The handling of bulk solids has been tossed around for decades — literally. From fertilizer to food products, sugar to sludge pellets, and coffee to catalysts, the practice of heating, cooling or drying has been a part of virtually every industry built around free-flowing materials since the Industrial Revolution.
Developing or specifying standard design panels that can be optimized for specific applications allows oven and dryer OEMs to avoid having to develop custom combustion controls for each heat processing system.
When selecting a safety control system for a combustion application, it is essential to recognize that many trade-offs will need to be weighed before making a decision. In simple terms, the reliability will decrease when adding safety to any system.
What is the product that made you stop and ask, “Where have you been all my life?” For me, it’s a tight race between my smartphone and heated car seats. For many companies engaged in operations involving thermal processing, I suspect it will be the advent of cloud-based predictive maintenance and remote process management platforms.
Adding sensors and analytical capabilities can help plants get a handle on early fouling or loss of heat transfer in heat exchangers. Wireless sensors gather data that can be used to improve performance, cut costs and reduce energy consumption.
Aside from simple blending processes, most chemical processes involve a temperature change in one way or another. For example, products may need to be heated to facilitate a reaction, or cooled to control reaction rate. Many of these applications involve using a heat exchanger to add or remove heat from the process fluid.
Secondary and even tertiary energy-recovery systems for thermal oxidation systems help reduce energy costs. Securing a more cost-efficient operation is an ongoing objective; however, energy-recovery systems are not simply off-the-shelf, bolt-on packages with a plug-and-play manual.
Reheat furnaces are responsible for bringing cold metal to the correct temperature for hot-forming applications such as rolling, extruding or forging. To optimize quality and reduce wastage, the temperature needs to be consistent throughout the product, which requires accurate temperature monitoring.
If you are like many manufacturing engineers today, you may think the legacy controls on your air pollution control equipment are working well enough. But, is the production output as good as it could be if the reliability of your oxidizer or scrubber were increased?
The spectrum of applications found in the process industries means that burner designs must vary widely. Smaller burners are utilized in paint booths, ovens and furnaces while larger burners are specified for incinerators, thermal oil heaters and oxidizers.