As Process Heating wraps up another year of serving industrial processors who use low temperature industrial heating equipment and supplies, its editorial staff offers readers this handy reference guide to the feature articles published in 2015.
Industrial Boilers and Steam Heating
Equipment Overview: Industrial Boilers
Used for generating steam for power, process heating or space heating, or to produce hot water to heat products or a hot water supply, an industrial boiler delivers steam or hot fluid to the end use point at the desired pressure and temperature. April 2015, page 26
Improve Your Combustion Equipment Performance
Stop burning profits with an oven or furnace retrofit. If your company’s efficiency is not best-in-class, retrofitting will almost always provide significant risk minimization and a robust return on investment. Russ Chapman, Firebridge Inc. August 2015, page 19
10 Tips for Preparing a Temporary Steam Plant
If your plant relies on an industrial steam plant as an essential part of your process, there is a good chance you will someday need a temporary steam plant. Expect the worst and prepare a contingency plan. Michael Medina, Nationwide Boiler. September 2015, page 15
On-Demand Steam Boilers Improve Food and Brewing Processes
Two processors take advantage of quick-to-temperature boiler systems to reap operational and environmental advantages. November 2015, page 32
Industrial Combustion and Burners
How to Maximize Burner Efficiency
Because natural gas energy costs are a major cost factor for many industrial processes, it makes sense to carefully analyze how the natural gas is being used and whether the system is running at peak efficiency. Mark Lampe, Honeywell Environmental and Combustion Controls Division, Maxon brand. February 2015, page 36
Combustion Solutions for Meeting Ultra-Low NOX Emissions
A variety of options can help processors meet increasingly stringent regulations for NOX emissions. The two most proven are surface-stabilized, 100 percent premix and high IFGR with staged combustion burners. Bob Rizza, Power Flame Inc. May 2015, page 26
Modular Ultra-Low-NOX Emission Burners for Drying Applications
The design of a modular ultra-low-NOX burner allows users to tailor it to suit the drying process applications it needs to serve. Jessica Irons, Eclipse, a company of Elster Thermal Solutions/ May 2015, page 20
Equipment Overview: Industrial Burners
An apples-to-apples comparison of the capabilities of a range of burner manufacturers, our Equipment Overview on Burners will help you narrow the field of potential suppliers to those that can satisfy your process needs. August 2015, page 38
Industrial Cooling
How to Size Chillers for Condensing Applications
Selecting proper cooling capacity for chillers used condensing applications helps ensure high performance and process reliability. Mark Diener, Julabo. September 2015, page 30
Industrial Dryers
How to Prevent Dryer System Fires and Explosions
Three central causes create the conditions that allow fires and explosions to occur in dryer systems: high oxygen content, dirty ductwork and poor operations. Knowing what causes fires and explosions is the first step in prevention. Becky Long, Thompson Dehydrating Co. February 2015, page 16
Act Now to Prevent Dryer System Fires and Explosions
In Part One of this series, we discussed why uncontrolled, unplanned fires and explosions are undesirable and described the primary conditions that can lead to fires and explosions in direct-fired rotary dryer systems. This month, we take an in-depth look at how to minimize the risk of fires and explosions in dryer systems. Becky Long, Thompson Dehydrating Co. April 2015, page 14
Dryers Ensure Proper Filter Manufacturing
The manufacturing of filters for reverse osmosis requires carefully designed drying systems. Bob Narang, Radiant Energy Systems Inc. and Rick Luedtke, Radiant Energy Systems Inc. April 2015, page 31
Drying Process Effects on Rayon Fibers
Process air temperature and retention time are two parameters that rayon producers can adjust to produce the highest quality fibers at the highest production rates. Tests show how adjusting the parameters affects fiber color strength and oil pickup. Shannon Stanforth, Buhler Aeroglide. June 2015, page 14
Using Rotary and Fluid Bed Dryers for Drying Frac Sand
Frac sand plays the essential role of preventing fractures in oil and gas wells from closing prematurely, Rotary and fluid bed dryers are used to thermally treat the frac sand to remove impurities before it is injection in the fissures. David Phillips, Heyl & Patterson Inc. June 2015, page 19
Like the flights in a rotary dryer lift the material to be dried, our Equipment Overview on Dryers guides you through your selection options. June 2015, page 24
Avoid 4 Common Mistakes When Specifying Dryers
Industrial dryers do an effective job of evaporating moisture and bringing product to specific moisture-content levels. To ensure your industrial dryer is sized to deliver the moisture-content level you need, avoid these four common mistakes made when specifying an industrial dryer. Craig Anderson, Almo Process Technology, Tom Schroeder, and Jarrett Bowling, Almo Process. September 2015, page 26
Drying Frac Sand with Rotary Dryers
Because frac sand must have less than one percent moisture, drying is an essential step in processing the material. Rotary dryers deliver. Savannah Ardmire, Vulcan Systems. October 2015, page 28
Improved Drying of Agglomerated Materials
Carefully selecting the drying technology and drying process conditions when thermally processing agglomerated products can result in improved product quality or performance of the downstream processes. November 2015, page 14
Improving Dryer Moisture Control
Are you overdrying your product simply to ensure that it is dry enough? An in-dryer moisture-content sensing and control system may offer a way to control your dryer based on the feed’s moisture content without dead time in control response. November 2015, page 25
Industrial Heat Transfer Fluids and Thermal Fluid Heaters
Equipment Overview: Heat Transfer Fluids
In Process Heating’s annual Equipment Overview on Heat Transfer Fluids, we have compiled the data you may need to choose a fluid that can operate effectively in elevated temperatures. Characteristics such as density, film coefficient, viscosity, pour point and thermal conductivity are listed. January 2015, page 16
Preparing for a Thermal Fluid Heater
Failure to adequately plan for the arrival of a new heater can cause major frustrations and unnecessary costs. Here are some common issues related to scheduling and preparation for installation of a new heater. Ron Henry, Heatec Inc. May 2015, page 14
6 Takeaways for Heat Transfer Fluids
Giving careful consideration to heat transfer fluids provides optimal system performance. Gain insight into common problems with industrial thermal fluid heating and get takeaways you can put into action in your plant. Conrad E. Gamble, P.E., Therminol by Eastman. June 2015, page 28
Testing PG- and DPO-Based Heat Transfer Fluids
Testing evaluates and compares the performance of propylene glycol (PG) and 1,3 propanediol (PDO) when used as a heat transfer fluid. Lirys Crawford, DuPont Tate & Lyle Bio Products. June 2015, page 33
How to Start Up and Shut Down Heat Transfer Systems
Follow these guidelines to ensure a smooth startup and shutdown of your heat transfer system. Alison Davis and Jed Seybold, Radco Industries Inc. October 2015, page 36
Industrial Heating
5 Essential Rules for Effective Heat Transfer Design
Electric heaters can deliver heat just where you need it and, when teamed with proper thermocouple placement, keep your process in control and at a steady state. But, poor heating system design or sensor placement will result in less than ideal results, increased scrap and premature heater failures. Jeff Wheeler and Ken Sunden, Nexthermal. April 2015, page 20
Equipment Overview: Convection and Conduction Heaters
Whether you need hot air, water or other media to indirectly heat your process and product, or you need a contact heater to drive the temperature up just where you need it, convection and conduction heaters are the tools for the job. Find prospective suppliers using our Equipment Overview. May 2015, page 36
How to Achieve Longer Heater Life
Proper selection of the heating element for a given industrial application ensures longevity of the electric heater. Eric Zulkiewicz, Industrial Heater Corp. August 2015, page 25
Equipment Overview: Infrared Heaters
An apples-to-apples comparison of the capabilities of infrared heater manufacturers, our Equipment Overview will help you narrow the field of potential suppliers. Find gas-fired and electrically heated infrared emitters for any process need. September 2015, page 34
Follow the process of selecting the heating method for a process or product. Like many other products that must be process heated, an electric motor stator has areas of high mass and materials of construction that are sensitive to overheating. What is the best way to heat such a part without creating defects? Peter Caine, HeatTek Inc. October 2015, page 32
Using Electric Immersion Heaters in Process Heating
Many factors make electric immersion heaters a smart choice for modern process heating applications. Ilan Toledano, Wattco. October 2015, page 24
Industrial Heat Exchangers
Suitable for a range of applications, plate heat exchangers provide benefits such as energy savings and lower installation costs. Klas Abrahamsson, Alfa Laval. March 2015, page 15
The Use of Duplex Stainless Steel Tubing in Heat Exchanger Service
When selecting a tube material for a heat exchanger, many different options are available depending upon the application, design and operating conditions. Yong J. Kim, Webco Industries Inc. March 2015, page 32
Comparing TEMA Type BEM vs. BEU Heat Exchangers
Examining the pros and cons of each of these TEMA type heat exchangers can help you find the one that’s right for your process. Allan Fox, Perry Products. April 2015, page 28
Comparing Leak Detection Methods for Power Generation Condensers
Condensers are used in power plants to recycle exhaust steam for thermoelectric heating, but they also are relied on to maximize turbine efficiency by maintaining a proper vacuum. Effective leak detection is needed to ensure that vacuum leaks do not occur. Benjamin Fried, CTRL Systems Inc. August 2015, page 30
Preheating Outside Air with Steam Coils
Use these 10 design and installation tips to ensure long industrial steam coil life and performance. Jeremy Olberding and Dave Smith, Colmac Coil Manufacturing Inc. September 2015, page 18
Equipment Overview: Heat Exchangers
When selecting the type of heat exchanger to use, construction materials, heat transfer medium, flow arrangement and heat transfer method are all factors to consider. Our Equipment Overview on Heat Exchangers helps you find potential suppliers that can provide just what you need. October 2015, page 12
Advantages of Hairpin-Style Heat Exchangers
Hairpin heat exchangers are suited for applications that require high thermal performance and a compact footprint. November 2015, page 36
Industrial Ovens
Hybrid Drying Systems Provide Process Solutions
Complex processes require well-engineered systems to create the optimal scenario for the end user. Infrared and convection systems both have their strong points, and when combined, they create a winning arrangement. Justin Sierpinski, Casso-Solar Technologies LLC. January 2015, page 22
Advanced Thermal Process Controls Provide Benefits
Process controls that recognize and respond to part temperature rather than oven chamber temperature can improve overall product quality and reduce process time. Frank Geracie, Wisconsin Oven. February 2015, page 22
Whether you want a booster oven or a completely new thermal processing system, use Process Heating’s annual Equipment Overview on Ovens to find suppliers and save time specifying your oven. March 2015, page 20
Industrial Oven Buying Tips
Finding a qualified manufacturer relies on more than oven price. Selecting the vendor as carefully as you select your heating equipment will help ensure a system that will deliver for the long term. Byron Stokes, Hix Ovens. April 2015, page 28
Industrial Oxidizers and Pollution Control Equipment
Finding an Oxidizer for Your Process Plant
Selecting an oxidation system for a specific process stream requires an in-depth analysis of the operating parameters. February 2015, page 31
Selecting the Correct Combustion System for Your Thermal Oxidizer
At the heart of any oxidizer is the burner used to destroy harmful emissions such as hazardous air pollutants and volatile organic compounds. October 2015, page 16
Air Pollution Control Drives Hot Water Supply
A green initiative provides benefits for a Fortune 500 company. The aluminum can manufacturer captures waste heat and repurposes it to create hot water used elsewhere in the can-making process. October 2015, page 20
Industrial Process Heat Recovery
Condensing Heat Recovery for Industrial Process Applications
Capturing heat that would otherwise escape the process through the stack, waste heat recovery allows industrial thermal processing operations to recover and reuse process heating. February 2015, page 26
Understand the importance of using heat recovery in industry. April 2015, page 35
Industrial Process and Temperature Control
Best Practices in Control of Process Heating Operations
Considering the number of variables present, gaining precise control of a process heating application can be a difficult task. Effective communication is necessary to properly implement a system in which temperatures can be controlled and monitored accurately. January 2015, page 28
Equipment Overview: Temperature Controllers
You know you need to get control of your process. But, what kind of control does your process need? Process Heating helps you select an industrial temperature controller and equipment supplier. February 2015, page 40
How to Perform Temperature Profiling in Hazardous Environments
Instrumentation for temperature profiling in oil and gas, refining and petrochemical applications is available, but care must be taken during installation and use. March 2015, page 24
7 Ways to Create Accurate Oven Temperature Profiles
To troubleshoot an oven and fine-tune a heat-treatment process before problems occur, operators can establish an oven temperature profile, also known as a thermal profile. By collecting, viewing and analyzing this set of time-stamped temperature data, operators have the true picture of what is going on inside their process. March 2015, page 28
Integrating Multigenerational Automation Systems
Getting an automation system that includes multigenerational and multivendor components to work together can be a challenge. But, that approach may be the only option when there are not any practical alternatives, and end-users must be prepared to deal with the inherent challenges. May 2015, page 30
Monitoring Steam Traps with Wireless Instrumentation
Failed steam traps can cost a plant millions in repair costs and downtime. The two primary causes of steam-trap failure are dirt, which can plug the trap or cause it to leak, and pressure surges, which can damage internal components. Learn how to avoid these pitfalls. May 2015, page 22
Monitoring Cooling Towers Optimizes Safety and Reliability
Installing remote monitoring via a condition-monitoring system on a wireless network provides a cost-effective means of control. August 2015, page 15
Secure Remote Monitoring and Supervisory Control
Whether they call it cloud computing, Software as a Service (SaaS), Industry 4.0 or the Industrial Internet of Things (IIoT), most will agree that the biggest challenge right now is security. These new technologies bring new challenges, but there are solutions. August 2015, page 22
Maintaining the right temperature is crucial to proper curing in industrial coating applications. August 2015, page 28
4 Steps to Mitigate Sensor Failure Risks
Factors to consider when selecting an industrial temperature sensor include what can happen if the temperature sensor fails. Will your process go offline or produce thousands of dollars in scrap? September 2015, page 22
Auto vs. Manual Tuning for Temperature Loops
Autotuning PID capabilities in temperature controllers solve most problems if used properly, but they do not always work as desired. Sometimes, a good old-fashioned manual approach is the solution. November 2015, page 20
Near Infrared Spectroscopy Improves Plant Profitability
Automated process control technology helps optimize chemical plant operations. By providing precisely measured values over the entire production process, near infrared spectroscopy helps to bring plant capacity to full utilization, thereby minimizing waste and downtime. November 2015, page 28
Industrial Water Treatment
There are 10 primary forms of corrosion, but it is rare that a corroding structure or component will suffer from only one. Identifying corrosion and taking corrective actions reduce risks. June 2015, page 37
Filtration Cleans Up a Soap-Maker’s Process
A self-cleaning filtration system improves product quality and reduces downtime and labor. August 2015, page 34
Special Sections
Manufacturing Spotlight
Learn about the latest heat processing technology with this special section of products, tips and application ideas from industrial heating equipment manufacturers. January 2015, page 32
Case History Success Stories
Learn about heat processing technology with this special section of products, tips and application ideas from industrial heating equipment manufacturers. March 2015, page 42
