New Process Heater Technology
Offers Increased Efficiency
By combining a helical heat exchanger, shared-wall radiant U-tube and helical flame stabilization element, a new process heater is said to offer 70 to 80 percent greater efficiency over current state-of-the-art radiant tube combustion systems. Developed with funding from the U.S. Department of Energy's Industrial Technologies Program, the technology, known as the advanced process heater (APH), represents a potential annual fuel savings of 102 trillion BTU when compared to a state-of-the-art radiant tube combustion system, according to the research.

The technology is suitable for the chemical, strip and wire annealing, heat treating and aluminum industries. Two commercial APH hybrid prototypes were designed, installed and demonstrated on a batch-wire annealing furnace with success. This resulted in three spin-off products: a high-temperature heat exchanger; a new radiant heat transfer system; and a hybrid or integral APH, which will be commercialized by Erie, Pa.-based Spinworks LLC.

The low-cost, high-temperature heat exchanger, Heatcor-451 will produce preheated air temperatures from 451 to 900°F (232 to 464°C). Its target application is in strip-steel annealing furnaces. A typical annealing furnace contains 100 radiant tubes with a rating of 50 million BTU/hr and an annual fuel cost of $1.9 million. The new unit is designed to work in conjunction with existing systems. The Heatcor-451, when combined with the SpyroCor radiant heat transfer system, is expected to save approximately 40 percent of current-level BTUs of energy consumed per year. Demonstrations of this product will occur early this year.

The SpyroCor radiant heat transfer system (RHTS) is a patent-pending system designed to be used as a stand-alone system or in combination with the Heatcor-451. The RHTS uses a ceramic compression system that allows the elements to be mounted in vertical radiant tubes. Typical applications include strip-annealing, wire-annealing, aluminum annealing and general heat treating. Commercialized in 2006, the RHTS has saved more than 15 trillion BTUs of energy so far, according to the company.

The Heatcor Ready to Fire (RTF) is a hybrid ceramic heat exchanger and burner that can be directly mounted on a metallic radiant tube. When used in conjunction with the RHTS, fuel savings approaching 50 percent can be achieved, according to the company. The RTF was demonstrated in 2007 on a wire annealing furnace. Commercialization activities will begin in 2008 and 2009. Energy savings of 120 million BTU per installation, per year, are anticipated.

Temperature Profiling Guides Released
Companies interested in temperature profiling reflow ovens can request a Mega M.O.L.E. 2.0 and M.A.P. guides from Electronic Control Design (ECD) Inc., Milwaukie, Ore. M.A.P. is a company-specific acronym for "Machine, Assembly, Process" that takes a systematic approach to the:

• Machine, a reflow oven.
• Assembly, a printed circuit board.
• Process, the thermal profile specified by the solder paste manufacturer for proper reflow.

The M.O.L.E. Profiler depends on the M.A.P. software to control how it collects and interprets data. Several kinds of data runs may need to be performed to achieve desired information, or the same data run may be performed repeatedly over time to monitor one process. To request copies of the guides, visit the web site or call (503) 659-6100.

Consider Catalytic Infrared for Food Processing
Catalytic infrared can be used in processes to add value, improve quality and yield, and reduce operating costs in many segments of the agricultural/food processing industry.

Temperature Circulator Q&A
In the dark about temperature circulators? Understand the basic terms and sizing information.

Getting Control of Cooling Processes
From simple to complex cooling processes: What you should know when shopping for temperature controls for your refrigeration equipment.

Don't Let Profits Go Up In Smoke
Reducing energy consumption in emission control systems by capturing waste heat rather than exhausting it can help you increase profitability.

Recycle?
Should you recycle the energy you've invested in making process heat? And if so, how?

Impedance Heating System
Heating system provides uniform heat with minimal footprint and uses the pipe itself as the heating source using the Joule effect. Impedance heating system directly warms the piping to provide even, smooth heating along the entire circumference and length of the heated area. This method creates a heating system that needs no additional piping, valves or flanged connections. It can be used to maintain a liquid temperature or can add additional power to heat up liquid flow.
Chromalox Inc., (412) 967-3800

Compact Setting Display Unit
Model OP10 is intended to be used in conjunction with the company's SR Mini, SRV and SRZ systems. The compact setting display unit allows operators to monitor up to 99 channels or troubleshoot where a PC is not available. Any Modbus register address can be used to set or display data. The unit may be panel mounted or hung on a DIN rail. The LCD display also is IP66 rated.
RKC Instrument, (574) 273-6099

Panel-Mount Controllers
DIN-sized controller incorporates the company's integrated control loop functions into a 1/16 or 1/32 DIN controller. The panel-mount units are customizable and configurable to suit the application. For example, the control can be ordered as a PID controller; an over- or under-limit control; or an integrated control including each of those functions.
Watlow, (800) 928-5692

Energy Cogeneration System
Energy Conservation System (ECS) provides steam flow rates from 3,500 lb/hr and up. The small cogeneration system consists of a backpressure steam turbine used in parallel with an existing pressure-reducing valve or pressure-reducing de-superheating station. Steam is expanded in the backpressure turbine (ECS), which drives the generator, thus converting the heat energy of the steam to electrical power. A control valve regulates the steam flow rate to the turbine to maintain the requisite steam pressure at the outlet of the turbine. This control ensures correct steam pressure for the process.
Pennant International Corp., (877) 597-8727