Process Heating Oct'17

October 2017 Volume 24, Number 10
Heaters
Help Deliver
FOOD
PACKAGING
SAFETY
Follow us on:
www.process-heating.com
Reliability
that comes at
no extra
charge.
Choosing the right burner is key in maximizing boiler performance.
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W h e re R e l i a b i l i t y C o m e s S t a n d a rd
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OCTOBER 2017 Volume 24 Number 10
18
Features
Online Exclusives
12 Thermal Fluid Heaters
The Importance of Expansion and Drain Structure Hurricane Harvey Moves Turbomachinery Meeting to December
in Hot Oil Systems The 46th Turbomachinery and 33rd International Pump Users Symposia (TPS
Preplanning during design can save time and money during 2017) will now be held December 12-14, with short courses held December
11. The conference and exposition, sponsored by the Turbomachinery Lab
planned or unplanned shutdowns.
at Texas A&M University, was delayed when Hurricane Harvey hit Houston.
18 Heaters Partnership Improves Awareness of Need for Industrial
Heaters Help Deliver Packaging for Food Safety Cybersecurity
and Consumer Acceptance The International Society of Automation (ISA) formed a global
Packaging innovations such as heat-sealed packages, tamper- partnership with Siemens to improve awareness of the need for
resistant bottles and shrink wrap are all a result of evolution industrial cybersecurity. The alliance specifically focuses on broadening
in process heating technologies. Though process heating is understanding and adoption of industrial automation security standards.
essential to many effective packaging solutions, too often, it is Acquisition of BJM Pumps Completed
an afterthought. Private equity firm May River Capital completed its acquisition of BJM
Pumps LLC, which provides submersible pumps for demanding applications
22 Portable Chillers in industrial and municipal/wastewater environments.
How Variable-Speed Portable Chillers Can Help
An alternative for process cooling applications, variable-
speed compressors coupled with advanced PLCs continuously
Always Online
Archives Energy Notes column Digital Editions
monitor the heat load and adjust the compressor speed for
Calendar of Events Equipment Overviews Buyers Guide
peak efficiency and temperature control. Drying Files columns Heating Highlights Archived Webinars
26 Combustion New Products Industry News
Improved NOX Limitation Standard to Reflect Check out our redesigned site with more frequent updates and web exclusives!
Combustion Efficiency
In many locations throughout North America, nitrogen oxide Quick links point the way:
(NOX) emissions of gas-heated furnaces and ovens are limited www.process-heating.com/connect
by code or law. This is typically the case in urban areas or in
places where special topographical characteristics intensify the Go Mobile
Use your smart phone to read Process Heating, wherever you are! Point
negative local and regional effects of NOX emissions. your phone or tablets camera at the image
at right to scan the QR code with your mobile
30 Temperature Sensors phone or tablet. Your device will display the
Temperature Measurement Flexibility Helps Quality mobile version of the current issue of Process
and Validation Heating instantly!
Understanding different sensor types helps create better Your mobile service provide may charge for
temperature profiles. data transmission usage. Contact your mobile
provider for details on your data plan and limits.
34 Equipment Overview
Industrial Heat Exchangers
An apples-to-apples comparison of the capabilities of
industrial heat exchanger manufacturers, our Equipment About the Cover
Overview will help you narrow the field of potential suppliers. Packaging innovations such as heat-sealed
October 2017
packages, tamper-resistant bottles and Volume

24, Number 10
Columns & Departments shrink wrap are all a result of evolution in

process heating technologies, notes Jeff
4 Commentary 45 Advertiser Index Myatt of Osram (www.osram-americas. Heate
Help Deliversr
6 Inner Workings 45 Classified Directory com). Learn more about heat processing FO
PACKAGINOD
G
10 Calendar 46 Places & Faces technologies for food packaging and SAFETY
38 Product Highlights 46 Contact Us other processes in the article beginning
44 Front & Center on page 18. Follow us
on:
www.p rocess-
heating .com
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 OCTOBER 2017 3

Commentary
Heat
Learn about Heat Transfer Fluids Processing

Technologies
for Process Heating for these
As fate would have it, the first article I freezing points, are particularly well suited
9 Industries
ever worked on for Process Heating related for food processing applications, breweries
to heat transfer fluids. Check Your Fluid and wineries, and refrigerated warehouse
Before It Checks Production appeared in as well as commercial applications such as Chemicals/
our May/June 1995 issue, and it focused on supermarkets and ice rinks. Petrochemicals
the common tests that are performed on Are you struggling with these common
industrial heat transfer fluids to determine problems related to using glycol-based
whether a fluid changeout was needed By Linda Becker fluids:
in a system. (Unfortunately, PH content Food Processing
published prior to 1998 was lost in the great Mac Overdilution of glycols, biofilm fouling and scale
hard-drive crash of 1997. If youd like to read Check formation?
Your Fluid Before It Checks Production, Ill post a Short fluid lifetime?
PDF to this column on our site.) Air entrainment and foaming? Finishing
You may be thinking, if we covered heat transfer
fluids in 1995, has much changed? Is there anything Our speakers Kevin Connor of Dow, Kevin
new to learn? Absolutely! Standards are developed Coscia of Dynalene Inc. and Alfonso Sira of Hough-
and changed, and materials developments drive fur- ton Chemical will offer key insights during this
Plastics/Rubber
ther equipment enhancements. one-hour event. Register for this event at http://bit.
In this issue, The Importance of Expansion and ly/glycolfluidswebinar and watch it live or on demand.
Drain Structure in Hot Oil Systems is a prime On December 5 at 2 p.m. ET, Process Heating and
example. The article, written by the engineering team experts working daily with mineral oil and silicone
at Sigma Thermal, explains the design principles heat transfer fluids will present An Insiders Guide Pharmaceuticals
that must be considered when designing a thermal to Fluid System Maintenance. In the final episode
fluid heating system. Learn key design principles for of Process Heatings heat transfer fluids webinar series,
expansion tanks and the drain structure, and under- our panel goes beyond the basics to deliver practical
Pulp/Paper/
stand how these systems play a part of the overall tips from those working with heat transfer fluids
Wood/Converting
thermal heating system. every day. Learn the insiders tips for preventive main-
This fall, Process Heating and our sister publication, tenance for thermal fluid heating, including:
Process Cooling, will present two hour-long webinars
on heat transfer fluids. How to pipe in a nitrogen system. Ethanol/
On October 12 at 2 p.m. ET, Process Cooling and Design elements in system filtration. Biodiesel
experts working daily with low temperature heat How to remove water and deal with water
transfer fluids will present Using Glycol Heat Trans- contamination.
fer Fluids for Effective Process Cooling. The unique How to deal with water contamination. Packaging/
collaborative event means that you can gain honest Printing
insights into low temperature heat transfer fluids and All of the webinars in the Process Heating heat
how they can best perform in your plant. During the transfer fluids series are available for on-demand
webinar, you will: viewing. To register for the December 5 event or
watch past episodes, visit http://bit.ly/2xgckEA.
Electronics
Understand the regulatory needs for a given
application and location.
Understand why the heat transfer fluid freezing
point affects system operation. Visit www.process-heating.com
Learn about effective corrosion control when using to read industry-focused content
glycol fluids. as well as thousands of articles
Linda Becker, Associate Publisher and Editor, covering industrial heat
processing equipment.
Glycol-based heat transfer fluids, which have low BeckerL@bnpmedia.com
4 OCTOBER 2017 Process Heating

DESIGN THE
PERFECT PRODUCT
Customize our thermal processing ovens and furnaces
to fit your application needs, in any environment.
Call our Engineering

Design Center
570-538-7200
Or email
info@thermalproductsolutions.com
Applications
Military and aerospace
Consumer product testing
Clean room applications
Explosive environments
Inert gas atmospheres
High temps and vacuums
Small footprint designs
Robotic load/unload
Web-based management
Pollution control
Aftermarket service
Start-up and training
Installations
Temperature uniformity
Preventative maintenance
Retrofits
Refurbished equipment
Rental equipment
Address: 2821 Old Route 15 | New Columbia, PA 17856 | USA

Phone: (570) 538-7200 | Fax: (570) 538-7380
www.thermalproductsolutions.com
Inner Workings
Powder Coating Show Returns to Indianapolis
The 2018 Powder Coating Technical CSB Advises Caution for restarts, including:
Conference will be held March 12-15 Chemical, Oil Facilities in
at the J.W. Marriott in Indianapolis. Wake of Hurricane Harvey Use appropriate management-of-
The four-day event, produced by the In the wake of Hurricane Harvey, oil change (MOC) processes before
Powder Coating Institute (PCI), will and chemical facilities in the Gulf Coast modifying any startup procedures,
include a tabletop exhibition. region will begin restarting facilities equipment or staffing arrangements
The event begins with the shut down to weather the storm. due to the impact of the hurricane.
conference and exhibition on March The U.S. Chemical Safety and Hazard Make sure that adequate staffing
12-13, closing on the morning of Investigation Board (CSB) issued and expertise are available before
March 14. Attendees can learn a safety alert urging them to take starting up. Recognize that human
about powder coating during special precautions. The CSB notes that performance may be compromised
general sessions and by attending startup of major processes at chemical due to crisis conditions.
a concurrent technical program. facilities is a hazardous phase. Facilities Use up-to-date startup procedures
The tabletop display area will allow should pay particular attention to and ensure that the available staff
attendees to interact with powder process safety requirements during are trained in how to execute them.
coating manufacturers and get this critical period to ensure a safe Evacuate nonessential personnel,
hands-on experience with powder return to normal operations. including personnel in trailers, from
coating application equipment. Other The safety alert outlines specific the vicinity of process units that are
exhibitors include system houses, procedures to help ensure safe starting up.
chemical suppliers and various service
providers for the powder coating
Images courtesy of U.S. Geologic Survey
industry.
Following the technical conference,
PCIs Powder Coating 101: Basic
Essentials Hands-On Workshop will be
offered on March 14-15. The workshop
covers the basics of powder coating
operations and concludes with hands-
on training demonstrations at an area
powder coating facility. Hurricane Harvey made landfall on the Gulf Coast of Texas as a Category 4
Visit www.powdercoating.org for hurricane on the night of August 25, 2017. It then stalled over southeastern Texas
more information. as a tropical storm and continued to creep northeast over Louisiana.

Inner Workings
Additional safety protocols require are linked to a back-end digital Thermal Fluid Maker Adds
checking bulk storage tanks for monitoring system and a master Refurbished Heaters,
evidence of floating displacement data management system. According Refurbishing Services
or damage, notes the CSB. The to the company, the networking For processors that need a quick-ship
safety board also reminds facilities of production processes has thermal fluid heater, Fulton Thermal
to examine insulation systems, evolved into an intelligent lifecycle Corp., Pulaski, N.Y., is offering used,
sewers, drains, furnace systems, management platform designed to refurbished thermal fluid heaters
electric motors and other equipment, Industry 4.0 principles. from stock.
including warning systems, to make
sure they are fully functional.
You can download the safety alert
at CSBs website (www.csb.gov).
Ohio Plant Produces

2 Million Jeep Wrangler
Body-in-Whites
Thermal Fluids that
go beyond precise
temperature control
Working closely with equipment manufacturers and our customers, weve
gained an intimate and unrivaled understanding of real-world concerns for
heat transfer fluids. Our full range of environmentally responsible thermal
KUKA Toledo Production Operations
fluids and unique and innovative system cleaners make Duratherm a single
(KTPO) celebrated the completion of
its two millionth Jeep Wrangler body- source for all aspects of heat transfer fluid applications.
in-white.
The wholly owned subsidiary of
KUKA Systems North America LLC
has built the body-in-white of all Operating range -84C to 338C (-120F to 640F)
Wranglers sold worldwide both Non-toxic/non-hazardous
two-door and four-door models
since beginning operations in 2006. Complete engineering data
It took seven years for the company
to build the first million but only four OEM system design collaboration
to make the second million because
it expanded output to keep up with Online thermal fluid calculators
demand for the vehicle. Body-in-white 24/7 technical support
is the stage of vehicle manufacturing
where a car body's sheet metal Free fluid analysis
components have been welded
together but no moving parts have Fast response to all inquires
been assembled to the frame.
With a fleet of 259 robots, KTPO
produces 828 body-in-whites per
day over three daily shifts in its
330,000 ft2 body shop. Assembling 1 800 446 4910
the body-in-white involves welding www.durathermfluids.com
the underbody, windshield and 2016 Duratherm.
closures together. The plant's

robotic fleet and 60,000 other inputs

Inner Workings
aging oven to an aerospace parts

manufacturer. It will replace an
antiquated oven that was having
difficulties meeting AMS 2750E Class 2
specifications.
With a maximum temperature
rating of 650F (344C), the oven
is constructed with tongue-and-
groove panel assemblies that include
Wisconsin Ovens high efficiency
panel seams and provide better
insulating efficiency. The recirculation
system utilizes combination airflow
to maximize heating rates and
temperature uniformity of the
product.
The used heater stock program that conducted the assessment.

allows processors experiencing The certification recognizes the
production losses to restart processes integrity of both the PLC and its
with minimal downtime by buying development lifecycle. It includes
used equipment. Used heaters offer communication-robustness testing
the same capabilities as standard, as well as functional and software
newly built Fulton coil heaters and can development security assessments.
be used many process applications. The ISASecure program has been
The thermal fluid heaters have a developed by the ISA Security
90-day warranty and standard Fulton Compliance Institute (ISCI) with a goal This will be the third industrial
factory and engineering support. to improve cybersecurity for industrial oven supplied to this company by
In other company news, Fulton automation and control systems. Wisconsin Oven. It was fully factory
Thermal will offer refurbishment and According to ISA, the ControlEdge tested and adjusted prior to shipment.
retrofit services for existing heater PLC is the first of its kind to be
installations via its Fulton Service awarded the ISASecure Level 2 Boiler Provider Adds
Solutions. Services include pump certification. The Level 2 certification Maintenance Facility
rebuilds, low emission retrofits, burner builds on Level 1 capabilities by in Oklahoma
repair and replacement, refractory providing additional security features Nationwide Boiler Inc. extended its
repair and replacement, valve such the detection of unauthorized network of storage and maintenance
replacement, coil leak testing and changes and additional protection facilities for rental and stock boiler
repainting. against denial-of-service attacks. equipment.
The controller is used in balance- Located in in Broken Arrow, Okla.,
PLC from Honeywell of-plant control applications such as the site is owned by Applied Global
First to Receive ISASecure water treatment, pump systems and Cogeneration (AGC), a cogeneration
Level 2 Certification material handling. system supplier with a 112,000 ft2
Honeywells ControlEdge manufacturing and test facility.
programmable logic controller Aerospace Parts The Fremont, Calif.-based
(PLC) received ISASecure Embedded Manufacturer Purchases Nationwide Boiler has seven other
Device Security Assurance (EDSA) Aging Oven storage and maintenance facilities
Level 2 certification by exida, the ISO Wisconsin Oven Corp. shipped in Alabama, Iowa, Michigan, Ohio,
17065-accredited certification body an electrically heated aluminum Pennsylvania and South Carolina.

Inner Workings
Oven Cures Paint on Steel,

Aluminum Test Coupons
Process Heating Equipment
Thermal Fluid Systems
Water - Glycol Systems
Indirect Bath Heaters
A gas-heated cabinet oven is being used for curing paint on Electric Process Heaters
steel and aluminum test coupons at a manufacturers facility.
Manufactured by Grieve Corp., Round Lake, Ill., the oven Direct Fired Heaters
has 100,000 BTU/hr installed in a modulating gas burner, and
a 600-cfm recirculating blower provides horizontal airflow to Waste Heat Recovery
the workload.
Conveyor Oven Provides Process

Pro Skid Packages
Automated Batch Process
An air purifying systems manufacturer received shipment of Systems Service & Parts
a Gruenberg indexing conveyor oven.
The oven, which has a maximum temperature rating of
450F, will provide an automated batch process. The system
consists of an oven module and a 30 wide by 18 long
conveyor.
The design is for index positions within the oven chamber.
A set loading position is determined by physical stops 1-866-923-6121
that will allow the manufacturers product to be placed in info@sigmathermal.com
the same position each time to alleviate the potential for Georgia, USA
vertical-lift door crashes. Five products are loaded on the
load conveyor, indexed into the chamber, soaked for 15 to 40
www.sigmathermal.com
minutes, and indexed out.

Calendar Events
October 27-29 Drying Theory Put to 30 Fundamentals of Industrial

Practice Seminar, Raleigh, N.C. Process Heating Online Course
3-5 Industrial Combustion Presented by Bhler Aeroglide. (course begins; continues for six
Workshop, Rockford, Ill. Presented Call 919-278-2864 or visit weeks). Presented by Industrial
by Honeywell Combustion Safety. www.buhlergroup.com/drying. Heating Equipment Association.
Call 216-749-2992 or visit Visit www.ihea.org.
www.combustionsafety.com. 27-29 Boiler and Pressure
Vessel Repair Seminar (RO), 31-Nov. 2 Chem Show,
8-11 ASTM Committee C16 on Columbus. Presented by Javits Center, New York.
Thermal Insulation Fall Meeting, National Board of Boiler and Call 203-221-9232 or visit
Sheraton New Orleans. Pressure Vessel Inspectors. www.chemshow.com.
Call 610-832-9678 or Call 614-888-8320 or visit
visit www.astm.org. www.nationalboard.org. November
10-12 Vapor Control Course, 23-24 Hydraulic Institute 6-9 ISA Process Control and
Tulsa, Okla. Presented by Fall Conference, Renaissance Safety Symposium and Exhibition,
John Zink Institute. Worthington, Fort Worth, Texas. Houston Marriott Westchase,
Call 918-234-5710 or visit www. Produced by the Hydraulic Institute Houston. Presented by International
johnzinkinstitute.edu. (HI). Call 973-267-9700 or visit Society of Automation. Call 919-
www.pumps.org. 549-8411 or visit www.isa.org.
12 Using Glycol Heat Transfer
Fluids for Effective Process 24-26 The Quality Show, Donald 6-9 International
Cooling Webinar, 2 p.m. ET. E. Stephens Convention Center, Instrumentation Symposium
Register or learn more at Rosemont, Ill. Call 844-644-7449 or (IIS), co-located with ISA Process
webinars.process-cooling.com. visit www.qualityshow.com. Control and Safety Symposium and
ARI Valves can take the heat

Theres no margin of error when it comes to reliability of the valves
in your system. While you may not have to protect against lava ow,
we can solve your problems up to 800F! ARI Valves are the choice of
industrial professionals. Our quality assurance system is in accordance
with DIN ISO 9001. You can trust our bellows-seal valves to perform
under adverse conditions and never need to replace stem packing.
ARI Valves are in Heat Transfer Service Around the Globe. So if you are
responsible for the security and safety of your companys system, make
certain that ARI Valves are the choice. When things get hot, you should
specify ARI Valves for Thermal Transfer Fluid Applications.
ARI ValvesThe Obvious Choice
60
ARI Valve Corporation

1738 Sands Place, S.E. Marietta, Georgia 30067 U.S.A.
Fax: (770) 933-8846 Phone: (770) 933-8845
www.arivalve.com

Calendar Events
Exhibition, Houston. Presented by Presented by Rockwell Automation. Georgia World Convention Center,
International Society of Automation. Visit www.rockwellautomation.com. Atlanta. Call 770-493-9401 or visit
Call 919-549-8411 or visit www.ippexpo.com.
www.isa.org. December
February
6-9 Fabtech Expo, McCormick 5 Insiders Guide to Fluid
Place, Chicago. Cosponsored by AWS, System Maintenance Webinar, 2 4-8 Cooling Technology
FMA, SME, PMA and CCAI. p.m. ET. Register or learn more at Annual Conference,
Call 888-394-4362 or visit webinars.process-heating.com. Hilton Houston North, Houston.
www.fabtechexpo.com. Call 281-583-4087 or visit
12-14 Turbomachinery www.cti.org.
7-9 Drying Theory Put to & Pump Symposia,
Practice Seminar, Joinville, Brazil. George R. Brown Convention Center, 12-14 National Ethanol
Presented by Bhler Aeroglide. Houston. Rescheduled due to Conference, JW Marriott San
Call 919-278-2864 or visit Hurricane Harvey. Antonio, Hill Country Resort &
www.buhlergroup.com/drying. Visit tps.tamu.edu/updates. Spa, San Antonio, Texas.
Hosted by the Renewable Fuels
7-10 Fired Process Heater January 2018 Association (RFA).
Course, Tulsa, Okla. Presented by Call 832-653-4046 or visit
John Zink Institute. 22-24 AHR Expo, McCormick www.nationalethanolconference.com.
Call 918-234-5710 or visit Place, Chicago. Call 203-221-9232
www.johnzinkinstitute.edu. or visit www.ahrexpo.com. 21-22 Food Processing Expo,
Sacramento Convention Center,
15-16 Automation Fair, George R 30-Feb. 1 International Sacramento, Calif. Call 916-640-8150
Brown Convention Center, Houston. Production & Processing Expo, or visit www.clfp.com/expo.
Heating, Cooling & Heat Reclaim Coils

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Thermal Fluid Heaters
The Importance of
EXPANSION AND
DRAIN STRUCTURE
in Hot Oil Systems
Preplanning during design can save time and money during planned or
unplanned shutdowns.
By the Applications ing temperature, accommodations must with these systems daily and understand
Engineering Team, be made for that expansion. It also is their key terms intimately, process engi-
inevitable that some part of the system neers charged with thermal processing
Sigma Thermal
will require service in the future. At that operations may not be. As a refresher, the
point in time, the system will need to be most common components and concepts
T
he provisions made for thermal partially or fully drained, depending upon used in expansion and drain system de-
expansion and draining of the the nature of the service required. A little signs are defined (see sidebar on page 15).
thermal oil are key factors to thought and preplanning can make drain- Next, consider the design principles for
consider for the successful in- ing a system relatively easy, potentially some system components and analyze how
stallation of any thermal oil heating sys- saving time and money during planned or they are employed during commissioning
tem. Important system design principles unplanned shutdowns. and the everyday operation of a thermal
like this often are overlooked; instead, the There are many ways to design expan- oil system.
focus is placed on specific components like sion and drain systems, and all have their
pumps, valves or the heater itself. advantages and disadvantages. Despite the Expansion Volume
Because most thermal fluid heating differences, most designs incorporate stan- Because the fluid within a closed-looped
systems are closed-loop systems, and be- dard parts and related theories. Though system is heated during liquid phase, it will
cause thermal oil expands with increas- thermal fluid heating manufacturers work expand. Your system must be designed to

accommodate the liquid expansion to avoid

the overflow of hot oil into the operating
facility or overpressurization of your system
Vcold := 1000 gal =133.681 ft3 Vexp := Vhot Vcold = 281.69 gal
devices and associated equipment damage.
First, let us look at how to calculate the Next, calculate the density of Therminol Tank Dimensions
amount a fluid will expand from its cold- 55 at 550F. Now that we know how much the fluid
fill volume to its max-operating level. Be- will expand, we must select the right ex-
cause the fluid volume is changing but the lb pansion tank size to accommodate the
fluid mass is not, this is a simple conserva- hot := 42.6 3 expansion. Generally, you will need some
ft
tion of mass equation. excess volume (commonly 20 to 25 per-
The mass of fluid in the system depends cent) to account for the possibility of cal-
upon the volume of liquid (when the system culation errors (impossible!) or in case the
is first filled) and the ambient temperature. m=Vcold *cold=Vhot *hot system has temperature excursions above
In this example, we will use Thermi- the anticipated operating temperature.
nol 55 while filling at 60F. The equation Keep in mind that having some volume of
shows the density of Therminol 55 at 60F. Mass is conserved. Therefore, solve for vapor space (vapor-disengagement area)
the expanded volume: at the top of the tank is crucial for deaera-
tion and vapor removal during startup or
lb
cold := 54.6 cold when new fluid is added. In addition, all
ft3 Vhot := Vcold . = 1281.7 gal systems should include a level switch to
hot maintain a minimum liquid level in the
Assume total system volume all of expansion tank. Such factors will reduce
the users, piping, cold-fill level in the ex- The difference in volume is the amount the available volume in the tank; there-
pansion tank, etc. and calculate the total of fluid expansion that we must accom- fore, they must be accounted for in the
system volume at initial fill (cold). modate. final tank size selection.
This multi-heater system is shown with expansion tanks, nitrogen blanket manifolds and double-leg drop piping structure.

For instance, continuing the previous tors and plant personnel also must be well Using an inert-gas blanket system (usu-
example (calculating fluid expansion), thought out. Expansion tanks are occa- ally nitrogen).
we will presume that the next and largest sionally full of hot thermal oil making Using a bladder-style expansion tank
standard tank size is 400 gal. Also assume them both burn and fire hazards. (only possible on lower temperature sys-
the minimum fill in the tank (to satisfy the The ideal height for the expansion tank tems).
level switch) is 35 gal (typically specified is above the highest liquid level in the sys- Sealing the tank with nitrogen in the
by the manufacturer). tem. This can be system piping, the heater vapor space.
We will explore each option.

Vspare := 400 gal 281.69 gal 35 gal = 83.31 gal Inert-Gas Blanket System. If an inert
gas blanket system is used, either plant
As a percentage, this leaves you with or sometimes the thermal fluid space with- nitrogen (if available) or bottled nitrogen
about 21 percent volume remaining in the in a user (for instance, the heat exchanger, may be used to fill the vapor space in the
tank. calendar roll or press platen). The bottom expansion tank to a relatively low pressure
of the tank should be several feet above the (5 to 10 psig is typical). This will vary de-
Selecting the Location highest point (5 is a good rule of thumb). pending upon the net positive suction head
of the Tank This provides several benefits, including: (NSPH) requirements of the pump and
Now that we have sized the tank, we must the vapor pressure of the fluid. The amount
think about where we want to place it. Sev- Creating static head above the pump in- of nitrogen used will depend on how of-
eral factors govern the location of the ex- let to prevent pump cavitation. ten the system temperature is cycled. Re-
pansion tank. These factors are important Aiding in degassing of the system. member, the change in temperature will
and should be thoroughly discussed when change the system volume. If the system
laying out the system. Generally, many of What happens if the tank cannot be is cooled, the fluid will contract, and the
these factors are installation specific (e.g., placed at the highest point? Do not aban- liquid level in the expansion tank will drop.
location of available safe containment, don all hope. While not ideal, there are This change in level (and, thus, volume)
maintenance access). The safety of opera- ways to accommodate this, including: must be made up by adding more nitro-
gen. Conversely, if the system is heated, the
liquid level will rise and push some of the
nitrogen out.
Bladder-Style Expansion Tank. Using
a bladder-style expansion tank separates
the liquid in the tank from the vapor space.
The vapor space then is charged with air
to some pressure. As the system expands,
the air in the vapor space increases in pres-
sure. As the system cools, the pressure in
the vapor space will fall (but never below
the original charge pressure). Also, as pre-
viously mentioned, bladder tanks can only
be used at lower temperatures because they
typically are made from some type of rub-
ber compound. Commonly, they are found
in water-glycol systems. They also can be
used in thermal oil systems if the bladder
materials are compatible with the oil and
the operating temperature.
Sealing the Tank with Nitrogen in the
Vapor Space. Sealing the tank with nitro-
gen in the vapor space is similar to using
the bladder-style expansion tank, but no
barrier exists between the fluid and vapor
space. To keep the fluid from oxidizing, an
This single heater system has an elevated atmospheric expansion tank, double-leg
drop piping structure and drain tank with a fill-and-drain pump. inert gas must be used.
Though all three methods can be used,

careful consideration must be used if ei- Air.

ther of the last two options is chosen to Water. Common Terms
ensure the rise in liquid level does not in- Low molecular weight components of for Thermal Fluid Heaters
crease the pressure in the tank above its the thermal fluid (also known as low-
design rating. A pressure safety valve is boilers).
critical to protect the tank if it is not open The most common components and
to atmosphere. These constituents must be removed for concepts used in both expansion and
trouble-free system operation. The ease drain system designs are defined.
Degassing the System with which these gases can be removed is
Each thermal fluid system, when initially heavily dependent upon the system piping Expansion Tank. Vessel designed to
filled, will contain several undesirable con- design and expansion tank elevation. contain thermal expansion within a
stituents. As the system is operated over Generally speaking, piping should be closed loop thermal fluid system.
time, or when maintenance is performed, designed to minimize local high points, Drain Tank. Vessel designed to contain
new fluid can be added that can create and the expansion tank should be above all or part of a thermal fluid systems
conditions similar to the initial fill. If not the highest point of the system. Piping also volume.
removed, these gases can create flow stabil- should be designed to include high point Containment Area. An area designated
ity problems and pump cavitation that will vent valves. If the tank is the highest point, as a safe zone for vents or overflow
prevent the system from operating reliably. then removing these troublesome elements discharge from pressure safety valves
The most common constituents are: from the system can be accomplished rela- and/or vents and drains of a thermal
fluid system.
Inert Gas Blanket. A system that applies
inert gas pressure (typically nitrogen at
the expansion tank) to prevent oxidation
of thermal oil and/or to create system
pressure to overcome height restrictions
for an expansion tank.
Thermal Buffer. A vessel that
cools thermal oil before it enters an
atmospheric expansion tank to help
minimize oxidation of the oil.
Deaerator. A vessel created to
continually assist in the degassing of a
thermal fluid system.
Cold Seal Tank. Vessel constructed
to create a cold fluid seal between
ambient air and any hot fluid that
may be present in the expansion tank,
helping to minimize oxidation of the
thermal oil.
Heatup Line/Valve. The line
connected to the expansion tank, from
a low pressure part of the system, to
create flow through the expansion
vessel when the heatup valve is open
to assist in deaeration during thermal
oil cookout.
Double-Leg Drop. A piping structure,
consisting of a block and bypass valve,
that forces a high volume flow rate
through the expansion tank, to aid in
deaeration during thermal oil cookout.
This electric thermal oil system package includes an integral expansion tank
and tower.

Preventing Fluid Degradation

If properly designed and maintained, ther-
mal fluid systems are easy to operate, and
the life of the fluid within the system can
be sustained for a long time. If the fluid
should degrade, it will diminish the perfor-
mance of your system. There are a couple of
reasons why fluid degradation could occur:
oxidation and contamination.
Oxidation. Thermal fluids, when ex-

posed to oxygen, especially at elevated
temperatures, will oxidize and break
down into lower molecular weight com-
ponents. They also can form acidic by-
products that can damage system com-
ponents.
Contamination. The most common
contaminant is water, but contamina-
tion can also be due to a leak on the pro-
cess side of the system (a heat exchanger
tube, reactor jacket, etc.).
Preventing oxidation is simple in con-

cept; either remove the heat or remove the
This thermal oil heat exchanger secondary loop package offers a modular oxygen at the interface point in the expan-
expansion tank tower mounted above the pump skid. sion tank. Removing the oxygen typically
is done with an inert gas blanket as pre-
tively easily through the disengagement mosphere or using an inert gas blanket viously described. If you do not have the
space in the expansion tank. Otherwise, with settings that allow it to sweep the ability to inert the expansion tank, and it is
high point vent valves must be used, and vapor from the expansion tank through directly open to atmosphere, removing the
the system should be vented (burped) inter- continuous purge. heat is the only solution.
mittently until vapor is no longer present. A deaerator performs a similar function As a rule, the expansion tank and the
Depending upon the piping design and as the double-leg drop arrangement, but it piping leading to the tank should not be
expansion tank elevation, there are a few is a part of the system-return piping. Also, insulated. This allows any hot fluid that ex-
methodologies that can be used to effec- a deaerator is used continuously rather pands into the tank to cool before it hits
tively get the vapor to the highest point. than exclusively during commissioning. the vapor-disengagement space at the top
These include a double-leg drop or heatup While deaerators are effective for continu- of the tank. Most often, expansion piping
line piping arrangement connecting to the ous deaeration, it is worth noting that they alone does not allow enough surface area
expansion tank or a deaerator are not always as effective as forcing large to cool the expanding fluid before it gets to
A double-leg drop arrangement allows volumes of flow through an elevated ex- the tank. In those cases, the use of a ther-
all or a portion of the fluid to flow through pansion tank. Also, they do not necessarily mal buffer allows the fluid to cool by creat-
the tank during commissioning. A heatup negate the need for a double-leg drop or ing more surface area and residence time
line piping arrangement achieves the same heatup line piping structure. than the expansion piping alone.
purpose, but it does so with smaller piping Simple centrifugal deaerators are com- Preventing contamination can be tricky.
and by using pressure differential across mon, but there are many types that can be It is not always a dramatic event that is
different parts of the system to drive flow used effectively. Regardless of the vessel noticeable. Impurities often creep into a
through the expansion tank. By forcing design, the basic premise is to allow the system over time, and they will not neces-
circulation through the expansion tank vapor and liquid to disengage and rise up sarily create an increase in system volume
while the fluid is being circulated, the va- to the expansion tank instead of disengag- or an obvious change in performance. Be-
por in the system can disengage from the ing within the expansion tank. The vapor cause there are many potential sources of
liquid level in the tank. As a result, it can should flow up and out of the system, and contamination, and because it can be hard
be vented from the top of the tank. This the liquid flow down and back to the suc- to detect with observation alone, the best
can be done with the system open to at- tion side of the pump. defense is to have the fluid tested at least

yearly. Most fluid manufacturers offer this service at no charge.

Based on the results, the fluid manufacturer usually can pinpoint
the root cause of the contamination.
Drain Tank Sizing

Inevitably, at some point in the life of any thermal fluid system,
the system will need to be drained to perform maintenance or to
perform a repair. There is also a benefit to routing things like pres-
sure safety valve (PSV) discharge and emergency drain lines to a
location where the thermal oil is safely contained. Routing these
devices to small drums or inadequate containment vessels may
not be sufficient. Many smaller systems do not have a dedicated
drain tank, and this can be a problem in case an emergency repair
is needed or a safety relief event is triggered. It is highly recom-
mended to have the drain tank sized for the entire system volume
(e.g., smaller systems upward to 10,000 gallons) or adopt a design
that segments the system in such a way that sections can be isolated
and drained independently. This is common with larger systems.
Normally you want a 20 to 25 percent buffer with the drain tank
size. Depending upon your insurance carrier, the drain tank typi-
cally will be placed away from any building or main process areas.
What happens if the expansion

tank cannot be placed at the
highest point? Do not abandon
all hope. While not ideal, there are
ways to accommodate this, including
using an inert-gas blanket,
selecting a bladder-style tank or
sealing the tank with nitrogen in
the vapor space.
It is also noteworthy that relatively low cost reversible fill-and-

drain pumps are available. They will make filling and draining of
the system considerably easier. When designing the system pip-
ing, be sure to pay special attention to creating low point drains
and connecting that piping back to a central drain tank. A small
amount of investment in a drain tank, fill-and-drain pump and
well-planned drain piping can save hours or even days during com-
missioning and maintenance activities.
A manufacturer of thermal fluid heaters, Sigma Thermal is based in

Marietta, Ga. The company can be reached at 678-616-2820 or visit
www.sigmathermal.com.

Heaters
With laminating, drying, pasteurizing, curing,

flashing, evaporating, sterilizing, sealing, shrinking
and recycling, it is not uncommon for automated
machines to utilize or add several types of heating
products throughout the packaging process.
Heaters Help Deliver

PACKAGING FOR
FOOD SAFETY
and Consumer Acceptance
Packaging innovations such as heat-sealed packages, tamper-resistant bottles and
shrink wrap are all a result of evolution in process heating technologies. Though
process heating is essential to many effective packaging solutions, too often, it is
an afterthought.
By Jeff Myatt, safety concerns, and increased scrutiny has in process heating, the speed at which the
Osram led advocates to demand sustainable, recy- machines are capable of printing, cutting,
clable and safer materials for consumers. seaming, filling and wrapping has im-
F
ood- and medicine-safety con- In addition to the innovations derived for proved handling and process times. Despite
cerns have led to many packag- convenience, improved printing and mark- process heatings crucial role in the packag-
ing innovations over the years. ing drive material choice. Branding largely ing industry, it seems to take a back seat in
Perishable foods, dairy products leads the innovation march because market- many minds. Only rarely is it discussed for
and pharmaceuticals have pushed packag- ers use branding opportunities to set their what it is: a critical piece of equipment for
ing inventors to increase shelf life, enhance products apart from one another. Shapes, ensuring effective packaging.
safety measures and create convenient stor- colors and presentation all factor into pack-
age options for consumers. From the food aging designs and material selection. Popularity of Plastic
humans consume to pet food, concerns Like other innovation-driven industries, Packaging Drives Innovation
over contaminants leaching into the food the packaging industry has tapped auto- Before delving into some of processes that
chain have raised material risk awareness. mation in its quest to develop new and ensure packaging is safe, secure and adapt-
The race for convenience has raised several better materials. Thanks to advancements able, a look at the evolution of packaging

Heaters
materials and the concerns around recycling urgency. Hesitations Around BPA
them is necessary. No lesson on packag- Today, the plastics industry boasts an One such concern is Bisphenol A, which
ing history would be complete without an improved environmental footprint. De- is better known as BPA. BPA is an envi-
introduction to plastic packaging. Love it spite the progress that has been made, and ronmental chemical building block that
or hate it, plastic has dominated the pack- the increased awareness of plastics impact, is used primarily to make polycarbonate
aging industry since its introduction in the it is still nearly impossible to drive down a plastic and epoxy resins. Polycarbonate
early 1900s. It is lightweight, malleable freeway or swim in an ocean without see- plastic is the most popular lightweight,
and easy to manufacture. Today, plastic ing the impact plastic resins have on our high performance plastic and is used in a
resins and other derivative materials con- planet. If not properly recycled, the prod- wide variety of common food and drink
tinue to play an integral role in packaging. uct will not degrade or breakdown within packaging. Despite its tough, resilient and
From tamperproof seals to shrink wrap- our lifetime. That is why reinventing plas- heat-resistant nature, many countries have
ping and to multipack water bottles tics using biodegradable solutions and banned the use of BPA with consumables
all made with process heating plastic packaging them with Earth-friendly pro- for fear of BPA leaching. Just recently, the
packaging protects products until they are cess heating solutions is a necessity for FDA banned its use for infant food pack-
put to use. the ecosystem and for the safety of our wa- aging and teething or oral products.
Fast foods popularity after World War ter sources and food chain. BPA is one of the most extensively
II created a packaging boom, produc- Despite the industrys recent innova- tested materials in use today, according to
ing numerous short-term and condiment tions, scrutiny over potential long-term experts with BiphenolA.org. (It has been
packaging innovations. The increased out- hazards and exposure to BPA-based plas- studied for more than 40 years.) The orga-
put led to mountains of trash and spawned tics still remains contestable. nization claims scientific evidence clearly
Thanks to advancements in process heating, the speed at which the machines are capable of printing, cutting, seaming, filling
and wrapping has dramatically improved handling and process times. Things like sealing, tamper-resistant bottles and shrink
wrap are all a result of evolution in process heating. Shown here is a threaded in-line heater.

Heaters
supports that BPA is safe to use and that Tylenol Tampering Curtails troduced shortly after the Tylenol tam-
there is no basis for human health con- Consumer Trust pering case. By 1989, the measures were
cerns from exposure. They go on to say Consumers are not only concerned about standard practice, and published guidelines
that levels of BPA leached into food are materials safety. Tampering also has been a were produced by the FDA.
extremely low, and that the amount is, on serious issue, and one that led to significant
average, five parts per billion under typical changes in the packaging industry. In the Process Heating Makes Safer
conditions for packaging products. At that early 80s, Tylenol found itself at the center Packaging Possible
level, people would have to consume 1,300 of a crisis: Bottles of the over-the-counter What many do not realize is that pack-
pounds of food and beverages every day for pain reliever had been tampered with and aging changes like foil seals and shrink-
an entire lifetime to exceed a safe level. poisoned with cyanide. Several people wrapped tops could not have been intro-
Despite these findings, most of the re- died as a result of the poisoning. Tylenol duced without process heating. Process
search from this group of experts is dated. ordered a mass recall of its product and ac- heating technology has remained a critical
Furthermore, there is evidence and re- tively participated with the media to avoid element in keeping products safe and se-
search to the contrary, showing cognitive additional deaths and reputation damage. cure as demands on heating components
deficits, anxiety, obesity and cancer from Tylenol insisted the poisonings were per- have been pushed to the limits. It is not
exposure to BPA. As the FDA continues petrated outside of the factory and investi- hard to see why. What drives the need for
to be pressured by advocates, more research gators agreed. Those responsible, who were more process heating solutions? Constant
is expected, and limitations to exposure are never caught, allegedly removed the Tyle- improvement to automation lines, research
advised for those concerned about the im- nol from the retail shelves and tampered and testing, and new processes are just a
pact and long-term ramifications. Moving with the contents. few of the things forcing the process heat-
forward, bioplastic alternatives from Today, great measures are taken to alert ing industry to expand their offerings.
things like wheat, sugarcane and corn consumers of product tampering, and there With laminating, drying, pasteuriz-
are positioned to be a responsible choice have been significant safety improvements. ing, curing, flashing, evaporating, steriliz-
for the planet and safer to the consumers Updates like foil seals, shrink-wrapped ing, sealing, shrinking and recycling, it is
who use it. tops and gelatin-covered tablets were in- not uncommon for automated machines
to utilize or add several types of heating
products throughout the packaging pro-
cess. In addition, continued demands are
placed on heating components to produce
higher temperatures at faster speeds. Pack-
aging manufacturers are constantly look-
ing for ways to improve process times, sup-
port new material initiatives, reach more
customers and improve quality. Process
heating technology helps them do this.
In addition to process heatings tradi-
tional electric air heater elements, infrared
heaters are just as important. The non-
contact, efficient use of power can radiate
wavelengths that rapidly heat surfaces,
focus energy where needed, and activate
adhesives used to seal in freshness. Combi-
nations of the technologies have been used
for years because they have the ability to
scale up and down as the industry changes.
Beyond the packaging industry, it is
known that UV light can damage and
even kill biologicals (think sunburns and
skin cancer). All UV wavelengths alter
cells and are capable of destroying biologi-
Food and medicine safety concerns have led to many packaging innovations over
cal tissues. In the packaging industry, UV
the years. Perishable foods, dairy products and pharmaceuticals have pushed
packaging inventors to increase shelf life, enhance safety measures and create disinfection systems are used throughout
convenient storage options for consumers. food processing plants, pharmaceutical
facilities and hospital facilities. Because of

Heaters
Packaging changes like foil seals and shrink-wrapped tops Jeff Myatt is product marketing manager
could not have been introduced without process heating. of process heating products in Osrams
Process heating technology has remained a critical element Professional and Industrial Applications
in keeping products safe and secure as demands on Division. The Wilmington, Mass.-based
heating components have been pushed to the limits. company can be reached at 978-570-3000 or
visit www.osram-americas.com.
their construction, UV lamps are usually

in a sealed environment with regenera-
tive circulating heated air. Duration of UV
exposure is the key to its effectiveness to
disinfect and sterilize packaging materials
and the automated machine parts. Steps
like UV disinfection systems play a major
role in keeping consumer packaging secure
and protected.
Thermal Fluids that
In conclusion, the packaging indus-
try has come a long way. Packaging helps go beyond precise
solve consumer problems, improve prod-
uct safety and answer a number of seri- temperature control
ous concerns. Without innovations in
process heating technology and the kind
of safe packaging that it provides, changes Working closely with equipment manufacturers and our customers, weve
to problematic packaging and materials gained an intimate and unrivaled understanding of real-world concerns for
would take far too long or may not even heat transfer fluids. Our full range of environmentally responsible thermal
be possible at all. Packaging manufactur- fluids and unique and innovative system cleaners make Duratherm a single
ers must ensure they are implementing
source for all aspects of heat transfer fluid applications.
solid process heating procedures and safe
packaging standards. If they do not, they
risk the safety of their consumers and the
health of planet Earth. Operating range -84C to 338C (-120F to 640F)
Non-toxic/non-hazardous
Complete engineering data
Additional Reading
For more information on the studies discussed in
this article, please see the following sources.
OEM system design collaboration
Online thermal fluid calculators
Plastics and Sustainability: A Valuation of En-
vironmental Benefits, Costs, and Opportunities
for Continuous Improvement, Trucost, 2016,
https://plastics.americanchemistry.com/study- 24/7 technical support
from-trucost-finds-plastics-reduce-environ-
mental-costs/.
Potential Exposure to Bisphenol A from Food-
Free fluid analysis
Fast response to all inquires
Contact Use of Polycarbonate Resins. Howe,
S.R. and Borodinsky, L. 1998. Food Addit. Con-
tam. 15(3):370-5. Abstract available at PubMed,
http://www.bisphenol-a.org.
Low circulating levels of bisphenol-A induce
cognitive deficits and loss of asymmetric spine
synapses in dorsolateral prefrontal cortex and
hippocampus of adult male monkeys. Els-
1 800 446 4910
worth, J. D., Jentsch, J. D., Groman, S. M., Roth,
R. H., Redmond, E. D. and Leranth, C. (2015), www.durathermfluids.com
J. Comp. Neurol., 523: 12481257. doi:10.1002/ 2016 Duratherm.
cne.23735.

Portable Chillers
How
VARIABLE-
SPEED
PORTABLE Some portable chillers use
CHILLERS
components such as R410A
refrigerant, scroll compressors,
microchannel condensers,
low noise fans, stainless steel
Can Help
brazed-plate evaporators and
modern controls to improve
performance and reliability.
An alternative for process cooling applications, variable-speed compressors

coupled with advanced PLCs continuously monitor the heat load and adjust
the compressor speed for peak efficiency and temperature control.
By Tom Stone and hot gas bypass design to maintain the For example, a hot gas bypass system,
demand on the compressor. This design limited to 75 percent of compressor
Steve Wojcieszek,
avoids wide fluctuations in the coolant capacity on a 10-ton chiller, delivers
Thermal Care
temperature delivered to the process. stable water temperature down to a 2.5-
A
packaged system housed in a A hot gas bypass is an electronic valve ton heat load. As the heat load falls
single cabinet with mounted located on the high pressure refrigerant below the 2.5-ton mark, the compres-
casters, a portable chiller line downstream of the compressor. The sor is forced to cycle on and off as its
contains an integral tank and chillers controller typically a micro- last means of temperature control and,
pumping system and uses refrigeration to processor reads the water temperature ultimately freeze protection. With any
cool a water circuit for industrial processes returning from the process. The control- motor, rapid cycling is detrimental to
that generate heat. The removal of this ler actuates the valve as needed, allowing the life expectancy. This is known as
heat allows for increased productivity and, a portion of hot refrigerant gas to be short cycling. An anti-short-cycle timer
therefore, increased profits. Effective cool- reinserted or bypassed directly into is employed to protect the compressor
ing using portable chillers is the backbone the low pressure refrigerant line upstream from premature failure.
of process industry applications such as in- of the evaporator. The evaporator is the A conventional hot gas bypass sys-
jection molding. heat exchanger that transfers heat from tem coupled with a widely varying pro-
Conventionally, a portable chiller uses a the process water to the refrigerant cir- cess heat load leads to rapid temperature
compressor running at a continuous speed. cuit. Introducing the hot, high pressure swings delivered to the process. Many
This type also is known as a fixed-speed refrigerant to the low pressure side creates process cooling applications require stable
compressor. Regardless of the require- a false load on the system. This allows the incoming cooling temperatures. Avoiding
ments placed on it by the process load, the compressor to continue running at 100 fluctuations like this is crucial to consis-
speed remains the same. percent speed and maintains a stable pro- tent output from the process and elimi-
Fixed-speed chiller systems employ a cess water temperature. nating scrap.

Portable Chillers
An Alternative to can lead to a 51 percent energy savings. tection, phase protection and correction,
Fixed-Speed Chillers with With the variable-speed chiller design, maximum operating current detection,
Hot Gas Bypass incoming utility power is connected to discharge line temperature protection and
Variable-speed chillers offer an alternative an inverter control drive using frequency anti-short-cycling control.
for process cooling applications. They use modulation to adjust compressor motor Energy savings are one of the most
variable-speed compressors coupled with power output. The inverter control drive prominent benefits of chillers designed
advanced PLCs. The controller continu- speeds up or slows down the compressor, with variable-speed compressors.
ously monitors the heat load and adjusts matching system load demand accurately. Variable-speed technology offers ben-
the compressor speed for peak efficien- The sophisticated electronics incorporated efits beyond energy savings, however.
cy and temperature control. The speed in the inverter control drive provide addi- One of the most important is soft-start
adjustment eliminates the need for hot tional levels of compressor protection control, which provides two ancillary
gas bypass. These chillers ensure the work that surpass the levels of protection found benefits: First, it effectively eliminates
done closely follows the energy required, in fixed-speed systems. Active protec- peak demand penalty costs, and second,
effectively eliminating energy waste. tion algorithms improve reliability and it reduces mechanical stress on all system
Studies by one manufacturer have shown safeguard the compressor and inverter components. The life expectancy of all
that a 20 percent reduction in motor speed control. Key features are locked rotor pro- system components is extended.
10-Ton Air-Cooled Variable-Speed Compressor Option Payback

(Years based on $0.10/kWHr power cost)
Process Load as Percent of Available Chiller Capacity
Hours/Year
50% 55% 60% 65% 70% 75% 80% 85% 90%
Based on 50 Weeks/Year
4,000 hours/year
1.1 1.2 1.3 1.4 1.6 1.9 2.4 3.2 5.1
(16 hours/day, 5 days/week)
6,000 hours/year
0.7 0.8 0.9 0.9 1.0 1.2 1.6 2.1 3.4
8,400 hours/year
0.5 0.6 0.6 0.7 0.7 0.9 1.1 1.5 2.4
20-Ton Air-Cooled Variable-Speed Compressor Option Payback

(Years based on $0.10/kWHr power cost)
Process Load as Percent of Available Chiller Capacity
Hours/Year
50% 55% 60% 65% 70% 75% 80% 85% 90%
Based on 50 Weeks/Year
4,000 hours/year
1.4 1.4 1.4 1.4 1.5 1.8 2.2 3.3 6.5
6,000 hours/year
0.9 0.9 0.9 0.9 1 1.2 1.5 2.2 4.4
8,400 hours/year
0.7 0.7 0.7 0.7 0.7 0.8 1.1 1.6 3.1

Portable Chillers
10-Ton Chiller Energy Use 20-Ton Chiller Energy Use
100% 100%
90%
90%
80%
80%
Power Use (% of Full Load Power)
Power Use (% of Full Load Power)

70%
Energy Savings 70%

60%
60%
50%
40% 50%
30% 40% Energy Savings
20%
30% 40% 50% 60% 70% 80% 90% 30%
30% 40% 50% 60% 70% 80% 90%
Load Percentage (% of Full Capacity)
Load Percentage (% of Full Capacity)
Fixed-Speed Compressor (Hot Gas Bypass Capacity Control)

Fixed-Speed Compressor (Hot Gas Bypass Capacity Control)
Variable-Speed Compressor (Variable Speec Capacity Control)
Variable-Speed Compressors (Variable Speed Capacity Control)
FIGURE 1. This energy comparison chart shows the FIGURE 2. The energy use of a 20-ton chiller
difference in energy use between a 10-ton variable- (which used two 10-ton variable-speed compressors)
speed compressor and a fixed-speed compressor. is shown vs. a 20-ton fixed-speed compressor.
What Kind of Energy Savings In a second example, compare the per- fixed-speed compressor to generate energy
Can I Expect? formance of a fixed-speed vs. variable- savings. It efficiently handling loads from
Compared to a typical chiller with a fixed- speed compressor on a 20-ton chiller 3 to 20 tons, and it delivers energy savings,
speed compressor, a chiller with a variable- (table 2). In this case, a portable chiller especially in the 3 to 8 ton range and the
speed compressor can provides power sav- with two 10-hp compressors generates 13 to 16 ton range.
ings at partial loads. For instance, compare savings over a wider range. This spe- Note that the energy savings are not as
the performance of a fixed-speed vs. vari- cific chiller design combines a 10-ton significant in the middle-load range where
able-speed compressor on a 10-ton chiller variable-speed compressor with a 10-ton either compressor fixed or variable
(figure 1). At a 30 percent load, for example,
the variable-speed compressor consumes 24
percent of full-load power. The fixed-speed Effective cooling using portable chillers is
chiller consumes 85 percent of full-load
power. Using a variable-speed compressor
the backbone of process industry applications such as
at this load would provide energy savings injection molding.
of more than 50 percent (table 1).

Portable Chillers
would be running near its full capacity of

10 tons. The curve for the 20-ton fixed
4 Questions to Consider Before
speed chiller is a bit different too (figure
2). It has two 10-ton compressors so that
Purchasing a Variable-Speed Chiller
it can run on just one (half power, more
or less) until the second compressor needs
1. What is my load profile? Does my heat load vary widely?
to kick in. Still, it is clear that there are
You should consider if your heat load spends a lot of time operating well
significant energy savings to be realized.
below the chillers available capacity.
In conclusion, the energy savings gener-
ated by variable-speed compressors enable
2. Will I require flexibility to move the chiller among various different
rapid payback on an investment, particu-
applications? If you have multiple processes that run intermittently with
larly under low and partial-load conditions.
different heat loads, a single variable-speed chiller may be the best solution
In the end, one must weigh the ben-
rather than purchasing multiple individual chillers of different sizes.
efits of employing variable-speed technol-
ogy. Key benefits that support the switch
3. Does standardizing to one chiller size make sense?
include stabilizing the process, preserving
If you can cover a variety of heat loads with one style chiller, you can benefit
the equipment investment and saving on
from commonality of parts.
electrical costs.
4. Are energy savings or green initiatives important to my company?
Tom Stone is the Eastern U.S. regional
In some instances the electrical costs alone justifies the decision. Other
manager and Steve Wojcieszek is director of
times, a company is working toward a more environmentally friendly culture.
industrial sales with Thermal Care. The Niles,
This is reinforced with the energy savings from the variable-speed chiller.
Ill.-based company can be reached at 847-
966-2260 or visit www.thermalcare.com.
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Industrial Gases/Combustion
Improved NOx
LIMITATION STANDARD
to Reflect Combustion Efficiency
In many locations throughout North America, nitrogen oxide (NOx) emissions
of gas-heated furnaces are limited by law or code. This is typically the case in
urban areas or in places where special topographical characteristics intensify the
negative local and regional effects of NOx emissions.
By Martin Schoenfelder, showing how a one-dimensional emis- even if clean fuels such as hydrogen or
sions-limitation standard can lead to ad- natural gas are being used. The main source
Steven Mickey and
verse effects, preventing a well-intended of NOx in gas-heated industrial furnaces
Joachim G. Wuenning, initiative from achieving its goals or even is called thermal NO. There are two other
WS Thermal Process Technology Inc. leading to the exact opposite. It further modes of formation: prompt NO and fuel-
outlines an approach for a very simple cor- bound NO. These are, however, both negli-
W
hile the approach of rection of the current one-dimensional gible in industrial furnaces.
limiting hazardous formula in order to properly reflect com- The formation of thermal NO is de-
emissions is for the bustion efficiency and, therefore, actually fined by the extended Zeldovich Mecha-
benefit of the environ- achieve its intended goals. nism.[5,6]
ment and society, the method used to N2 + O NO + N
define the limitation can significantly NOx Formation in Gas-Heated N + O2 NO + O
alter its outcome (e.g., if it does not ac- Industrial Furnaces N + OH NO + H
count for the full extent of influencing Nitrogen oxides are highly undesirable
factors). In particular, this is the case for emissions because they can be directly As implied by the name thermal NO,
the combustion efficiency in gas-heated harmful to our health and contribute to the formation is temperature-driven and
industrial furnaces. ozone formation and acid rain.[1] NOx can be described with an exponential
This article presents a simple example can be generated in combustion processes, function. Peak temperatures, therefore,

Temperature, F
Reacting Air 32 482 932 1382 1832 2282 2732
fuel 100 0
and air Fuel
= 1
75 = 0.8
Waste gas losses, %

25
Regenerative burner = 0.6
Efficiency, %
Recuperative burner = 0.4
50 50
Flame Flame Temperature Strong Plug in or central heat exchanger
stabilization fronts supervision recirculation = 0.2
25 = 0 75
air preheat temperature
Relative air preheat
exhaust temperature
0 100
Air 0 250 500 750 1000 1250 1500
Fuel Mixing of air and fuel with exhaust prior to
Flame supervision and ignition reaction (no flame front) Exhaust temperature, C (prior to heat exchanger)
FIGURE 1. Illustration of FLOX combustion

FIGURE 2. Efficiencies of different types of gas-
technology and effect on temperature profile
burner technology (courtesy of WS)
(courtesy of WS)
contribute greatly to NOx emissions. The gas heating. reduction techniques such as FLOX com-
peak temperature in a combustion pro- Due to the location of the furnace, the bustion, the regenerative system can still
cess is typically found in the reaction zone South Coast Air Quality Management achieve 0.08 pounds/MMBTU (70 ppm)
(conventionally this is the flame). Tradi- District (SCAQMD) has set a strict limit at 3 percent O2. Based on the limits de-
tionally, this has led to a trade-off between of 0.06 pound/MMBTU (50 ppm) NOx fined by the SCAQMD, however, the
burner efficiency and NOx emissions, be- at 3 percent O2 for the combustion pro- company is being forced to use the inef-
cause preheating combustion air (being the cess at the highest furnace temperature. ficient cold-air burner system since the
most effective efficiency technology) also This limit is based on a one-dimensional highly efficient regenerative burners lead
increases the flame temperature and, thus, approach and, as such, does not consider to a slightly higher NOx concentration
leads to higher NOx emissions. adjustments for high-efficiency technolo- than the specified limit of 0.06 pounds/
Lowering peak temperatures while still gy. The limit is also not defined on an abso- MMBTU (50 ppm) at 3 percent O2.
maintaining complete combustion is the lute scale such as pounds per year, but it is The one-dimensional standard defined
goal of NOx-reduction techniques, which given as a concentration in the exhaust gas. by the authorities, therefore, prevents the
has been a main focus in combustion re- This implies that all available technologies use of the best-available technology since
search over the last several decades. The emit the same total volume of exhaust gas- the limitation of a concentration (pounds/
most common methods currently used in es. This assumption is false, however, due MMBTU or parts per million pollutant
industrial furnaces are air/gas staging, flue- to different combustion efficiencies of the in exhaust at a specified oxygen content)
gas recirculation and flameless-combus- various available combustion technologies. does not consider the total amount of
tion techniques such as FLOX (figure 1). In this example, the high furnace tem- exhaust gas produced by each alternative
perature and the operating time per year combustion setup. The reference cold-air
Example make efficiency measures highly desirable. burner system only achieves an efficiency
A company is planning to build a new forge Compared to a cold-air burner system (i.e., of approximately 37 percent LHV at the
furnace in the Los Angeles, Calif., area. Per no heat recovery), a modern regenerative- specified furnace temperature. Hence, an
design, the furnace needs to be operated up burner system will achieve fuel savings on equivalent of roughly two-thirds of the
to 2282F (1250C) and requires a net heat the order of 53 percent. While a cold-air natural gas combusted is wasted through
input of 10 MMBTU/hour (3,000 kW burner system will achieve the required the stack of the furnace. At the same time,
LHV) for the intended application. The NOx concentration of 0.06 pounds/ the alternative regenerative-burner solu-
furnace is going to be operated 6,000 hours MMBTU (50 ppm) at 3 percent O2, the tion achieves a combustion efficiency of 78
per year with an average load factor of 75 high air preheat of a regenerative-burner percent LHV and a significantly decreased
percent. Since electricity is very expensive system would lead to an increase in its spe- use of natural gas along with proportion-
and also not desirable for heating industri- cific NOx emissions (i.e., concentration in ally less exhaust gases (figure 2).
al furnaces for environmental reasons, the the exhaust). The resulting annual energy savings
companys preferred technology is natural Due to the use of appropriate NOx- compared to the cold-air burner system

Efficiency ratio/correction factor NOx emissions/limits
NOx emissions/limits, ppm @ 3% O2

100 2.50 120 0.16
90 110
NOx emission/limits, lb./

Correction factor [-]
80 Regenerative burner 2.00 100 0.13
for efficiency
Efficiency LHV, %
70 90 it adjusted
Correction factor 80 New NOx lim 0.10
1.50
MMBTU
60 70 Correction factor
50 60 0.07
40 1.00 50
30 Cold air burner 40 0.05
30 Regenerative burner
20 0.05 20 0.03
10 10
0 0.00 0 0.00
1500 1600 1700 1800 1900 2000 2100 2200 2300 1500 1600 1700 1800 1900 2000 2100 2200 2300
Furnace temperature, F Furnace temperature, F
Annual natural gas consumption Annual NOx emissions

40.00 4000 8800
Energy use, GWh natural gas
Regenerative burners Regenerative burners
NOx emissions per year, kg
NOx emission per year, lb

35.00 Cold-air burners 3500 Cold-air burners
30.00 Example furnace 3000 Example furnace 6600
25.00 2500
20.00 2000 4400
15.00 1500
10.00 1000 2200
5.00 500
0.00 0 0
1562 1652 1742 1832 1922 2012 2102 2192 2282 1562 1652 1742 1832 1922 2012 2102 2192 2282
Furnace temperature, F Furnace temperature, F
FIGURE 3. Cold-air burner vs. regenerative burner illustration of efficiency ratio, correction factor, traditional one-
dimensional NOx limit, NOx limit corrected for efficiency, energy use and absolute NOx emissions per year. Data for
exemplary furnace application as defined in the article is highlighted in green.
equates to 19 GWh, which equals the an- is currently defined favors the inefficient with an efficiency factor.
nual natural gas use of 851 average U.S. and higher-emission technology rather While option 1 seems to be straight-
households.[4] Even though the specific than a far more advantageous combus- forward at first, it can be difficult to ver-
NOx emissions of the regenerative-burner tion technology using less energy with ify compliance in real-world applications.
system are slightly higher than the refer- significantly lower overall emissions. The There is typically no emissions-monitoring
ence system, the absolute amount of NOx next section introduces a simple correc- device permanently installed to prove the
emitted is, in fact, significantly lower. tion method to account for the differenc- true absolute amounts of a pollutant emit-
The inefficient cold-air burner system es in efficiency. This method can be used ted per year. It would be possible, however,
emits 8,172 pounds (3,707 kg) of NOx to correct the emissions limit in order to use extrapolated values based on actual
per year, whereas the high-efficiency re- to easily equate two or more alternative measurements to prove compliance with
generative system only emits 5,419 pounds technologies. the limitation defined as an absolute value.
(2,458 kg). This equates to 33 percent low- Option 2 could be used in a very similar
er actual NOx emissions in the same time Improved Formula for way to todays standard approach. Current-
span (values derived from energy-based Emissions-Limit Calculation ly, the limitation of the concentration of a
emission factors for natural gas H).[2] In general, there are two possible methods pollutant in the exhaust is spot-checked
At the same time, a CO2 reduction to better define the emissions limitation over the course of a typical operation cycle.
of approximately 4,244 (3,850 metric) in order to make sure its actual goal will In the case of NOx emissions, an exhaust-
tons per year can be achieved due to the be achieved. gas analyzer probe is inserted into the ex-
increased fuel efficiency (based on CO2- haust system and several NOx readings are
emission factor 0.126 pounds/ft (2.02 kg/ 1. The overall absolute emissions of a pol- taken over a certain period of time. These
m) for natural gas H). For just one furnace, lutant can be limited. For example, the values are then averaged in order to com-
this difference is equivalent to removing limit could be given in pounds per year. pare them to the limit previously set for
820 passenger cars from the road.[3] 2. The limitation of an emissions concen- the audited furnace.
To summarize, the way the standard tration in flue gases can be corrected At the same time, exhaust-gas analyz-

ers typically also determine the efficiency compared to the option that would have cal combustion efficiencies for different
of a combustion system based on the had to be selected previously. available technologies.[2,7]
CO2 content and the temperature of the Figure 3 illustrates a broader compari- The example discussed represents a
exhaust. These efficiency readings or the son of cold-air and regenerative-burner typical furnace application. Due to the
published/guaranteed efficiency from the systems over a range of operating tem- disincentive set by the current approach
manufacturer can then be used to adjust peratures. The graphs show that the more for defining the emissions limitation, less
the emissions limitation for increased ef- efficient combustion system consistently efficient technology has to be selected. For
ficiency (or vice versa, penalize the ineffi- offers lower overall NOx emissions and only one exemplary furnace, this leads to
cient technology with the same factor). also leads to significant energy savings. 19 GWh of additional energy use, 4,244
Assume that the reference system (ref ) In addition, the energy-savings effect in- (3,850 metric) tons of additional CO2
is defined as the most efficient combustion creases with the operating temperature, emissions and 33 percent higher NOx
technology that still achieves the emissions making the overall environmental benefits emissions than what could be achieved
concentration limit EB as defined by the especially important for high-temperature with a more sophisticated combustion
authorities. If the reference technology is applications. system. This equates to potential savings
able to achieve lower specific emissions, equivalent to the average annual natural
EB should be set according to this lower gas use of 851 U.S. households and NOx
value. Furthermore, assume that there is reductions equivalent to removing 820
a more fuel-efficient technology available
Lowering peak passenger cars from the road.
(eff ) that does not meet the limitation for temperatures while still Extrapolated to hundreds of furnaces,
specific emissions. the effects quickly become highly relevant
The corrected emissions concentration maintaining complete to the public and society. A simple correc-
limit EN shall serve as the new limit for tion to the standards set by the authorities
the high-efficiency technology because combustion is the goal will therefore lead to significant positive
it represents the value at which the total effects for both the environment and the
absolute emissions of the more efficient of NOx-reduction economy.
system are equal to those emitted by the
less efficient system. If the high-efficiency techniques. Contact Dr. Martin Schnfelder, VP technical
alternative stays below this new emissions sales; WS Thermal Process Technology Inc.,
limit EN, it is the environmentally favor- 8301 West Erie Avenue, Lorain, OH 44053;
able solution, because not only is the total Conclusions tel: 440-385-6829; fax: 440-960-5454; e-mail:
amount of pollutant emitted lower than for This article shows that the method cur- wsinc@flox.com; web: www.flox.com
the reference system but also the total fuel rently used to define the limitation of pol-
consumption. lutant concentration in the exhaust of a
combustion system often does not achieve References
1. United States Environmental Protection
its intended goal. Without proper quanti- Agency (EPA), Office of Air Quality Plan-
fication and integration of the process in- ning and Standards: NOx How nitrogen
puts (fuel), the standard method can even oxides affect the way we live and breathe,
Triangle Park, NC, 1998
act counterproductively to its intentions. 2. J. G. Wnning, A. Milani: Handbook of
For the example defined in the previous An undifferentiated limitation of Burner Technology for Industrial Furnaces,
section, the corrected specific emissions volume-based pollutant concentra- 2nd Edition, Vulkan Verlag, Essen, 2015
3. United States Environmental Protection
limit EN for NOx computes to: tion (NOx) is only possible if all avail- Agency (EPA), Office of Transportation
able technologies use the exact same and Air Quality: Greenhouse Gas Emis-
amount of fuel to heat a furnace. Since sions from a Typical Passenger Vehicle,
Ann Arbor, Michigan, 2014
this is rarely the case, we propose using 4. U.S. Energy Information Administration:
an emissions limit corrected for com- Residential Energy Consumption Survey,
bustion efficiency. Its compliance can be 2009
5. Y. B. Zeldovich; The Oxidation of Nitrogen
checked just as easily as the current, typi- in Combustion Explosions, Acta Physico-
cally undifferentiated concentration limit chimica 21: 577628, U.S.S.R., 1946
The regenerative-burner system emit- since exhaust-gas analyzers not only re- 6. G. A. Lavoie, J. B. Heywood, J. C. Keck;
Experimental and Theoretical Study of Ni-
ting 0.08 pounds/MMBTU (70 ppm) at 3 veal emission concentration but also the tric Oxide Formation in Internal Combus-
percent O2 stays well below the corrected efficiency of a combustion system. As an tion Engines, Combust. Sci. Tech. 1 (4):
limit EN of approximately 0.14 pounds/ alternative, authorities could also easily 313326, 1970
7. R. J. Reed; North American combustion
MMBTU (105 ppm) at 3 percent O2, thus define classes of combustion equipment handbook. North American Mfg. Co., 2014
saving 33 percent NOx emissions per year based on existing literature showing typi-

Temperature Sensors
TEMPERATURE
MEASUREMENT
FLEXIBILITY
Helps Quality and Validation
Understanding different sensor types helps create better temperature profiles.
By Stew Thompson, Why Use Different vert the voltage to a temperature reading.
CAS Dataloggers Inc. Sensor Types? Because of the low voltages involved with
Available in several designs, temperature thermocouple measurements, signal noise
O
ven temperature data is criti- sensors use different methods to record is often an issue, particularly in industrial
cal to the entire process, in- data at varying degrees of accuracy. This environments. If you need higher accuracy,
cluding preheating, curing means that all temperature data is not wires with reduced errors also are available.
and drying. Using different equal. Each type has advantages and dis- Cost. Semiconductor devices are an-
types of temperature sensors, you can find advantages for particular applications. other low cost choice. They incorporate
out if your oven interiors are uniform in Flexibility. Thermocouples are the most a solid-state device to generate a voltage
temperature or if there are uneven zones typically used sensors available, due in part or current output proportional to tem-
impacting consistency. to their wide operating range (typical accu- perature. Much like thermocouples, they
With universal inputs, all the sensors are racy of 1 to 2F). Consider thermocouples have a limited operating range and accu-
recording data on the same device using when you want a low cost device that offers racy. Consider using semiconductors when
the same software to keep it simple and ease of use. A thermocouple uses two metal budget is a factor and you have a specific
to store the data to internal memory. It is alloy wires fused together to produce an temperature range in mind.
all with a goal of increasing profitability, output voltage related to the temperature Stability. Resistance temperature de-
product coverage and optimizing the oven in the oven. A datalogger measures this tectors (RTDs) are sensors which have a
heat treatment process. voltage and applies an equation to con- resistance that increases linearly with the

Temperature Sensors
temperature within your oven. The most couples (down to an accuracy of 0.01C) different types. This includes thermistors,
common RTD consists of a fine platinum but only over a limited temperature range RTDs and air temperature sensors.
wire wound around a cylinder. To measure (typically -40 to 302F [-40 to 150C]). For thermocouple applications, some
temperature, the datalogger will source Each family of thermistors has a specific loggers also utilize a cold junction reference
a known current through the RTD and resistance versus temperature characteristic to compensate for any offset voltage that
measure the resulting voltage, from which that the oven datalogger must be able to occurs at the connections between the ther-
it can calculate the resistance. Finally, us- accommodate. mocouple wires and the logger. Addition-
ing the slope of the resistance versus tem- Consider RTD/thermistor sensors ally, an analog-to-digital converter (ADC)
perature curve and the 0C resistance, the when price is not a factor, and you need helps to ensure precision measurements.
datalogger can calculate the surrounding high-precision measurements for a narrow Using a temperature datalogger
temperature. RTDs typically are more sta- temperature window. equipped with universal analog inputs, you
ble and accurate than thermocouples, but can log data from several different types of
they have a more limited operating range. Temperature Measurement temperature sensors. This is especially use-
Similar to RTDs, thermistors provide a for Process Optimization ful if you do not know which sensor types
change in resistance that is related to tem- While many logger models are designed you need, or if you want to experiment
perature. However, thermistors resistance to connect to specific sensor types (for ex- with different temperature sensor types.
change is highly nonlinear. This means that ample, Type K thermocouples), universal For example, maybe you want to run ther-
they offer higher accuracy than thermo- loggers are able to record data from many mocouples to the logger, but your readings
This universal analog input datalogger offers a USB port and drive.

Temperature Sensors
keep getting signal interference. You also

can connect RTDs.
Adding Sensor Power. In the setup sec-
tion of many logger software applications,
you can select a sensor power timer for the
temperature input channel you want. For
example, you can choose to have the con-
nected temperature sensors take a minute
or more to power up, helping to ensure that
they take a stable reading. Many software
packages also will show you sensor power
wiring diagrams for the loggers blocks.
When all this is completed, you can send
this setup to the datalogger so it is saved
for future use.
Setting up a Temperature Channel.
To set up a temperature channel, fol-
low these steps: run the logger software,
go to the setup section or tab, select the
first temperature channel, select your sen-
sor type (for instance, thermocouple Type
K), and input the temperature range you
want to monitor. You can also add scal-
Temperature dataloggers can be enclosed within stainless steel barrier. ing, choose the temperature scale (F/C)
and other options. Diagrams show where
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Temperature Sensors
to connect into the block of the logger. To

simplify multichannel applications, you New Thermal Barrier Temperature Performance
also can enter names for different sensors
for easy reference. 400
New Barrier with Phase Change Heat Sink
350 New Barrier without Heat Sink
Monitoring Air Temperature
inside the Oven 300
Time (mins)
You may think that the interior of your oven
is a relatively stable environment, but inside 250
there are air currents and flows that often
200
cause product defects due the unpredictable
temperature. To help ensure a quality prod- 150
uct and process repeatability, you can use
100
specialized sensors to monitor air tempera-
ture and airflow in oven interiors simulta- 50
neously with temperature monitoring.
0
100 150 200 250 300
Oven Temperature (C)
A thermal barrier protects the datalogger as it passes through the oven.
temperature profile for surface coating and you can use datalogger analysis software to
through process applications. display stored data and get the inside view
Naturally, temperature recorders need on the heat treatment process. For exam-
thermal protection as they collect data ple, you can begin fine-tuning the process
alongside your parts or products during parameters to achieve greater uniformity.
a run or sit within walk-in ovens. When Presented in chart or graph format, the
housed within a stainless steel thermal bar- time-stamped temperature data also serves
rier for heat absorption, the oven logger is as a QA report for vendors and customers.
safe to record for the duration of the spe- It can help prove that products have passed
cific time period listed for the enclosure. through the process at the proper tempera-
In this way, you can derive temperature ture for the proper duration.
profiles for different applications including Many oven loggers also offer tempera-
Temperature dataloggers can work curing, baking and more. ture profile software packages designed
with different sensor types. As the datalogger passes through the exclusively for the paint and finishing
oven, it samples the interior temperature industry. These programs enable users to
The universal inputs on a datalogger can via the connected external temperature store preprogrammed cure data, to display
connect with air temperature and airflow sensors trailing out of slots in the enclo- calculated cure percentages and other de-
sensors to give you the necessary multival- sure. The oven datalogger then stores and sired features.
ue data. Along with standard temperature timestamps the temperature data onto By using different types of temperature
monitoring, this allows you to create an ac- internal memory for data download and sensors to record the temperature data of an
curate temperature profile. If you need to analysis via USB interface with PC. ovens interior, it is possible to equip yourself
view data in real time, fast-response probes with the high level of data needed to create
are available in clip-on, magnetic and com- Document Product Quality a detailed temperature profile. Whether
bination types to capture both air tempera- and Validate Your Process you are curing parts or replicating a batch
ture and surface measurements. With the data collected over several runs, of perfectly roasted potatoes, temperature
Typically, a temperature recorders ana- you should be able to optimize your pro- profiling can serve as a guide needed to sta-
log input channels can accept different cess efficiency all with the goal of in- bilize and optimize the process.
types of thermocouple probes (for exam- creasing repeatability, product quality and
ple, Type T and Type K), capturing data profitability. This can take the form of Stew Thompson is a technical writer with
at a high sample rate (for example, eight minimizing curing times, ensuring more CAS DataLoggers Inc. The Chesterland, Ohio-
times each second). This creates the high even part coverage and other benefits. based company can be reached at 440-729-
level of detail needed to generate a full Equipped with this temperature data, 2570 or visit www.dataloggerinc.com.

Equipment Overview Heat Exchangers
When selecting the type of heat exchanger to use, construc- Our Equipment Overview on Heat Exchangers in print
tion materials, heat transfer medium, flow arrangement and heat and online at www.process-heating.com/directories offers
transfer method are all factors to consider making the selec- a side-by-side comparison of industrial heat exchanger manu-
tion process a difficult job. But, Process Heating has something facturers to show you which companies manufacture the types
to help you out: Our Equipment Overview on Heat Exchangers you want. Cross-check multiple headings by skimming down
will allow you find a few potential suppliers that can provide just specific columns to find those manufacturers that have experi-
what you need. ence with the type of equipment you want. Weve even identified
CONSTRUCTION MATERIALS OF CONSTRUCTION FLOW ARRANGEMENT

You also can conduct your
supplier search online!
Tubular, Shell-and-Tube, Plate Baffle
Multi-Pass, Parallel Plate Multi-Pass

Tubular, Shell-and-Tube, Rod Baffle
Multi-Pass, Parallel Counterflow

Multi-Pass, Cross Parallel Flow
Multi-Pass, Cross Counterflow
Extended Surface, Plate-Fin
Extended Surface, Tube-Fin
www.process-heating.com/
Multi-Pass, Divided Flow

buyersguide
Tubular, Double-Pipe
Tubular, Spiral Tube
Fluoropolymers
Plate, Gasketed
Stainless Steel
Plate, Lamella
Plate, Welded
Plate, Brazed
Exotic Metals
Carbon Steel
Plate, Spiral
Aluminum
Titanium
Graphite
Ceramic
Companies
Copper
Nickel
Other
Other
Brass
Glass
Advanced Coil Technology LLC
www.advancedcoiltechnology.com
Process Technology
www.processtechnology.com
Aaron Equipment Co.
ACS Group, Application Engineering
Advanced Heat Recovery, Aqua Innovations Inc.
Adwest Technologies Inc., Ceco Environmental
AGC Heat Transfer Inc.
Alfa Laval Inc.
Allegheny Bradford Corp.
American Industrial Heat Transfer
Ametek Chemical Products
Ametek Fluoropolymer Products
Anguil Environmental Systems Inc.
API Heat Transfer
APV, An SPX Brand
Baelz North America
Bell & Gossett
Cast Aluminum Solutions, Cast-X Circulation Heater
CCI Thermal Technologies Inc.
Chemineer, a brand of NOV
Chester-Jensen
Chromalox
Colmac Coil Mfg. Inc.
DDI Heat Exchangers Inc.
DECA Srl
Delta Tee International
Diversified Heat Transfer
DME Co.
Doucette Industries Inc.
DRS Marlo Coil, Leondardo DRS
Enecon Corp.
Enerquip LLC
Epcon Industrial Systems LP
Exergy LLC
Feldmeier Equipment Inc.
Fin Tube Products Inc.
Fluorotherm Polymers Inc.
GEA PHE Systems North America
GF Piping Systems
Gooch Thermal Systems Inc.
Manufacturers listed in this Equipment Overview responded to a special mailing by Process Heating and do not necessarily represent the entire industrial heat exchanger market.
To be included in future listings, contact Linda Becker or email BeckerL@bnpmedia.com.

those companies that offer aftermarket parts for their equipment. Info Request button to create a prepopulated form. Fill in your
Visit www.process-heating.com/directories and select the contact information and send it. If you realize you want to add
Equipment Overview on Heat Exchangers to use our RFP more companies, just click on the Add Suppliers button in the
Builder and request information via a single form. On any page contact form. All responses from suppliers will be sent directly to
in the Equipment Overview, click the plus sign next to those you or the contacts you designate.
suppliers you wish to add to your distribution list. Once you've If you need more information than what we have specified here
selected the companies you are interested, click on the Submit An and on our website, www.process-heating.com/buyersguide.
MEDIUM PROCESSED METHOD OF HEAT TRANSFER MANUFACTURING PROCESS INDUSTRIES SERVED
parts/supplies for our heat exchangers.

Ethanol/Biodiesel Fuels/Oil & Gas
We manufacture aftermarket
Evaporation/Condensation
Chemicals/Petrochemicals
Single Pass, Parallel Flow
Single Pass, Counterflow
Pulp/Paper/Converting
Single Pass, Crossflow
Plastics/Rubber/Vinyl
Multi-Pass, Split Flow
Packaging/Printing
Heat Transfer Fluid
Fibrous Effluent
Steam to Liquid
Pharmaceutical
Liquid to Liquid
Vapor Recovery
Feed Preheater
Pasteurization
Heat Recovery
Reactor Slurry
Heat Transfer
Interchanger
Gas to Liquid
Steam to Air
Air to Liquid
Refrigerant
Distillation
Electronics
Gas to Air
Finishing
Air to Air
Reboiler
Cooling
Steam
Water
Glycol
Other
Other
Other
Food
Gas
Air
Oil
*
*
Yes
Yes
Yes
Yes
Yes
Yes
*
*
Yes
Yes
Yes
Yes
*
Yes
*
Yes
Yes
Yes
Yes

Yes

Yes

*

*

Yes
*
Yes
Yes
*
Yes
Yes
*
Yes
Yes
Yes
Yes
*
*
Companies with in front of their name have an advertisement in this issue.

Equipment Overview Heat Exchangers
CONSTRUCTION MATERIALS OF CONSTRUCTION FLOW ARRANGEMENT
You also can conduct your
supplier search online!
Tubular, Shell-and-Tube, Plate Baffle
Multi-Pass, Parallel Plate Multi-Pass

Tubular, Shell-and-Tube, Rod Baffle
Multi-Pass, Parallel Counterflow

Multi-Pass, Cross Parallel Flow
Multi-Pass, Cross Counterflow
Extended Surface, Plate-Fin
Extended Surface, Tube-Fin
www.process-heating.com/
Multi-Pass, Divided Flow

buyersguide
Tubular, Double-Pipe
Tubular, Spiral Tube
Fluoropolymers
Plate, Gasketed
Stainless Steel
Plate, Lamella
Plate, Welded
Plate, Brazed
Exotic Metals
Carbon Steel
Plate, Spiral
Aluminum
Titanium
Graphite
Ceramic
Companies
Copper
Nickel
Other
Other
Brass
Glass
Graham Corp.
Greenwood Engineering Inc.
Harbridge Systems
Heat and Control Inc.
Heat Transfer Systems Inc.
Heatec
Heresite Protective Coatings LLC
Honeywell Thermal Solutions, Exothermics
Hydro-Thermal Corp.
Industrial Heat Transfer
Isotherm Inc.
JLS International
Koch Heat Transfer Co.
Komline-Sanderson
Litre Service Inc.
Luvata Grenada LLC
Lytron Inc.
Madden Manufacturing
Manning & Lewis Engineering Co.
Mascoat
Metso Minerals Industries Inc., Pyro Processing
MicroThermics Inc.
Mokon
Multitherm
Munters Corp.
Opti-Temp Inc.
Parker Boiler Co.
Paul Mueller Co.
Pick Heaters Inc.
Plate Concepts Inc.
Polaris Heat Exchangers LLC
PolyScience
Premier Furnace Specialists/BeaverMatic Inc.
ProSonix LLC
R.P. Adams, Subsidiary of Service Filtration Corp.
RAS Process Equipment
Robson Industries Inc.
Rubicon Industries
Sentry Equipment Corp.
Smithco Engineering
Standard Exchange
Sterling Products Inc.
Super Radiator Coils
Swep North America Inc.
Tek-Temp Instruments Inc.
Terlet USA
Thermal Transfer Systems Inc.
ThermTech Inc.
Thomas C. Wilson LLC
Tranter Inc.
Trent Inc.
Vilter Manufacturing LLC
Watlow
Waukesha Cherry-Burrell, An SPX Brand
WCR Inc.
Webco Industries Inc.
Xchanger Inc.

MEDIUM PROCESSED METHOD OF HEAT TRANSFER MANUFACTURING PROCESS INDUSTRIES SERVED
parts/supplies for our heat exchangers.

Ethanol/Biodiesel Fuels/Oil & Gas
We manufacture aftermarket
Evaporation/Condensation
Chemicals/Petrochemicals
Single Pass, Parallel Flow
Single Pass, Counterflow
Pulp/Paper/Converting
Single Pass, Crossflow
Plastics/Rubber/Vinyl
Multi-Pass, Split Flow
Packaging/Printing
Heat Transfer Fluid
Fibrous Effluent
Steam to Liquid
Pharmaceutical
Liquid to Liquid
Vapor Recovery
Feed Preheater
Pasteurization
Heat Recovery
Reactor Slurry
Heat Transfer
Interchanger
Gas to Liquid
Steam to Air
Air to Liquid
Refrigerant
Distillation
Electronics
Gas to Air
Finishing
Air to Air
Reboiler
Cooling
Steam
Water
Glycol
Other
Other
Other
Food
Gas
Air
Oil
Yes
*
Yes
Yes
Yes
*
Yes
Yes
*
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
*
Yes
Yes
Yes
*
Yes
Yes
Yes
*
*
Yes
Yes
Yes
*
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
*
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
*
*
Yes
Yes
*
Yes

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.
BriskHeat Grieve Corp.

Heating Mantles for Laboratory Use Oven Dries Water from Piston Rings
Metal-housed heating man- on Racks
tle are suited for laboratory A 500F (260C),
settings including research top-loading oven,
and development laborato- No. 844 is used for
ries that employ round-bot- drying water from
tom flasks for heating liq- racks of piston rings
uids. Model HM is made to at the customers
fit precisely around boiling facility. Work-
and distillation-style round- space dimensions
bottom flasks to provide measure 48 x 48 x
consistent, easy-to-control 36", and 40 KW are
heat. The metal-housed installed in Incoloy-
heating mantles fit flasks sheathed tubular
with capacities between 50 heating elements. A 4200-cfm, 3-hp recirculating blower
and 6,000 ml and provide provides horizontal airflow to the workload. This oven has 4"
high temperature capabilities up to 842F (450C). They are insulated walls, an aluminized steel exterior and Type 304, 2B
offered in tabletop designs and are available with built-in finish stainless steel interior with continuously back welded
controllers. The plastic-coated, chemically resistant metal seams. Additional features include an air-operated rear slid-
housing is thermally insulated for safe touch. ing door, reinforced 0.25" steel plate top and wear bars at
888-501-7491 sides of workspace. The floor of the workspace is reinforced
www.briskheat.com for 1000 lb loading at removable subway grate.
847-546-8225
Buhler Aeroglide www.grievecorp.com
Real-Time Data Monitoring For Optimum
Dryer Performance Thermcraft
AeroPro Moisture Control Box Chamber Furnaces
gives dryer operators Box-type chamber furnaces are suited for use in nearly all
access to full-time, types of thermal processing and heat treating applications. A
real-time monitoring pair of twin box furnaces will be used to process turbine parts
with hardware, software for a manufacturer of power generation turbines. Each of the
and ongoing process furnaces is equipped with multiple heavy-duty cast-plate
expertise, combined heaters with heavy-gauge wire-wound elements totaling 130
with technical support, KW of power. The vertical lift doors are opened and closed
to ensure efficient dryer using dual synchronized pneumatic cylinders. Temperature
operations. The moisture controls include a single-zone controller with integrated
control device reduces time-based moisture deviation with digital chart recorder/data acquisition and an independent
a control algorithm that improves dryer yield. It also reduces overtem-
dryer energy consumption, according to the manufacturer. perature
Microwave sensor technology, coupled with algorithms, controller,
deliver a closed-loop system for automated dryer control. In both read-
operation, discharged product passes through an analysis ing Type
chute, where approximately 20 percent is diverted to a sens- K thermo-
ing chamber that slows the product flow for analysis. The couples.
microwave sensor gathers moisture data and sends it directly Power is
to the moisture control systems control panel. Automation controlled
then makes necessary dryer adjustments that can instantly by zero-cross SCR power controllers in a three-phase configu-
produce product consistent to the target moisture content. ration and monitored by one ammeter per phase.
919-851-2000 336-784-4800
www.buhlergroup.com/drying www.thermcraftinc.com

Learn from two high-prole Keynotes and over
a dozen subject matter experts about industry
QUALITY trends and new technologies that may solve the

challenges facing your business.
Education
Interact with thousands of experienced and

skilled quality engineers, manufactures and
production managers over 3 days to discuss
challenges, share experiences and build QUALITY
important relationships.
Networking
Explore a resource-rich exhibit hall and take away

actionable ideas on the latest test, measurement &
inspection equipment services and software that can
QUALITY improve quality in your manufacturing planning.
Solutions
Register for FREE Today! Quali tyS how.co m
Only Qu ali ty
October 24 26, 2017
Donald E Stephens Convention Center
Rosemont, IL
Platinum SIlver Bronze Collaborative

Sponsor Sponsor Sponsor Partners
Product Highlights
Xchanger Inc. Carlo Gavazzi Inc.

Heat Exchangers with Bolt-On Transitions Self-Learning 40-hp Soft Starters with
Heat exchangers Integrated Overload Protection
are available with A soft-starter for
optional bolt-on three-phase induc-
transitions that tion AC motors, the
ease access to the RSGD needs only
core and improve three settings. The
exchanger body self-learning algo-
strength. In most rithm adjusts the soft
applications, the starter parameters
simple bolted to work with varying
flange can significantly reduce labor costs and downtime for load conditions. It is
inspection and cleaning. The C-Series unit shown, designed active at every start
for 15 psig, can be used for heating pneumatic conveying air to ensure that the motor always starts with the optimal set-
to reduce or prevent product cooling during transport. They tings. New current-balancing algorithm keeps the current un-
can also be used to control humidity levels by combining a balance to less than 15 percent. The line includes an option
cooling core and reheating core in the same unit. for Class 10 electronic overload. Phase-sequence protection
952-933-2559 can be enabled and disabled through the use of an inte-
www.xchanger.com grated pushbutton. Torque controlled ramp-down provides
smooth deceleration of motors. Features include operational
Frigel current 12 to 45 A; up to 40 hp rating; and operational volt-
Central Cooling System, Process Pump age capacity of 220 to 600 VAC.
Sets with Variable-Frequency Drives 847-465-6100
www.gavazzionline.com
Conair Group
Adiabatic Cooling Towers
Cut Power, Water Consumption
EarthSmart ESTW Series eliminate the constant water
consumption and treatment requirements of conventional
evaporative towers, utilizing closed-loop cooling that isolates
process water from contamination. The adiabatic cooling
towers cycling it, through finned heat exchangers, where
ambient air absorbs process heat and cools it for recirculation.
During periods where ambient air is warmest and maximum
cooling capacity is needed, the adiabatic towers use top-
mounted fans to draw warm air through wetted adiabatic
panels located in front of the finned heat coils. The towers
controls automatically manage the adiabatic process, vary-
Designed to be used with the companys central cooling ing water volume and fan speed to reduce the temperature
systems, Aquagel GPV pump sets help ensure the pumps of the ambient air passing through the heat exchangers.
operate at peak efficiency with lowest possible energy The line includes eleven
consumption. The pump sets with variable-frequency drives models capable of
(VFDs) allow users the ability to gain precise control of the handling nominal
units. The pump sets are part of the companys line of pump- process coolant
ing, reservoir and filtration systems for its Ecodry or Heavygel flow rates of 45 to
central cooling systems. With the addition of the companys 510 gal/min (170 to
3PR control console, users can monitor all data in real time for 1,930 l/min), with
the pump stations. Users can access full operating schematics cooling capacities
that monitor pump performance such as pressures, flow rates ranging from 17
and VFD capacity. tons to 195 tons.
847-540-0160 724-584-5500
www.frigel.com www.conairgroup.com

FABTECH 2017
CHICAGO
NOV 6 9
| | |
REGISTER TODAY FABTECHEXPO.COM

LEARN MEET EXPLORE BE PART OF THE
EXPERIENCE THE FUTURE OF

METAL FABRICATING AND MORE
ONLY AT FABTECH
#FABTECH17
NORTH AMERICAS LARGEST METAL FORMING,

FABRICATING, WELDING AND FINISHING EVENT
Product Highlights
GF Piping Systems Advanced Thermal Solutions (ATS)

Solid-State Electric Actuator Heat Sinks Provide Cooling for Systems
with Adequate Airflow
A high aspect ratio
design allows the Pin
Fin heat sinks to provide
low thermal resis-
tance from base
to fins in systems
where the airflow
measures more
than 200 linear feet
per minute. The cross-
Model EA15 is suited for smaller diameter, open/close ball cut design also allows the heat sinks
valve applications in chemical processing, refrigeration and to be effective in systems where the airflow
water treatment. As a part of the companys EA25-250 actua- is ambiguous. The high efficiency platform products, made
tor series, the device incorporates standard features such from extruded aluminum, are available in component sizes
as open/close limit switches; a seven-segment error code from 0.39 x 0.39" (10 x 10 mm) to 2.36 x 2.36" (60 x 60 mm).
display; adjustable internal heating element; and a chemi- Heat sink heights range to 1" nominal (25 mm). At higher
cally resistant polypropylene housing. Designed to operate airflows, the heat sinks can provide thermal resistance as low
quarter-turn valves, the actuator delivers a nominal torque of as 4.5F/W (2.5C/W). They can be attached with standard
10 Nm and a peak torque of 20 Nm. thermal tape or the companys clip kit.
800-854-4090 781-769-2800
www.gfps.com www.qats.com
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For over 100 years, the Chem Show continues to connect leading manufacturers of equipment, systems and
services for the CPI with tens of thousands of professionals from every segment of the process industries.
FREE REGISTRATION AT CHEMSHOW.COM

Versatile MTH SAVE BIG WITH MICROFUSION
Series Burners
Swing-away air
housing
Low NOx/CO
emissions without
FGR
Our latest SCR controller is ultra-compact, designed for years of
Up to 5:1 turndown reliable power control, saving you panel space and installation costs.
Single-phase, three-phase 4-SCR and
3-phase 6-SCR configurations
Auto-Ranging Input Voltage (UL: 24-600
VAC, 45-65 Hz, CE: 24 - 690 VAC0
Where Reliability Comes Standard Optional: 1% accuracy true RMS power 18760 Lake Drive East
Phase-Angle, Zero-Cross, Current Chanhassen, MN 55317
608-305-8001 Rage of 8A 400A Zero-Cross (800) 765-2799 | (952) 474-6200
ind-comb.com Transformer Mode www.ccipower.com
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coming up short?
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When you have assurance, you have confidence
youre 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
To Sign Up for Your sure you dont get short-changed.
FREE Subscription, go to
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PH Classifieds Display Classified Rates:
1X $125 3X $120 6X $115 12X $105
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
For $30 Liquid Cooled

we will
SEE YOUR AD HERE
post & link Air Cooled

your print ad on FOR GASES & LIQUIDS!
Talk Directly with Design Engineers!
www.process-heating.com Blower Cooling Vent Condensing
(952) 933-2559 info@xchanger.com
ADVERTISING INDEX
11 Advanced Coil Technology 507-451-0130 www.advancedcoiltechnology.com
10 ARI Valve 770-933-8845 www.arivalve.com
43 Chem Show www.chemshow.com
7 & 21 Duratherm 800-446-4910 www.durathermfluids.com
41 FABTECH www.fabtechexpo.com
48 Heatec, Inc. 423-821-5200 www.heatec.com
2 Industrial Combustion 608-329-3131 www.ind-comb.com
17 Process Technology 440-974-1300 www.processtechnology.com
10 & 32 Protection Controls 847-674-7676 www.protectioncontrolsinc.com
39 Quality Show www.qualityshow.com
9 Sigma Thermal 866-923-6121 www.sigmathermal.com
5 Themal Product Solutions 570-538-7200 www.thermalproductsolutions.com
47 Wisconsin Oven 262-642-3938 www.wisoven.com

Places Faces
Systems expand the coverage of

Metso's Neles and Jamesbury valve
SUBSCRIPTIONS
and positioner product families in For subscription information or service, please contact
Customer Service at:
India. The distribution network also will Phone: 800-952-6643 or Fax: 847-763-9538
provide support in services. Email: processheating@omeda.com
PUBLISHING STAFF
Group Publisher DARRELL DAL POZZO
847-405-4044 dalpozzod@bnpmedia.com
Associate Publisher and Editor LINDA BECKER
262-564-0074 BeckerL@bnpmedia.com
Technical Editor REED MILLER
412-306-4360 reed@process-heating.com
London-based Lloyds Register issued
Associate Editor BILL MAYER
its first certification of a part produced 412-306-4350 bill@process-heating.com
Contributing Editor JOY LEPREE ANDERSON
through additive manufacturing for 856-582-9554 joylepree@gmail.com
the oil-and-gas industry. The part, a Nationwide Boiler Inc., Fremont, Art Director MANDA CHAN
323-486-8080 Chanm@bnpmedia.com
titanium gateway manifold for pipelines, Calif., represents Webster Production Manager SOUZAN AZAR
was designed by Surrey, England- Combustion Technology LLC, 248-786-1700 AzarS@bnpmedia.com
Advertising Director SUSAN HEINAUER
based Safer Plug Co. (SPC) and Winfield, Kan., in central and northern 412-306-4352 HeinauerS@bnpmedia.com
built by the additive manufacturing California following an agreement Classifieds & Reprint Sales BECKY MCCLELLAND
412-306-4355 McClellandB@bnpmedia.com
production company 3T RPD using between the two companies.
ADVERTISING SALES
powder bed fusion. The entire process Webster manufactures industrial and NORTH AMERICA Susan Heinauer Advertising Director
412-306-4352 FAX 248-502-1046 HeinauerS@bnpmedia.com
was overseen and certified by Lloyds commercial boiler burners. Nationwide
NORTH AMERICA Frank Prokos National Sales Manager
Register using its framework, which is involved in boiler system sales, 847-405-4033 MOBILE 312-343-3253 ProkosF@bnpmedia.com
SELECT ACCOUNTS Rick Groves GrovesR@bnpmedia.com
guides manufacturers on additive- rentals, leasing, turnkey installations, 248-244-6444 MOBILE 610-517-9592 FAX 248-502-2109
manufacturing processes to certify operations and repair. SELECT ACCOUNTS Steve Roth steve@process-heating.com
520-742-0175 MOBILE 847-922-0910 FAX 847-620-2525
components. The manifold will be EUROPE Hamilton Pearman European Sales Representative
included in an assembly for a suite of +33 (1) 45 93 0858 pearmanh@bnpmedia.com
pipeline isolation tools. CORPORATE DIRECTORS

Publishing: JOHN R. SCHREI
Corporate Strategy: RITA M. FOUMIA
Patrick McKenna was promoted to Creative: MICHAEL T. POWELL
Events: SCOTT WOLTERS
president and CEO for Ipsen USA,
Finance: LISA L. PAULUS
Cherry Valley, Ill. Also, Pete Kerbel Information Technology: SCOTT KRYWKO
was promoted to vice president of Human Resources: MARLENE J. WITTHOFT
Production: VINCENT M. MICONI
sales at Ipsen USA. Clear Seas Research: BETH A. SUROWIEC
GF Piping Systems Irvine, Calif.-
CORPORATE STAFF
Ava Drayton was based facility was recognized with BNP Media Corporate Office 248-244-6400
Directory Development Manager ERIN MYGAL
named vice president, the Pacific Southwest Regional
248-786-1684 mygale@bnpmedia.com
food and beverage, for Outstanding Building of the Year award
AUDIENCE MARKETING
Charlotte-based SPX in the industrial office building catego- Audience Marketing Coordinator ASHLEY BURTON
Flow Inc. Drayton will ry. The campus includes warehouse Integrated Media Coordinator MAGDALENA
PERKOWSKI
be responsible for driv- and manufacturing space as well as Audience Audit Coordinator CAROLAN BIENIEK
Drayton ing market share in the offices for engineering, technical sup- LIST RENTAL
Americas. At the same time, SPX Flow port and training, and a showroom for POSTAL & EMAIL CONTACTS
KEVIN COLOPY Sr. Account Manager
named Pierre Sbabo as the vice presi- the company's piping solutions. Phone: 402-836-6265
dent of its food and beverage business Toll Free: 800-223-2194, ext. 684
Email: kevin.collopy@infogroup.com
in EMEA. SPX Flow manufactures After more than MICHAEL COSTANTINO Senior Account Manager
Phone: 402-836-6266
engineered flow components, process 15 years with BJM Email: michael.costantino@infogroup.com
equipment and turnkey systems. Pumps, Old Saybrook, SINGLE COPY SALES
Conn., Jay Gallagher, ANN KALB
kalba@bnpmedia.com
Metso strengthened its presence who served as Atlantic GET MORE ONLINE
in India with the signing of four regional sales man- Search and read our archives. Every article and column
nonexclusive distribution agreements Gallagher ager, retired. Steve published in Process Heating since 1998 is available online!
for its valve products. The agreements Mosley, who has served as BJMs WWW.PROCESS-HEATING.COM
with Fluidline Systems, General application engineer for five years, BNP MEDIA HELPS PEOPLE SUCCEED IN
Energy Management Systems Ltd. will succeed Gallagher as the Atlantic BUSINESS WITH SUPERIOR INFORMATION
(GEMSL), SB Enterprise and Proflo regional sales manager.
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Bath Heaters
Glycol Heaters
Electric Heaters
Regen Gas Heaters
Waste Heat Recovery
Fuel Gas Conditioning
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
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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

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October 2017 Volume 24, Number 10

packages, tamper-resistant bottles and Volume

Columns & Departments shrink wrap are all a result of evolution in

www.process-heating.com OCTOBER 2017 3

Learn about Heat Transfer Fluids Processing

4 OCTOBER 2017 Process Heating

Call our Engineering

Address: 2821 Old Route 15 | New Columbia, PA 17856 | USA

Powder Coating Show Returns to Indianapolis

6 OCTOBER 2017 Process Heating

Ohio Plant Produces

closures together. The plant's

www.process-heating.com OCTOBER 2017 7

aging oven to an aerospace parts

The used heater stock program that conducted the assessment.

8 OCTOBER 2017 Process Heating

Oven Cures Paint on Steel,

Process Heating Equipment

Thermal Fluid Systems

Water - Glycol Systems

Indirect Bath Heaters

Conveyor Oven Provides Process

www.process-heating.com OCTOBER 2017 9

October 27-29 Drying Theory Put to 30 Fundamentals of Industrial

ARI Valves can take the heat

ARI ValvesThe Obvious Choice

ARI Valve Corporation

10 OCTOBER 2017 Process Heating

Heating, Cooling & Heat Reclaim Coils

advancedcoiltechnology.com | 507.451.0130 | sales@advancedcoiltechnology.com

www.process-heating.com OCTOBER 2017 11

12 OCTOBER 2017 Process Heating

accommodate the liquid expansion to avoid

www.process-heating.com OCTOBER 2017 13

We will explore each option.

14 OCTOBER 2017 Process Heating

careful consideration must be used if ei- Air.

www.process-heating.com OCTOBER 2017 15

Preventing Fluid Degradation

Oxidation. Thermal fluids, when ex-

Preventing oxidation is simple in con-

16 OCTOBER 2017 Process Heating

yearly. Most fluid manufacturers offer this service at no charge.

Drain Tank Sizing

What happens if the expansion

It is also noteworthy that relatively low cost reversible fill-and-

A manufacturer of thermal fluid heaters, Sigma Thermal is based in

www.process-heating.com OCTOBER 2017 17

With laminating, drying, pasteurizing, curing,

Heaters Help Deliver

18 OCTOBER 2017 Process Heating

www.process-heating.com OCTOBER 2017 19

20 OCTOBER 2017 Process Heating

their construction, UV lamps are usually

www.process-heating.com OCTOBER 2017 21

An alternative for process cooling applications, variable-speed compressors

22 OCTOBER 2017 Process Heating

10-Ton Air-Cooled Variable-Speed Compressor Option Payback

20-Ton Air-Cooled Variable-Speed Compressor Option Payback

www.process-heating.com OCTOBER 2017 23