www.process-heating.com | January 2011 | Volume 18, Number 1
A Steamy Situation Using boilers in process heating applications delivers benefits.
Periodical Class
18 Heat Transfer Fluid Guide 24 Preventive Maintenance Plan 33 Manufacturing Spotlights
These heaters will be fully assembled and checked at our factory before delivery.
Get a complete heater package Need a new heater? Get a complete heater package from Heatec. A complete package eliminates hassles, saves you time and saves you money. Our package includes design, manufacturing, factory assembly, on-site setup and startup. We also offer maintenance contracts and provide free phone support. Heaters have many components from a variety of manufacturers. It’s always best to mate these components with the heater and adjust them before the heater is shipped to you. This eliminates most compatibility problems. Our goal is that setup of our heater at your plant will be trouble free, without undue rework. Most setups should only require re-assembly of parts dismantled
for shipping, plus connection of electrical power and piping. Complete factory assembly eliminates last-minute fieldwork that can cause startup delays. It also eliminates buck passing if things don’t go right. Moreover, if a problem develops later, you won’t have to wrangle with a variety of component suppliers to fix it. So, when you buy a new heater, always choose a manufacturer that provides a complete package. Heatec has this capability, which sets us apart from others. Call today and let us answer any questions you have about our heater packages.
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January 2011 Volume 18 • Number 1
www.process-heating.com WEB EXCLUSIVES: READ MORE AT WWW.PROCESS-HEATING.COM Q Steam Tips Here are a few ways to handle condensation and scale in boilers.
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Features 18
Equipment Overview: Heat Transfer Fluids Selecting the heat transfer fluid is the most important decision to make in specifying a system because the fluid’s properties have to be matched to the process requirements, and the equipment has to be matched to the fluid properties. Use our Equipment Overview to learn more about a fluid’s properties and narrow the field.
Ovens Before you take the plunge and make a commitment, make sure you understand what preventive maintenance (PM) is and its potential results. With a bit of planning, preventive maintenance can help you improve efficiency and profitability.
Q Midwestern Town Saves Time, Money and Energy with Wastewater Upgrade Peru Utilities needed to upgrade its two wastewater treatment facilities to reduce operations costs and expand capacity.
UPDATED DAILY Q New Products
Q Industry News
Q Archives Q Calendar of Events Q Drying Files columns
Q Energy Notes column Q Equipment Overviews Q Heating Highlights
Q Digital Editions Q Buyers Guide Q Archived Webinars
Check out our redesigned site with more frequent updates and web exclusives!
Heat Exchangers Meeting Mandates
31
A preventive maintenance program can provide benefits above and beyond what you might expect to see, including an improved company image and more satisfied employees.
ALWAYS ONLINE
A Real Resolution
28
The DOE estimates that boilers account for 35 percent of the energy consumed in this country, which is why the agency launched an initiative in 2000 with a number of development partners to create a model for a Super Boiler that would increase efficiency of boilers and reduce dependence on imported oil.
Q Preventive Maintenance: Bonus Points
Heat Transfer Fluid Guide
24
Q Turning Up the Heat for Better Efficiency
Q Go Mobile
Replacing an aging, energy-guzzling boiler with a Super Boiler — the ultra high efficiency boiler developed in part by the U.S. Department of Energy (DOE) — is not the only way to make progress toward meeting the agency’s aggressive goals for increasing boiler efficiency and reducing emissions. By retrofitting older boilers with flue gas condensing heat exchangers, it is possible to turn old boilers green.
Use your smart phone to read Process Heating, wherever you are! Simply visit http://gettag.mobi/ with your phone’s browser to install the Microsoft Tag app. Then, point your phone’s camera at the tag below to be taken to our current issue online — instantly.
Steam Heating
The reader works on most current smart and advancedd ffeature phones, h includi l d ing Windows Mobile (5.5 and above), iPhone, Blackberry, Symbian and J2ME.
A Steamy Situation Powered by an electric boiler, steam cleaning is effective at “melting away” grease and oils and removing soils and dirt from heavy equipment and process parts.
33
Heat Processing Focus Manufacturing Spotlight Enlighten yourself on the latest heat processing technology with this special section of products, tips and application ideas.
Columns & Departments 8 10 16 47
Editor’s Page Inner Workings Calendar Products
About the Cover Ajax Boiler Inc., Santa Ana, Calif., designs and manufactures boilers and water-heating equipment, including high-efficiency, condensing boilers for process water heating applications. To learn more about boilers, see page 31.
52 Classified Directory 53 Advertiser Index 54 Places & Faces
PROCESS HEATING (ISSN 1077-5870) is published 12 times annually, monthly, by BNP Media, 2401 W. Big Beaver Rd., Suite 700, Troy, MI 48084-3333. Telephone: (248) 362-3700, Fax: (248) 362-0317. No charge for subscriptions to qualified individuals. Annual rate for subscriptions to nonqualified individuals in the U.S.A.: $115.00 USD. Annual rate for subscriptions to nonqualified individuals in Canada: $149.00 USD (includes GST & postage); all other countries: $165.00 (int’l mail) payable in U.S. funds. Printed in the U.S.A. Copyright 2011, by BNP Media. All rights reserved. The contents of this publication may not be reproduced in whole or in part without the consent of the publisher. The publisher is not responsible for product claims and representations. Periodicals Postage Paid at Troy, MI and at additional mailing offices. POSTMASTER: Send address changes to: PROCESS HEATING, P.O. Box 2146, Skokie, IL 60076. Canada Post: Publications Mail Agreement #40612608. GST account: 131263923. Send returns (Canada) to Pitney Bowes, P.O. Box 25542, London, ON, N6C 6B2. Change of address: Send old address label along with new address to PROCESS HEATING, P.O. Box 2146, Skokie, IL 60076. For single copies or back issues: contact Ann Kalb at (248) 244-6499 or
[email protected].
www.process-heating.com • J a n u a r y 2 0 1 1
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By Linda Becker
Commentary Prepared or Not, the Cold Weather Is Here
9 Heat Tracing Tips Some process equipment needs special attention in winter to ensure freeze protection or maintain proper flow. Because the heating equipment —heat tracing, for example — may not be needed during the warmer months, it can be overlooked until it’s time to use it. Did you find yourself in this situation? If so, here are nine tips from Tyco Thermal Controls, Menlo Park, Calif., to help maintain your electric heat tracing. 1. Maintain — and update — installation and maintenance records. Complete documentation will allow you to verify completed system tests, original electrical values and performance changes. 2. Check heat tracing components. Damaged components can result in water ingress, corrosion, or the loosening of electrical connections. 3. Check your insulation. Insulation plays a critical role in the overall heat tracing system. Also, perform an insulation resistance test on all heat tracing circuits. 4. Check your power distribution panel and secondary wire and conduit. Visually inspect the conduit distribution system for openings in the conduit, damaged or missing components, or low-point drains.
5. Test all ground-fault breakers according to the manufacturers’ instructions. 6. Check your thermostat or control system. They allow you to run automatic tests and capture alarm and fault information, which is useful if troubleshooting your heat tracing system becomes necessary. 7. Energize each heat trace circuit to ensure that no short circuits or ground faults exist and that RTDs are functioning properly. 8. Stock critical spare components and cable. If your system still fails after all your checks, stocking spare components and cable will allow for timely repairs or replacements. 9. Don’t wait until winter to check your electric heat tracing system! Or if you have, don’t skip maintenance checks just because you “don’t have the time now.” Happy heating in the New Year.
Linda Becker, Associate Publisher and Editor,
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Inner Workings
20 Full-Tuition Scholarships Available for Manufacturing Workers
by Incoloy-sheathed, mineral-insulated rod elements located behind side duct sheets. Air is circulated by heavy-duty fan impellers on either side of the chambers.
The manufacturing industry needs a highly educated and competitive workforce. To help meet that demand, workers currently employed in U.S. manufacturing jobs have an opportunity to improve their skills with no-cost access to further education. The Manufacturing Institute of the Washington, D.C.-based National Association of Manufacturers and the University of Phoenix have come together to offer manufacturing employees full-tuition scholarships. Gaining advanced training can help manufacturing employees advance professionally and personally. Recipients can earn a degree at a University of Phoenix campus near his or her home or online. The 20 fulltuition scholarships will help workers hoping to complete their undergraduate or master’s degrees. The deadline for application is January 31, with a March 15 award date. Some of the criteria are:
General Mills is a well-known name to anyone who has gone to a grocery store or watched television commercials on a Saturday morning. But here is a lesser-known fact: the Lucky Charms cereal you or your kids dig into at breakfast soon may be made using a unique form of renewable energy. The company plans to deploy its first onsite biomass steam boiler in early 2011 at its milling plant in Fridley, Minn., where it produces oat flour for its signature cereals, including Lucky Charms. The boiler will burn the plant’s leftover oat hulls, the outer casing that is removed from the grain’s dense center. While the dense center begins process of becoming breakfast cereal, the hulls will be used as fuel to run the process.
• Applicants must be currently employed by a manufacturer in the United States. • Applicants residing in California, Florida, Indiana, Michigan, North
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Carolina, Ohio, Texas or Washington will be given priority consideration. • Applicants must submit completed essays. • Applicants must submit two letters of recommendation. Additional eligibility requirements and the application form are online. To learn more, visit www.phoenix. edu, type in “manufacturing scholarship,” scroll to the heading “General Content” and click on “Manufacturing Institute Scholarship.”
PTFE Heated on Ovens’ Rotating Tables Greene, Tweed & Co., a maker of sealing materials headquartered in Kulpsville, Pa., has installed two high-specification Carbolite ovens to increase the capacity and consistency of the raw material sintering operation at its U.K. manufacturing facility. The company uses several proprietary polytetrafluoroethylene (PTFE) formulations for its products, which are molded in both tube and bar form in the facility before being sintered and then machined to custom designs. Carbolite, Hope Valley, U.K., supplied the ovens to join two existing 10-yearold units. The new ovens each have a maximum volumetric capacity of 61 ft3 (1.73 m3) and a maximum operating temperature of 797°F (425°C). According to Carbolite, temperature uniformity is guaranteed to be better than ±9°F (±5°C) but typically it is expected to be as good as ±5.4°F (±3°C). The tube and bar being processed stand on rotating tables, ensuring that heat is applied evenly to all the material. The tables, which are perforated to improve air circulation throughout the chamber, rotate approximately once every two minutes. Heating is provided
Lucky Charms Feed Boilers as Well as Kids
The new boiler will replace a naturalgas boiler, making the mill partially self-sustaining, in addition to cutting its carbon footprint by 21 percent by reducing carbon emissions. Because the hulls release the same carbon they absorbed from the atmosphere as plants, the process is essentially carbon neutral. The hulls have 80 percent of the energy of coal without the harmful effects on the environment. “General Mills is committed to reducing our environmental footprint in areas like water, solid waste, energy and greenhouse gas emissions,” says Gregg Stedronsky, General Mills vice president for engineering. “That’s good for the planet and good for our business.” Energy produced from burning the oat hulls will be enough to produce 90 percent of the steam needed for making oat flour and heating the
Inner Workings At Goodyear’s tire plant in Union City, Tenn., a steam boiler system assessment followed by a load management strategy saves the plant $875,000 a year.
Photo courtesy of Goodyear
Fridley plant, and that only takes 12 percent of the leftover hulls. General Mills’ remaining oat hulls are sold to the Koda facility, which is a partnership between the Shakopee Mdewakanton Sioux Community and Rahr Malting Co. This facility creates enough energy to power 30,000 homes in Shakopee, Minn. General Mills supplies about a third of the Koda facility’s fuel needs. The biomass boiler project will help the milling plant save more than $500,000 in natural gas costs every year.
Goodyear Analyzes Boiler, Saves Nearly $1 Million The Goodyear tire plant in Union City, Tenn., is saving energy, which helps keep the plant’s operating costs down. A Save Energy Now assessment from the U.S. Department of Energy in 2006 identified opportunities to improve the efficiency of the plant’s steam system. Working with a DOE energy expert, the company’s employees, including Dennis
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Burden, a Goodyear energy manager, learned how to analyze the plant’s steam system and identify areas of natural gas savings to improve efficiency. “The program helped bring together plant resources to implement findings
or assist in completing projects already in progress,” Burden says. “Energy savings go directly to the bottom line, helping the plant compete in this global market.” Goodyear implemented DOE recommendations that have helped the facility save $875,000 annually in energy costs. Employees optimized boiler operations and developed a load management strategy shortly after the assessment was completed. They also insulated the tire presses and plan to start recovering wasted heat in the near future. Additionally, results from the assessment were deemed applicable to several other Goodyear plants and are being shared with those facilities — 60 in total — at monthly energy conference calls.
Inner Workings
NEW FULL FEATURE
Revised Infrared Handbook on Sale The second edition of the “Infrared Process Heating for Industrial Applications Handbook” now is on sale through the Industrial Heating Equipment Association. The publication is produced by the Infrared Equipment Division of IHEA. The handbook provides a quick introduction to the many applications of infrared heating in industrial processes. Infrared heat processing first was developed in the 1930s for curing paint on automobile bodies. Since then, infrared has been used in hundreds of different applications such as curing metal finishes and protective coatings, fusing thermoset and thermoplastic powder coatings, forming molded plastics, bonding adhesives and metals, processing foods, and drying papers, inks and fabrics. The guide is $15 for IHEA or IRED members, and $20 for non-members. Order the handbook at www.ihea.org.
Manufacturing to Help Spur Lubricant Sales A Freedonia Group Study, “Lubricants to 2014,” notes that U.S. demand for lubricants will reverse recent declines, supported by increasing manufacturing output, a turnaround in motor vehicle production and an acceleration in the number of automobiles in use. Higher quality base stocks as well as syn-
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Inner Workings thetic types will increase their share of the market, according to the Cleveland research company. The study analyzes the 2.1 billion-gal U.S. lubricant industry, presenting historical demand data for the years 1999, 2004 and 2009, with forecasts for 2014 and 2019 by base oil, product (for example, engine oils, process oils, general industrial oils, transmission and hydraulic fluids, metalworking fluids) and market. The study also considers market environment factors, details industry structure, evaluates company market share and profiles 35 industry players, including Shell, Exxon Mobil and Chevron. The study can be purchased in print or a PDF format at www.freedoniagroup.com.
Dewater Paper Web Better, Cheaper Tests at the Voith Paper Technology Center in Heidenheim, Germany, and initial field tests at customer sites have
Protect finned tube coils from corrosive atmospheres with Heresite’s baked phenolic coating. It is the proven choice in processes around the world for service in corrosive fumes and salt atmospheres. For Shell and Tube Heat Exchangers, Heresite can provide protection with the licensed Saekaphen Si series. Typically used in heat exchangers, condensers
shown that using newly developed suction roll covers and felts can achieve increases in dry content of up to 1.5 percent without the need for large investment costs, says the manufacturer. The technology that Voith applied to the polyurethane roll covers leads to deeper and wider grooves, resulting in shortened flow paths for the extracted water, the company says. This increased capacity enables larger quantities of water to be removed quickly and efficiently. The increased water quantities and resulting increased dry content are made possible by the structurally engineered felt with optimized absorptive capacity. The structure enables the felt to bridge the open spaces created by the grooving, reducing the risk of marking the paper. According to the company, SolarMax, the combination of suction roll cover and felt, offers maximum dewatering of the paper web and thus the highest possible dry content.
and evaporators, tube bundles can be protected from many acids, salts, water and alkaline services. Heresite coatings reduce maintenance costs with less downtime and permit the use of less costly alloys to reduce capital costs. Learn the whole story on corrosion resistance by contacting your local Heresite representative. 822 South 14th Street, P.O. Box 250 Manitowoc, WI 54220 Phone: 920-684-6646 • 800-558-7747 Fax: 920-684-0110 www.heresite.com E-mail:
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