Boilers and heat exchangers are integral parts of many industrial plants. Often, when people think of protecting these components from corrosion, their minds fast-forward to corrosion issues that occur after the equipment is installed.

Like many of the process industries, thermal processing is a critical necessity to the oil-and-gas industry. Applications range from simple line heaters being fed from a single well to safety instrumented systems at a large-scale refinery. Regardless of the application, the thermal process is measured based on how safe, environmentally friendly and efficient it is.

As a design engineer responsible for developing and specifying boilers, dryers, furnaces, heaters, ovens and other industrial heating equipment, you face a daunting labyrinth of standards and industry regulations.

Many industries face periods of increased process steam requirements, commonly known as peak or seasonal demand. Whether it is processing the food we eat, the gasoline that fuels our vehicles or any other valued product, there likely will be occasions where demand exceeds steam production capability.

When a facility’s boiler is seemingly operating without issues, it is easy to put off cleaning for a few weeks, months or even years. But, what seems like a time-saving trick or a way to stretch a budget allocation can lead to inefficiency, safety concerns and a shorter equipment lifespan.

One of the most crucial aspects of the overall health of an industrial heater is its insulation resistance, which can be affected by many factors. Faulty elements, age, moisture ingress and long periods of downtime can all negatively impact the health of an industrial heater.

It is not uncommon to see well-used ovens and dryers — perhaps 40 or 50 years old, in some cases — in plants throughout the process industries.

Andreas Kratzer, Ph.D., was named president and CEO of Bühler Aeroglide, Cary, N.C. Kratzer previously served as managing director for the Bühler AG, Pasta and Noodles Business Unit in Uzwil, Switzerland. Bühler Aeroglide manufactures dryers, ovens, roasters, toasters and hot air expansion systems for the food, feed and industrial product markets.

Rockford Systems LLC expanded its industrial safety solution portfolio into the fuel and thermal safety fields by launching a Combustion Safety division. The newly formed division will provide turnkey solutions for organizations that use thermal processes in their operations. 

A flow meter calibrated for a “standard” natural gas mix may result in compromised flow measurement accuracy if the natural gas composition in the pipe does not match the mix the flow meter has been calibrated to measure. The challenges users face when the natural gas composition varies from place to place is the focus of a case study from Fox Thermal, Marina, Calif.

Albemarle Corp. ordered pyro-processing and comminution equipment for its lithium hydroxide processing plant at its Kemerton site near Bunbury in Australia. The construction of this greenfield project started in January 2019, and production is scheduled to commence in 2021.

Thermal Product Solutions shipped a Gruenberg explosion-resistant truck-in oven to a company in the defense security industry. The front-loaded unit utilizes horizontal airflow, which maximizes heating rates and temperature uniformity of the product load. It has a maximum temperature rating of 280°F (138°C).

More than 30 students from the Discovery ChalleNGe Academy toured Nationwide Boiler’s 26,000 ft² shop in Fremont, Calif., where employees demonstrated skills such as welding, pipe fitting, electrical work, fabrication and equipment assembling. The students also learned about other professional career opportunities including engineering, sales and marketing.

A custom part manufacturer took delivery of a custom curing cell that includes two dual-strand chain conveyor ovens and material handling equipment with chain-driven line rollers (CDLR) and pop-up transfers. Manufactured and supplied by Lewco Inc., a single lane oven with accumulation preheats the parts and keeps them warm until the operator is ready for the filling process. 

Tasi Group, a privately owned business focused on test, measurement, inspection and assembly equipment, acquired Onicon Measurement Solutions. Onicon specializes in the design and manufacture of flow meters and energy-measurement systems. The company's products can be used to measure steam, natural gas, airflow and liquid flows. 

A fully integrated, dual-zone temperature control heater/chiller combo package allows manufacturers to implement energy-efficient control systems that include variable-speed compressors and fan motors to control temperature in a range of production processes.

Five electrically heated, standard draw batch ovens will be used by East Carolina Metal Treating, Raleigh, N.C., for stress relieving. The ovens have a maximum operating temperature of 1250°F, says oven maker Wisconsin Oven. 

The air-cooled Ultima U 75-160 Series is capable of both air and water cooling. 

The walk-in oven has 4” thick insulated walls and an aluminized steel interior and exterior.  A four-port vacuum manifold, with pressure gauge and hand valve on each port, is included on the oven, as is a solenoid valve to bleed air into the manifold and a resin trap leading to the vacuum pump.

Unfired steam generators produce clean steam with steam or high temperature hot water as an energy source. The steam generators are suited for clean steam applications, humidification, sterilization, food processing and parts cleaning. 

Backflush seawater filters use a mix of materials to meet harsh environmental conditions. Plenty brand automated backflush seawater intake filters remove debris down to 570 microns nominally, including sand, shells and other particles, from the uplift pumps.

A high percentage of available chlorine in a heavy-duty, high sequestered formulation helps ensure maximum performance in breweries, milk plants and similar food, beverage and dairy plants.

Solid-state switches integrate monitoring features for quick failure detection besides the switching function. Timely failure detection eliminates the need for rework and prevents scrap, leading to better production throughput and better quality products.

Promag W is offered with welded flanges as well as with lap-joint flanges. The 0 DN inlet option allows for measurement performance of ±0.5 percent or better when the meter is installed immediately after an obstruction, says the manufacturer.

Interflon Paste HT1200 is formulated with soft, nontoxic ceramic materials for environmental and operator safety. The lubricant and assembly paste with MicPol is rated food safe (NSF H1, kosher, and halal) and withstands temperatures up to 2192°F (1200°C).

In food processing, dairy, beverage, chemical, petrochemical and pharmaceutical facilities, maintaining a clean environment is critical. High temperature washdown equipment is used to efficiently clean and sanitize equipment in place to keep production running on time.

R-Series V supports an operating temperature range of -40 to 185°F (-40 to 85°C). They are available in two types: rod style and profile style. 

Blue M industrial ovens have temperature ranges of 27°F (15°C) above ambient to 662°F (350°C). They are designed with semi-perforated walls that allow for tuning of the oven airflow to maximize heating rates and uniformity.

Designed to protect and warm the contents of containers in hazardous areas, ATEX-certified heaters for drums, IBC tanks and gas bottles can be safely used in hazardous areas.

Ceramic PTC circuit-protection thermistors combine a high voltage rating with low resistance. Series CL20 provides an alternative to fixed resistors and is optimized for inrush current limiting in heater applications, precharge circuits, degaussing circuits, and overcurrent protection.

The LX Gas/Low NOX Series is offered with boiler models ranging from 50 to 300 hp.  The industrial boilers use natural gas or propane and are available in a range of steam pressure options (300, 170 or 15 MAWP).