www.process-heating.com | May 2011 | Volume 18, Number 5
Dry Spot Use our Equipment Overview to fi find nd manufacturers of process dryers and better understand their capabilities.
Periodical Class
18 Radiant Wraps Up Wire Heating 27 Standardizing Control Systems
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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omega.com, of Course!
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May 2011 Volume 18 • Number 5
www.process-heating.com WEB EXCLUSIVES: READ MORE AT WWW.PROCESS-HEATING.COM Q Compressed Air Best Practices Guide
page
page
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Q Heat Exchanger Design Simplified
Heat Exchangers The Importance of Research Understanding the impact of heat exchanger design and operation is essential for successful implementation.
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If you are looking for a method to answer design and operation questions related to your heat exchanger, there is an advanced tool for the design, rating and simulation of heat exchangers and fired heaters.
UPDATED DAILY
Heaters Radiant Heat Wraps Up Wire Heating How does using radiant heat reduce costs and optimize processing in wire, cable and tubing applications? Wire and tubing applications present processing challenges — and opportunities.
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Q Motor Control Centers Further Reduce Costs and Save Time In addition to the process automation system and industrial controls, IFCO also is using Allen Bradley’s motor control centers (MCCs) that reduce wiring costs and unnecessary use of raw materials.
Features 15
Manufacturing facilities require compressed air for many uses and applications – pushing and pulling, loosening and tightening, extending and retracting.
Equipment Overview: Dryers
Q New Products
Q Industry News
ALWAYS ONLINE 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
Dry Spot Use our Equipment Overview to find manufacturers of process dryers and better understand their capabilities.
27
Controls
Check out our redesigned site with more frequent updates and web exclusives!
Standardizing Systems Standardization of process automation systems helps reduce costs and improve efficiency for an oven and furnace maker.
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Heat Recovery Recovering Heat Saves Energy, Lowers Costs Capture and reuse heat from your compressed air system and reap process benefits, including an improved bottom line.
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, h includi l d ing Windows Mobile (5.5 and above), iPhone, Blackberry, Symbian and J2ME.
About the Cover page
32 Columns & Departments 6
Editor’s Page
36 Advertiser Index
8
Inner Workings
37 Classified Directory
12 Calendar
A turnkey fishmeal processing plant can include equipment such as a cooker, oil decanter, evaporator and, of course, a dryer. Photo courtesy of the Dupps Co. (www.dupps.com), Germantown, Ohio. To learn more about dryers, turn to page 22.
38 Places & Faces
34 Products
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 • M ay 2 0 1 1
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By Linda Becker
Commentary Understand the Fluid Heaters Standard
NFPA 87 and You For the first time, the National Fire Protection Association has issued a guidance document specifically for fluid heaters. The new NFPA 87 covers fluid heaters, including thermal fluid heaters and process fluid heaters, and asserts that the fluid will be flowing, under pressure and indirectly heater. Do you use fluid heaters in your facility? Then you need to get “in the know” about this new standard. Fortunately, a webinar, or online seminar, brought to you by Process Heating, can help you gain the knowledge you need. On June 9 at 2 p.m. ET, plan to join us for “New NFPA Recommendations for Fired Heaters: How They Affect You.” According to NFPA’s own description of the standard, the 2011 NFPA 87: Recommended Practice for Fluid Heaters, was developed in response to requests from manufacturers, insurance companies, trade associations and users for safety guidance for fuel-fired and electric fluid heaters. Its scope includes: • • • •
Heater location and construction as well as heating systems. Commissioning and operations. Maintenance, inspection and testing. Heating system safety equipment and application.
Packaged Gas Burner
During the webinar on June 9, you can learn directly from the NFPA 87 Committee Secretary what this publication means to your operation. Dr. Rick Martin, principal of the consulting firm Martin Thermal Engineering Inc., is an expert in heating and combustion equipment, specializing in investigations of explosions, fires and hazardous material releases. During the hour-long presentation, you will have a chance to: • Hear a concise summary of NFPA 87. • Learn how NFPA 87 could positively or negatively affect your operation or product development. • Ask questions and hear his answers live. The no-cost webinar is made possible due to the support of sponsors Ari Valve Corp., Heatec, MP Pumps and Sigma Thermal. To sign up for the webinar, visit webinars.process-heating.com.
Linda Becker, Associate Publisher and Editor,
[email protected] PBGII New and Improved
Many standard and configurable options available to suit a wide variety of applications with high thermal turndown and low CO and NOx emissions
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• Flame rod or UV scanner flame supervision
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• Multiple mounting configurations ®
Hauck Manufacturing Company, PO Box 90, Lebanon, PA 17042 Phone: 717-272-3051 Fax: 717-273-9882
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Inner Workings
Infrared Emitters Allows Automated Heating Processes The coatings that give corrosion protection to large metal components, provide clear varnish on plastic products, and allow for colored décor on stone all require a drying process. Infrared systems help ensure that the heating steps needed to dry these products are carried out as efficiently and uniformly as possible. Small, irregularly shaped stones or other bulk materials dry just as reliably with infrared heating technology as do large-surface metal parts, according to Heraeus Noblelight GmbH, headquartered in Hanau, Germany.
The drying of a decorative coating on stones is tested in the in-house laboratory at Heraeus Noblelight.
Metal plates must be heated homogenously over the entire surface to ensure coating quality. A precisely matched emitter arrangement in combination with the right control system will bring significant improvements, Heraeus says. An appropriate guidance system ensures the optimum alignment of stones or granules to the radiation, and bulk materials can be dried efficiently. No coating process is exactly the same, but lacquers and paints should always be dried as quickly as possible. Many coatings set challenges that cannot be met with standard heat 8
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M ay 2 0 1 1 • Process Heating
sources, and the coating system defines the data framework. For example, water evaporates more slowly than do solvents, therefore infrared emitters dry water-based lacquers significantly faster because the emitters are optimally matched to the absorption properties of water. Nano coatings to some extent require very high temperatures, which can be reliably delivered by infrared emitters. Powder coatings must be gelled very quickly, so infrared drying saves time and money because only the coating and surface are heated. The result is that the products are ready for further processing much more quickly after the heating stage. Industry keeps pushing the limits, wanting to dry lacquers and coatings ever faster. However, at the same time, the drying must produce a top quality product using the minimum amount of energy. Energy reduction and material costs are important to end-users in their struggle to maintain or improve competitiveness. Often, companies find it more sensible and cost effective to optimize an existing system by adding infrared to it rather than introduce an entirely new system or set up a new plant, Heraeus says. Infrared heating technology offers several benefits that optimize energy consumption in industrial heating processes: • • • •
High heat transfer capacity. Contact-free heat transfer. High efficiency. Efficient energy transfer by using optimum wavelengths. • Energy use confined to the working area by matching emitters to product shape. • Energy used only when required because of fast response times. According to Heraeus, infrared heat is suited for heating processes with
the challenges of space, time or quality, because infrared emitters can be selected for use with product and process to save money and energy.
Removing Water at 10.47 T/Hr Allgaier Process Technology GmbH, Uhingen, Germany, has received its fourth dryer order this year for a bentonite dryer system to be used at an Italian plant in the manufacturing of clay bricks. Bentonite is essentially an impure clay made of absorbent aluminium phyllosilicate. Specs for the new dryer, which will be used to remove moisture from the clay, are: • • • • • • •
10.49' dia. 75.45' long. 40.78 t/hr wet bentonite. 36 percent initial moisture. 14 percent discharge moisture. 10.47 t/hr water evaporation. Natural gas heat.
Allgaier bentonite dryers already are operational in Russia, France and Poland. For more information, contact Almo Process Technology Inc., Liberty Township, Ohio, at www.almoprocess.com.
Prototype Bakes Perfect Buns Every Time A production-line imaging and control system has been developed that automatically inspects the quality of sandwich buns exiting the oven and adjusts oven temperatures if it detects unacceptable product. “We have closed the loop between the quality inspection of buns and the oven controls to meet the specifications required by food service and fast food customers,” says Douglas Britton, senior research engineer at Atlanta’s Georgia Tech Research Institute, where the process was developed. “By creating a more accurate, uniform and faster assessment process, we are able to minimize waste and lost product.” During existing inspection processes, workers remove a sample of buns
Inner Workings This prototype imaging system inspects the quality of sandwich buns, automatically adjusting oven temperature if product color does not meet established requirements. The system has been operating at a baking facility for more than a year.
each hour to inspect their color. If the buns appear too light or too dark, they manually adjust the oven temperature. But with more than 1,000 buns leaving a bakery production line every minute, there is a great need for automated control to make more rapid corrections to produce buns of consistent color, size, shape and seed coverage. “Automated control over the baking process is necessary to produce a consistent product through batch changes, shift changes, daily and seasonal temperature and humidity changes, and variations in ingredients,” Britton says. Working with baking company Flowers Foods, headquartered in Thomasville, Ga., and Baking Technology Systems (BakeTech), a baking equipment manufacturer in Tucker, Ga., Britton and GTRI research scientist Colin Usher have tested their industrialquality prototype system. Made of stainless steel, the equipment is dust and water resistant, and mounts to existing conveyor belts as wide as 50". Britton and Usher tested the system in a Flowers Foods baking facility for a year, running it regularly for hour-long intervals. During the testing phase, the system successfully inspected a variety of buns, including seeded, unseeded, and those of different sizes and shapes. For the past year, the system has been fully operational at the plant.
“Without the imaging system, it would be impossible for an operator to respond quickly enough to make the correct changes to the oven to improve the target color of the product,” says Stephen Smith, BakeTech’s vice president and director of engineering. As fresh-baked buns move along Flowers’ production line, a digital camera captures their image. The software identifies those buns not measuring up to color requirements and sends the information to the oven controllers, which adjust the oven temperature to correct the problem. “Our system reduces the time between noticing a problem and fixing it,” GTRI’s Usher says. “The window for correction is short, though, because an entire batch may only take 12 minutes to bake and the buns stay in the oven for eight minutes, providing a four-minute window to correct the temperature of the batch once the first buns come out, so that the rest of the buns in the batch are an acceptable color when they come out of the oven.” The system also automatically records data such as shape, seed distribution, size and contamination to generate production reports that are immediately available for statistical process control. Another feature of the system is that the conveyor belt can be any color except the color of the buns. This allows the system to image buns on almost any conveyor belt surface or in pans. In the future, the imaging system could be adapted to control the quality of other bakery products, such as biscuits, cookies, crackers, bread and pies, GTRI says. The prototype system was shown at the International Baking Industry Exposition in Las Vegas. Initial fund-
Because our products are top quality Despatch never cuts corners. The products we build are manufactured to the highest industrial standards. Despatch ovens have a reputation for superior process control and dependable operation. Every oven is thoroughly tested and inspected prior to shipment.
INSPIRED INNOVATION
Thermal Processing Technology
phone: 1-952-469-5424
[email protected] www.despatch.com © 2011 Despatch Industries. All rights reserved.
Inner Workings ing for the project was provided by Georgia’s Traditional Industries Program for Food Processing, which is managed through the Food Processing Advisory Council.
Monitoring Heat Control when Manufacturing Fiberglass Insulation No question about it, Stan Banaszkiewicz can take the heat. In fact, it’s his job — everywhere he goes, it’s hot. Banaszkiewicz is plant engineer at CertainTeed Insulation Canada Inc., an Ottawa manufacturer of fiberglass insulation for home, industrial and commercial use. To produce the insulation, it is necessary to melt glass, of which 80 percent is recycled. The process requires temperatures ranging from 1,652°F (900°C) to as high as 2,192°F (1,200°C). Before melting, ingredients are added and the molten glass flows from the furnace to the forehearth and finally into the bushing. Eventually, the molten
glass drops down though an orifice in the channel to a centrifugal spinner. The glass is forced through the spinner’s tiny holes and comes out as glass fiber. But the heat is still on and the complex process is not over yet. In the next step, the glass fiber is formed and collected on a conveyor where polymers are added to keep it together. From there, it goes to the curing oven where the additives harden. The fiber then gets cut and sliced, Banaszkiewicz says.
To control the fiber’s quality throughout the manufacturing process, it is important to control the temperature in the electric forehearth, which is done by increasing or decreasing the power, according to Banaszkiewicz. Based on the temperature of the glass in each zone, power adjustments are made to each forehearth zone. The need to measure the temperatures in the glass-fiber manufacturing process led Banaszkiewicz to Rayek’s Marathon FA1G sensor, a fiber-optic infrared thermometer for measuring glass temperatures from 1,382 to 3,047°F (750 to 1675°C). With applications ranging from measuring molten glass in the forehearth to measuring the packingmaterial temperature for regenerator airflow control, the FA1G thermometer was a fit with CertainTeed’s needs. Installed in 1996, the system of Raytek FA1G sensors has provided a variety of measurements in many locations, Banaszkiewicz says.“We measure the
PROVEN SOLUTIONS SINCE 1851 Struthers Wells, a division of TEi, stands the test of time by setting global standards of excellence in the design and manufacture of custom built Fired Heating Systems and Waste Heat Recovery Boilers. Our experienced engineers and dedicated project teams are committed to maintaining the legacy by continuing to provide proven solutions in all applications of fired heater technology to the Chemical, Petrochemical, Petroleum and Power industries. Struthers Wells is a division of Thermal Engineering International (USA) Inc. which is a Babcock Power Inc. company.
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8833 N. Sam Houston Pkwy. West, Houston, TX 77064 TEL 281.664.8020 | FAX 832.237.8758 |
[email protected] www.strutherswells.com
Inner Workings temperature of the glass through the holes on top of the forehearth, so the sensor can actually see the glass,” he says. Prior to installing the FA1G sensors, Banaszkiewicz used platinum thermocouples placed in the glass. Depending on the manufacturing process, the FA1G sensors cost about half that of platinum thermocouples, providing money- and time-saving advantages, according to Raytek. For more information on Santa Clara, Calif.-based Raytek and the Marathon FA1G sensor, go to www.raytek.com.
Steam Assessment Nails 6-Week Payback At some chemical plants, steam systems account for the most end-use energy consumption. By conducting energy assessments of their steam systems, chemical plants can uncover important opportunities to improve energy efficiency, leading to significant energy savings, lower emissions
and higher productivity. A few years ago, Dow Chemical’s St. Charles operations management team at its petrochemical plant in Hahnville, La., took on the task of uncovering natural gas savings in its plant’s steam system. The plant undertook a Save Energy Now energy assessment, which was performed by the U.S. Department of Energy, and found several ways to increase steam-system efficiency. Plant personnel improved their steam-trap program and enhanced their ongoing leak-repair campaign. The combined annual energy and cost savings that resulted from just the two efficiency measures totaled 272,000 MMBTU and $1.9 million. With project costs of approximately $225,000, the simple payback was around six weeks.
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Because we have the most experience Despatch has over 100 years of proven success in partnering with customers to deliver complex thermal processing solutions. We are committed to working with you to learn the details of your unique process in order to design and engineer a custom piece of equipment that will meet your specific requirements.
INSPIRED INNOVATION
Thermal Processing Technology
401 Magnolia Avenue Croydon, Pa 19021 | (Phone) 215-788-5528 | (Fax) 215-788-7737 You can visit us on the web: www.tek-tempinstruments.com or email
[email protected] phone: 1-952-469-5424
[email protected] www.despatch.com © 2011 Despatch Industries. All rights reserved.
Calendar of Events May 16-19 — Boiler Operator (Level I) Training Seminar, Garden City, Kansas. Hosted by Kansas Industrial Technical School (Garden City Ammonia Program). Call (620) 271-0037 or www.boilerlicense.com.
Heat.
17-20 — Chinaplas 2011, Guangzhou, China. Visit www.chinaplasonline.com. 17-19 — Eastec, Eastern States Exposition Hall, West Springfield, Mass. Hosted by Society of Manufacturing Engineers. Call (800) 733-4763 or visit www.sme.org/eastec.
Cool.
24 — Fan Systems Management Workshop, Nashville, Tenn. Call (615) 232-6815 or visit www.eere.energy.gov/ industry. 24-25 — Web Coating and Drying Seminar (West Coast), Ontario, Calif. Hosted by AIMCAL. Call (803) 802-7820 or visit www.aimcal.org. 31-June 2 — Semicon Russia, Moscow. Hosted by Semiconductor Equipment and Materials International (SEMI). Call 7 495 978 6291 or visit www.semiconrussia.org.
June 1-3 — Steam Systems Specialist Qualification Workshop, Stockton, Calif. Call (800) 244-9912 or visit www.eere.energy.gov/industry. 6-8 — Sensors Expo & Conference, Donald E. Stephens Convention Center, Rosemont, Ill. Call (800) 748-5045 or visit www.sensorsexpo.com. 7-9 — Ipsen-U Vacuum Furnace Technical Training, Rockford, Ill. Call (800) 727-7625 or visit www.ipsenusa.com. 7-9 — Plastec East, Jacob K. Javits Convention Center, New York. Call (310) 445-4200 or visit www.canontrade shows.com/expo/plastecshows. 8-10 — Cracking Furnaces: Reaction and Combustion Fundamentals Seminar, Tulsa, Okla. Call (918) 234-5710 or visit www.johnzink.com. 16 — Pumping Systems Management Workshop, Morgantown, W.V. Call (304) 293-2867 or visit www.eere.energy.gov/ industry.
July 12-14 — Semicon West, Moscone Center, San Francisco. Hosted by Semiconductor Equipment and Materials International (SEMI). Call (408) 943-6997 or visit www.semiconwest.org.
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Inner Workings Although Midland, Mich.-based Dow had been aware that the efficiency of these systems could be improved, the assessment quantified the potential energy savings in a manner that made it more compelling to implement the improvements.
Developing Instruments for 175 years This year, Palmer Instruments Inc., Asheville, N.C., celebrates its 175th anniversary. Started in 1836 as the L.T. Wells and J. Foster Mathematical and Philosophical Instrument Makers in
Cincinnati, Ohio, the company became the James Foster Jr. Co. in 1852. The need to improve kerosene safety in the 1850s led to the development of the Foster automatic oil tester, a closedcup design instrument considered by many to be the first thermometer manufactured in the United States. Becoming the R.P. Palmer Co. in 1872, the firm specialized in mechanical temperature and pressure devices. The firm joined forces with digital temperature specialist Wahl Instruments in 1997 to become Palmer Wahl. For more information, go to www.palmerwahl.com.
WHAT’S HAPPENING TODAY? Visit www.process-heating.com and read daily updates • Technology Developments and Trends • Joint Ventures and Acquisitions • • New Web Site or Internet Services • New Sales Representatives • and Features or Distributors • New Personnel or Personnel Promotions • Address and Phone Number Changes • • Special Sales and Warranty Programs
Major Contracts New Product Introductions or Improvements to Existing Products ISO and Other Certifications
Web-exclusive stories are only found on www.process-heating.com, not in the pages of Process Heating magazine.
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
and evaporators, tube bundles can be protected from many acids, salts, water and alkaline services. Heresite coatings reduce maintenance costs with less downtime and permit the use of less costly alloys to reduce capital costs. Learn the whole story on corrosion resistance by contacting your local Heresite representative. 822 South 14th Street, P.O. Box 250 Manitowoc, WI 54220 Phone: 920-684-6646 • 800-558-7747 Fax: 920-684-0110 www.heresite.com E-mail:
[email protected] Because we deliver your order on time Short lead times and on-time delivery are just two of the ways that Despatch Industries keeps customers on the fast track to success. We also provide on-site training, installation and start up. With a global network of service and support technicians we are there when you need us to help keep you up and running.
INSPIRED INNOVATION
Thermal Processing Technology
phone: 1-952-469-5424
[email protected] www.despatch.com © 2011 Despatch Industries. All rights reserved.
Heat EExchangers
of
The
efer Jr., and James T. Scha i th ur m ya th Sa y By Vija earch Inc. (HTRI) Heat Transfer Res
Understanding the impact of heat exchanger design and operation is essential for successful implementation.
U
nderstanding process conditions and potential problems can influence design decisions that improve operation. At the other end of the spectrum, troubleshooting exchanger performance requires a working knowledge of the design attributes. At our research and technology center, Heat Transfer Research Inc. uses industrial-scale equipment as well as computational fluid dynamics (CFD) and other simulation capabilities to study the impact of heat exchanger design attributes and operational problems on performance.
This article discusses the benefits of a design change in the shape of a tube in d an air-cooled condensing system. It also a highlights how the study of heat exchangh er performance trends can help pinpoint e operational problems and identify design o improvements. i
B Benefits of Noncircular Tube Geometries T P Power plants use A-frame air-cooled cond densers to cool exhaust steam from the llow pressure stage of a steam turbine. An A-frame air-cooled condenser, whether mounted on the ground or on columns, offers users several advantages over the horizontal tube arrangement typical for API 661 applications. First, the higher duty per unit of ground area with inclined tubes reduces the required footprint. Second, tube inclination facilitates condensate drainage, resulting in higher condensate loading in each tube without generating excessive pressure drop (figure 1). Just as with other heat exchangers, the tube geometry in air coolers greatly impacts a unit’s efficiency and perfor-
mance. A-frame heat exchangers mance have finned elliptical, oval, flat or circular tubes. While the circular circula tube geometry is easier to manufacture and can withstand higher factur pressures for a given wall thickness, pressu it also increases the air-side pressure drop and leads to a non-uniformity in th the mean temperature difference across acro tube rows. Noncircular tube geometries N modify mod the air-side flow in a manner similar to the wings of an aircraft or the streamlined contours craf of a sports car. As shown in figure 2, tthe noncircular geometry: • Delays boundary layer separation. • Reduces the size of wakes. • Reduces form drag, thereby reducing the power consumed by the fans. The air-side heat transfer rate increases because the r boundary layer now contacts a greater l portion of the finned area, reducing the number of tube rows required for a given duty and providing a more uniform temperature difference between the air and the process fluid. A uniform mean temperature difference across all tube rows reduces condensate subcooling and the occurrence of freezing in the first tube row. Additionally, elliptical or flattened tubes increase the condensate loading with low two-phase pressure drop on the tube side. The net result of these effects is a better thermal design. Other factors such as cleaning and fouling potential often dictate the final choice of tube geometry for A-frame applications. However, noncircular tubes offer some benefits that circular tubes do not.
Using a Heat Exchanger Thermal Flow Loop Combining applied research with practice offers plant engineers and designers of heat exchanger systems the best understanding of underlying processes and potential improvements. www.process-heating.com • M ay 2 0 1 1
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Heat Exchangers Vapor and noncondensables
WEB EXCLUSIVE
Reflux module
Downflow module
Heat Exchanger Design Simplified If you need to answer design and operation questions related to your heat exchanger, there is an advanced tool for the design, rating and simulation of heat exchangers and fired heaters. READ MORE @ WWW.PROCESS-HEATING.COM
Plant engineers often are faced with reconciling computer simulations of different operating conditions with plant operating data. Invariably, the simulations and actual plant data differ, and the engineer must determine if the difference is due to plant instrumentation, the accuracy of the simulation predictions, or degradation of plant equipment. HTRI recently designed and constructed a heat exchanger thermal flow loop for use
Condensate Fan
Figure 1. The A-frame air-cooled condenser has downflow and upflow reflux zones.
in training of plant engineers. Using the heat exchanger thermal flow loop in conjunction with HTRI’s simulation software provides a method to answer design and operation questions. In 2011 we plan to open training sessions with the demonstration loop.
Two Coils
The demonstration loop consists of three heat exchangers (figure 3). Exchanger 1 (E1) heats test fluid in the hot loop using an electric heater. The hot fluid flows from E1 to Exchanger 2 (E2), where the heat is rejected to the cold loop inside E2. In the
are Better than One Designed with twin helical coils the General Combustion HYT Series heaters offer the highest efficiency available. The HYT is designed for high temperature applications and its small, compact package makes it the ideal choice for limited space environments and easy installation. The General Combustion HYT is suitable for use with a wide range of fuels and thermal fluids making it the most versatile and efficient heater available. For reliability you can trust and efficiency you can bank on... Call the experts at General Combustion.
HERE’S WHY . . . • • • • • • •
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Highest efficiency available Reduced operating costs Lower stack temperatures Compact construction for easy installation Safe, low-pressure operation No castable refractory Factory tested for optimum performance
M ay 2 0 1 1 • Process Heating
5201 N. Orange Blossom Trail, Orlando, FL 32810 • Phone (407)290-6000 • Fax (407) 578-0577
Heat Exchangers Fins E1 Wake region
Electric Heater Exchanger 1 (E1) Electricity to Fluid
Hot Loop Boundary layer separation E2 Boundary layer
Shell-and-Tube Exchanger Exchanger 2 (E2) Fluid to Fluid
Cold Loop Tube wall
E3
Stagnation point
Air
Figure 3. A heat exchanger thermal flow loop is shown in this schematic. Analyzing thermal performance during the design stage is important to help determine final design criteria.
Air
Air
Figure 2. This diagram shows the effect of tube geometry on airflow.
cold loop, the heated fluid travels from E2 to Exchanger 3 (E3) where it rejects heat to room air. The flow demonstration loop uses industrial instruments to monitor
operating heat exchanger performance. PH Vijay Sathyamurthi is an engineer with the research staff, and James T. Schaefer Jr. is a
SYSTEM DOWN!
Air Cooler Exchanger 3 (E3) Fluid to Air
project engineer for engineering services at Heat Transfer Research Inc., College Station, Texas. For more information, call (979) 6905050 or visit www.htri.net.
MultiTherm’s Heat Transfer Fluids Keep All Systems
GO! Run your system more efficiently, for longer periods, with less down time. Make System Maintenance a Priority!
1-800-339-7549 www.multitherm.com www.process-heating.com • M ay 2 0 1 1
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17
Heaters
Radiant Heat WRAPS UP
Wire Heating This 360° clam shell heater has a ceramic emitter.
H
ow d does using i radiant di t h heatt reduce d costs and optimize processing in wire, cable and tubing applications? Wire and tubing applications present processing challenges: • The product runs continuously. • The material being processed has a relatively small size. • The material is sensitive to both temperature and touch. Wire and tubing also are exposed to a range of operations, including drying, printing, striping, curing, preheating, heat shrinking and sintering. Manufacturers want to maximize output while controlling energy costs and minimizing capital invest-
ment in terms of both the direct cost of the oven and the indirect cost of floor space the oven requires. i
3 Methods of Heat Transfer To understand the benefits of radiant energy in this application, it is important to understand basic heat transfer. There are three methods by which heat is transferred: conduction, convection and radiant. Conduction heats through the physical contact between the heat source and the target. Convection transfers heat through the movement of heated air around the product. And, radiant heats through the transmission of electromagnetic waves that energize the atoms on any surface they hit. Because conduction heaters must be in physical contact with the product, they will not work for wire and tubing.
Radiant ovens provide benefits in wire, cable and tubing processing. By Tad McGwire, Industrial Heater Corp. 18
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M ay 2 0 1 1 • Process Heating
Convection ovens require an energy source, an air circulation system and, if gas is used as the fuel, a ventilating system. Also, because air is a relatively poor conductor of heat, convection ovens have long startup periods and require insulation to prevent heat losses to the surrounding atmosphere. The additional insulation also means convection ovens are slow to cool, and if the line stops or slows due to breakdown or changeovers, the product could be overheated if the oven is heated beyond the product’s maximum temperature. The primary advantage to convection heat is that the heat energy can be conducted deeper into the part. This often requires a longer dwell time in the oven, which means wire and tubing processors may need to slow the line speed or increase the oven length. Radiant, or infrared, heat does not heat the surrounding air and does not become heat until it is absorbed by the surface it contacts. Any object with a temperature above absolute zero emits radiant energy in the form of electromagnetic waves. The electromagnetic waves are measured primarily by their frequency and length (microns). The lengths of the waves are directly correlated to the temperature of the heat source (emitter) and are broken into three categories: • Short (3,000 to 6,800°F [1,649 to 3,760°C]). • Medium (500 to 2,999°F [260 to 1,648°C]). • Long (0 to 499°F [-18 to 259°C]). As temperature increases, the length of the waves get shorter and the frequency
Heaters Metal sheath emitters can be used in a keyhole oven.
increases. This range can be plotted tted using gy is calcuPlanck’s curve, and peak energy lacement. lated using Wien’s Law of Displacement. This data can be used to guide the ials are forchoice of emitter. Many materials giving and can absorb radiant energy over a range of temperatures. As an example, an 16°C) proemitter operating at 600°F (316°C) °F (538°C) duces waves at 7 μm and 1,000°F at 3.5 μm. Plastic tubing and plastic-like materials receive at both wavelengths but the 600°F is gentler or softer on the plastic. Radiant ovens may allow for better control of the process and to maximize output.
Radiant’s Cost Effectiveness To illustrate the energy efficiency of radiant heat, we need to go through the StefanBoltzman equation, which calculates the total amount of energy in watts generated by a heater at any given temperature. From this calculation, we can see that the output in watts of a radiant heater increases to the fourth power for every degree in temperature rise. For example, an increase in temperature of 5°F in the heater converts into an increase of 625 W radiated.
WEB EXCLUSIVE Emissivity of Common Materials Emissivity is one of the most important factors when designing a radiant oven. READ MORE @ WWW.PROCESS-HEATING.COM
Convection heaters increase output only on a one-to-one ratio. Radiant ovens have a faster warmup time that is, depending on the emitter used, sometimes measured in seconds, meaning less energy is used getting ready to run. Once the product is running, exponentially more energy input into the system (StefanBoltzman) gets transmitted onto the product, reducing energy costs. A radiant oven typically is smaller than a convection oven, and it does not need an air circulation system or additional insulation. There are several important factors to the successful design of a radiant oven for a given application. The most important is the emissivity of the material bring processed. Emissivity is a measure of how much radiant energy can actually be absorbed by the material as a percentage of the energy generated: the higher the emissivity, the more energy that is absorbed. Absorption rates are measured against a theoretical “black body” which absorbs 100 percent of the energy transmitted and has an emissivity of 1. Below is a chart of emissivity rating for some common materials. The percentage of energy that is not absorbed is either reflected from the tar-
get or passes passe through (transmission) the material. Clearly, material that is shiny Cl or polished reflects most of the waves and has a low emissivity w while darker, or oxidized parts w absorb the energy and have a higher emissivity. h Emissivity is also a measure of the percentage of s energy transmitted from the e heat source. The key operating h characteristics for radiant emitch ters are shown in table 1. sho In addition to emissivity, any oven design will need to incorporate: • Temperature change in the material (Final Temperature – Starting Temperature). • Size and weight of the wire or tubing. • Specific heat of the material. From this information, the oven designer can calculate the approximate wattage required. Once that is determined and based on the watt density capabilities (watts per square inch of surface area) of the selected emitter, we will know how many heaters are required, which in turn will dictate the size of the oven. The optimized oven design will array the heaters to direct as much radiant energy onto the product as possible. Since wire and tubing products tend to be round, the heaters should be arrayed in a circular fashion around the product. The design will also minimize the distance from the emitters to the product. The emitters should be backed by polished-steel reflectors so that any energy waves transmitted through the product, reflected off the product surface or simply
Table 1. Infrared Heater Comparison Chart Wavelength Temperature (°F) Quartz Tube
Short 0.72 - 1.50 6800 to 3000
Medium 1.51-5.40 2999 to 500
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Mechanical Strength
Heat/Cool
Max. Temperature
Max. Watt Density
Weak
Fast
4,000
100
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1,650
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1,200
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1,400
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Metal Sheath
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Ceramic
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Mica Strip
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Flat Panel
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www.process-heating.com • M ay 2 0 1 1
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Heaters
An optimized oven design will array the heaters to direct as much radiant energy onto the product as possible.
missing the target will be redirected back toward the product, maximizing energy utilization. To summarize, radiant energy allows for flexibility in the design of your oven by better matching the heat source to the processing requirements of the wire, cable or tugging being processed. Radiant heaters efficiently transmit energy input into the system into the product and have fast startup times, thereby reducing energy costs. Finally, radiant ovens tend to be physically smaller, reducing the indirect cost of floor space and the direct capital cost of the oven. PH Tad McGwire is president of Industrial Heater Corp., located in Cheshire, Conn. The company can be reached at (800) 822-4426 or
[email protected].
DMV
PH05091Wys.indd 1
4/20/09 9:22:58 AM
DMV Solution The DUNGS Dual Modular Valve (DMV) system provides a compact, integrated solution for reliable combustion control. Proof of Closure using a Valve Proving System or Valve Seal Overtravel-Interlock to meet code requirements
DMV Simplicity Comply with double valve requirements with a single control. The DMV features two valves in one body, available in single stage, two stage, fast opening or slow opening. Systems from 1/2” NPT to 5” ISO flanged.
DMV Advantage
www.dungs.com/usa 20
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M ay 2 0 1 1 • Process Heating
DMV-DLE 702/622
Streamline your combustion system by saving space, time and labor with the DMV by directly mounting a pressure regulator, pressure switches, butterfly control valve, valve proving system, and/or a vent line connection. Call, Fax or E-Mail for more information
Karl Dungs Inc. 3890 Pheasant Ridge Drive NE Blaine, MN 55449 Phone: (763) 582 1799 Fax: (763) 582 1799 E-mail: info@ karldungsusa.com
FREE 60-min. Webinar Register Now at http://webinars.process-heating.com
New NFPA 87 Recommendations for Fluid Heaters: How They Affect You June 9 | 2:00 p.m. EDT For the first time, the National Fire Protection Association has issued a guidance document specifically for Fluid Heaters. The new NFPA 87 covers both Process Fluid Heaters and Thermal Fluid Heaters. Learn directly from the NFPA 87 Committee Secretary what this publication means to your operation, and when and how to register your comments on it. While the document is not yet mandatory, it is moving in that direction. Your comments during the public comment period are the only way you can shape further development of NFPA 87 and its rules for Fluid Heater safety. Why you should attend: • Hear a concise summary of NFPA 87, which covers both Process and Thermal Fluid Heaters. • Learn how NFPA 87 could positively or negatively affect your operation or product development. • Ask the NFPA 87 Committee Secretary your questions directly and hear his answers live.
Advertising Sponsors:
SPEAKER Dr. Rick Martin Principal of the consulting firm Martin Thermal Engineering Inc. MODERATOR Linda Becker Editor and Associate Publisher Process Heating Magazine
Register for FREE at http://webinars.process-heating.com Can’t attend live? Register to receive the on-demand version.
Equipment Overview Dryers
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C CPM Wolverine Proctor www.cpmwolverineproctor.com w D Despatch Industries www.despatch.com w H Hix Corp. www.ovens-dryers.com w K Komline-Sanderson www.komline.com w M Marsden Inc. www.marsdeninc.com w T TPS-Gruenberg www.thermalproductsolutions.com w W Wyssmont www.wyssmont.com w Aaron Equipment Advance Systems Inc. Ajax Tocco Magnethermic Corp. Alstom Power Inc, Raymond and Bartlett-Snow American Process Systems, Member Eirich Group Applied Chemical Technology APV, An SPX Brand B.N.W. Industries Baker-Rullman Mfg. Inc. Barr-Rosin Inc. BBC/Black Body Belco Ind. Inc. Bepex Intl. Blasdel Enterprises Buhler Aeroglide C. A. Litzler Co. Inc. Carrier Vibrating Equip. Inc. Casso-Solar Technologies LLC CCI Thermal Technologies Cincinnati Indl. Machinery Cire Technologies Inc. Clextral CMM Group LLC Commercial Dehydrator Systems Inc. Compact Engineering Ltd. Conair Group Davron Technologies Inc. 22
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Batch/Cabinet
Dryers Supplier Companies
Continuous Conveyor
Dryer Configuration
You also can conduct your supplier search online! www.process-heating.com Click on Equipment Overviews, then on Dryers.
Convection, Flotation
Photo courtesy of Dupps
hether you want a batch, paddle or web dryer, or something else altogether, you are looking in the right place. The following pages are filled with Process Heating’s annual Equipment Overview on Dryers. Search by dryer configuration or type, material processed, energy source, manufacturing process or industry. Cross-check multiple headings to find those manufacturers who have experience with the type of equipment you want. We’ve even identified those companies that offer aftermarket parts for their equipment.
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Or, you can conduct your search at www.process-heating.com using our online Equipment Overview. The online version includes advanced search capabilities that allow you to narrow by multiple category headings with a click of the mouse. Some manufacturers have upgraded listings that include built-in hyperlinks that allow you to visit their websites. If you need more information than what we have specified here and on our website, and you would like to talk to
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Laminating
Heat Shrinking
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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 dryer market. To be included in future listings, contact Linda Becker at (847) 405-4020 or e-mail
[email protected].
Material Dried
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Steam
Spray
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Microwave
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a manufacturer immediately, complete contact information is included in the online Equipment Overview. So, to get started on your dryer manufacturer search, simply point your browser to http://www.process-heating.com/buyersguide/415/ibg.html.
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www.process-heating.com • M ay 2 0 1 1
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23
Equipment Overview Dryers
Dedert Corp. DeVries Drying Systems Inc. Dri-Air Industries Inc. Dupps Co. Engineered Product Sales Corp. Etter Engineering Evaporator Dryer Technologies Inc. Fannon Products Co. Feeco International Inc. Fluid Energy Processing & Equipment FMC Technologies Inc. Fostoria Process Equipment Div. GEA Barr-Rosin GEA Process Engineering Inc. George Koch Sons LLC Gerref Industries Inc. Glenro Inc. Global Technologies LLC Grieve Corp. Heraeus Noblelight Inc. Heyl & Patterson Inc., Renneberg Div. Indesco Oven Products Inc. Infratrol Mfg. Intek Corp. International Thermal Systems LLC ITW Finishing Equip. Americas Jensen Industries Inc. Lanly Co. Lectrodryer Leister USA Littleford Day Inc. Louisville Dryer Co. M-E-C Co. MCD Technologies Inc. Megtec Systems Metso Minerals Industries Inc. Novatec Inc. Nyle Systems LLC Patterson Industries (Canada) Ltd. Precision Control Systems Precision Quincy Corp. Process Heating Corp. Process Thermal Dynamics PSC Inc. Radiant Energy Systems Inc. Radyne Corp. Solar Products Inc. Thermal Engineering Corp. Thermcraft Inc. Thompson Dehydrating Co. Inc. Universal Dynamics Inc. Vector Corp. Wenger Manufacturing Inc. Wisconsin Infrared Systems Wisconsin Oven Corp. 24
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Convection, Flotation
Convection, Impingement
Convection, Counter-Flow
Conduction
Combination Infrared/Convection
Centrifugal
Other
Wickett
Web
Warp
Tunnel
Tower
Dryer Type
Tenter Frame
Tensionless
Skein
Shelf/Tray/Truck
Rotary
Roll/Cylinder
Ring
Paddle
Loft
Festoon/Loop
Deck
Can/Drum
Batch/Cabinet
Dryers Supplier Companies
Continuous Conveyor
Dryer Configuration
You also can conduct your supplier search online! www.process-heating.com Click on Equipment Overviews, then on Dryers.
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Ethanol/Biodiesel Fuels
Electronics
Chemicals/Petrochemicals
Pre- and Post-Drying
Pasteurizing
Industries Served
Moisture Profiling
Laminating
Heat Shrinking
Heat Setting
Granulating
Fusing
Finishing
Drying
Dehydrating
Curing
Calcining
Manufacturing Process
Other
Water-Based Materials
Solvent-Based Materials
Solids
Slurries
Powders
Pastes/Mixes
Other
Material Dried
Steam
Propane
Oil
Natural Gas
Hot Water
Hot Oil (Thermal Fluid)
Electricity
Dual Fuel
Other
Energy Source
Vacuum
Steam
Spray
Radio Frequency
Microwave
Infrared, Short Wave
Dryer Type
Yes Yes Yes Yes * * Yes Yes Yes Yes Yes Yes Yes Yes * Yes Yes Yes Yes Yes Yes Yes Yes Yes * Yes * Yes Yes Yes Yes Yes Yes Yes Yes Yes * Yes Yes Yes * * Yes Yes Yes Yes * Yes Yes Yes Yes Yes Yes Yes Yes
www.process-heating.com • M ay 2 0 1 1
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STANDARDIZING
Systems A lthough industrial ovens and furnaces operate on a simple concept, it takes considerable engineering and manufacturing expertise — combined with the right automation controls — to optimize the technology and make it viable in a range of applications. It is precisely these capabilities that have helped propel Rochester, N.Y.-based Industrial Furnace Co. (IFCO). The com-
pany designs, constructs and upgrades boilers, incinerators, kilns, smelters, multiple hearth furnaces, heat treat furnaces and fluidized bed reactors, but it also offers complete solutions that incorporate electrical, mechanical and process engineering capabilities as well as concept analysis, laboratory testing, field installation, startup and training. Because the company’s technology includes heat pro-
Standardization of process automation systems helps reduce costs and improve efficiency for an oven and furnace maker. By Engineers at Rockwell Automation
cessing systems that generate emissions below EPA guidelines, the company’s systems can be used in a range of applications such as tungsten recovery, magnesium production and activated carbon production from coal. In this age of sustainable manufacturing and production, one furnace application garnering considerable interest is the incineration of bio-solids in wastewater treatment plants. Instead of hauling waste off-site for disposal in a landfill, many treatment plants are using multiple hearth furnaces to convert the cake-like sludge into ash. The ash then is sold to fertilizer or cement manufacturers. In addition, the plant can use heat from the process to generate steam to produce electric power, turning what was previously a financial liability into an asset. To enable these technological advances, the heat processing equipment maker invested in its design and manufacturing capabilities, establishing engineering teams with specialized mechanical, electrical and integration expertise. Equally important has been the company’s willingness to apply innovative automation and control technology efforts to streamline its engineering, design and startup processes.
Process Automation System At the center of IFCO’s furnaces is a process automation system, the PlantPAx based on the Rockwell Automation Integrated The electrical house main control enclosures and motor control centers (MCCs) with networked I/O help reduce wiring costs. www.process-heating.com • M ay 2 0 1 1
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Controls Architecture platform. A unified process, discrete and information solution, the process control system is built on Allen-Bradley ControlLogix programmable automation controllers (PACs). These devices use a common control engine and development environment for a range of disciplines — from process to safety to motion. The system controllers are configured using the company’s RSLogix 5000 software, which helped IFCO reduce engineering time and streamline integration and troubleshooting. The software offers a common tag-based structure that uses real names rather than physical addresses. Tag names can be shared between controller programs, human-machine interfaces (HMIs) and other applications, helping reduce configuration and integration costs. In addition to standardizing on the process automation system, IFCO also uses a range of Allen-Bradley industrial control components. Regardless of the application, most IFCO’s furnaces have a similar design.
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IFCO’s electrical house main control enclosure helps engineers reduce costs and improve efficiency.
This allows modular software to deliver significant value to the equipment manufacturer. By using the software’s built-in instruction set and user-defined, add-on instructions (AOIs), IFCO’s designers save engineering time by creating a custom, commonly used library code that can be tested once and used multiple times. The library maintains logic blocks for each device, so the engineer only needs to determine how the device will work for the particular project. The engineer then can select the correct logic block to import into the program. Because the logic blocks integrate with each other, the engineer only needs to import the proper function for each device, and the software does the rest. “The modular software code has proven to be a huge time saver,” says Mike Hilton, director of electrical instrumenta-
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Thermal Fluid Heater Steam Boiler Medium Temp Process Heaters Heating Medium: Thermal Fluids Temp Range: 350° - 650°F BTUs: 126,000 - 6,250,000
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Available with: Expansion Tanks with Level Controls Distribution/Air Separation Tanks Air-Cooled 650° Pumps Custom Skid Mounts
Steam Boilers: NEVER A COMPROMISE FOR QUALITY OR SAFETY
Parker Boiler Co. 5930 Bandini Blvd. Los Angeles, CA 90040 (323) 727-9800 Fax: (323) 722-2848
[email protected] www.parkerboiler.com 28
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M ay 2 0 1 1 • 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
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All Units Available with: Expansion Tanks with Level Controls Distribution/Air Separation Tanks Air-Cooled 400° Pumps Custom Skid Mounts Natural Gas, #2 Oil, Propane, Combination Fired, Low NOx, or Bio Fuel Firing
All Parker Boilers Use a Flexible Staggered Tube Design with 8 to 10 Pass Flow with a 25-Year Guarantee Against Thermal Shock.
Fives North American provides a wide range of systems and services. 185 standard burner models built for fuel efficiency and increased production The best available low NOx technology Comprehensive array of process control products and systems
www.fivesgroup.com/fivesna
TEL 216.271.6000
FAX 216.641.7852
[email protected] Controls One of IFCO’s hearth furnaces stands tall in Gabbs, Nevada.
tion and controls with IFCO. “Having faceplates for repeatable processes and functions reduces design time.” The control platform also supports open networking standards such as EtherNet/IP, ControlNet and DeviceNet. Because these networks share a common application layer, the networks have a seamless flow of information between them. This allows IFCO engineers to configure the furnace from a single point as well as access the system’s information remotely to monitor performance and troubleshoot problems. Since standardizing on the control technology, IFCO is able to design and implement its systems faster than before. Previously, a typical furnace project would take about 12 to 18 months to complete. The company now can deliver a furnace in about 10 to 12 months.
WEB EXCLUSIVE Motor Control Centers Further Reduce Costs and Save Time In addition to the process automation system and industrial controls, IFCO also is using Allen Bradley’s motor control centers (MCCs) that reduce wiring costs and unnecessary use of raw materials. READ MORE @ WWW.PROCESS-HEATING.COM
“To help meet our installation deadlines, it’s critical that we use as much as we can from previous jobs,” says Hilton. “That’s precisely what the software allows us to do. With the standards library we’ve developed using add-on instructions, we’ve been able to cut our engineering time in half.” Another advantage of the solution is the compatibility and interoperability of all the products, which eases configuration and helps reduce integration and
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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troubleshooting time. As a result, startups are about 30 percent faster, according to Hilton. “With the added flexibility of the system, we are able to very quickly make design changes on the mechanical and process end,” he says. “Also, the tag-based development environment allows us to do a lot of concurrent engineering design, helping us commission and start up a furnace in a couple of weeks rather than the typical three to six weeks.”
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.
The library maintains logic blocks for each device. While many companies rely on these same control technologies to achieve cost savings and design efficiencies, the results IFCO has achieved are due to their willingness to maximize their investments. This investment includes not only the automation and control technology, but also encompasses the highly skilled personnel, engineering tools and support resources needed to meet the company’s performance, customer satisfaction and efficiency objectives. PH
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.
For more information, please contact Milwaukee-based Rockwell Automation’s Power, Control and Information Solutions headquarters at (414) 382-4444 or visit www.rockwellautomation.com.
ARI Valves…The Obvious Choice
ARI Valve Corporation 1738 Sands Place, S.E. · Marietta, Georgia 30067 U.S.A. Fax: (770) 933-8846 · Phone: (770) 933-8845 www.arivalve.com
PH04104ARI.indd 1
CPM Wolverine Proctor LLC
251 Gibraltar Road Horsham, PA 19044 Phone: 215.443.5200 Fax: 215.443.5206 Email:
[email protected] www.cpmwolverineproctor.com
3/26/10 2:13:40 PM
CPM Wolverine Proctor LTD
3 Langlands Avenue Kelvin South Business Park East Kilbride Glasgow, UK G75 0YG Tel: 44 (0) 1355.575350 Fax: 44 (0) 1355.575351 www.wolverineproctor.co.uk Email:
[email protected] www.process-heating.com • M ay 2 0 1 1
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Heat Recovery
Recovering Heat Saves Energy,
LOWERS COSTS Capture and reuse heat from your compressed air system and reap process benefits, including an improved bottom line. By Bob Baker, Atlas Copco Compressors LLC
N
oted American philosopher and author Henry David Thoreau once quipped, “First, there is the power of the Wind, constantly exerted over the globe… Here is an almost incalculable power at our disposal, yet how trifling the use we make of it.” Thankfully, technology and ingenuity have helped address Thoreau’s concerns for greater harmony between human ambition and our energy use. Compressed air, often referred to as the fourth utility along with the Big Three — electricity, gas and water — is frequently utilized as a means to power applications throughout the manufacturing process. Technological advances, coupled with rising energy costs, have in recent years enabled — and, in many cases, required — manufacturers, much to Thoreau’s point, to make compressed air a more valuable and appreciated commodity. While technology upgrades can certainly help improve efficiency, the compressed air process still requires intensive energy use. Within many compressed air systems, only about 15 percent of the energy input is ultimately delivered as compressed air energy. The remaining energy is converted to heat that is generated as a physical and natural byproduct when air is compressed. In order for a compressed air system to function properly, that heat must be removed before the air can be moved through a piping
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M ay 2 0 1 1 • Process Heating
With an air-cooled compressor, the discharged hot air can be routed through ducts to a nearby warehouse space or loading dock. This supplements the facility’s heating costs in the winter.
system. The more heat energy that can be recovered and reused throughout this process, the greater overall efficiency the system will exhibit. The temperature level of the recovered energy helps determine its enduse applications and, ultimately, its value.
Ways to Use Captured Heat Two common ways to reuse this energy, which depend on the use of an air-cooled or water-cooled machine, are through hot air or heated water. In an air-cooled compressor, the heat is immediately discharged directly across airto-air heat exchangers to the compressor room. With an air-cooled compressor, the discharged hot air can be routed through ducts to a nearby warehouse space or loading dock. This supplements the facility’s heating costs in the winter by offsetting money and energy that would otherwise be used to heat this space — essentially eliminating a redundant function, at least in certain applicable
situations. Air dampers, fans and thermostat controls can help regulate distribution of the heat recovery throughout the manufacturing facility and even into adjoining buildings. With water-cooled compressors, which provide more efficient energy-recovery methods, this heat is pulled away from the compression elements as well as the oil cooler, the intercooler and aftercooler, and routed to a cooler or chiller. With water-cooled compressors, an even greater amount of energy can be recovered, yielding additional costs savings. Built-in energy recovery systems within the compressor circulate cooling water through the compression element water jackets, air and water coolers to generate hot water up to 194°F (90°C). This can be of particular use to food manufacturing and processing facilities, where there is a consistent need for readily available hot water for tasks such as equipment cleaning and sanitation, preheating water, cleanup and general heating. In
Heat Recovery
Oxidizers Ovens Furnaces
Utilizing heat recovery with a compressor can harness and recycle 90 percent (or more, in optimal conditions) of those energy costs as heat recovery from the compressed air process for alternative uses within the manufacturing process.
these instances, the compressor becomes the alternative energy source for any scalding, cleaning, sterilization, heating and melting applications, providing year-round savings. Return on investment for energy recovery systems through collected heat is usually as fast as one to three years. However, in order for recovery to remain reliable and regular, a stable heat energy demand is needed. To help manufacturers realize greater energy savings, some oil-free compressors can allow recovery of 90 percent of the electric power needed to operate the compressor as hot water. In optimal design conditions, heat recovery and use in other areas of the facility can provide a 100 percent return on the cost to operate the compressor — meaning managers can recoup all of the costs they would otherwise spend for these applications through compressor use, rendering the compressor revenue neutral or “carbon zero.” Any power that would have been used to otherwise heat water for these applications is offset or eliminated.
WEB EXCLUSIVE Compressed Air Best Practices Guide Manufacturing facilities require compressed air for many uses and applications. READ MORE @ WWW.PROCESS-HEATING.COM
Built-in energy recovery systems within the compressor circulate cooling water through the compression element water jackets, air and water coolers to generate hot water up to 194°F (90°C).
¾ Oxidizers RTO Recuperative Catalytic
Energy costs have been on the rise throughout the last decade and show no signs of slowing down. But that does not mean that utility bills need to follow the same course. When electricity costs hold at $0.08/ kWh, the annual cost to operate a 200 hp air compressor reaches $112,000. Utilizing heat recovery with a compressor can harness and recycle 90 percent (or more, in optimal conditions) of those energy costs. Conserving energy is no longer a luxury that manufacturers can take to simply endear themselves with conservationists; saving energy is a crucial component to any manufacturer’s bottom line. PH
Ovens & ¾ Furnaces Conveyorized Low Temp. & High Temp. Batch
Bob Baker is a senior marketing support specialist for Atlas Copco Compressors LLC, Rock Hill, S.C. For more information, call (803) 8177200 or visit www.atlascopco.com/us.
936-273-3300
[email protected] www.epconlp.com www.process-heating.com • M ay 2 0 1 1
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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.
Quartz Infrared Heating Elements The CE-certified quartz infrared heating elements offer a heavy-wall quartz sheath in 0.625" standard diameter to resist corrosion and chemical vapors. They are available in sizes 500 to 4,000 W and 120, 208 and 240 V as well as other voltages. Ceramic insulators provide positive electrical insulation. They can be used for curing, baking and drying applications and are capable of reaching full heat in 40 to 65 sec. Watt densities are 50 W/in2 (8 W/cm2). Process Technology (440) 974-1300 • www.process-technology.com
3-A Approved Sanitary Probes Designed with integral transmitter and M12 connector, PRS-TMM12 Series is designed for use in sanitary or hygienic
Marsden’s Gas IR Systems
Replacement Emitters
clean-in-place applications in the food, dairy, beverage and biopharmaceutical industries. The transducers are manufactured with 316L stainless steel housings that meet the dimensional and finish requirements of 3-A Standard 74-03 and ASME BPE-2007. The devices are welded and processed to provide a clean, smooth, 32 μin. or better surface finish in the wetted areas for clean-in-place processes. Omega Engineering Inc. (203) 359-1660 • www.omega.com
Class A Oven Able to process a range of materials, Model 49C-650D is used by heat processors that require a Class A oven. Weighing in at 1,180 lb, the oven has two independent 5.9 ft3 oven chambers. It can reach a maximum temperature of 650°F (343°C). Precision Quincy Corp. (815) 338-2675 • www.precisionquincy.com
NEW FULL FEATURE
COMBUSTION SAFEGUARD FORM 6642FF
High Quality Innovation.
Cost-Effective Renovation.
For over 30 years, Marsden has brought the most innovative drying solutions to industrial applications. Our US manufactured Gas IR systems with their unique Embedded Combustion® technology continues to set the standard in Safety, Performance, Reliability and Value.
Now Marsden offers M2 metal fiber replacement emitters. With increased fuel efficiency, greater longevity, faster heat up and cool down with operating temperatures to 2200˚F, it’s the costeffective way to replace your current burners and still get MARSDEN.
Monitor and control burners in new, replacement or retrofit applications. Designed to reach new levels of operating control and safety. Full Feature Combustion Safeguard including: r 3FMBZDPOUBDUTGPSIJHIàSFMPXàSFDPOUSPM r 1SPPGPG$MPTVSF r 1SPPGPG)JHI'JSF1VSHF r 1VSHF5JNJOH r 1SPPGPG-PX'JSF4UBSU r *HOJUJPO5SJBM5JNJOH r 1JMPU*OUFSSVQU5JNJOH r "MBSNPVUQVU r &JHIU4UBUVT-JHIUT r 0QFSBUFTXJUI'MBNF3PEBOEPS Ultra-Violet Scanner r "WBJMBCMFJO/&."FODMPTVSFXJUI WJFXJOHXJOEPXBOEJMMVNJOBUFE1PXFS 0GG0O3FTFUTXJUDI 'PSPWFSZFBST XFIBWFQSPWJEFE&MFDUSJDBM4BGFUZ &RVJQNFOUGPS*OEVTUSZ'PSDPNQMFUFJOGP DPOUBDUVTBU FNBJM!QSPUFDUJPODPOUSPMTJODDPNPSWJTJUPVSXFCTJUF BUXXXQSPUFDUJPODPOUSPMTJODDPN
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
marsdeninc.com • 856.663.2227 34
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Product Highlights 550°F Bench Oven No. 983 is used for curing medical instruments and employs 3 kW Incoloy-sheathed tubular heating elements. Workspace dimensions are 26 x 22 x 16". The electrically heated 550° F (~288°C) bench oven has 3" insulated walls; a Type 304, 2B finish stainless steel interior; and a #4 brushed finish stainless steel exterior. Two 13 x 4" access slots are equipped with insulated covers on the rear wall of the oven. Grieve Corp. • (847) 546-8225 • www.grievecorp.com
Batch Oven Cures Composites Gas-fired batch oven is used to cure composite parts. The curing oven has chamber dimensions of 8 x 10 x 8' and a maximum operating temperature of 500°F (260°C). The normal operating temperature is 250°F (121°C). It is constructed with 4" thick tongueand-groove panel assemblies and 20-gauge aluminized steel interiors and ductwork. The heating system has a low NOX 400,000 BTU/hr air heat burner. It also includes a motorized gas control valve, flame detector and flame relay with alarm horn. Wisconsin Oven Corp. (262) 642-3938 • www.wisoven.com
Desiccant Dehumidifiers Series HCE is designed to efficiently dehumidify to low moisture levels and ranges in sizes from 15,000 to 40,000 cfm. Each dehumidifier’s casing is manufactured of fully welded, strain-hardened aluminum to ensure zero air leakage. The electrical control system meets UL and NEC standards. Units are PLC controlled, and all controls are mounted in a NEMA 4 control enclosure. Weather-tight construction and low profile cassette design make them suitable for outdoor or indoor mounting. Munters Corp., DH Division (800) 843-5360 • www.munters.us
DC Solid-State Switches Series LVD is designed to disconnect 12 or 24 V battery systems from their loads when the battery voltage falls below a preselected DC voltage. The disconnect switch also will automatically reconnect the load circuit once the battery voltage returns to a normal value after charging. The DC output, low-voltage-disconnect solid-state switches are offered in an encapsulated panel mount package with screw terminals. Six threshold voltages are available. Crydom Inc. • (619) 210 1550 • www.crydom.com
s&LUID0ROCESS(EATINGs s &LU UID 0ROCESS (EATIN UID NG s s$ESIGN,%NGINEERAND-ANUFACTUREs #ONTACTOUR%NGINEERING3ALESTEAMDIRECTLY TEL s&AX INFO HUBBELLHEATERSCOM wwwHUBBELLHEATERSCOM
4(%%,%#42)#(%A4%2#/-0ANY www.process-heating.com • M ay 2 0 1 1
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Product Highlights Thermal Imaging Camera HeatSeeker 160 has a Class II laser and delivers a high resolution thermal image (160 x 120, 19,200 pixels) and a twomegapixel visual image. It provides sharp images in the temperature range of 14 to 482°F (-10 to 250°C) with accuracy of ±2°C. Designed for non-contact preventive maintenance, it identifies potential problems before they occur by detecting hot spots on motors, switch gear, processing pipes, compressors and fuse panels. Applications include energy audits or identifying inefficient heating and cooling transfer. Ideal Industries Inc. (800) 435-0705 • www.idealindustries.com
Sheet Molding Compound Preheater
Advertising Index
Macrowave SMC Preheater provides uniform heating throughout the entire thickness of the sheet molding compound instantly without requiring any temperature differential to force heat by conduction from the surface to the center. Facilitating the movement and distribution of fibers throughout mold-
36
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ed parts, improving their strength and surface finish, the radio frequency (RF) preheater reduces press cure time. It is capable of preheating SMC loads up to 30 x 84". Radio Frequency Co. Inc. (508) 376-9555 • www.radiofrequency.com
Springless Diaphragm Valves Series DCS/RDCS is suited for use with the company’s Series DCT1000 and Series DCT500 duct collection timer boards. A springless design offers durability and a good cleaning pulse. Both have the option for either coupling or NPT connections. The coupling connection allows for a quick and simple installation. Only the stub pipe and blow tube need to be cleaned and deburred before the valve is fit into position. Dwyer Instruments Inc. (800) 872-9141 • www.dwyer-inst.com
Sunlight-Readable Displays for Explosion-Protected HMI Systems The PC-based, explosion-protected operating systems can be fitted with 15" displays that reduce glare and reflections to a minimum. The Open HMI Series can be read even in bright sunlight because a filter pack effectively diverts even strong incoming ambient light. R.Stahl Inc. • (800) 782-4357 • www.rstahl.com
Page
Company
Phone
Fax
31
ARI Valve
(800) 933-8845
(770) 933-8846
Web
4
Bloom Engineering Co.
(412) 653-3500
(412) 653-2253
www.bloomeng.com
[email protected] 31
CPM Wolverine Proctor
(215) 443-5200
(215) 443-5206
www.cpmwolverineproctor.com
[email protected] www.arivalve.com
E-Mail
[email protected] 9
Despatch Industries
(952) 469-8278
(952) 469-8206
www.despatch.com
[email protected] 11
Despatch Industries
(952) 469-8278
(952) 469-8206
www.despatch.com
[email protected] 13
Despatch Industries
(952) 469-8278
(952) 469-8206
www.despatch.com
[email protected] 6
Elster Hauck Kromschroeder
(717) 272-3051
(717) 273-9882
www.hauckburner.com
[email protected] [email protected] Emerson ASCO
(800) 972-2726
(973) 966-2448
www.asco.com
39
Epcon Industrial Systems
(936) 273-3300
(936) 273-4600
www.epconlp.com
[email protected] 29
Fives North American Combustion
(216) 271-6000
(216) 641-7852
www.fivesna.com
[email protected] 14
Fulton Thermal Corp.
(315) 298-5121
(315) 298-5311
www.fulton.com
[email protected] 16
General Combustion
(407) 290-6000
(407) 578-0577
www.gencor.com
[email protected] 2
Heatec
(800) 235-5200
(423) 821-7673
www.heatec.com
[email protected] 40
Heatec
(800) 235-5200
(423) 821-7673
www.heatec.com
[email protected] 13
Heresite Protective Coatings
(800) 558-7747
(920) 684-0110
www.heresite.com
[email protected] 35
Hix Corp.
(800) 835-0606
(620) 231-1598
www.ovens-dryers.com
[email protected] 35
Hubbell Electric Heater Co.
(800) 647-3165
(203) 378-3593
www.hubbellheaters.com
[email protected] 20
Karl Dungs Inc.
(763) 582-1700
(763) 582-1799
www.dungs.com/usa
[email protected] 12
Komline-Sanderson
(800) 225-5457
(908) 234-9590
www.komline.com
[email protected] 34
Marsden Inc.
(856) 663-2227
(856) 663-2137
www.marsdeninc.com
[email protected] 17
MultiTherm
(800) 225-7440
(610) 408-8365
www.multitherm.com
[email protected] 3
Omega Engineering Inc.
(203) 359-1660
(203) 968-7192
www.omega.com
[email protected] 28
Parker Boiler Co.
(323) 727-9800
(323) 722-2848
www.parkerboiler.com
[email protected] 30
Payne Controls
(800) 331-1345
(304) 757-7305
www.payneng.com
[email protected] 34
Protection Controls
(847) 674-7676
(847) 674-7009
www.protectioncontrolsinc.com
[email protected] 7
Sigma Thermal
(678) 324-5721
(678) 254-1762
www.sigmathermal.com
[email protected] 21
Southern California Gas Co
(800) 427-2000
(866) 364-9024
www.socalgas.com
none
10
Struthers Wells
(281) 664-8016
(832) 237-8758
www.babcockpower.com
[email protected] 11
Tek-Temp Instruments Inc.
(800) 259-4212
(215) 788-7737
www.tek-tempinstruments.com
[email protected] 26
TPS-Gruenberg
(570) 538-7200
(570) 538-7380
www.thermalproductsolutions.com
[email protected] 20
Wyssmont
(201) 947-4600
(201) 947-0324
www.wyssmont.com
[email protected] M ay 2 0 1 1 • Process Heating
PH Classifieds
Send advertising copy to: Process Heating/Attn. Becky McClelland Phone: (412) 306-4355 • Fax: (248) 502-1076 E-mail:
[email protected] Display Classified Rates: 1X $100 • 3X $95 • 6X $90 • 9X $85 • 12X $80
Equipment for Sale
CAN-ENG FURNACES INTERNATIONAL LTD.
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
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Liquid Cooled
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www.leisterusa.com Toll-free: (855) Leister
[email protected] Near Zero Emissions. Quality. Efficiency. Reliability.
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Locate the industrial equipment, components and services specifically used in applying, transferring, measuring, monitoring and controlling heat in the manufacturing operations that you need! • Search by Company Name or Product Category • Downloadable Product Spec Sheets • Alpha Company Listings • Live Web & Email Links • Product Photos
2011 Buyers Guide Start your search today! Watch for expanded - listings! www.process-heating.com/buyersguide www.process-heating.com • M ay 2 0 1 1
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Places & Faces Bishop-Wisecarver Corp., Pittsburg, Calif., appointed Nandan Mehta vice president of marketing. With a strong mechanical engineering and business development background, Mehta has more than 20 years of experience working in various markets including aerospace, power generation, defense, appliance, medical devices and automotive.
Fieldbus Foundation, Austin, appointed Larry O’Brien global marketing manager. O’Brien has 18 years experience in the process automation business as a research director and analyst, and has closely tracked and reported on developments surrounding fieldbus issues for much of his career.
Fluke Corp., Everett, Wash., published its 2011 Test Tools Catalog. To request a copy, visit www.fluke.com.
Metallized Carbon Corp., Ossining, N.Y., redesigned its website,
According to the organization, honorees demonstrate real and sustained ethical leadership within their industries, putting into business practice the institute’s credo of “Good. Smart. Business. Profit.” Alliance to Save Energy plans to host its annual Energy Efficiency Global Forum in Brussels in April. The event, now in its fourth year, brings together officials from government, industry and nonprofit organizations to discuss trends and issues in energy efficiency. Go to http://tinyurl.com/6dyql9w.
Teledyne Scientific & Imaging LLC, a subsidiary of Teledyne Technologies Inc., both of Thousand Oaks, Calif., has acquired a majority interest in Nova Research Inc., Solvang, Calif., which manufactures compact medium-wave and short-wave infrared camera systems, and designs integrated circuits and integrated camera electronics.
For the fifth consecutive year, International Paper, Memphis, has been a recipient of the World’s Most Ethical Companies award by the Ethisphere Institute, New York. The designation recognizes companies that go beyond making statements about doing business ethically and instead translate those words into action. 38
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Group Publisher • DOUG GLENN (412) 306-4351 •
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Commerce Secretary Gary Locke has launched the Renewable Energy
and Energy Efficiency Export Initiative. The effort, co-chaired by the Department of Commerce and Department of Energy, brings
self-lubricating carbon/graphite products for pump, oven, conveyor, damper, petrochemical and chemical processing applications.
Senior Group Publisher, Manufacturing Group TOM ESPOSITO • (610) 436-4220 ext. 8530
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www.metcar.com. The site describes the company’s engineered
PUBLISHING STAFF
together eight federal agencies to coordinate efforts and boost exports in renewable energy and energy efficiency industries. The initiative will offer financing mechanisms for companies looking to expand abroad, increase the number of trade promotion events, direct agencies to improve export services, and lower trade barriers for companies. Visit the Renewable Energy & Energy Efficiency Exporter Portal at www.export.gov/ reee for more information. In May, the United States will host high level representatives from China for the second U.S.-China Energy Efficiency Forum, which is open to the public. The event, scheduled for Berkeley, Calif., will highlight energy efficiency cooperation and partnerships between the two countries.
SINGLE COPY SALES ANN KALB • (248) 244-6499 •
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Scan this QR code* to learn more about the modular gas safety shutoff valves. * Requires QR code reader.
Cut your fuel train down to size Big flows. Small footprint. Designers everywhere are downsizing their fuel trains using the new modular gas safety shutoff valves from ASCO. Optimized valve geometry delivers extremely high flow rates and very low pressure drop. Simply connecting two valves together yields a significantly smaller double valve footprint. And those high flow capabilities mean designers can now select their gas train components for smaller size – and lower cost. For locations with low gas supply pressure, and for heating equipment with high firing rates, just apply ASCO and watch the advantages stack up.
The ASCO trademark is registered in the U.S. and other countries. The Emerson logo is a trademark and service mark of Emerson Electric Co. © 2011 ASCO Valve, Inc.
800-972-ASCO (2726) | www.ascovalve.com/ModularValves | e-mail:
[email protected] 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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