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www.process-heating.com • N ove m b e r 2 0 1 1

|

25

Equipment Overview

Temperature Sensors THERMOMETERS

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

INFRARED

Advertising Index 26

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Page

Company

Phone

Fax

Web

E-Mail

12

Exergen Corp.

(617) 923-9900

(617) 923-9911

www.exergen.com

[email protected]

3

Exothermics Inc.

(419) 729-9726

(419) 729-9705

www.exothermics.com

[email protected]

7

Fulton Thermal Corp.

(315) 298-7182

(315) 298-5311

www.fulton.com

[email protected]

20

General Combustion

(407) 290-6000

(407) 578-0577

www.gencor.com

[email protected]

2

Heatec

(423) 821-5200

(423) 821-7673

www.heatec.com

[email protected]

32

Heatec

(423) 821-5200

(423) 821-7673

www.heatec.com

[email protected]

11

Hix Corp.

(620) 231-8568

(620) 231-1598

www.ovens-dryers.com

[email protected]

12

Hubbell Electric Heater Co.

(203) 378-2659

(203) 378-3593

www.hubbellheaters.com

[email protected]

10

Micron Fiber-Tech

(386) 668-7895

(386) 668-7462

www.mft-co.com

[email protected]

11

Moore Industries Inc.

(818) 894-7111

(818) 891-2816

www.miinet.com

[email protected]

19

MultiTherm

(610) 408-8361

(610) 408-8365

www.multitherm.com

[email protected]

10

Palmer Wahl Instrument Group

(828) 658-3131

(828) 658-0728

www.palmerwahl.com

none

13

Paratherm Corp.

(610) 941-4900

(610) 941-9191

www.paratherm.com

[email protected]

23

Parker Boiler Co.

(323) 727-9800

(323) 722-2848

www.parkerboiler.com

[email protected]

6

Payne Controls

(304) 757-7353

(304) 757-7305

www.payneng.com

[email protected]

4

PHG Energy

(615) 251-8619

none

www.phgenergy.com

[email protected]

31

Sigma Thermal

(678) 324-5721

(678) 254-1762

www.sigmathermal.com

[email protected]

9

Southern California Gas Co.

(213) 244-3635

(866) 364-9024

www.socalgas.com

[email protected]

8

Struthers Wells

(281) 664-8021

(832) 237-8758

www.babcockpower.com

[email protected]

N ove m b e r 2 0 1 1 • Process Heating

Thermal Imagers

• •

•

• • •

Optical Pyrometers

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•

Multi-Wavelength

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Single Wavelength

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Dual Wavelength

•

Ratio

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Remote Recording

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Printing

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Datalogging

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Computer Interface

Voltage

Thermocouple

Emissivity, Fixed

Emissivity, Automatic

Emissivity, Adjustable

Liquid-in-Glass

Current

Process Technology Pyromation Inc. Quality Thermistor Inc. Quantem Corp. Raytek Reotemp Instrument Spectrum Sensors & Controls Temp-Pro Inc. Tempco Electric Heater Corp. Temperature Specialists Inc. Temtex Temperature Systems Thermal Corp. Thermocouple Technology Inc. ThermX Southwest Wahlco Inc. Watlow Wika Instrument Corp. Williamson Corp. Zytron Control Products Inc.

Fiber Optic

Companies

Digital (Hand-Held)

Bimetal

OUTPUTS

Element: Nickel Element: Nickel-Ion Element: Platinum, DIN Element: Platinum, JIS

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Sanitary Thermowell Element: Type E Element: Type J Element: Type K Element: Type T Averaging Hand-Held General Purpose MgO Insulated Plastic Machinery Style Sanitary Thermowell

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THERMISTORS

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•

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•

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•

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Chips/Disks/Flakes

Non-Linear (NTC)

THERMOCOUPLES

Linear (PTC)

Plastic Machinery Style

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Element: Wire Wound

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Element: Copper

Thermal Line Scanners

RTDs TEMP TRANSMITTERS

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www.process-heating.com • N ove m b e r 2 0 1 1

•

•

|

27

RESHAPE THE FUTURE OF PLASTICS From the plastics of today to the engineered materials of tomorrow, our industry unites in 2012 to Break the Mold at The International Plastics Showcase. For the first time ever, professionals from around the world will gather in Orlando to uncover the latest tools and techniques needed to reshape the industry itself — and continue our impressive evolution. Make plans now to participate in NPE2012 and see the latest in bio-renewable thermoplastics, injection molding, polymer nanocomposites, nanofibers and the green technologies that are changing the way we do business. Join tens of thousands of like-minded professionals to share success stories and explore solutions to the exciting challenges we face today and tomorrow. The must-attend NPE2012 promises to deliver everything plastics — and your greatest opportunity to reshape your organization for maximum productivity. Visit us online at www.npe.org.

The International Plastics Showcase April 1– 5, 2012 | www.npe.org Orange County Convention Center Orlando, Florida USA

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.

PROCESS HEAT

The Next Generation

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) LHS Air Heater

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]

Statement of Ownership, Management, and Circulation (Requester Publications Only) Publication Detail 1 Publication Name 1 Publication Number 2 ISSN 3 Filing Date 4 Issue Frequency 5 Number of Issues Published Annually 6 Annual Subscription Price 7 Complete Mailing Address of Known Office of Publication 7 7 Contact Person 7 Telephone 8 Complete Mailing Address of Headquarter or General Business Office of Publisher 8 9 Publisher (Name and complete mailing address) 9 9 9 Editor (Name and complete mailing address) 9 9 9 Managing Editor (Name and complete mailing address)

HEAT EXCHANGERS ▼

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PROCESS HEATING 09/01/2011

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Talk Directly with Design Engineers! Blower Cooling

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Air Cooled

PROCESS HEATING 012-863 1077-5870 09/28/2011 MONTHLY 12 115.00 2401 W BIG BEAVER RD STE 700 TROY, OAKLAND, MI 48084-3333 CATHERINE RONAN (248) 244-8259 2401 W BIG BEAVER RD STE 700 TROY, MI 48084-3333 ANNE ARMEL 155 N PFINGSTEN RD STE 205 DEERFIELD, IL 60015-5293 LINDA BECKER 155 N PFINGSTEN RD STE 205 DEERFIELD, IL 60015-5293

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www.process-heating.com • N ove m b e r 2 0 1 1

| 29

®

Places & Faces Pittsburgh-based Heyl & Patterson Inc., a manufacturer of thermal processing systems and bulk materialhandling equipment, signed an exclu-

sive representative agreement with Tecnagent, a marketer of mining equipment based in Santiago, Chile. The agreement combines Heyl & Patterson’s engineering and manufacturing skills with Tecnagent’s sales and marketing expertise in Chile.

Doug Chancellor has joined the Eurotherm sales and marketing team of Invensys Operations Management, Plano, Texas, as a territory sales manager for the South Central region. Chancellor brings more than 20 years of experience working in the industrial automation market and will report to Steve Miller, national sales and marketing manager. In related company news, Paul Baker was promoted to support services manager for Invensys Eurotherm in the United States. In his new role, Baker’s main focus will be on increasing support service revenues and providing customer service. He also will be responsible for managing field service and technical support personnel. The National Fire Protection Association (NFPA), Quincy, Mass., has named Jeff Sargent and Tim McClintock as regional electrical code specialists. Sargent and McClintock will support state adoptions of NFPA 70, National Electrical Code (NEC), and related NFPA electrical standards.

Schaffner Group signed an asset purchase agreement to acquire the dry-type transformers operations of American transformer manufacturer MTC Transformers Inc. as of September 1, 2011. Under the trans30

|

N ove m b e r 2 0 1 1 • Process Heating

action, Schaffner is acquiring MTC Transformer’s Wytheville, Va., production site, and Roanoke, Va., sales office, as well as the well-established MTC Transfomers brand. Parsippany, N.J.-based Pump Systems Matter, the Morris County Chamber of Commerce, PS&G and Schneider Electric are partnering to host a one-day course on November 16 in Florham Park, N.J. The course is designed to help pump users learn how to identify and reduce hidden operating and energy costs in their pump systems and ultimately increase profitability of their business. For more information or to register, visit www.pumpsystemsmatter.org.

Lauren Manufacturing, New Philadelphia, Ohio, a manufacturer of custom engineered seals and gaskets, received a supplier quality excellence process certification award from

Caterpillar Inc.

PUBLISHING STAFF Senior Group Publisher, Manufacturing Group TOM ESPOSITO • (610) 436-4220 ext. 8530 Publisher • ANNE ARMEL (847) 405-4043 • [email protected] Associate Publisher and Editor • LINDA BECKER (847) 405-4020 • [email protected] Contributing Editor • JOY LEPREE ANDERSON (856) 582-9554 • [email protected] Art Director • COURTNEY FATHERS (248) 244-1292 • [email protected] Production Manager • BETH MCCLELLAND (412) 306-4354 • [email protected] Reprint Sales • JILL DEVRIES (248) 244-1726 • [email protected] E-Media Sales • SUSAN HEINAUER (412) 306-4352 • [email protected] Classifieds • BECKY MCCLELLAND (412) 306-4355 • [email protected] Publishing Director, Manufacturing and Gaming Groups JOHN R. SCHREI • (248) 786-1637

EDITORIAL OFFICE 155 N. Pfingsten Road, Suite 205, Deerfield, IL 60015 (847) 405-4000 • FAX (248) 502-1001

ADVERTISING SALES NORTH AMERICA • Sean Meaney • National Sales Manager 530 Humiston Drive • Bay Village, OH 44140 (440) 895-0919 • FAX (248) 502-1051 • [email protected] NORTH AMERICA • Anne Armel • Publisher 155 N. Pfingsten Road, Suite 205 • Deerfield, IL 60015 (847) 405-4043 • FAX (248) 786-1441 • [email protected] EUROPE • Carolyn Eychenne • European Sales Representative 7 rue de Maurepas • 78000 Versailles France tel/fax: 011 33 1 30 21 15 62 • [email protected]

CORPORATE STAFF BNP Media Corporate Office • (248) 244-6400

BNP CUSTOM MEDIA GROUP CHRISTOPHER WILSON (248) 244-8264 • [email protected]

GraalBio Investimentos S.A., an

SINGLE COPY SALES

integrated second generation biofuels and biochemicals company whollyowned by the Brazilian entrepreneurial group Graal Investimentos S.A., and Chemtex Italia S.r.l., a global technology and engineering company and a subsidiary of Italy’s Gruppo Mossi & Ghisolfi (M&G),will collaborate on the development and construction of the first industrial scale cellulosic ethanol plant in Brazil. It is is expected to begin operations by 2013. Chemtex and GraalBio are also in discussions regarding a broader cooperation to develop and produce biofuels and biochemicals in Brazil.

ANN KALB • (248) 244-6499 • [email protected]

Montreal-based Matrox Graphics Inc.’s Mura MPX Series video wall controller boards were selected by French

•

AV integrator AGELEC to drive its AGCWall Series video wall controllers.

LIST RENTAL KEVIN COLLOPY • Sr. Account Manager (800) 223-2194 x684 • [email protected] MICHAEL COSTANTINO • Sr. Account Manager (800) 223-2194 x748 • [email protected]

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Got Maintenance? Plant operators are finding out the advantages of having their heaters serviced by Heatec on a regular basis. There are important benefits of having a contract for our service technicians to do preventative maintenance once or twice a year. An important benefit is safety. Our technicians make sure all limit devices are working properly. Insurance companies usually prefer that specialists, such as Heatec technicians, perform services related to safety. Fuel savings is another important benefit that results from maintenance that includes tuning the burner. Moreover, preventative maintenance usually eliminates unexpected heater

shutdowns at times that interrupt production. Preventative maintenance can usually be done without adversely affecting production schedules. Another benefit is usually a reduction in costs for each service call. This results from lower travel expenses when our technicians can make service calls at other plants in the same area. Moreover, many of our technicians reside in diverse locations that reduce travel to plant sites. Call today to find out what kind of service contract would work best for you.

HEATEC

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