February 2018 • Volume 25, Number 2

Optimizing
POLLUTION-
CONTROL
Equipment

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 FEBRUARY 2018 Volume 25 • Number 2

22
Features
Online Exclusives
12 Burners
Heat Recovery for Process Efficiency Flow Configurations for Air-to-Air Exchangers
Recapturing waste heat allows you to capture thermal energy An important consideration when selecting a heat exchanger is what type
you would otherwise let escape up the stack and put it to work of flow configuration makes most sense for the process. Generally, one of
in your process.
four flow configurations are used for plate type heat exchangers. Each is
18 Pollution Control named for the direction of the two flows (process and waste heat).
How Deliberate Integration of Air Pollution-Control
Equipment Optimized Production Victaulic to Build Manufacturing Facility in Pennsylvania
Improved overall operation is possible when entire plant Victaulic, a manufacturer of mechanical pipe joining solutions, plans to
operation is considered rather than sub-optimizing choices build an additional state-of-the-art manufacturing center in Lehigh Valley,
around pollution-control equipment. Pa. The 400,000 ft2 facility is expected to break ground later this year and
22 Valves/Piping be fully operational in 2019.
Craft Brewery Drives Success with Process
Automation Swap New Hand Soldering World Champion Crowned
When an important calculation for a new controls solution was Sixteen competitors from around the world participated in the Hand
overlooked, the result threatened to keep a new brewery aging Soldering World Championship. IPC — Association Connecting Electronics
tank offline. Substituting solenoid valves with built-in power Industries hosted the event in cooperation with productronica 2017.
management brought the equipment online.
26 Heat Transfer Fluids Always Online
Flashpoint Concerns in a Closed-Loop ■ Archives ■ Energy Notes column ■ Digital Editions
Thermal Oil System ■ Calendar of Events ■ Equipment Overviews ■ Buyers Guide
When it comes to industrial heat transfer fluids, flashpoint is a ■ Drying Files columns ■ Heating Highlights ■ Archived Webinars
very misunderstood value. Is it an important value? Yes, but in ■ New Products ■ Industry News
the right context. Check out our redesigned site with more frequent updates and web exclusives!
29 Burners
Direct-Contact Water Heaters for Concrete Plants Quick links point the way:
Direct-contact water heaters minimize downtime, produce hot www.process-heating.com/connect
water on demand and offer fuel savings.
32 Boilers Go Mobile
Use your smart phone to read Process Heating, wherever you are! Point
Boiler Cleaning Drives Benefit to Bottom Line
your phone or tablet’s camera at the image
Effective boiler cleaning can restore boiler surfaces — and at right to scan the QR code with your mobile
efficiency. phone or tablet. Your device will display the
36 Fans/Blowers mobile version of the current issue of Process
Centrifugal Fans for Power & Glass Process Cooling Heating instantly!
In any process cooling application where centrifugal fans Your mobile service provide may charge for
provide the essential flow and pressure ingredients, proper data transmission usage. Contact your mobile
selection is critical. provider for details on your data plan and limits.
40 Equipment Overview
Temperature Controllers
What kind of control does your process need? Process Heating
helps you select an industrial temperature controller and About the Cover
equipment supplier. A high efficiency recuperative thermal February 2018
• Volume
25, Numbe
r2

oxidizer, designed by Pollution Systems

Columns & Departments (www.pollutionsystems.com) was used
to increase on-stream time and reduce
4 Commentary 45 Advertiser Index maintenance at an animal-feed product POLLUTION-g
Optimizin

6 Inner Workings 45 Classified Directory facility. Learn about optimizing pollution- CONTROL
Equ ipment
10 Calendar 46 Places & Faces control equipment in an article beginning
42 Product Highlights 46 Contact Us on page 18. Follow us
on:

www.pr ocess-h
eating.c om

PROCESS HEATING (ISSN: Print 1077-5870 and Digital 2328-9996) is published 12 times annually, monthly, by BNP Media, Inc., 2401 W. Big Beaver Rd., Suite 700, Troy, MI 48084-3333. Telephone: (248) 362-3700, Fax: (248) 362-0317. No charge for subscriptions to
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www.process-heating.com FEBRUARY 2018  3

Commentary
Find Solutions for Heat Transfer,
Heat Recovery
In this issue of Process Heating, we include
articles about heat transfer fluids, heat
recovery and pollution control technologies,
among others.
Long-time readers of this column will
be familiar with Process Heating,’s webinar
series on thermal fluids for high temperature
industrial processes. There’s just a few more By Linda Becker
months to view the on-demand webinars
on our website. (Visit www.process-heating.com/
HTFwebinars to register or login.)
Fortunately, that’s not the end of our thermal fluid
coverage. In this issue of Process Heating, Mark Smith
of MultiTherm looks at “Flashpoint Concerns in a
Closed-Loop Thermal Oil System.” Smith explains
how flashpoint testing is conducted and looks at
conditions that could support a thermal fluid flash fire.
Elsewhere in this issue, Jessica Irons of Honeywell
looks at using air-to-air heat exchangers for industrial
process heat recovery. Even when fuel prices are
relatively low, as they are now, companies in energy-
intensive industries can realize a relatively short
payback from adding heat recovery system, Irons
says in “Heat Recovery for Process Efficiency.” But,
of course, to best realize that heat recovery, it pays
to carefully consider your process, the materials
being used for heat recovery, and the equipment
that best can handle the flow with minimal areas
of inefficiency. For instance, dimple-plate-type heat
exchangers are better able to withstand dirty process
airstreams but sinusoidal- or wave-plate exchangers
offer better heat transfer effectiveness. Can your
process use a sinusoidal-plate exchanger or will the
airstream media demand another design? Making the
wrong choice can diminish expected ROI from heat
recovery, so it pays to weigh choices carefully.
Another system that can offer good ROI if
carefully selected for the process and plant equipment
is pollution-control equipment. In “How Deliberate
Integration of Air Pollution Control Equipment
Optimized Production,” Kevin Stevens of Pollution
Systems notes that many companies focus on
specifying equipment for air pollution control
independently from efforts to design and optimize the
production processes. By taking a holistic approach,
industrial processors can reap greater efficiencies and
achieve better long-term operating and economic
4  FEBRUARY 2018 Process Heating
Heat
Processing
Technologies
for these
results. Many industrial thermal systems
9 Industries
can benefit, Stevens says. For instance, the
exhaust from air-abatement equipment can
be used as an input for a boiler system. Chemicals/
Other possible reapplications of exhaust Petrochemicals
waste heat include preheating combustion
air in process ovens or preheating fresh air
for the facility.
Recapturing waste heat to repurpose Food Processing
it in the plant requires thinking about your process
in ways you may not have before. Another article in
this issue explains how looking at a known process
with new eyes can help solve process bottlenecks. Finishing
“Craft Brewery Drives Success with Process
Automation Swap” describes how one brewery’s
plan to add additional brewing capacity in the
form of three heating/cooling loops on a new uni-
Plastics/Rubber
tank was nearly derailed by unexpected results with
solenoid diaphragm valves. By looking at the power-
management challenge from many angles, the valves-
maker was able to suggest a solution that allowed
the brewery to stay on a tight startup schedule while Pharmaceuticals
gaining full tank temperature control.
Also in this issue, “Direct-Contact Water Heaters
for Concrete Plants” explores using on-demand water
Pulp/Paper/
heating for industrial processes such as cement plants.
Wood/Converting
For processes that require hot water in the 140 to
160°F (60 to 71°C) range, on-demand water heating
systems allow users to avoid stored heating losses and
free up plant space. Robert Rizza of Power Flame Inc., Ethanol/
and Michael Maddox of CEI Enterprises explain the Biodiesel
technology and how ultra-low-NOX premix burners
allow the burners to stay below emissions limits.
Finally, in “Boiler Cleaning Drives Benefit to Packaging/
Bottom Line,” Ray Field of Goodway Technologies Printing
describes how a maintenance plan that includes
chemical and mechanical cleaning can keep industrial
boilers clear of scale buildup and maintain effective
Electronics
heat transfer. Benefits from planned boiler cleanings
include improved energy efficiency.
Visit www.process-heating.com
to read industry-focused content
as well as thousands of articles
covering industrial heat
Linda Becker, Associate Publisher and Editor,
processing equipment.
BeckerL@bnpmedia.com
YO U R I N D U S T R Y VA L U E S YO U R E X P E R T O P I N I O N

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Inner Workings
Shelf Oven Dries Powdered Resin
A 550°F (288°C) shelf oven with
12 kW in Nichrome wire heating
elements will be used for drying
powdered resin in trays. A 1,000-cfm,
1-hp recirculating blower provides
horizontal airflow to the workload.
Manufactured by Grieve Corp.,
Round Lake, Ill., the oven includes
a digital-indicating temperature
controller, manual-reset excess-
temperature controller with separate
contactors, recirculating blower-
airflow safety switch and a 10”
diameter circular chart recorder. The
unit, which has 4” insulated walls and
four independent doors for access to
6  FEBRUARY 2018 Process Heating
workspace, includes a digital timer for the temperature required to precisely
each compartment and a button and control the paper drying process.
pilot light to indicate end of cycle. Employed at multiple points in the
operation to measure the temperature
Papermaking Machinery of the swimming roll that is rotating
Manufacturer Uses up to 400 rpms, the sensors signal air
Noncontact Infrared jets to open or close in order to cool
Sensors the drum and keep it at 194°F (90°C).
Papcel, a Czech Republic-
based papermaking machinery
manufacturer, is employing Exergen’s
noncontract infrared sensors in its
Softcalender paper machine to ensure
optimal operational efficiency and
paper quality.
Exergen’s IRt/c.5 sensors maintain
 Inner Workings

Precise temperature measurement Pollution Control sales goals.

is critical in print production because
overheating can damage the drum,
sensors and other equipment,
potentially costing thousands of
dollars. In addition, if substrates
measure below or above very specific
temperature ranges, the end quality
can be degraded.
Systems Maker Marks
Record Month
Citing record-breaking sales in
December, Milwaukee-based Anguil
Environmental Systems credits the
strong year-end showing for helping
the company surge past its annual
According to the family-owned
air and water pollution control
equipment supplier, Anguil received
four orders for eight systems totaling
more than $20 million in bookings
during one week in December.
The orders spanned the carbon

New Hand Soldering World

Champion Crowned
Sixteen competitors from around
the world participated in the Hand
Soldering World Championship. IPC
— Association Connecting Electronics
Industries hosted the event, in
cooperation with productronica 2017,
on November 17, 2017.
With a functional board and score
of 473 out of a possible 500, the
winner was Zhang Yi of China. Second
place went to Vietnam’s Vu Thi Xuan,
and third place went to Hasrol Mizom
Hosson of Malaysia.
Product drying parameters
are made to be met.
CUSTOMIZED DRYERS
DESIGNED TO MATCH THE TASK
Customization is the key to a dryer meeting your specific
product needs. Wenger delivers unsurpassed quality in custom
convection drying with options at virtually all major decision
points – single or multiple pass and stage, a variety of widths,
heat sources, and capacities.
Know more about Wenger dryers as the best choice for a new
process or for replacing older, less efficient dryers.  
Email us at info@wenger.com today.

Assemblies were judged on

soldering in accordance with
IPC-A-610F Class 3 criteria. Other
criteria included the speed at which
the assembly was produced and
overall electrical functionality of the
assembly. Judges were from China,
Estonia, France, Holland and the
United States.
“The world championship hand
soldering competition required the
competitors to hone their best skills
and focus on a very complex board,”
said Kris Roberson, IPC director of PHONE: 785.284.2133 | EMAIL: INFO@WENGER.COM | WENGER.COM
certification. “Of the 16 competitors, USA | BELGIUM | TAIWAN | BRASIL | CHINA
only six completed a functional board.”

www.process-heating.com FEBRUARY 2018  7

Inner Workings

in Bietigheim-Bissingen, Germany.
Dürr has implemented numerous
projects for Groupe PSA, including
the integration of Dürr’s energy-
efficient dry separation system at the
company’s Sochaux plant in France.
Current projects include a new final
assembly shop at Sevel Nord, France,
and a new paint shop in Kenitra,
Morocco. Dürr is now one of fewer
than 10 core suppliers to PSA, which
includes automotive brands Peugeot,
Citroën, DS Automobiles, Opel in
Germany and Vauxhall in Great Britain.

Anguil Environmental — led by Gene, Deb and Chris Anguil — provides pollution Industrial Oven Cures
control, water treatment and energy recovery systems for industrial applications. Rubber Auto Hoses
A manufacturer of automotive parts
fiber, composites, converting, and to help ensure that the smallest added an industrial oven to cure
semiconductor/chip manufacturing components of a steam system are rubber automotive hoses. Wisconsin
industries and included systems given proper attention in order Oven Corp., East Troy, Wis., shipped
processing emissions ranging from to provide extended and efficient the natural gas direct-fired batch oven
5,000 to 200,000 scfm. system operation. FCI is a non- with a separate cooling chamber.
All of the orders, for systems such as profit trade association with a The unit, which has a maximum
regenerative thermal oxidizers (RTOs), membership comprising the leading temperature rating of 500°F (260°C),
multi-stage direct-fired thermal manufacturers of fluid control and has sufficient capacity to heat 300 lb of
oxidizers (DFTO) and heat exchanger conditioning equipment. steel and 300 lb of rubber from 70 to
systems, were placed by existing 350°F (21 to 177°C) within 45 minutes
customers. Anguil is celebrating 40 Dürr Group Named when loaded into an ambient oven.
years in business in 2018. Primary Supplier for Guaranteed temperature uniformity of
Auto Manufacturer ±10°F (5.5°C) at 350°F was proven by a
Steam Traps Guide Updated International automotive nine-point profile test.
“Steam Traps: Critical Engineered manufacturer Groupe PSA has chosen The oven is constructed with
Devices for Optimal Performance of the Dürr Group as a primary supplier tongue-and-groove panel assemblies
Steam Systems,” an updated technical in its global network. The core connected via Wisconsin Oven’s high
sheet from Fluid Controls Institute supplier status was announced during efficiency panel seams. The company
(FCI), is available as a free download a management meeting between the says its panel seam design provides 25
from the institute’s website two companies at Dürr’s headquarters percent better insulating efficiency.
(www.fluidcontrolsinstitute.org).
Improper selection of steam
traps can lead to inefficient steam
system performance, including poor
heat transfer and possible water
hammer, FCI notes. The technical
sheet discusses the importance of
steam trap function and selection for
the effective removal of condensate
and air from steam systems. Simple
selection guidelines are provided
for applications such as removing
condensate from steam distribution
piping (drip) and after heat
exchangers (process).
Tech Sheet ST-105 also is intended

8  FEBRUARY 2018 Process Heating

 Inner Workings

The oven is rated for Class A Mexico increase in frequency or The CSB said that there is a lesson
use with the capacity to dilute the intensity, it is imperative that facilities facilities in the Gulf should note:
products of combustion produced have effective emergency response “Reassess continuity of operations
during the process and render them procedures in place, the CSB notes. plans and worst-case scenario
nonflammable. The backup generators at Arkema assumptions. Plan and plan again.
were elevated 2’ off the ground Don’t be lulled into a false sense of
Chemical Plants Need while the flooding exceeded 3’ in the safety by thinking that it can't or
Effective Emergency vicinity of the generators. won't happen here.”
Response Procedures,
Notes CSB Chair

The ongoing investigation into the

fires at the Arkema chemical plant
in Crosby, Texas, which occurred as a
result of Hurricane Harvey last August,
continues. U.S. Chemical Safety
Board (CSB) Chairperson Vanessa
Allen Sutherland issued a statement
updating the investigation progress as
well as a 2D animation of the events
leading to the fire at www.csb.gov.
A two-member CSB team
deployed to Houston on September
5 and arrived on-site September 6,
according to Sutherland’s statement.
The team photo-documented the
site, identified evidence of interest
and had initial company meetings.
The CSB remained on site two weeks
to collect evidence and conduct
site interviews. During the last week
of October, the team conducted
interviews at Arkema’s corporate
headquarters in Pennsylvania.
According to the CSB, due to
Hurricane Harvey, the water rose so
rapidly at the Arkema site that the
first combustion occurred less than
72 hours after flooding commenced.
The facility was not prepared for such
heavy rainfall, which led to a rapid
flood rate. Facilities across the Gulf
Coast experienced similar problems.
As tropical storms in the Gulf of

www.process-heating.com FEBRUARY 2018  9

Calendar Events

February San Antonio, Texas. Hosted by the March

4-8 — Cooling Technology
Institute Annual Conference,
Hilton Houston North, Houston.
Call 281-583-4087 or visit
www.cti.org.
4-9 — ASME Boiler and Pressure
Vessel Code Week, J.W. Marriott Las
Vegas Resort & Spa, Las Vegas.
Call (212) 591-8533 or visit
www.asme.org.
6-7 — Powder Coating 202:
Optimizing Your Powder Coating
Operation Workshop, Atlanta.
Produced by Powder Coating
Institute (PCI).
Call 859-525-9988 or visit
www.powdercoating.org.
12-14 — National Ethanol
Conference, J.W. Marriott San
Antonio, Hill Country Resort & Spa,
Renewable Fuels Association (RFA).
Call 832-653-4046 or visit www.
nationalethanolconference.com.
21-22 — Food Processing Expo,
Sacramento Convention Center,
Sacramento, Calif.
Produced by California League
of Food Processors.
Call 800-258-6094 or visit
www.foodprocessingexpo.org.
26-March 2 — Hydraulic Institute
Annual Conference,
Wigwam Resort, Litchfield Park, Ariz.
Produced by HI.
Call 973-267-9700 or visit
www.pumps.org.
26-March 1 — Hands-On Boiler
Training Course (Level I), Garden
City, Kansas. Call 620-271-0037 or
visit www.boilerlicense.com or
www.ammoniatraining.com.
5-8 — GFSI Global Food Safety
Conference, Tokyo.
Call +33 (0)1 41 33 63 69/73,
send an email to tcgffoodsafety@
theconsumergoodsforum.com or
visit www.tcgffoodsafety.com.
11-13 — Seafood Expo North
America/Seafood Processing
North America, Boston Convention
Center, Boston. Call 207-842-5538
or visit www.seafoodexpo.com.
12-13 — Powder Coating 2018
Technical Conference, J.W. Marriott,
Indianapolis. Produced by Powder
Coating Institute (PCI).
Call 859-525-9988 or visit
www.powdercoating.org.
12-14 — SNAXPO, Atlanta.
Call -703-836-4500, ext. 201, or
visit www.snaxpo.com.

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10  FEBRUARY 2018 Process Heating

 Calendar Events

14-15 — Powder Coating 101: Basic Program (GCAP), Steam Boiler Div. 10-12 — Vapor Controls Systems
Essentials Hands-On Workshop, Call 620-271-0037 or visit Course, Tulsa, Okla. Presented by
J.W. Marriott, Indianapolis. Produced www.boilerlicense.com or John Zink Institute.
by Powder Coating Institute (PCI). www.ammoniatraining.com. Call 918-234-5710 or visit
Call 859-525-9988 or visit www.johnzinkinstitute.edu.
www.powdercoating.org. 26-29 —Aquatech Annual
Convention and Exposition, 15-19 — Corrosion Conference
14-16 —Semicon China, Shanghai Colorado Convention Center, Denver. & Expo 2017, Phoenix Convention
New International Exhibition Center Produced by Water Quality Association Center, Phoenix.
(SNIEC), Shanghai, China. Produced (WQA). Call 630-505-0160 or visit Produced by NACE International.
by Semiconductor Equipment And www.wqa.org/convention. Call 800-797-6223 or visit
Materials International (SEMI). www.nacecorrosion.org.
Call 408-943-6982 or visit April
semiconchina.org. 16-18 — Pack Expo East,
3-5 — Power Boiler Burners Pennsylvania Convention Center,
18-21 — IIAR Ammonia Course, Tulsa, Okla. Presented by Philadelphia. Call 571-612-3200 or
Refrigeration Conference & John Zink Institute. visit www.packexpoeast.com.
Exhibition, Broadmoor Hotel and Call 918-234-5710 or visit
Resort, Colorado Springs, Colo. www.johnzinkinstitute.edu. 16-19 — Hands-On Boiler Training
Call 703-312-4200 or visit Course (Level I), Garden City, Kansas.
www.iiar.org. 8-11 — ASTM Committee C16 Presented by Garden City Ammonia
on Thermal Insulation Spring Program (GCAP), Steam Boiler Div.
19-22 — Hands-On Boiler Training Meeting, Sheraton San Diego Hotel Call 620-271-0037 or visit
Course (Level I), Garden City, Kansas. & Marina, San Diego. Call 610-832- www.boilerlicense.com or
Presented by Garden City Ammonia 9678 or visit www.astm.org. www.ammoniatraining.com.

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 Burners
HEAT RECOVERY
for Process Efficiency
Recapturing waste heat allows you to capture thermal energy you would
otherwise let escape up the stack and put it to work in your process.
Air-to-air heat exchangers provide an effective means of capturing this otherwise
lost resource.
By Jessica Irons,
Honeywell
W
ith an ever-increasing
focus on energy efficien-
cy and improving system
performance, industrial
processors are looking for ways to achieve
these goals while reducing costs and mate-
rial usage wherever possible. One proven
way to increase energy efficiency and reduce
fuel usage is to recover heat from industrial
processes. Waste heat is unused heat given
off by a process or equipment in the form
of thermal energy — that is, heat not be-
12  FEBRUARY 2018 Process Heating
ing captured to heat some other product
or process. Waste heat can be thought of
as free energy. Though, of course, there is
a cost to create it, waste heat is thermal
energy you would otherwise let escape up
the stack rather than using in your process.
Implementing ways to capture waste heat
energy can improve efficiency while help-
ing processors save money.
Even when fuel prices are low, com-
panies in energy-intensive industries can
see a benefit and enjoy a relatively short
payback from utilizing some type of heat
recovery system to improve the efficiency
of their processes.
Plate-type heat exchangers
use nested plates to separate
two airstreams. Dimple-plate
types are better for process
steams that are dirty and could
potentially cause clogging
between the plates.
Basic Heat Recovery Method
for Process Heating
The most straightforward method of
capturing waste heat energy is a heat
exchanger. A heat exchanger is a device
used to transfer heat from one medium
— typically air, gas or fluid — to another
medium. The two media are separated by
a solid wall, plate or tube. The exchanger
uses the properties of thermodynamics
and fluid mechanics to heat or cool one
medium to the desired temperature. A ba-
sic schematic of a process oven with heat
recovery demonstrates the general process
(figure 1).
 Burners

Process Oven with Heat Recovery

Outside Air
Heat
Exchanger

Process
Oven
Burner

Process Oven

FIGURE 1. The most straightforward method of capturing waste heat energy is through the use of a heat exchanger.
Shown here is a basic schematic of a process oven with heat recovery.

In many industrial applications, the

waste heat will be in the form of a gas —
usually, it is heated air or steam. Thus, air-
to-air heat exchangers are quite common
in industrial applications. (Air-to-air heat
exchangers also are found in many com-
mercial buildings, HVAC systems and
even in some modern houses.)
Air-to-air heat exchangers are used for
many industrial applications:

• Heat recovery for preheating the same

process or other processes.
• Combustion air preheating.
• Oven/furnace makeup air preheating.
• Fume preheat on catalytic/recuperative
thermal oxidizers.
• Secondary heat recovery on regenerative
oxidizers.
• Heat exchange and recovery for volatile
FIGURE 2. Tubular-type heat exchangers use a series of tubes to allow the
organic compound (VOC) concentrators.
exchange of heat between the two media.

One of the benefits of using a heat ex-

changer to recover waste heat is that they air. This is particularly helpful when the ex- Heat Exchanger Types
are designed and built such that the air haust has excess dirt or dust particles that The most common types of air-to-air heat
containing the waste heat does not come could contaminate products or equipment exchangers are tubular and plate styles.
into contact with the new, clean process elsewhere in the process. Tubular. Tubular-type heat exchangers

www.process-heating.com FEBRUARY 2018  13

 Burners

tubes. For ease of cleaning, make sure the

FIGURE 3. Plate-type heat exchangers use a series of nested plates
to allow the exchange of heat between the two media without the two
airstreams coming into contact with each other.
use a series of tubes to allow the exchange
of heat between the two media. The waste
stream passes over the tubes, preheat-
ing the process stream flowing inside the
tubes. Depending on the needs of the ap-
plication, the configuration can be reversed
such that the waste stream flows through
the tubes and the process air flows over the
dirty stream flows through the inside of
the tubes.
Tubular-type heat exchangers are not
as effective at transferring heat as plate
types. However, they can withstand higher
temperatures, can be made out of exotic
materials and take a lower pressure drop.
They tend to weigh more than plate types,
and improper installation and consistent
high/low temperature cycling can promote
cracking of the tubes. Additionally, due
to the reduced effectiveness of the tubu-
lar type, the exchangers end up being big
and long, taking up additional space in the
plant. The size also can increase the stress
on the tube end welds.
Plate. Plate-type heat exchangers use
a series of nested plates to allow the ex-
change of heat between the two media
without the two airstreams coming into
contact with each other.
The two most common plate styles are
dimple plate and wave/sinusoidal plate.
Dimple-plate types are better for process
steams that are dirty and could poten-
tially cause clogging between the plates.
Sinusoidal- or wave-plate types offer the
best heat transfer effectiveness. The basic
premise behind the plate technology is to
have a pattern in the plate that causes a lot
of turbulence in the air as it flows around
the plates, which increases heat transfer.

Things to Consider Before

Selecting an Exchanger
When selecting an appropriate heat ex-
changer for your process, consider things
such as durability, exchanger life expec-
tancy, ease of installation, maintenance re-
quired, ease of cleaning and space available
to install the exchanger.
Dimple-plate heat exchangers tend to be
the most durable of the three types because
thick plates are used, and they are designed
to withstand dirty process airstreams. Tu-
bular heat exchangers have a shorter life
expectancy because the expansion and
contraction of the tube material — due to
temperature changes over time — make
FIGURE 4. Sinusoidal- or wave-plate heat exchangers offer the best heat
transfer effectiveness. The basic premise behind the plate technology is the tubes more susceptible to wear and
to have a pattern in the plate that causes a lot of turbulence in the air as it breakage. Sinusoidal-plate-type exchang-
flows around the plates, which increases heat transfer. ers tend to be more fragile, with thinner
plates. They must be monitored closely to

14  FEBRUARY 2018 Process Heating

 Burners

ensure they do not overheat. Overheating

Process Diagram Cooled Process
Exhaust could cause failure of the plate, thus losing
(IU Configuration Shown) heat transfer effectiveness and compromis-
ing cleanliness of the process airstream.
It is also important to ensure that the
filter for the air intake to the process and
exchanger is replaced on a regular ba-
Cool Air To sis. Excess debris in the filter could cause
Be Heated
the airflow to the exchanger to be com-
promised, reducing the effectiveness and
performance of the unit. Additionally, if
the filter is dirty or not installed properly,
dirt and dust could make its way into the
equipment and cause plate failures.
Lastly, it is important to remember that
when considering a heat exchanger de-
sign, plate or tube spacing is a key factor
Recovered Heat in performance (table 1). Tubes or plates
packed more closely can offer more heat
transfer surface area in a smaller footprint.
The tradeoff is they are more difficult to
Process clean, and you may experience a higher
Exhaust pressure drop across the exchanger. Tubes
or plates packed less closely are less effec-
FIGURE 5. A vertical flow pattern (IU) is the best configuration for heat tive but easier to clean. The tradeoff is you
transfer. It is the most effective, heats the process air most evenly and has may have a smaller pressure drop across
fewer ineffective zones. The potential ineffective zone is shown in yellow in the exchanger.
this diagram.

FIGURE 6. An indirect air heater,

which combines an ultra-low NOX
burner with a sinusoidal-plate heat
exchanger can provide low emissions
and effective process air heating.

www.process-heating.com FEBRUARY 2018  15

 Burners

Air-to-Air Heat Exchanger Selection Guide

Tubular Sinusoidal Plate Dimple Plate

Temperature Low to High Low Low

Price Lower Highest Moderate

Heat Transfer Lower High Medium

Effectiveness

Flow Configurations Variety Variety Variety

Process Air Dirty Clean Moderate

Cleanliness

Easy to Clean? Yes No Moderately

Thick plates for abrasive/

High temperature heat
Compact, high heat transfer corrosive applications,
Key Differentiators recovery, customizable flow
effectiveness, lighter weight in-line dimples accommodate
configurations
dirtier streams
Robust heat recovery is
High heat transfer Process air is dirty, abrasive,
Choose When needed, high temperature
effectiveness is required corrosive
applications

TABLE 1. When considering a heat exchanger design, plate or tube spacing is a key factor in heat exchanger
performance.

Flow Configurations for
Air-to-Air Exchangers
Another important consideration when
selecting a heat exchanger is what type of
flow configuration makes most sense for
the process. Given that each exchanger will
carry two flowing media, transferring heat
between them, four flow configurations are
available for plate-type heat exchangers.
• IU — One vertical stream and one in a
U pattern.
• LL — Both flows in an L pattern.
• IZ — One vertical stream and one in a
Z pattern.
• LU — One flow in an L pattern and one
flow in a U pattern.
Each configuration has pros and cons.
One thing to be aware of when selecting
a flow configuration is any potential inef-
fective zones. In these areas, hot and cold
spots are created by the airflow pattern,
and limited heat exchange is taking place.
In any given flow configuration, there
are two things going on:
• Separate ineffective zones exist for each
side (pass) of the exchanger. Certain in-
effective zones are created in each of the
flow patterns except for the vertical (I)
pattern.
• The ineffective zones can change loca-
tion depending on flow rate. For exam-
ple, in a U flow pattern, at low flow rates,
the ineffective zone is on the far side of
the exchanger. With high flow rates, the
ineffective zone is on the near side of the
exchanger.
For air-to-air heat recovery in waste heat
applications, a vertical flow pattern (IU) is
the best configuration for heat transfer. It
heats the process air most evenly and has
fewer ineffective zones. It also is easiest to
clean for applications such as food, where
washdown is required. Water or cleaning
solutions can literally be pumped into the
top of the exchanger, and the solution will
flow in the direction of gravity without
concern of getting caught somewhere in
the exchanger.

16  FEBRUARY 2018 Process Heating

 Burners

Fuel Savings Achieved Using a Plug-In Recuperator

Furnace Exhaust Preheated Combustion Air Temperature (°F)
Temperature (°F) 600 800 1000 1200 1400 1600
2400 26% 32% 38% 43% 47% 51%
2200 23% 29% 34% 39% 43% 47%
2000 20% 26% 31% 35% 39% 43%
1800 18% 24% 28% 33% 37% 40%
1600 17% 22% 26% 30% 34%
1400 15% 20% 24% 28%
1200 14% 19% 23%
1000 13% 18%
TABLE 2. The fuel savings achieved at varying preheated combustion air temperatures and exhaust temperatures
when using a plug-in recuperator is shown.

The LU flow pattern — one in an L

pattern and one in a U pattern — also has
two ineffective zones. Depending on the
orientation of the heat exchanger, debris
or condensation can collect in the bottom.
Another type of tubular heat exchanger
used for industrial waste heat recovery is
a plug-in recuperator. As the name im-
plies, it is plugged into the exhaust stream,
paired with an eductor, and uses waste
heat to preheat the combustion air. Table 2
shows the potential fuel savings that can be
achieved when using preheated combus-
tion air (PCA) from any heat exchanger
like the plug-in recuperators. This data is
calculated based on the difference of avail-
able heat with and without a recuperator.
Keep in mind this data is for preheated
combustion air only, not for process air.

The LL flow pattern — where each Whole System Thinking

stream flows in an L shape — is the most
common for heat recovery applications.
It transfers heat less effectively than the
IU pattern, and the air to be heated will
be a little hotter on the far side of the ex-
changer. The ineffective zones are on either
side of the L flows, creating two ineffective
zones instead of just one.
The IZ flow pattern — one vertical
stream and one in a Z pattern — is less
common. It can be useful to help fit in an
existing space. It also creates two ineffec-
tive zones on either side of the exchanger.
When a heat exchanger such as a sinusoi-
dal plate is paired with a complete system
— which includes a burner, controls, recir-
culation fans and all system components
— it can be inserted into a process where
it is critical to have a supply of clean, in-
directly heated process air. Recirculating
heaters are designed to prevent the prod-
ucts of combustion from getting into the
process airstream. This is especially im-
portant in applications such as food and
beverage, pharmaceuticals and automotive
paint finishing.
Energy equals money, and waste heat is
essentially free energy. If you are looking
for ways to improve the overall efficiency
of your process, improve fuel savings and,
ultimately, save money, consider installing
a heat exchanger to recover process heat in
almost any application.
Jessica Irons is a product marketing manager
at Honeywell Thermal Solutions.
The Rockford, Ill.-based company can be
reached at 815-877-3031 or visit the website
at www.thermalsolutions.honeywell.com.

www.process-heating.com FEBRUARY 2018  17

 Pollution Control A high efficiency recuperative
thermal oxidizer was used to
increase on-stream time and reduce
maintenance at an animal-feed
product facility.

How Deliberate Integration of

AIR POLLUTION-
CONTROL EQUIPMENT
Optimized Production
Improved overall operation is possible when entire plant operation is considered
rather than sub-optimizing choices around pollution-control equipment.

By Kevin Stevens, erating and economic results. This includes Careful consideration of these specific
Pollution Systems positively impacting their facility’s energy attributes can yield opportunities to opti-
requirements. mize facility performance.

A
ir pollution-control equip-
ment is generally regarded as a
non-core operation — and yet
another unavoidable cost of
doing business. Often, companies focus on
air pollution control independently from
their production processes and only evalu-
ate their technology’s energy efficiency
while meeting the target emission levels.
If, however, air pollution equipment was
judiciously evaluated throughout the entire
operation, companies could improve their
processes and achieve better long-term op-
System aspects that should not be
overlooked when assessing air treatment
equipment include:
• Its suitability with the characteristics of
the exhaust gas.
• Its reliability and maintenance.
• The degree of equipment automation.
• Possible effects of air pollution control
on production processes.
• Opportunities to integrate this equip-
ment with other process heating re-
quirements.
Many industrial processes involve a
heating stage during production that
generates an exhaust gas containing vola-
tile organic compounds (VOCs) or other
pollutants that must be treated prior to
discharge into the atmosphere. Thermal
oxidation of VOCs to less harmful car-
bon dioxide and water occurs at elevated
temperatures — generally between 1250
and 1650°F (676 and 899°C) — to achieve
target air emission requirements. Standard
air-abatement equipment used to destroy
VOCs as well as odors includes:

18  FEBRUARY 2018 Process Heating

 Pollution Control

The exhaust from the air abatement
equipment can be used as an input
into a boiler system to optimize
facility operations. At this animal-
feed supplement manufacturing
facility, the appropriate technology
for long-term industrial use is a
direct-fired oxidizer.
• Regenerative thermal oxidizers.
• Recuperative thermal oxidizers.
• Direct-fired thermal oxidizers.
• Flares.
• Enclosed flares.
• Catalytic oxidizers.
Each pollution-control device has
strengths and weaknesses, which depend
upon the application and the process con-
ditions for which it is used. When evalu-
ating the necessity of meeting air-permit
requirements in relation to production
requirements, new and different solutions
may materialize.
Usually, the temperature required to
operate pollution-control equipment is
significantly higher than the temperature
for heating processes required in a plant’s
production. Herein lies an opportunity to
improve overall facility results that is of-
ten overlooked.
When the entire facility is considered
— including the air pollution-control
equipment — the possible energy savings
opportunity can be estimated by consider-
ing how much energy is leaving the facility
through the exhaust stacks relative to the
energy requirements to operate the facility.
In other words, operations that discharge
large amounts of heat into the atmosphere
— as would be the case if employing an
enclosed flare or direct-fired oxidizer —
could instead recover some of that heat and
utilize it somewhere in the main produc-
tion process or facility. This improves ef-
ficiency and reduces energy consumption.
Using Recovered Energy
to Preheat Fresh Air
One way to achieve such improved efficien-
cy and reduced energy consumption is to
use secondary heat recovery from a recuper-
ative oxidizer to preheat fresh air for other
processes in the facility. The following case
illustrates the execution of this approach.
The parallel heat exchanger design allows for significant
process flexibility in terms of changes to flow rate and
ambient temperature as well as any future temperature
setpoint adjustments, should they be required.
An animal-feed-products manufacturer
had to increase production capacity in its
Midwest facility to meet an increase in
demand. New air pollution-control equip-
ment was required to effectively reduce
odors in 40,000 scfm of VOC-laden pro-
cess air, generated in the production of ani-
mal supplements.
Energy consumption and long-term
reliability and maintenance were consid-
ered seriously in the equipment selection
and design. A high efficiency recuperative
thermal oxidizer was appropriate in order
to increase on-stream time and reduce
maintenance.
This equipment accomplishes energy re-
covery by using a heat exchanger — typi-
cally a shell-and-tube design — to transfer
some of the heat exiting the reactor to pre-
heat the process gas prior to entering the
recuperative thermal oxidizer. The primary
heat exchanger was economical at between
50 to 80 percent thermal efficiency. With
the opportunity to preheat incoming pro-
cess air, a recuperative thermal oxidizer’s
steady operation and flexibility of design
and control allowed it to become a more
integral part of the production process.
Furthermore, a secondary heat exchang-
er was incorporated with the recuperative
thermal oxidizer to preheat fresh air for use
in the process dryers. By integrating auto-
mated controls on the heating air for these
dryers, the target temperature of the dryer
air was consistently maintained — as was
product quality.
The animal-feed-products manufacturer
also incorporated several other energy-
saving features into the system. They in-
cluded proportioning air-to-fuel valves on
the gas train and high efficiency fans with
variable-frequency drives.
Other oxidizer technologies that have
higher energy-efficiency ratings in isola-
tion — including catalytic and regenerative
oxidation systems — were not appropriate
for this application due to the particulates
present in the airstream. Overall, the sys-
tem was designed to reduce fuel consump-
tion by more than 50 percent compared to
a typical recuperative thermal oxidizer of
the same size.
Using Available Energy for
Process Ovens
Another example of air pollution equip-
ment being carefully evaluated with the
overall production process occurred at a
coil-coating facility in Texas. Air pollu-
tion-control equipment was required to
treat approximately 45,000 scfm of VOC-
laden gases at a minimum of 90 percent
destruction efficiency. The exhaust exited
the process ovens at 530°F (277°C). Also, it
was necessary to raise the gas temperature
to 1500°F (815°C) in the presence of oxy-
gen to achieve the targeted environmental
requirements. Important goals included
that the equipment be designed for reliable
long-term industrial use, low maintenance
and reduced energy consumption — with
no impact on the production process.

www.process-heating.com FEBRUARY 2018  19

 Pollution Control

23,690 to 30,900 scfm

34,500 to 45,000 scfm
70ºF
1070ºF

Primary Secondary
HX (1) HX (2)
Combustion Chamber 1500ºF 80% 80%
1500ºF
98+% Destruction STACK 34,500 to 45,000 scfm
Removal Efficiency 385ºF
(DRE) Secondary
HX (3)
1500ºF 80%

34,500 to 45,000 scfm 23,690 to 39,000 scfm

529ºF 950ºF

FIGURE 1. A recuperative thermal oxidizer with parallel heat exchangers uses the available energy to preheat
incoming fresh air to provide air to the process ovens, eliminating the need for additional heating with oven burners.

In this case, a sub-optimal solution
would have been to incorporate a high
efficiency regenerative thermal oxidizer
(RTO) at the end of pipe. Although a re-
generative thermal oxidizer has great ther-
mal efficiency, backpressure fluctuations on
the process due to poppet-valve and airflow
changes — along with higher maintenance
concerns — made it less than ideal to meet
the objectives. Additionally, regardless of
the thermal efficiency, the exhaust from the
regenerative thermal oxidizer would con-
tain significant energy because the temper-
ature into the system was 530°F (277°C).
In this scenario, the design team deter-
mined that a recuperative thermal oxidizer
with parallel heat exchangers would best
meet the operational and environmental
objectives. Such a system uses the available
energy to preheat incoming fresh air to pro-
vide 950°F (510°C) air to the process ovens.
For the coil coater, this eliminated the need
for additional heating with oven burners.
Figure 1 depicts how this is accomplished.
The secondary heat exchanger, hav-
ing an efficiency of 80 percent, was used
to preheat fresh air for the oven while the
primary heat exchanger, also at 80 percent
efficiency, utilizes the remaining available
energy to preheat the incoming waste gas
stream to the oxidizer.
The solution provides stable flows, pres-
sures and temperatures throughout the
system and, in terms of maintenance, is the
least demanding. Finally, the parallel heat
exchanger design allows for significant
process flexibility in terms of flow-rate
changes, ambient temperature changes
and future temperature setpoint changes,
should they be required. This design can
track to the 950°F (510°C) preheated fresh
air setpoint or any new setpoint, which
is an advantage over having the heat ex-
changers arranged in series.
Using Energy from Exhaust
for Process Boilers
Another possible implementation for fa-
cility optimization is using the exhaust
from the air-abatement equipment as an
input into a boiler system. It was necessary
for a manufacturer of animal-feed supple-
ments in South Dakota to treat process
exhaust for odors prior to discharge from
the facility. The process flow was 5,000
scfm, ranged from 200 to 270°F (93 to
132°C), and contained particulate and
condensable materials.
The design team for the pollution-
control technology determined the best
technology for long-term industrial use in
this case was a direct-fired oxidizer. Other
systems such as a regenerative thermal
oxidizer would have increased downtime
and required higher maintenance due to
sensitivity to particulate and condensable
materials in the stream.

20  FEBRUARY 2018 Process Heating

 Pollution Control

the entire plant operation rather than sub-

optimizing choices around the pollution-
Each pollution-control device has strengths and control equipment. Though considering
the overall facility and process heating
weaknesses, which depend upon the application and requirements when selecting air pollution
equipment is often overlooked, there are
the process conditions for which it is used. benefits to this approach.
Secondary heat recovery from thermal
When evaluating the necessity of meeting air-permit oxidizers can be used to preheat incom-
ing process air. Equipment can be com-
requirements in relation to production requirements,
pletely integrated with production and
new and different solutions may materialize. eliminate the need for auxiliary heat for
process ovens. The exhaust may even be
used in equipment such as boilers. By tak-
ing a holistic view of the entire facility, it
Compared to alternative thermal treat- before entering the oxidizer is one op- is possible to develop and execute creative
ment options, the penalty for a direct- tion that recaptures some of the energy. concepts and solutions that reduce overall
fired oxidizer is high gas consumption. When considering other facility energy energy consumption and improve plant
The exhaust from a 5,000-scfm direct- requirements, however, the opportunity operability.
fired oxidizer at around 1500°F (815°C) to use this heat in the boiler rather than
leaves the facility with energy of about discharging directly to atmosphere allows Kevin Stevens is the president of
13.5 million BTU/hr — a current value for even-higher energy recovery and lower Pollution Systems. The Woodlands,
estimated at about $340,000 per year for overall facility energy requirements. Texas-based company can be reached at
continuous operations. The addition of In summary, improved overall operat- 866-672-4067 or visit the website at
a heat exchanger to preheat the exhaust ing results are attainable by considering www.pollutionsystems.com.

COMPREHENSIVE
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www.process-heating.com FEBRUARY 2018  21

 Valves/Piping
CRAFT
BREWERY
Drives Success with
PROCESS
AUTOMATION
SWAP
When an important calculation for a new controls solution was overlooked, the
result threatened to keep a new aging tank for a brewery offline. Substituting
solenoid valves with built-in power management brought the equipment online.
By Don Launder,
Asco by Emerson
N
ot many Americans like warm
beer — except, of course, pro-
cess cooling engineers who
work for breweries. They know
that maintaining elevated temperatures
within a metal tank in the brewhouse is
critical throughout much of the fermen-
tation process. Only at the proper time is
coolant — often a mix of glycol and water
— circulated by a programmable control-
ler that opens and closes valves, directing
flow through a tank jacket. The resulting
temperature drop stops fermentation and
readies the brew for the next step.
As cooling processes go, it is not partic-
ularly complicated. However, sometimes
trouble can arise. This article will explore
how selecting valves for an expansion
22  FEBRUARY 2018 Process Heating
project at a regional craft brewery raised
issues that may interest engineers working
in other process cooling applications.
With the ascension of craft beer in the
past few decades, the beer business is boom-
ing. The industry’s success extends beyond
the brewing behemoths that used to own
almost all the beer aisles in the local liquor
store to include a small but increasingly sig-
nificant portion of the industry: the craft
brewery. Companies in this segment — to-
day perhaps 15 percent of the U.S. beer mar-
ket — usually are defined as relatively small
enterprises that are independently owned.
Craft breweries typically use traditional
ingredients and fermentation processes —
though often with innovative twists.
One particular brewery in New England
was an early entrant in the market for fresh,
local craft beers. It recently found that
rising consumer demand for its products
required an expansion of its facility. The
traditional manufacturing systems it had
in place were well established. But to add
more capacity — and make room for fresh,
innovative products — the planners needed
new equipment.
Understanding the Craft
Brewing Process
As chemists like to say, “Technically speak-
ing, beer is a solution.” The vast majority of
beers are made from a few ingredients —
grain, hops and yeast — mixed into water.
(Added flavorings such as pumpkin spice
are optional or heretical, depending on
your viewpoint.) An increasingly bewilder-
ing variety of beers combine these elements
according to different recipes. The New
England brewer routinely produces ales,
stouts, India pale ales (IPAs), ciders, porters
and lagers as well as occasional or seasonal

offerings such as bocks or barleywines.
While beer variants incorporate specific
changes based on the style being brewed,
in general, a brewery follows a common set
of brewing processes:
• Malted barley grain is crushed and then
mixed with hot water to form a mash to
break down starches into sugars.
• Sweet liquid (wort) is filtered from the
spent grains and then boiled. Flower-
cones from a vining plant called hops
are added to provide varying degrees of
bitterness for the final product.
• The hopped wort is clarified, quickly
cooled and transferred to a uni-tank ves-
sel with yeast. There, fermentation and
aging/conditioning can take place.
Only at the proper time is coolant — often a mix of glycol and water — circulated by a programmable controller that opens and
closes valves, directing flow through a tank jacket. The resulting temperature drop stops fermentation and readies the brew for
the next step.
• During aging, the yeast converts most
(but not all) of the sugars in the mix to
alcohol, among other complex biochem-
ical processes.
Tank temperature is an important vari-
able in beer fermentation and storage.
To control coolant flow to the insulating
jackets of the uni-tanks used in the rest of
the plant, brewery managers had standard-
ized on two-way normally closed solenoid
diaphragm valves, Model 8210 Series from
Asco. These general-service valves provide
long service life, low internal leakage, high
flow and ultra-high reliability. Tied into a
PLC running multiple tanks in the brew-
ery’s plant automation system, the valves
provided good results for years.
www.process-heating.com FEBRUARY 2018
Valves/Piping
Brewery Expansion Plan
Highlights Automation Needs
When the New England brewer decided to
expand, increasing fermentation and stor-
age capacity by adding another uni-tank
became a focal point of the process auto-
mation action. Like others in the brewery,
the new tank would be an approximately
5,283-gallon (20,000-liter) stainless steel
model. It would be located outside the
plant with a coolant-supplied insulating
jacket. The jacketing would maintain the
optimum brewing temperature in the face
of New England’s hot summers and ex-
tremely cold winters.
For the new tank, brewery manag-
ers specified the same two-way normally
closed solenoid diaphragm valves used
 23
 Valves/Piping
The Next Generation solenoid valves
include built-in power-management
technology and advanced
electronics for voltage ranging.
These features mean the valves can
accept both AC and DC voltages
without affecting performance.
on its predecessors. However, the manag-
ers soon realized that the existing PLC
lacked sufficient input/output capacity to
control this additional equipment. Add-
ing an entire new PLC would represent
expensive overkill for automating a single
tank. Instead, the team purchased and in-
stalled a smaller, considerably less costly
micro-PLC.
As the project neared completion, tim-
ing was tight — especially given the is-
sue of tank scheduling. In a thriving craft
brewery that has grown large enough to
produce multiple products, scheduling can
demand as much skill as more traditional
parts of the brewer’s art. Ongoing distribu-
tor deliveries, seasonal releases and fresh
product introductions must be balanced
with available tank capacity — and with
the different timing needed to craft each
variety of beer according to the complex
Lessons Learned from the Brewery Project
• Consider compatibilities and capacities when implementing new cooling control equipment.
• Always add up the amperages.
• Evaluate whether newer, low power valve solutions offer advantages your cooling application can use.
24  FEBRUARY 2018 Process Heating
biochemical requirements of its creation.
For example, grain-to-glass duration may
be only a few weeks for most ales but sev-
eral months for most lagers.
In this case, by the time that the tank,
micro-PLC and valves were installed,
complex scheduling constraints meant
that the new system had to be ready to
begin fermenting its first batch in two
weeks. If not, the brewery’s entire produc-
tion schedule would suffer.
Troubleshooting the New
Control System
At almost the last minute, trouble arose.
When final testing commenced on the
new tank, it was apparent that coolant
would flow normally if only a single valve
were energized. However, if more cooling
was needed and the loop’s second and third
valves were opened, the fuse on the sys-
tem’s circuit would immediately be blown.
Stressed, the project manager called the
team at Asco responsible for valve solu-
tions. Could they figure out the problem?
Was some flaw in the valves causing the
short circuits?
After a troubleshooting visit and inves-
tigation, the team determined that there
was nothing wrong with the new tank’s
valves. When tested one at a time, each of
the three operated normally. Energizing
all three of them simultaneously, however,
tripped the circuit. A representative from
the valve maker suggested the microPLC
could be at the heart of the problem. Con-
sulting the manual for the microPLC
quickly revealed the problem.
Before purchasing the downsized con-
troller, the brewery’s project manager
had confirmed that it possessed the right
complement of function blocks to perform
the needed valve control. But the manager
lacked the representative’s specialized fa-
miliarity with process automation, and
calculating the amperage totals for any as-
sociated equipment had been overlooked.
Unfortunately, unlike the familiar stan-
dard PLC used for the main plant auto-
mation system, the micro version was rated
for 20 W. Because each valve drew 17 W,
operating more than one exceeded the
controller’s maximum amperage rating.
Once the source of the circuit tripping
was identified, the challenge was clear. How
could the system be altered to get the tank
up and running in less than two weeks?
Solenoid Valves
with Built-In Power Handling
The project manager considered putting in a
rush order for a full-fledged PLC to do the
job. But again, that seemed like costly over-
kill for this relatively modest control task.
Fortunately, the valve-maker’s repre-
sentative had a better idea. After a quick
consultation and a look at product speci-
fications — including a calculation of am-
perage totals — the project manager or-
dered three solenoid valves, Asco RedHat
Next Generation.
This choice offered several advantages.
First, the new valves came with built-in
power-management technology and ad-
vanced electronics for voltage ranging.
These features mean that the new Next
Generation valves can accept both AC
and DC voltages without compromising
performance. The valves also provide surge
protection to help extend switch life and
eliminate external snubber circuits.
But for the brewery, this valve selection
meant something even more important.
Instead of the 17 W draws required by
 Valves/Piping

In processes such as those at a brewery, maintaining elevated temperatures within a metal tank in the brewhouse is critical
throughout much of the fermentation process.

the valves on their other tanks, the new
valves only draw 2 W of AC power con-
sumption each.
This low power rating allows users in
many applications to reduce the size and
cost of other system elements such as pow-
er supplies. By swapping out the valves, it
ensured that the existing micro-PLC could
handle the total amperage when the three
valves controlled coolant flows on the new
tank. This low power consumption even
contributed to the facility’s overall “green”
initiatives, reducing the brewery’s carbon
footprint while helping to cut energy costs.
The valves were available via a quick-
ship program. To meet the brewery’s tight
timeline, the valves were delivered over-
night. After quick installation and success-
ful testing, the tank was up and running
in time to accommodate the brewery’s
expanded product schedule. From the first
call about the issue to successful startup of
the expanded system, the entire process
took less than 10 days.
You might say that a small bottleneck
almost tanked the project. Fortunately, the
brewery had process automation expertise
on tap.
Don Launder is a life science, food and
beverage specialist with Emerson. He is based
in Florham Park, N.J., and can be reached at
800-972-2726 or visit www.asco.com.

www.process-heating.com FEBRUARY 2018  25

 Heat Transfer Fluids

FLASHPOINT
CONCERNS
in a Closed-Loop
Thermal Oil System
While flashpoint test results provide data for comparing different fluids, any
extrapolation of these results into real-life situations must recognize the basic
conditions required for a vapor ignition to occur. If any of the conditions is not
met, vapor ignition cannot occur.

By Mark Smith, As the sample fluid is heated, the flame you. I will address that shortly.
MultiTherm is passed across the surface of the fluid Remember that heat transfer fluids are
at a height of ~0.04” (1 mm). The fluid is designed to absorb heat extremely quickly

W
hen it comes to indus-
trial heat transfer flu-
ids, flashpoint is a very
misunderstood value.
Is it an important value? Yes, but in the
right context.
There are two flashpoint tests that are
reported: open-cup and closed-cup tests.
Allow me to explain these tests.
Open Cup. The test fixture has a bea-
ker that holds a sample of the heat transfer
fluid being tested. On the test fixture, there
is a bracket, though which gas flows to cre-
ate a flame at the end of the bracket.
heated slowly, and the bracket passes across
the fluid until the fluid flashes over — just
a flash, no flame. At the point of this flash,
the temperature is noted. This value is the
open-cup flashpoint.
Closed Cup. This test uses a rig similar
to the open-cup test with one important
difference: In the closed-cup test, there is a
cover over the fixture to capture the vapors.
(By contrast, with the open-cup test, there
is no cover to capture the vapors.) As you
can imagine, the closed-cup test has lower
values as opposed to the open cup.
The real question is what that means to
— and give it off just as quickly. The faster
the absorption — and willingness to trans-
fer the heat to the process — the better the
heat transfer fluid.
This why it is important to insulate ev-
ery section of piping in the system except
where you want the heat to be delivered.
The insulation should be a closed-cell in-
sulation so that it does not absorb any heat
transfer fluid and hold it next to the hot
pipe if there is a leak. If a leak should occur,
the heat transfer fluid will find a path past
the insulation and drip — a visual indica-
tion that there is a leak. As the drip forms

26  FEBRUARY 2018 Process Heating


To help prolong the life of the
system and hot oil, a comprehensive
fluid analysis program consisting
of laboratory testing, evaluation
of your system performance and
discussion of the hot oil sample lab
results is recommended.
Heat Transfer Fluids
and falls away from the pipe, the fluid gives
off the heat extremely quickly and assumes
ambient temperature (well below the re-
ported flashpoint of the fluid). In other
words, a drip at elevated temperatures can
fall one to two feet and be at ambient tem-
perature. Also note that in this real-world
situation, there is no flame or ignition
source to ignite the fluid.
It is important to note that it is recom-
mended that all elbows or bends in the When maintaining a hot oil heat
piping with welded joints be exposed. Do transfer system, you must watch
not place insulation around those weld- over many things: heater or
ments. If, for some reason, there is a leak, exchanger, pumps, valves, expansion
it will be at that weld joint. By keeping the tank, piping, flanges, gaskets, studs,
nuts, seals and insulation.
weldment free of insulation, you will allow
the fluid to drip away from the pipe, and
thus avoid a safety hazard. Also, with the might ask why flashpoint is important at
joint uninsulated, any drips or leaks can be all. After all, good insulation techniques al-
noticed during a visual walk-through and low fluid leaks to be seen quickly.
fixed as soon as possible. Well, there are some situations where
Having explained what tests are used the flashpoint is a concern — and that is
to identify a fluid’s flashpoint, and having when the real-world replicates the testing
identified a real-world situation in which procedure.
a fluid’s flashpoint comes into play, one Can this happen? Yes.
Trusted Heat Transfer Fluids
Unmatched Customer Support
Same Day Shipping
REQUEST QUOTE 1-800-503-9533
www.process-heating.com FEBRUARY 2018  27
 Heat Transfer Fluids
Does this happen? Yes, but very rarely
does it.
Ignition sources can come from the
flame in the heater as well as from electric
control panels or other electronics. There
are many fail-safes around the thermal oil
system that will shut down the system, pre-
venting damage from a flashover of ther-
mal oil. This type of flashover will almost
never happen around the thermal heater.
The only time that I have heard of this
flashover of the thermal oil is when sys-
tems have been jumpered to prevent those
fail-safes from shutting down the system.
Why Is Flashpoint Important?
I have been doing work in an industry that
seems to like to install nitrogen blankets on
the expansion tanks. If the system is not
maintained properly, the nitrogen blanket
traps the light-end molecules in the system.
These light-ends get suspended in the heat
transfer fluid. Here is an example of a real-
world situation where this is dangerous,
and the heat transfer fluid could flash over.
Suppose you are utilizing fiberglass in-
sulation (not closed-cell insulation) that
has the white poly coating over the outside.
Is your
advertising
coming up short?
BPA makes
media buying better.
When you have assurance, you have confidence
you’re getting what you paid for. By advertising in a
BPA-audited publication, you know the circulation
is verified by an independent third-party who makes
sure you don’t get short-changed.
28  FEBRUARY 2018 Process Heating
Hot oils degrade over time, and
the rate of degradation can be
influenced by operating procedures,
equipment layout and equipment
malfunctions.
You might even have an aluminum clad
over the top to dress it up. You realize you
have a leak in the section of your piping.
Because you cannot stop production, you
do not shut down the system to allow it to
cool. So, the temperature of the pipe and
insulation are at your operating tempera-
ture. You want to investigate to find where
the leak is located, so you remove the alu-
minum clad (if you have it) and break into
the white poly coating of the insulation. A
fire ensues.
Let me explain what happened: When
you broke the poly coating, oxygen and
dust rushed into the location, which is
saturated with thermal oil and at operating
temperature. Dust has a low flashpoint —
around 110°F (43°C). With the presence
of oxygen and the heat from the thermal
oils system, the dust flashed over. The dust
acts as an ignition source just as the flame
does in the test fixture. This causes the
thermal oil to flash over and then catches
the oil on fire. Because the fiberglass insu-
lation is saturated in thermal oil, the fire
continues to burn.
Thermal fluid analysis can identify
signs of thermal cracking, oxidation
and contamination and help ensure
your system runs as productively
and efficiently as possible.
How can you prevent such an outcome?
If you had used closed-cell insulation, this
would not happen. When you removed
sections of the insulation, they would not
be saturated with thermal oil.
In conclusion, is the flashpoint impor-
tant? Yes, with the right understanding.
Can you take steps to ensure your system
is safe from having the oil flashover? Yes,
with the proper components and design to
your hot oil system.
Remember, safety first. It starts with the
design of the system and continues through
to your operating procedures. Hot oil sys-
tems can run flawlessly for years if you do
the right things to maintain them.
Mark Smith is the general manager
of MultiTherm, Devault, Pa. For more
information about heat transfer systems from
MultiTherm, call 610-408-8361 or visit
www.multitherm.com.
 Boilers
As concrete producers in colder
climates renovate their ready-mix
plants, they are finding that direct-
contact water heaters provide
ample hot water on-demand at
lower cost than traditional direct-
fired hot water tanks or boilers.

DIRECT-CONTACT
WATER HEATERS
for Concrete Plants
Direct-contact water heaters minimize downtime, produce hot water
on demand and offer fuel savings.

By Robert Rizza, ferently from direct-fired water tanks with
Power Flame Inc., firetubes, and from boilers. Typically, they
are vertical cylinders with a section of dif-
and Michael Maddox,
fusion material inside the top; a burner in
CEI Enterprises
the middle; and a collection area at the
bottom. Water is sprayed into the top of
collects briefly in the bottom of the cylin-
der and is pumped directly from there to
the mixing equipment.
Unlike a direct-fired tank with a fire-
tube, with direct-contact water heating,
there is no need to heat and store large

A
s concrete producers in cold-
er climates renovate their
ready-mix plants, they are
finding that direct-contact
water heaters provide ample hot water on
demand — at lower cost than traditional
direct-fired hot water tanks or boilers. Hot
water is required to ensure consistency of
the concrete mix during cold weather.
Direct-contact water heaters work dif-
the heater, and it migrates downward
through a section of diffusion material
called packing. Packing typically is made
from stainless steel formed into rings of
various shapes and sizes. These rings pro-
vide the surface area where heat is trans-
ferred to the water from burner gases.
As the water flows downward through
the packing, hot burner gases flow upward
through the falling water. The heated water
quantities of water before it can be used.
Direct-contact water heaters heat the water
on demand. These types of heaters also take
up less ground area than tanks. And, unlike
boilers, direct-contact water heaters are not
pressurized and require less maintenance.
One concrete producer recently in-
stalled its first direct-contact water heater
at one of its concrete plants. The company
determined that the direct-contact heater

www.process-heating.com FEBRUARY 2018  29

 Boilers

Direct-contact water heaters heat the water

on demand. These types of heaters also take
up less ground area than tanks. And, unlike
boilers, direct-contact water heaters are not
pressurized and require less maintenance.

30  FEBRUARY 2018 Process Heating


costs about half as much to operate as a
direct-fired water tank at one of their simi-
larly sized plants.
Generally speaking, direct-contact water
heaters can be more efficient than direct-
fired tanks with firetubes. There are a cou-
ple of reasons for this. First, their design
allows a higher percentage of heat from
the burner to be absorbed by the water.
By contrast, fired boilers and direct-fired
tanks have to maintain higher stack tem-
peratures in order to prevent exhaust gases
from condensing, which would cause rust
and eventually interfere with burner op-
eration. Higher stack temperatures mean
more heat is being carried out of the heat-
er. The direct-contact design readily allows
water vapor in exhaust gases to condense
and mix with the rest of the heated water.
Second, direct-contact water heaters do
not have to maintain the temperature of
several thousand gallons of water. Because
water is being heated and used on demand,
a standard burner is fired to heat only the
amount of water as it is used. This reduces
the amount of fuel used to heat the water.
Direct-Contact Water
Heater Maintenance
Direct-contact water heaters are low
maintenance, with nearly all components
easily accessed from the outside of the
heater. Some units are designed to ease ac-
cess to the heater’s packing material and
combustion area. Quick-release hatches
allow maintenance personnel to inspect
and change out the packing. Manways or
removable firing chamber heads provide
access to the lower half of the heater. Dur-
ing troubleshooting, technicians can open
the access hatches to inspect the packing.
Then, if it needs cleaning, it can be taken
out through the lower hatch, cleaned and
put back in through the upper hatch.
Some plants use mix water from a well.
Water is pumped from the well into a stor-
age tank that feeds the direct-contact water
heater. The water is heated to temperatures
of 140 to 160°F (60 to 71°C) — or even
higher — to overcome heat loss absorbed
by cold aggregate and ambient tempera-
ture. This ensures that the mix can still be
poured at optimum temperatures around
70°F (21°C).
Direct-Contact Water
Heater Controls
Typically, mix temperature control is
maintained through the heater’s control
panel. It has a digital controller that al-
lows plant personnel to enter the desired
water temperature.
Many heaters are equipped with UL-rat-
ed, NEMA 4 control panels that house the
heaters’ safety systems and PLC and digi-
tal controls. Compliance to UL standards
helps ensure the operator of the quality of
the electrical system and that the safety sys-
tem meets current requirements for unat-
tended operation. Low water-level switches
prevent the burner from firing unless water
is flowing through the heater. This prevents
the walls of the heater from being damaged
by overheating. High water-level switches
shut off the burner and water flow to the
heater. The NEMA 4 enclosure can provide
watertight protection against splashing wa-
ter, hose-directed water, rain, sleet, snow,
ice, dirt and windblown dust.
Emissions
One important aspect of having a success-
ful installation is working together — end
user and supplier — to establish the basic
design parameters of the system, operating
requirements and site-specific conditions.
These include water, electrical and fuel
supplies, and emission limitations.
Locations in ozone non-attainment ar-
eas need to carefully review the allowable
NOX and carbon monoxide (CO) emission
limits. Advances in ultra-low-NOX burner
technology, specifically 100 percent premix
burners, allow direct-contact water heaters
to meet the most stringent, 9 ppm NOX
emission limits with CO emissions below
50 ppm. Ultra-low-NOX premix burn-
ers generally are equipped with electronic,
microprocessor-based parallel combustion
controls to maintain set fuel/air ratios and
ensure emissions are met over the operat-
ing range of the heater. Other NOX control
methods involving flue-gas recirculation are
impractical on direct-contact water heaters
due to the high moisture content in the flue
gases, which could impact flame stability
and longevity of burner components.
In conclusion, like many companies
looking for competitive advantages, ready-
www.process-heating.com FEBRUARY 2018
Boilers
Direct-contact water heaters are
vertical cylinders with a section of
diffusion material inside the top, a
burner in the middle and a collection
area at the bottom. Water is sprayed
into the top of the heater and flows
down while hot burner gases flow up
through the falling water. The water
passes over the diffusion material,
called packing, which provides the
surface area to allow heat transfer to
the water from the burner gases. The
heated water collects in the bottom
of the cylinder before being pumped
to the mixing equipment.
mix plants are always looking for new
products that might help operations with
reliability improvements or cost reduc-
tions. Direct-contact water heaters have a
simple design that minimizes downtime,
produces hot water on demand and offers
fuel savings. Most designs use off-the-
shelf components, so it is possible to go to
a local burner supplier or electrical store to
get parts and components.
Making sure the heater manufacturer
has several full-time service technicians
and an in-house parts department or local
representatives will ensure support when
necessary.
Robert Rizza is the vice president of sales and
marketing with Power Flame Inc. The Parsons,
Kan.-based company can be reached at 620-
421-0480 or visit www.powerflame.com.
Michael Maddox is the advertising manager
with CEI Enterprises. The Albuquerque, N.M.-
based company can be reached at 800-545-
4034 or visit www.ceienterprises.com.
 31
 Boilers

Boiler cleaner systems can help

regain efficiency and save on
fuel costs quickly.

BOILER CLEANING
Drives Benefit to Bottom Line
Scale and soot buildup on the boiler surfaces causes the equipment to run harder
to maintain the same output, and both fuel and efficiency losses quickly ramp up.
Effective boiler cleaning can restore boiler surfaces and efficiency.

By Ray Field, and, if everything appears to be working to a 2 percent fuel loss. In high pressure
Goodway Technologies properly, routine maintenance may fall to applications, the resulting iron plus silica
the wayside. However, putting off a total deposits can result in fuel losses of up to

C
an boiler maintenance impact
your bottom line? You bet it
can. When a boiler is operating
at optimum efficiency, it can
help save thousands of dollars on a facil-
ity’s energy costs. Sounds great, but how
can you make sure that happens?
Energy efficiency in a boiler really cen-
ters on keeping the boiler clean and free of
scale and soot. The boiler is one of the most
complex systems in the facility — and also
one of the most dangerous. It is important
to incorporate boiler cleaning into the
maintenance plan.
Boiler cleaning is not always top of mind
cleaning until performance starts to suf-
fer means fuel and efficiency losses quickly
build. Out of sight should not mean out of
mind. Being proactive rather than reactive
when it comes to maintenance yields ben-
efits such as reducing downtime costs, sav-
ing energy, identifying recurring problems
and extending the life of the boiler.
Scale and soot buildup causes equipment
to run harder to maintain the same output.
Once scale forms on boiler surfaces, both
fuel and efficiency losses quickly ramp up.
According to the Department of Energy,
even normal scale (1/32” thickness) pro-
duced by low pressure applications leads
7 percent. And, while 2 percent may not
sound like much, the Environmental Pro-
tection Agency offers a helpful example:
A firetube boiler using 450,000 million
BTU of fuel (at $8 per million BTU), run
8,000 hours per year, with 1/32” of normal
scale, means a yearly operating cost spike
of more than $70,000.
Scale develops naturally, and it is in-
evitable that it is going to end up in the
equipment. It does not take much to start
impacting the efficiency of the equipment,
which in turn adds to operating expenses.
The primary concern is the heat transfer
surfaces where scale builds up. The scale

32  FEBRUARY 2018 Process Heating


creates a layer that affects heat transfer and
increases power usage, diminishing the ef-
fectiveness of the entire system.
As noted by research from North Caro-
lina State University, the reduced heat con-
ductivity of scale leads to big problems. If
left untreated, 0.5” thick scale can lead to a
70 percent increase in fuel usage and sig-
nificantly reduce overall boiler efficiency.
In other words, it does not take a lot of
scaling to equal big problems and unneces-
sary expenses.
While it may seem easy to push boiler
maintenance to the bottom of the to-do
list, preventive maintenance is the best
way to get ahead of scale buildup. An ideal
time to perform the boiler maintenance
and cleaning is during the summer months
when the boilers are shut down.
There are two types of tubular boilers:
firetube and watertube. In the watertube
boiler, water is carried in the tubes and
Firetube boiler cleaning systems can be compact, portable and easy to use. With some systems, one operator can thoroughly
clean a boiler in less time than is required by other cleaning methods simply by flipping a switch.
heated to the point that it becomes high
pressure steam. In the firetube boiler, water
surrounds the tubes and hot gases travel
through the tubes. Both watertube and
firetube boilers use similar methods for
cleaning.
Here are a few helpful tips to get started
with descaling:
• Incorporate both mechanical and chem-
ical cleaning.
• Conduct visual inspections.
• Monitor for evidence-based assessments.
• Measure the impact.
Incorporate Both Mechanical and
Chemical Cleaning. The removal of con-
taminants on both the waterside (scale
formation) and the fireside (soot and scale
formation) of boilers will result in substan-
tial energy savings. Scale deposits occur on
the waterside of boilers when calcium and
www.process-heating.com FEBRUARY 2018
Boilers
other minerals form insulating layers on
boiler-tube metal because of normal boiler
operating temperatures. Similarly, hot
gases and unburned carbon from fuel on
the fireside of boilers cause soot and scale
buildup, which also causes insulating layers
on the fireside of the tube.
An ongoing cleaning program that
consists of chemical descaling for the
waterside and mechanical (rotary clean-
ing tools) and industrial vacuums for the
fireside will enhance energy efficiency and
equipment life. While chemical descal-
ing is more commonly used for watertube
boilers, some firetube boilers do develop
scale deposits.
In a mechanical cleaning, moving brush-
es operate to scrape the scale off the walls
of pipes and tubes. The chemical process
involves circulating a chemical through
the tubes, which dissolves and flushes out
the scale. Incorporating a combination of
 33
 Boilers

Before

After

Reduced heat conductivity of scale leads to big problems: If left untreated, 0.5” thick scale can lead to a 70 percent increase in
fuel usage and significantly reduce overall boiler efficiency. Preventive maintenance is the best way to get ahead of scale buildup.

34  FEBRUARY 2018 Process Heating

 Boilers

both processes to effectively rid the equip-
ment of scale is recommended. Begin with
an initial chemical treatment that helps to
loosen scale, rust and other deposits before
following up with mechanical scrubbing.
Conduct Visual Inspections. While
one can schedule annual maintenance, it is
beneficial to also perform ongoing inspec-
tions to be on the lookout for any signs
of scale.
Monitor for Evidence-Based Assess-
ments. According to Hartford Steam
Boiler, evidence-based assessments are one
of the best ways to determine if chemical
cleaning is required. Regular monitoring
of flue-gas temperature also can indicate
a problem: If the temperature rises when
boiler load and excess air are held constant,
scale is the likely culprit. Other reasons to
consider a chemical clean include one or
more system failures due to corrosion or
when a significant amount (more than 10
percent) of the boiler tubing is replaced.
Measure the Impact. Take the time to
evaluate the impact of descaling. Com-
pare the energy bills prior to and after the
descaling. It is always good to share cost
savings and positive impact on the bottom
line, so make sure to highlight the success-
es in improving efficiencies.
Boiler cleaning is one area where
making the investment pays off
in the long run through increased
efficiencies and cost savings.
with the proper training. Boiler cleaning
equipment and methods have come a long
way, so the job can get done in a way that
is easier, faster and utilizes less manpower.
Part of the job is making sure one has the
right equipment, so take the time to re-
search the options.
Most of us understand the importance
of ongoing maintenance, but the reality of
reduced budgets or a limited amount of
personnel resources can trump the actual
implementation. Boiler cleaning is certain-
ly one area where making the investment
pays off in the long run through increased
efficiencies and cost-savings.
Do yourself — and your company — a
favor by developing a routine cleaning and
maintenance plan for your boiler, imple-
menting that plan and making sure that
you are sharing the impact and savings with
leadership and the maintenance team.
Ray Field is director of Goodway Liquid
Solutions with Goodway Technologies.
The Stamford, Conn.-based company
can be reached at 203-359-4708 or visit
www.goodway.com.

Testing Helps Maintain Gains GET IN THE

LOOP
Once a boiler maintenance program is in
place, be sure to include regular efficien-
cy testing. This can help identify certain
trends that signify it is time to clean the
boiler. For example, an increase in stack Follow/Like/Share
temperature can indicate soot or scale
buildup. Comparing the data and results
from test to test will help to identify main-
tenance requirements. There are many ef-
ficiency testers available that can fit within
the budget and meet the process needs.
Some companies offer a calculator that
allows users to enter their process infor-
mation, including annual operating hours,
type of fuel used and basic scaling infor-
mation. The tool can help calculate the
potential cost savings when using liquid
descaler to remove limescale from the wa-
terside of tubes.
Boiler cleaning can be a daunting task.
But there is a variety of equipment and
PROCESS-HEATING.COM/CONNECT
chemicals available that are easy to use

www.process-heating.com FEBRUARY 2018  35

 Fans/Blowers Cooling fans often are used in
power plants, as shown by this
installation of cooling fans at a
California power plant.

CENTRIFUGAL FANS
for Power & Glass Process Cooling
Power and glass are two industries among many where centrifugal fans provide
the critical pressures and airflow required for proper process cooling. In any
process cooling application where centrifugal fans provide the essential flow and
pressure ingredients, proper selection is critical.

By Kenny White, sure and airflow. While many process
AirPro Fan & Blower Co., and implementations exist, this article will
Brian Gleitz, explore two centrifugal applications: The
Peerless-Aarding fan on an air pollution-control unit in a
power production facility (for selective
turbines have been prepared with heat
recovery steam generators (HRSG) or
have not been treated for NOX removal. In
these applications, the exhaust tempera-
ture remained within an adequate operat-

P
rocess cooling is the function
of removing heat in order to
control or maintain appropriate
temperature levels. Almost ev-
ery manufacturing process produces a cer-
tain amount of excess heat due to friction
or process heating. From a shop compres-
sor to the power plant just outside town,
process air is required to generate the pres-
sure and airflow necessary to decrease or
maintain the proper temperatures.
Fans, both axial and centrifugal, are
the primary media to provide such pres-
catalytic reduction), and the blower on
a glass-tempering oven. In both cases,
industrial process fans provided effective
process cooling.
Controlling Temperatures
During Selective Catalytic
Reduction
With the increasing demands for environ-
mental controls on exhaust systems, selec-
tive catalytic reduction (SCR) is becoming
more common on the back end of com-
bustion turbines. Traditionally, combustion
ing range for the SCR or CO systems to
achieve desired emissions reduction.
On simple cycle systems where the
exhaust from the combustion turbine is
ducted straight through, the temperatures
are too high for reliable SCR operating
ranges (850 to 1100°F [454 to 593°C]).
One solution on these systems is to add
ambient air into the exhaust stream ahead
of the SCR catalyst. This reduces the
overall exhaust temperature to acceptable
ranges for NOX reduction (500 to 800°F
[260 to 426°C]).

36  FEBRUARY 2018 Process Heating


One way to accomplish this is to inject
ambient air into the system by providing
13 to 20” water column of pressure with
centrifugal blowers at a specified volume
rating. Injection of the ambient air typi-
cally takes place several feet upstream of
the catalyst face in order to fully mix and
establish a uniform temperature across the
gas path. The volume then is controlled
depending upon the temperature setpoint
of the exhaust by use of variable-frequency
drives (VFDs) or inlet vane dampers. The
cooling blowers usually are provided on a
skid arrangement: Two identical blowers
are mounted to mirror each other. This
allows the unit to continue to operate if
one blower is out of service. Downtime is
unacceptable on these systems, so redun-
dancy is a critical necessity for the facility.
This scrubber fan is installed at a mining facility in Arizona. High efficiency, corrosion-resistant industrial fans and blowers can
be manufactured with special alloys and coatings to withstand corrosive exhaust streams.
The blowers in the SCR system also
can assist in satisfying the pre- and post-
purge requirements of many combustion
turbines. Utilizing this system can reduce
the time required for pre- and post-purges.
As the demand for fast power, emis-
sions requirements on gas pipe lines and
the need for traditional temperature SCRs
increases, having a properly sized cooling
air-injection system is becoming a key
portion of the design.
Controlling Temperatures
During Glass Tempering
Manufacturing tempered glass is a detailed
and unique process that relies upon the
quick cooling of the glass to obtain the
purposes for which tempered glass is used.
The unique designs and characteristics of
www.process-heating.com FEBRUARY 2018
Fans/Blowers
centrifugal fans are a critical component of
the cooling process on a tempering system.
Tempered glass typically is about four
times stronger than ordinary, or annealed,
glass. When annealed glass shatters, the
result is sharp, jagged shards that can be
hazardous to a person or pet. By contrast,
tempered glass shatters into small, rela-
tively harmless pieces. Tempered glass is
used in applications where human or pet
safety is important such as automobile
glass, patio doors, shower doors, racquet-
ball courts or patio furniture.
During glass tempering, the centrifu-
gal fans play a key role in the cooling
process. Prior to the tempering process,
the glass typically is cut to size. The glass
then is fed through a heat-treat process
in which it passes through a tempering
 37
 Fans/Blowers
A scrubber fan is shown in use at an energy plant in New Mexico. The industrial fans used to process the air in scrubbers must
be efficient, corrosion resistant and adaptable.
oven that heats the glass to approximately
1200°F (649°C). The glass then undergoes
a rapid, high pressure cooling process
called quenching. This process lasts only
a few seconds. A continuous blast of
high pressure air — distributed through
a perforated panel on which the glass is
riding — cools the outer surfaces of the
glass more quickly than the center. As the
center of the glass cools, it pulls back from
the outer surfaces, forcing it into compres-
sion. While the center remains in tension,
the glass edges remain compressed, giving
the tempered glass its strength.
The perforated panels upon which the
glass panels ride are constructed with hun-
38  FEBRUARY 2018 Process Heating
dreds of holes that measure approximately
0.046” in diameter. The tempering process
requires significantly high airflow pres-
sures to effectively cool the glass in a short
period of time.
Due to the short time and high pressure
required to rapidly reduce the glass from
approximately 1200°F (649°C) to around
500°F (260°C), two centrifugal fans tied in
series are required to supply the necessary
pressure and airflow. The major variable
in this process is the pressure downstream
from the fans. This downstream condition
can create another variable to reconcile in
the tempering panel and cooling system
design. Fan curve characteristics can be
tricky when the pressure is on the dis-
charge side of the fan. In this situation,
the fans can be pushed into the peak of the
curve, which is a no-go zone for most fans.
Accuracy in the fan selection is critical to
the successful function of this setup.
By operating two fans in series, signifi-
cant pressures can be developed along with
the higher flows required for the tempering
process of very thin glass. (Very thin glass
is more difficult to temper.) Through this
process, properly designed and installed
blowers have been able to help glass-tem-
pering companies produce tempered glass
that is 0.125” thick. The cooling require-
ments of the thicker pieces of glass do not
 Fans/Blowers

require the speed of the thinner glass in

order to accomplish the tension versus the
compression characteristic.
Once the initial tempering process is
completed, the tempered glass continues
through an additional cooling process.
This subsequent stage requires another
centrifugal fan. Overall, the glass-tem-
pering process is unusual in the process
cooling arena. At the same time, it is just
one more way in which industrial fans are
being used for increased manufacturing
accomplishments.

An SCR fan skid is being used at New Jersey-based power generation facility. The
SCR process often is applied to boilers, incinerators and furnaces of power plants.

A cooling blower is installed in the

facility of a New York-based glass
door manufacturer.

In conclusion, power and glass are just

two industries where centrifugal fans
provide the critical pressures and airflow
required for proper process cooling. In any
process cooling application where centrifu-
gal fans provide the essential flow and pres-
sure ingredients, proper selection is critical
to the efficient and accurate operation
of the entire system. Factors such as the
required flow rate and pressure, ambient Cooling blowers often are used in glass-tempering applications as in this
and system air temperatures, installation installation at a Wisconsin facility. The tempering process requires significantly
high airflow pressures to effectively cool the glass in a short period of time.
elevation and system size requirements
must all be carefully evaluated to ensure
the appropriate fan is selected for the
project. When successfully sized, selected Kenny White is a senior sales engineer with AirPro Fan & Blower Co., Rhinelander, Wis., and Brian
and manufactured, centrifugal fans supply Gleitz is a project engineer with Peerless-Aarding, Dallas. For more information from AirPro Fan
an effective process air medium for most & Blower Co., call 715-365-3267 or visit www.airprofan.com. For more information from Peerless-
process cooling applications. Aarding, call 214-357-6181 or visit www.cecoenviro.com/peerless-aarding.

www.process-heating.com FEBRUARY 2018  39

 Equipment Overview
You know you need to get control of your process. But, what kind
of control does your process need? Process Heating helps you select
an industrial temperature controller supplier with our annual
Equipment Overview on Temperature Controllers. Manufacturers
are listed in print as well as online. Use it to cross check controller
types and features with those companies that manufacture them.
To view the matrix of controller manufacturers online, visit
Temperature Controllers
www.process-heating.com/directories. Scroll down and click
on the Temperature Controls Guide at the bottom of the page.
Online, you can view an overview of each manufacturer’s capabili-
ties, see all manufacturers that offer certain features, or search by
keyword. Also online, some manufacturers have upgraded listings
that include a link to the company website as well as datasheets and
other product information.

Inputs Outputs
Sensor

Time-Proportioning Relay
Time-Proportioning Logic

Time-Proportioning Triac
Thermocouple

Universal Thermocouple
Type N (Nicrosil/Nisil)
Relative Humidity

Universal Process

Dual (Heat/Cool)

Adaptive Tuning
Analog Current
Analog Voltage

Auto/Manual
Differential

Autotuning
Thermistor
Pyrometer

Type PL2

Cascade
Type D

Type K

Type R
Type B
Type C

Type S
Type E

Type T
Type J
RTD
Company
Tempco Electric Heater Corp. • • • • • • • • • • • • • • • • • • • • •
630-350-2252, www.tempco.com
Affiliated Steam Equipment Co. • 800-424-5392, www.affiliatedsteam.com •
Ascon Tecnologic, North America • 216-485-8350 x227, www.ascontecnologic.com • • • • • • • • • • • • • • • • • • • • • • • • • •
Athena Controls Inc. • 610-828-2490, www.athenacontrols.com • • • • • • • • • • • • • • • • • • • • • • • • •
Cantherm • 800-561-7207, www.cantherm.com •
Carlo Gavazzi Inc. • 847-465-6100, www.gavazzionline.com
Chromalox • 800-443-2640, www.chromalox.com • • • • • • • • • • • • • • • • • • • •
Cole-Parmer • 800-323-4340, www.coleparmer.com • • • • • • • • • • • • • • • • • • • • • • •
Convectronics Inc. • 978-374-7714, www.convectronics.com • • • • • • • • •
Cristal Controls Ltd. • 800-681-9590 x240, www.cristalcontrols.com • • • •
Custom Heat LLC • 978-777-4441, www.customheatllc.com • • • • • • • • • • • • • • • • • •
DME Co. • 248-398-6000, www.dme.net • • • • • •
Durex Industries • 847-639-5600, www.durexindustries.com • • • • • • • • • • • • • • • • • • • •
Dwyer Instruments Inc., Love Controls • 800-872-9141, www.dwyer-inst.com • • • • • • • • • • • • • • • • • • • •
Elan Technical Corp. • 952-452-8667, www.elantechnical.com • • • • • • • • • • • • • • • • • • •
Electronic Development Labs Inc. • 434-799-0807, www.edl-inc.com • • • • • • • • • • • • • • •
Etter Engineering • 860-584-8842, www.etterengineering.com • • • • • • • • • • • • • • • • • • • • • • • •
Eurotherm • 703-724-7300, www.eurotherm.com • • • • • • • • • • • • • • • • • • • • • • • •
Extech Instruments • 603-324-7800, www.extech.com • • • • • • • • • • • • • • • •
Gammaflux • 703-471-5050, www.gammaflux.com • • •
Gefran Inc. • 888-888-4474, www.gefran.com/en/us • • • • • • • • • • • • • • • • • • • • • • • • • • • •
Harrop Industries Inc. • 614-231-3621, www.harropusa.com • • • • •
Honeywell Process Control • 800-343-0228, www.honeywell.com/sensing • • • • • • • • • • • • • • • • • • • • • • • • • • • •
Indeeco • 314-644-4300, www.indeeco.com
Jumo Process Control Inc. • 315-437-5866, www.jumousa.com • • • • • • • • • • • • • • • • • • • • • •
Leister Technologies • 855-534-7837, www.leister.com •
MKS Instruments Inc. • 978-645-5500, www.mksinst.com • • • • • • • • •
Moore Industries • 818-894-7111, www.miinet.com • • • • • • • • • • • • • • • •
Nanmac Corp. • 508-872-4811 x265, www.nanmac.com • • • • • • • • • • • • • • • • • • • • •
Nextron Ltd. • 866-639-2875, www.nextron.ca • • • • •
Novus Automation • +55 51 33233600, www.novus.com.br/site • •
Omega Engineering Inc. • 203-359-1660, www.omega.com • • • • • • • • • • • • • • • • • • • • • •
Ordan Thermal Products Ltd. • 905-475-9292, www.ordanthermal.com • • • • • • • • • • • •
Oven Industries Inc. • 717-766-0721, www.ovenind.com • • • • • • • • • • •
Pentair, Industrial Heat Tracing Solutions • 650-216-1526, www.pentairthermal.com • • • • • •
Process Sensors Corp. • 201-485-8773, www.processsensorsIR.com • • • • • • •
Process Technology • 440-974-1300, www.processtechnology.com • • •
Siemens Industry Inc. • 215-646-7400 x3285, www.usa.siemens.com/temperature
Sterling Products Inc. • 262-641-8600, www.sterlco.com • •
Temp-Pro Inc. • 413-584-3165 x258, www.temp-pro.com • • • • • • • • • • • • • •
Thermalogic • 800-343-4492, www.thermalogic.com • • • • • • • • • • • • • • • • • • • • • • • • •
United Electric Controls • 617-926-1000, www.ueonline.com
Vulcan Electric Co. • 207-625-6950, www.vulcanelectric.com • • • • • • • • • • • • • • •
Watlow • 800-928-5692, www.watlow.com • • • • • • • • • • • • • • • • • • • • • • • • • • • •
Wavelength Electronics Inc. • 406-587-4910, www.teamwavelength.com • • • • • • •
West Control Solutions • 800-866-6659, www.west-cs.com • • • • • • • • • • • • • • • • • • • • • • • • • • • •
Yokogawa Corp. of America • 800-888-6400, www.yokogawa.com/us • • • • • • • • • • • • • • • • • • • • • • • • • •
Zytron Control Products Inc. • 609-771-0101, www.zytron.com • • • • • • • • • • • • • • • •
Companies with in front of their names have an advertisement in this issue.

40  FEBRUARY 2018 Process Heating

 Search Online at www.process-heating.com/directories
If you need more information, visit www.process-heating.com/ the plus sign next to those suppliers you wish to add to your list,
directories, scroll down and select the Equipment Overview on or the Add an Info Request button on any manufacturer’s listing.
Temperature Controls near the bottom of the page. Click on a Continue adding companies until you’re ready to submit your
company name to view complete contact information for each list. Once you’ve selected those you are interested in, click on the
manufacturer. Submit an Info Request button to create a prepopulated form. Fill
Use our RFP Builder to collect information from multiple sup- in your contact information and send it. All responses from suppli-
pliers. To do so, go to any Equipment Overview page and click ers will be sent directly to you or the contact(s) designated by you.

Control Modes Physical Features Additional Features Industries Served

Food Processing & Production

Agency

We manufacture aftermarket
Proportional w/Manual Reset

Max/Min/Average Statistics
DIN Size

Chemicals/Petrochemicals
Ramp/Soak Programming

Approval

Serial Communications
Connection, Hard Wire

Pulp/Paper/Converting
Universal Power Input

Plastics/Rubber/Vinyl
Load Current Display

temperature controls.
Configurable Display

parts/supplies for our

Configurable Alarms

Packaging/Printing
Load Failure Alarm
Field Configurable

Loop Break Alarm

Operator Lockout
Multiple Setpoint

Valve Positioning

Connection, Plug

Pharmaceuticals
Gain Scheduling

CUL Recognized
CE Certification
NEMA 4 Rating
Display, Single

UL Recognized
Ratio Control

Display, Dual
Fuzzy Logic

Front Panel

Electronics
Back Panel
Mounting

Finishing
DIN Rail
On/Off

Other
1/16
1/32
1/4
1/8
Full
PID

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• • • • • • • • • • • • • • • • • • • • • • • • • • Yes
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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 temperature
controller market. To be included in future listings, contact Linda Becker at BeckerL@bnpmedia.com.
www.process-heating.com FEBRUARY 2018  41
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’ websites.

GF Piping Systems Omega Engineering Inc.

Corrosion-Resistant Dosing Valve Mineral-Insulated Cables
Also called MI cables, mineral-insulated cables have
conductors or wires enclosed by a metal jacket and
insulated with hard-packed magnesium oxide (MgO). The
basic construction provides high temperature capability,
electrical isolation and physical protection for the
conductors when subjected to harsh environments. RTD
and thermocouple sensors manufactured from MI cable
are used in heat treating metals, solid-waste incinerators,
sintering powdered metals, firing ceramic materials, gas- or
oil-fired furnaces, fuel-fired heat exchangers, box furnaces,
and nuclear or hydrocarbon-based energy plants.
888-826-6342
omega.com/micable

Process Sensor Corp. (PSC)

Miniature Infrared Temperature Sensors
PSC-SSS-PM Series has 4 to 20 mA or RS485 Modbus
A corrosion-resistant pneumatic diaphragm valve is outputs, depending on the model selected. The PSC-SSS-
suited for highly corrosive dosing applications and PM is suited for general-purpose applications while the
open/close applications. Type 604/605 is designed and PSC-SSS-PM 2.2 is suited for high temperature applications.
tested to surpass two million lifecycles, according to the Up to 247 sensors may be installed on each Modbus
manufacturer. The 0.5" (d20) size valve is available in network. The sensors simplify setup for alarm relays and
body materials such as PVC, CPVC, PROGEF standard PP adjustments, replacing the need for additional PC boards
and SYGEF standard PVDF. The pneumatically actuated and software. An optional touchscreen display shows
dosing valve is pressure rated at 90 psi unidirectional the measured temperature and allows full and simple
with operating temperatures ranging from -4 to 284°F configuration of the infrared sensor, including alarms.
(-20 to 140°C), depending on body material. The threaded 201-485-8773
bonnet design eliminates the need for metallic body www.processsensorsir.com
bolts and re-torqueing after hot line shutdowns.
800-854-4090 E Instruments
www.gfps.com International
Hand-Held Industrial
Salisbury by Honeywell Combustion Gas and
Face-Shield Technology Helps Protect Emissions Analyzer
Electrical Workers from Arc Flash Suited for emissions monitoring
PrismShield incorporates nanotechnology that allows a of boiler, furnace and other
wider spectrum of light to enter the lens of the face shield. combustion applications, Model
This improves color recognition and color sharpness for E6000 measures up to six gases
electrical workers and reduces the need to lift the shield to simultaneously (O2, CO, NO, NO2,
see wires more clearly, particularly in dim light. Electrical SO2, CXHY(HC), H2S) and has a
workers sometimes lift up the face shield momentarily built-in printer and full-color
when there is a need to differentiate wire colors, a graphic display. Other features
practice that leaves them unprotected against arc flash, an include automatic data
explosion that can produce intense ultraviolet light and saving, expanded internal
temperatures up to 35,000°F. The arc-flash-protective face memory, and Bluetooth
shield uses a bronze lens tint and incorporates an anti- wireless communication
scratch, anti-fog lens coating. and software.
800-430-5490 215-750-1212
www.honeywellsafety.com www.e-inst.com

42  FEBRUARY 2018 Process Heating


Endress+Hauser
Coriolis and Electromagnetic
Flow Instruments
Smart Coriolis and electromagnetic flowmeters for the
hygienic industries have compact hygienic 316L stainless-
steel housings. The built-in web server provides universal
browser-based access to device, diagnostics and process
information from any device with an internet or Wi-Fi
connection. Proline 300 is designed to support an IP69
ingress-protection rating, making it impervious to water
ingress from high pressure washdown. The sensors are
designed according to ASME BPE, EHEDG and 3A standards
and provide full GMP compliance for sterile processes. The
mass flow meters are available in 11 models ranging in sizes
from 0.04 to 14" diameter for measuring flows up to 100,000
tons per day.
888-363-7377
www.us.endress.com
Selco Products Co.
IoT-Ready Electronic Thermostats
Many sensor styles, including NTC thermistors,
thermocouples (type J, K) and RTDs, can be used with the
company’s eCap Series to deliver energy savings through
switching power supply technology (<30 mW at idle
state). The sensor/thermostat combination can be used
in processes operating from -40 to 2012°F (-40 to 1100°C).
The thermostats have a 30 A relay to support heavy-duty
loads. Two versions offered have two relays (12 and 20 A)
and are oriented for cold applications and solid-state relay
output to drive external relays.
The electronic thermostat offers
high accuracy of temperature
control due to close differentials
and narrow tolerances. They are
SPST, offer tight temperature
accuracy (±1°F for RTDs and ±2°C
for thermocouples) and can be
programmed to open or close
on rise.
800-257-3526
www.selcoproducts.com
www.process-heating.com FEBRUARY 2018
Product Highlights
Flir Systems Inc.
Thermal-Imaging Cameras for
Smartphones and Tablets
Built on the company’s Lepton
thermal microcamera core, the Flir
One and Flir One Pro enable thermal
imaging using a smartphone or
table. Equipped with both a thermal
and a high definition visible camera,
the devices emboss high fidelity,
visible-light details onto the thermal
imagery. Flir One Pro’s expanded
temperature range means users can
measure temperatures between -4
and 752°F (-20 to 400°C) using up to
three spot temperature meters and
six temperature regions of interest.
866-477-3687
www.flir.com
Carlo Gavazzi Inc.
Phase-Monitoring Relays
Devices provide critical protection against phase loss
and improper phase sequence. Model DPB52 also
provides protection against under- and over-voltage. With a
low profile DIN housing and 17.5 mm width, the monitoring
relays can be installed in industrial cabinets as well as in
electrical distribution NORM panels. A built-in switch-
mode power supply allows DPA52 and DPB52 to filter
and minimize harmonic distortions. This can help prevent
devices from overheating and avoid failures and false
alarms that could lead to unexpected machine downtime.
The three-phase monitoring relays offer protection against
disturbances and transients.
847-465-6100
www.carlogavazzi.com
 43
Product Highlights

Continental Fan Co. Littlefuse Inc.

Mixed-Flow Inline Fans SCR Thyristor with 302°F
Model MID utilizes the company’s MF mixed-flow Impeller, Junction Temperature
incorporating adjustable-blade geometry for performance High
matching. Suitable temperature
applications SCR (silicon-
include controlled
process rectifier)
ventilation thyristors offer
and a junction
cabinet temperature of
cooling. 302°F (150°C)
The inline in compact
fan is surface-mount
available D-Pak (TO-252)
in diameters packaging. These
from 12 through devices are also
24" with capacities available in
ranging to 5,340 cfm. through-hole V-Pak (TO-251) packages. Standard SJ Series
Features include standard SCR thyristors have a low gate current trigger level of 6 or
NEMA motors; baked polyester powder coat finish; and 15 mA maximum at approximately 1.5 V. Sensitive models
selectable custom mounting arrangements. in the series feature a gate trigger current of less than 200
800-779-4021 μA. The sensitive gate devices can be triggered by sense
www.continentalfan.com coils, proximity switches and microprocessors.
800-999-9445
InfraTec GmbH www.littelfuse.com
Infrared Thermography Camera
Herrmann Ultrasonics
Ultrasonic Welding of Plastics
Acoustic waves (or ultrasound) are converted into
mechanical vibrations to generate molecular heat
the material
to be bonded
to accomplish
ultrasonic welding
of plastics. The
weld process is
managed by control
software and must
be adapted to the
geometry and
condition of the
Intended for preventive maintenance and facility welded parts, which
thermography applications, CompactIR 400 has 120,000 IR are made from
pixels (400x300), which allows temperature distributions amorphous or semi-
on the surface of test objects to be accurately recorded crystalline polymers.
and displayed. It also has high thermal resolution, so Each welding tool,
temperature differences of up to 45 mK can be detected. known as the
The temperature measuring range already reaches 1472°F sonotrode, is unique
(800°C) by default and can optionally be extended up to because it is adapted
3632°F (2000°C). In addition to the standard lens, telephoto to the application
and wide-angle lens can be supplied. at hand.
+49 351 871-8630 630-626-1626
www.infratec.eu www.herrmannultrasonics.com

44  FEBRUARY 2018 Process Heating

PH Classifieds Display Classified Rates:
1X $130 • 3X $125 • 6X $120 • 12X $110
Send advertising copy to:
Process Heating/Attn. Becky McClelland
Phone: 412-306-4355 • Fax: 248-502-1076
E-mail: becky@bnpmedia.com

Equipment for Sale

HEAT EXCHANGERS
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ADVERTISING INDEX
48 Heatec, Inc. 423-821-5200 www.heatec.com

11 Innovative Sensor Technology 702-894-9891 www.ist-ag.com/en-us

27 Isel 800-503-9533 www.calderafluids.com

10 Micron Fiber-Tech 386-668-7895 www.mft-com.com

21 Nestec Inc. 610-323-7670 www.nestecinc.com

47 NPE (The Plastic Show) www.NPE.org

10 Payne Controls 800-331-1345 www.payneng.com

11 Protection Controls 847-674-7676 www.protectioncontrolsinc.com

9 Tempco Electric Heater Corp. 800-323-6859 www.tempco.com

7 Wenger 785-284-2133 www.wenger.com

www.process-heating.com FEBRUARY 2018  45

Places Faces
Goodway Technologies, Stamford,
Conn., developed calculators to help
facility managers determine how
much descaler is required. Those
responsible for maintenance of
chillers, boilers, heat exchangers,
cooling towers, compressors or
condensers will benefit. The online
library includes descaling tools for
boilers, chillers, cooling towers, fluid
coolers and evaporative condensers,
plate-and-frame and shell-and- tube
heat exchangers. Visit the Resources
section on www.goodway.com.
Mokon, Buffalo, N.Y., expanded its
Duratherm Max line of water systems
to include a lower temperature D3
Series, which has capabilities up to
330°F (166°C).
Winfield Kan.-based Webster
Combustion Technology named
Pacific Combustion Engineering
as its manufacturer’s representative
for industrial and commercial
burners in Washington, Oregon and
northern Idaho.
Cody Unrau was named design
engineer for Continental Fan
Manufacturing Inc., Dayton, Ohio.
Galvan Industries Inc., Harrisburg,
N.C., launched a revamped hot-dip
galvanizing services website. Hot-dip
galvanizing prevents rust on steel used
in construction and in manufactured
parts by dipping it in molten zinc,
creating a barrier against corrosion.
The site, www.galvan-ize.com, is
mobile friendly.
Helsinki-based Metso is expanding the
coverage of its flow control solutions
with a distribution agreement with the
46  FEBRUARY 2018 Process Heating
Croatia-based company Eco Consult
d.o.o. The first order for control valves
was for a refinery expansion project
in Russia.
In other company news, Metso is
operating under a new model as of
January 1, 2018. Metso's new business
areas will be Mining Equipment,
Aggregates Equipment, Minerals
Services, Minerals Consumables,
Recycling, Valves and Pumps. The
heads of the business areas will report
to Metso's President and CEO Nico
Delvaux. The group's current reporting
segments, Minerals and Flow Control,
remain unchanged.
Miura Boiler Inc., Rockmart, Ga.,
developed a video describing its “full
steam in 5 minutes” LX and EX Series
boilers. Other features described in
the video include the company’s Quick
Ship Xpress program, which reduces
the need for rentals, and its “Safer by
Design” engineering. Watch it at
https://youtu.be/rlGUDczSALQ.
Lake Bluff, Ill.-based Buehler, an ITW
Co., a manufacturer of value-added
consumables and materials-testing
equipment, introduced a quick ship pro-
gram for its Wilson-certified Rockwell
hardness test blocks. Learn more at
www.buehler.com.
Chemical Coaters Association
International (CCAI), Taylor Mill, Ky.,
is accepting applications for the 2018
Matt Heuertz Scholarship Program.
Students currently enrolled in programs
that could lead to a career in the
finishing industry can apply at
www.ccaiweb.com.
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Technical Editor • REED MILLER
412-306-4360 • reed@process-heating.com
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412-306-4350 • bill@process-heating.com
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SPECIALISTS
IN PROCESS HEATING
Heatec has been designing and manufacturing
process heating systems for over 40 years. Our
experience and knowledge is a valuable tool for
you. We will help you choose the right system
for your process, custom design it and build it
to meet your specifications. When you need a
process heating system for your plant, talk to a
specialist. Talk to Heatec.

423.821.5200 www.heatec.com

H E AT E C , I N C . an Astec Industries Company

5200 WILSON RD • CHATTANOOGA, TN 37410 USA 800.235.5200 • FAX 423.821.7673 • heatec.com