October 2018 • Volume 25, Number 10

Improving the
Performance of
EXISTING
INDUSTRIAL
OVENS

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 OCTOBER 2018 Volume 25 • Number 10

27 About the Cover

The benefits of exploring the repair, rebuild
rebuil
or retrofit of an existing industrial oven
Features
October 2018
• Volume
25, Number 10

include reduced capital cost and a shorter

Improving the
schedule, notes Precision Quincy (www. Performance
of
14 Ovens pqovens.com) in an article beginning EXISTING
INDUSTRI
Improving the Performance of on page 14. Processors can save on OVENS AL
Existing Industrial Ovens
demolition, rigging and transportation,
Oven end-users often struggle with equipment that no longer meets
and the modified oven will offer
their current production or process needs. “Should we replace our
better performance and operating www.proc
Follow us
on:

ess-h eatin

existing equipment with a new oven, or repair, retrofit or rebuild

efficiency, says the South Beloit, Ill., oven g.com

the existing equipment?” is a familiar refrain. Case studies of real-life

manufacturer.
projects can help compare the alternatives — repair, retrofit or replace.

22 Combustible Dust Online Exclusives

Understanding Your Powder’s
On Demand Webinar
Self-Heating Hazards
Ensuring safety from fires and explosions in drying operations How to Select and Operate Fluid Heaters for Efficiency,
first requires the proper understanding of the thermal instability Quality and Safety
properties of the powder present in the plant. Four testing methods Explosions and fires in fuel-fired and electric fluid heaters due to
can effectively determine the powder’s thermal instability hazards and overheating or the release of flammable or combustible fluids from the
allow evaluation of the self-heating hazards. heater tubing can cause loss of life, property and production. In industrial
fluid heaters, such as those used to heat thermal fluids, where heated fluid
27 Dryers may flow under pressure, most causes of failures can be traced to human
Drying with IIoT and Cloud-Based error. • Register/login at bit.ly/PHfluidheaters
Data Management
No more is the industrial processing sector lagging behind the On Demand Webinar
consumer market in computing technology. Access to more and better Design, Operation and Troubleshooting Ovens and Furnaces
information about the drying process can improve your operations. This webinar covers three main aspects of ovens and furnaces: design,
Here are 10 ways the new frontier is changing the old models of dryer operation and — when trouble rears its head — troubleshooting. Major
operations as we know them. design elements include estimating the load, choice of burners, furnace
design, codes, combustion controls and, where required, air pollution
33 Heat Exchangers control. • Register/login at bit.ly/PHtroubleshootovens
Heat-Exchange Technologies for Effective
Food Pasteurization Always Online
Pasteurization is not the same as sterilization. Pasteurization methods ■ Archives ■ Energy Notes column ■ Digital Editions
such as high temperature, short time (HTST) and low temperature, long ■ Calendar of Events ■ Equipment Overviews ■ Buyers Guide
time (LTLT) have little or no impact on quality or taste, and they can ■ Drying Files columns ■ Heating Highlights ■ Archived Webinars
extend the shelf life of food products. ■ New Products ■ Industry News
Check out our redesigned site with more frequent updates and web exclusives!
36 Equipment Overview
Industrial Heat Exchangers Quick links point the way:
In print and online, use our Equipment Overview on Industrial Heat www.process-heating.com/connect
Exchangers to compare the products lines offered by industrial heat
exchanger manufacturers. Search by your process criteria to narrow the Go Mobile
field of potential suppliers. Use your smart phone to read Process Heating, wherever you are! Point
your phone or tablet’s camera at the image
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4 Commentary 45 Advertiser Index Heating instantly!
6 Inner Workings 45 Classified Directory Your mobile service provide may charge for
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42 Product Highlights 46 Contact Us

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 2018  3

Commentary
Mitigating Risks By
Understanding the Product
In my cub reporter days, I worked part-
time at a service station and auto parts
store. My job primarily consisted of accept-
ing payment from those purchasing gas and
selling the sundries one might pick up at
a neighborhood quick-stop shop. My area
occupied a small nook near the entrance,
while the rest of the building was given By Linda Becker
over to a complete automotive parts store
along with two repair bays where mechanics worked
during the day. The pay was great for a part-time job,
the job wasn’t taxing, and I met a lot of interesting
people. In all, it was ideal side-gig until the night it
burned to the ground.
As luck would have it, I was one of two who closed
up shop on the last night. A few hours later, a fam-
ily member of mine was driving by and noticed the
smoke and flames. The fire department was quickly
called, followed by a call to me. Strangely (or perhaps
not so strangely, in hindsight), the fire inspector
found all of these facts rather … convenient. Though
I hadn’t done anything wrong or out of the ordinary,
both my colleague and I faced some tough questions
about what had happened while we were closing shop.
We were both cleared when the cause was identified
as spontaneous combustion of some rags the mechan-
ics had left piled in a cardboard box.
Though decades have passed, I still remember my
surprise at the source. (This was before my Process
Heating days, and I didn’t understand yet how many
ways things can ignite if the three legs of the fire
triangle are satisfied.) I see echoes of that surprise
when I speak about the dangers of combustible dust.
Just as the mechanics grew lax with their oil- and
grease-filled rags, overlooking their hazard potential,
some of those in plants with chronic powder and dust
buildup throughout the plant may overlook the haz-
ards. Familiarity breeds complacency.
In his article, “Understanding Your Powder’s Self-
Heating Hazards,” Dr. Vahid Ebadat, the CEO of
Stonehouse Process Safety Inc., Princeton, N.J.,
focuses on methods to test dry bulk powders in your
facility to determine if, and at what quantity, the
material will self-heat, smolder and combust. As
Dr. Ebadat says, “Knowing your powder’s potential
4  OCTOBER 2018 Process Heating
Heat
Processing
Technologies
for these
9 Industries
for self-heating will allow you to specify
operating, storage, packaging and trans-
portation conditions that will reduce the Chemicals/
risk of self-heating.” The article describes Petrochemicals
four tests used to simulate the conditions
that the powder experiences during drying
and downstream processes to quantify the
powder’s potential for self-heating. Food Processing
Also in this issue, Steven Onsager and
John Hober of Precision Quincy, South Beloit, Ill.,
look at the reasons that ovens may require repair,
retrofits or even replacement. Industrial ovens are Finishing
incredibly long-lived process equipment — 20 and
30 years is common for process ovens, and even
50 years is not unheard of. At the same time, the
products for which the ovens are used for thermal
Plastics/Rubber
processing evolve with changes in customer demand,
manufacturing materials used, and markets served.
Though the oven’s most basic function — to ther-
mally process product — remains, such changes
may lead to a day when the processor realizes the Pharmaceuticals
oven is not meeting the company’s needs. In those
moments, a new system may be the best option, it
pays to weigh whether repairs or retrofits can rees-
Pulp/Paper/
tablish efficient processing.
Wood/Converting
In “Drying with IIoT and Cloud-Based Data
Management,” Paul McKeithan of Bühler Aeroglide,
Cary, N.C., explains how process automation and
controls allow you to monitor drying operations and Ethanol/
manage the process based on key performance indi- Biodiesel
cators. Smart sensors and integrated controls allow
drying product to precise moisture levels without
overdrying, helping processors to better control oper- Packaging/
ating costs. Printing
Finally, in “Heat-Exchange Technologies for Effec-
tive Food Pasteurization.” Matt Hale of Atlanta-based
HRS Heat Exchangers describes how pasteurization
technology may be able to help some food processors
Electronics
improve or upgrade current processing capabilities.
Visit www.process-heating.com
to read industry-focused content
Linda Becker, Associate Publisher and Editor, as well as thousands of articles
BeckerL@bnpmedia.com covering industrial heat
processing equipment.
Always There
When You Want It!
process-heating.com/digitaleditions
Digital Edition
Inner Workings
CSB Provides Update on
Deadly Fire at Pryor Trust Gas Well
The U.S. Chemical Safety Board (CSB)
released a factual update into its
ongoing investigation of the blowout
and fire at the Pryor Trust Gas Well on
January 22, 2018, in Pittsburg County,
Okla., that killed five workers. The CSB
determined the incident occurred
shortly after drilling crew members
removed the drill pipe from the well in
a process known as “tripping.”
The investigation has determined
the following timeline related to the
blowout and fire:
· January 21, 2018: Crew members
from the Patterson-UTI Drilling Co.
had been drilling a gas well for over
a week. Activities were being over-
seen by the operator of the well, Red
Mountain Operating (RMO).
· At 3:36 p.m., the Patterson crew
stopped drilling to remove the drill
pipe from the well and change the
drill bit.
· At 6:48 p.m., crew members began
the process of removing the drill pipe
from the well. The Patterson crew
pumped mud into the well during
the removal of the drill pipe with the
intent to keep the well full of mud.
That operation involved closing an
isolation valve to prevent mud from
flowing out of the well. By 10:30 p.m.,
the end of the drill pipe reached the
top of the curve in the well.
· January 22, 2018: At 12:35 a.m., the
crew pumped fluid — also referred
to as a “weighted pill” — above the
top of the curve to prevent gas influx
6  OCTOBER 2018 Process Heating
into the lateral portion of the well.
· At 1:12 a.m., the crew began remov-
ing the drill pipe from the vertical
section of the well. For this portion
of the operation, the Patterson
crew performed a “continuous fill”
tripping method. Mud was continu-
ously circulated in the wellbore us-
ing the trip tank pumps to keep the
well full by replacing the volume of
the drill pipe removed with drilling
mud. The isolation valve was open
for this operation.
· At the start of this procedure, the
drill pipe started pulling wet – mean-
ing the drill pipe being removed had
not drained and still contained mud.
The Patterson crew was aware that
the pipe was plugged. At this point,
the Patterson crew attempted to
pump a volume of mud also referred
as a “slug” into the drill pipe to push
the mud that remained in the drill
pipe out, but this was not successful
because the drill pipe was plugged.
Therefore, the drill pipe in the verti-
cal section was removed while it still
contained mud.
· By 6:10 a.m., the drill pipe and drill
bit were completely removed from
the well. At that time, the driller
closed the blind rams on the well’s
blowout preventer.
· At 7:57 a.m., the driller opened the
blowout preventer blind rams so
that a new piece of drilling equip-
ment called a bottom hole assembly
could be lowered into the well.
At 8:09 a.m., mud was pumped
through the bottom hole assembly
to test the new equipment.
· While the rig crew tested the bot-
tom hole assembly equipment, the
mud pits gained 107 barrels of mud.
Mud pit gains are an indication of a
possible gas influx in the well. Data
obtained by the CSB indicates that
conditions existed that could have
allowed a gas influx into the well-
bore during the tripping operation.
· At 8:35 a.m., with testing complete,
the bottom hole assembly was lifted
out of the wellbore. At 8:36 a.m., mud
blew upwards out of the well. The
mud and gas from the well subse-
quently ignited, causing a large fire.
In addition to the factual report, the
CSB released an animated timeline of
the events leading up to the incident.
Watlow Acquires
Semiconductor Equipment
Solutions Provider
St. Louis-based Watlow acquired
Yarbrough Solutions Worldwide, a
semiconductor equipment provider
that services semiconductor
fabrication companies globally by
developing, installing and servicing
solutions at its customers’ fabrication
plants. In performing these services,
the Austin, Texas-based company has
long utilized Watlow product offerings
such as electric heaters, temperature
sensors, temperature controllers and
power controllers.
“Adding Yarbrough’s know-how
and expertise to Watlow’s suite of
thermal system capabilities enhances
our ability to serve customers
through the entire semiconductor
fabrication process, from the tool
to the scrubber, to ensure thermal
optimization of the complete system,”
said Rob Gilmore, vice president
and general manager of Watlow’s
semiconductor business unit.

A key element of the acquisition
is a South Korean joint venture that
enhances Watlow’s presence in the
region. This joint venture between
Watlow and its partner, Global
Standard Technology Co. Ltd., will be
named Watlow Pacific Inc.
Electrically Heated Oven
Dries Small Parts
An electrically heated oven will be
used for drying small parts in a tray
at a manufacturing facility. The 250°F
(121°C) oven, designed and built by
Grieve, has 3 kW installed in Incoloy-
sheathed tubular heating elements. A
300-cfm, 0.33-hp recirculating blower
provides vertical airflow upward
through tray to the workload.
The oven holds one stainless
steel tray 6" wide by 18" long by 6"
deep with a perforated bottom. The
tray sets on a drip trap/air diffuser,
which is removable for cleaning.
Controls include a digital-indicating
temperature controller, manual-reset
excess-temperature controller with
separate contactors and a recirculating
blower airflow safety switch.
Motor Manufacturing Facility
Celebrates 120th Anniversary,
Opens Observatory
Opened in 1898, Siemens’ Norwood
Motor Manufacturing plant, just
outside of Cincinnati, is one of the
Inner Workings
company’s longest continuously frequencies from 10 to 300 Hz to
operating plants globally, says the address the increased use of variable-
company. To celebrate the milestone, frequency drives.
the facility recently opened a test Testing equipment includes two
observatory. The new equipment Sinamics Perfect Harmony GH180
extends Norwood’s testing range drives and two dynamometers.
from 10,000 to 20,000 hp at Generating power to test a 20,000-hp
Thermal Fluids that
go beyond precise
temperature control
Working closely with equipment manufacturers and our customers, we’ve
gained an intimate and unrivaled understanding of real-world concerns for
heat transfer fluids. Our full range of environmentally responsible thermal
fluids and unique and innovative system cleaners make Duratherm a single
source for all aspects of heat transfer fluid applications.
• Operating range -84ºC to 338ºC (-120ºF to 640ºF)
• Non-toxic/non-hazardous
• Complete engineering data
• OEM system design collaboration
• Online thermal fluid calculators
• 24/7 technical support
• Free fluid analysis
• Fast response to all inquires
1 800 446 4910
www.durathermfluids.com
© 2016 Duratherm.
www.process-heating.com OCTOBER 2018  7
Inner Workings

motor requires significant amounts of
electricity. By recycling power to the
grid, the equipment reduces power
loss by 90 percent. The test observatory
will allow customers to participate
by observing testing through bay
windows, direct cameras and mirroring
computers, which display real-time
critical data being gathered by sensors
attached to the motor.
The project, which began in 2016,
required excavating a 13’ deep hole,
driving 114 pilings for stability and
building a concrete vault to securely
support a fully loaded test stand. The
360-ton test stand rests on a self-
leveling air spring system designed to
support 500 tons when loaded with
motors and drives.
Enhancements to
Combustion Analyzer
Include Mobile App
An upgraded combustion and
emissions analyzer platform
includes sensor
protection, low-NOX
measurement, near-
field communications
(NFC) and the
ability to connect
to and control the
analyzer with a newly
released mobile app.
Bacharach’s PCA 400
is a hand-held unit
designed for on-demand or semi-
continuous sampling in light industrial
applications where compressors and
generators are present.
The complementary mobile app
allows users with mobile devices
to access additional capabilities,
including:
· Remote control to run or pause
combustion tests.
· Remote display of live values as
measured by the combustion ana-
lyzer on the mobile device.
· Save data function to create records
on the mobile device from combus-
tion tests.
· Ability to create PDF documents for
operational and regulatory compli-
ance reporting.
· GPS location data tagging for added
verification of equipment location.
· Data sharing to share reports di-
rectly from the mobile app by email
or to cloud storage services.
The analyzer is equipped with a
high speed pump and near real-time
display updates. The app is available
for iOS devices in the App Store and
for Android devices in the Google
Play store.
Inert Atmosphere
Ovens Cure Electronic
Components
A major U.S. manufacturer of
electronic components placed an
order worth more than $3 million with

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8  OCTOBER 2018 Process Heating

Despatch for inert atmosphere ovens.
The PND oven is currently used by
the manufacturer for critical thermal
processing needed to cure electronic
components.
Despatch’s PND oven is designed
to accommodate a range of processes
Heat Transfer
where an inert atmosphere is required
to prevent product oxidation. Typical
applications include curing, bonding
Fluids & Cleaners
and heat treating. The continuously
welded interior is suited for highly For Nearly Every Application:
corrosive conditions or where interior
cleanliness is critical. The unit also • High-Temperature • Water Removers
has adjustable recirculating air
louvers that allow fine-tuning to • Low-Temperature • Fire-Resistant
ensure uniform airflow and consistent
product heating even with varying • Ultra Low-Temp • Dual Use
load configurations. A heat exchanger
provides rapid cool-down. • High-Flash • Open Bath
• Food-Grade • All-In-One Fluid & Cleaner
Tissue Production Line
Destined for Argentina • High-Flash Food-Grade • Heavy Duty Cleaners
Valmet will supply an Advantage
DCT100HS tissue production line, • Low-Temp Food-Grade • Concentrate Cleaners
including an automation package,
to Papelera San Andrés de Giles in
Argentina. The line will help the
company meet the demand for tissue
products for the Argentinian market.
Startup is planned for the second half
of 2018.
The tissue machine, which has a
design speed of 6,561 ft/min (2,000
m/min), will add 35,000 tons of tissue
paper per year to Papelera San Andrés
de Giles' current production of facial,
toilet tissue and kitchen towels.
Valmet will deliver a tissue
production line with stock-preparation
systems and an Advantage DCT100HS
tissue machine. The automation
package includes Valmet DNA process
controls, tissue-line training simulator
and quality controls. Valmet also will
provide engineering, supervision,
training, startup and commissioning.

Roofing Manufacturer
Orders Conveyor Oven
An industrial roofing manufacturer
will use a large conveyor oven rated
for a maximum operating temperature REQUEST QUOTE 1-800-503-9533
of 350°F (177°C) to dry the water off

www.process-heating.com OCTOBER 2018  9


bad
corrosion?
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Proven protection for
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10  OCTOBER 2018 Process Heating
Inner Workings
a coated scrim at 200°F (93°C). The
finished product is used for various
roofing applications.
Designed and manufactured by
Lewco Inc., the oven has a single,
direct-fired, natural gas heater box
with a capacity of 400,000 BTU/hr.
It is equipped with two 8,000-cfm
circulation fans and a 1,000-cfm
exhaust fan. Variable-frequency drives
are included on both circulation
fans, allowing the user to adjust
the convection flow depending on
the product they are running. The
circulation fans and integral plenums
deliver uniform dual vertical airflow
throughout the workspace.
Controls include a Eurotherm
Nanodac temperature controller and
redundant high limit controller. A PLC
is interfaced with a remotely mounted
touchscreen HMI, allowing the user
to control all oven and conveyor
operations from one interface.
Systems Using
Urea-Based Selective
Catalytic Reduction
Tapped for Temporary-
Demand Applications
Selective catalytic reduction (SCR)
systems utilizing a 32.5 percent
liquid urea solution as the reagent
were used for a temporary rental
application for the first time, says
Nationwide Boiler Inc., Fremont, Calif.
Until the recent rental application,
anhydrous ammonia, a chemical
with stringent HAZMAT handling
requirements, has been the standard
reagent for rentals.
The rental project required two
trailer-mounted 99 million BTU/hr
saturated steam boilers. A second
project required six trailer-mounted
99 million BTU/hr superheated steam
boilers. A ground-mounted SCR
system utilizing urea as the reagent
was supplied for each boiler. In total,

Nationwide Boiler provided eight
urea-based SCR systems.
Nationwide Boiler Inc. has provided
systems utilizing a urea solution
(more commonly known as diesel
exhaust fluid, or DEF), for stationary
equipment for some time. The DEF
systems have been added to the fleet
of temporary process equipment
offered for lease by Nationwide.
Belt Conveyor Oven
Tempers Steel Parts
A tool and equipment manufacturer
will use an electrically heated
standard two-zone conveyor oven
to temper steel parts. The oven,
designed and built by Wisconsin Oven
Corp., East Troy, Wis., has the capability
to heat 1,800 lb of steel from 70 to
425°F (21 to 218°C) within one hour.
Guaranteed temperature uniformity
of ±10°F at 425°F was documented to
meet AMS 2750E, Class 2 furnaces and
Instrumentation Type C requirements.
The oven includes one profile opening
for each end, one access door in each
zone (two total), and a programmable
temperature controller with autotune
and overtemperature protection.
Online Tool Allows Users to
Configure, Purchase Heater
and Sensor Products
A new program, dubbed Select,
allows uses to identify, configure
and purchase some of Watlow’s
electric heater, temperature sensor,
temperature controller and power
controller products. Original
equipment manufacturers, authorized
Watlow distributors and end user
customers can all use the online tool.
From the online interfaces, users
Inner Workings
can choose a product, design it to fit heaters, Watconnect control panels,
their application, access drawings and mineral-insulated thermocouples,
technical content, and place an order. general application thermocouples,
Most products are shipped in five days RTD sensors, Fluent inline heaters,
or less, says Watlow. Products included F4T temperature controllers, D4T
via the Select program include Firerod dataloggers, EZ-Zone PM controllers,
cartridge heaters, screw plug heaters, EZ-Zone RM controllers and Din-a-
ANSI flange heaters, circulation Mite power controllers.
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
www.process-heating.com OCTOBER 2018  11
Calendar Events
October
4-5 — Powder Coating 101: Basic
Essentials Hands-On Workshop,
Atlanta. Produced by Powder
Coating Institute (PCI).
Call 859-525-9988 or visit
www.powdercoating.org.
14-17 — Pack Expo International,
Chicago. Produced by the
Association for Packaging and
Processing Technologies (PMMI).
Call 571-612-3200 or visit
www.packexpointernational.com.
14-17 — Healthcare Packaging
Expo, Chicago. Produced by the
Association for Packaging and
Processing Technologies (PMMI).
Call 571-612-3200 or visit
www.packexpo.com.
15-18 — Hydraulic Institute Fall
Conference, Hotel Bonaventure,
•
•
•
•
•
12  OCTOBER 2018 Process Heating
Montreal. Produced by HI. Call 973-
267-9700 or visit www.pumps.org.
21-24 — ASTM Committee C16 on
Thermal Insulation Fall Meeting,
Washington Hilton, Washington, D.C.
Call 610-832-9678 or visit
www.astm.org/committee/C16.htm
November
4-8 — International Water
Conference, Talking Stick Resort,
Scottsdale, Ariz.
Call 412-261-0710 or visit
www.eswp.com/water.
6-8 — Fabtech Manufacturing
Show, Atlanta. Produced by the
Society of Manufacturing Engineers.
Call 508-743-8544 or visit
www.fabtechexpo.com.
6-9 — Refrigerating Engineers
and Technicians Association
60
(RETA) Conference and Heavy
Equipment Show, Dallas Hyatt
Regency, Dallas.
Call 541-497-2955 or
visit www.reta.com or
www.reta-events.com.
December
4-6 — Power-Gen, Orange County
Convention Center, Orlando.
Call 918-831-9160 or visit
www.power-gen.com.
5-6 — Powder Coating 202:
Optimizing Your Powder
Coating Operation Workshop,
Atlanta. Produced by Powder
Coating Institute (PCI).
Call 859-525-9988 or visit
www.powdercoating.org.
2019 January
7-10 —Boiler Training Course
 Calendar Events

(Level 1), Garden City, Kansas. February April

Presented by Garden City Ammonia
Program (GCAP), Steam Boiler Div.
Call 620-271-0037 or visit
www.boilerlicense.com.
14-16 — AHR Expo, Georgia
World Congress Center, Atlanta.
Co-sponsored by by ASHRAE and
AHRI. Call 203-221-9232 or
visit www.ahrexpo.com.
21-24 — National Biodiesel
Conference and Expo, San Diego.
Presented by the National Biodiesel
Board. Call 573-635-3893 or visit
biodieselconference.org.
23-25 — Semicon Korea, COEX,
Seoul. Produced by Semiconductor
Equipment And Materials
International (SEMI).
Send an email to
semiconkorea@semi.org or
visit semiconkorea.org.
12-13 — Food Processing Expo,
Sacramento Convention Center,
Sacramento, Calif. Produced by
California League of Food Processors.
Call 800-258-6094 or visit
www.foodprocessingexpo.org.
March
26-28 — ProFood Tech Show,
McCormick Place, Chicago. Produced
by the Association for Packaging and
Processing Technologies (PMMI) and
International Dairy Foods Association
(IDFA). Call 571-612-3200 or visit
www.packexpo.com.
3-April 3 — ASTM Committee
C16 on Thermal Insulation
Spring Meeting, Sheraton Denver
Downtown, Denver.
Call 610-832-9678 or
visit www.astm.org.
9-11 — International Converting
Expo (ICE USA) 2019, Louisville, Ky.
Call 312-809-9260 or visit
www.ice-x-usa.com.
May
6-10 — General Meeting of the
National Board of Boiler and
Pressure Vessel Inspectors, Hilton
Caribe, San Juan, Puerto Rico.
Call 614-888-8320 or visit
www.nationalboard.org.
June
2-4 — Dairy, Deli, Bakery, Cheese,
Foodservice Products Seminar
& Expo, New Orleans. Hosted by
International Dairy Deli Bakery
Association and organized by Messe
Düsseldorf GmbH. Call 608-310-
5000 or visit www.iddba.org.

Design and Fabrication

of Heat Exchangers Markets
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since 1959 • Food • Nonwovens
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Working as
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20090 Segrate (Milan) Italy
info@deca.com - www.deca.com

www.process-heating.com OCTOBER 2018  13

 Ovens
Improving the
PERFORMANCE
OF EXISTING
INDUSTRIAL OVENS
Three case studies in repairing, rebuilding and retrofitting industrial ovens.
By Steven Onsager
and John Hober,
Precision Quincy
O
ven end-users often struggle
with equipment that no longer
meets their current produc-
tion or process needs. “Should
we replace our existing equipment with a
new oven or repair, retrofit or rebuild the
existing equipment?” is a familiar refrain.
The decision requires consideration of cost
and downtime implications, both of which
affect the capital expenditures budget and
bottom line. Case studies of real-life proj-
ects can help compare the alternatives —
repair, retrofit or replace.
14  OCTOBER 2018 Process Heating
There are many reasons why an oven
may suffer in performance when used for
industrial thermal processing. Sometimes,
the change in performance is gradual and
hardly noticed. Sometimes, the change is
rapid or catastrophic. Sometimes, the oven
just never really worked properly from the
start. The main reasons for poor oven per-
formance include:
• Physical damage.
• Old age or wear and tear.
• Relocation.
• Product changes.
• Process changes.
• Production rate changes.
• Never really worked from the start.
Catastrophic damage to an oven
means the equipment is no longer
usable. Examples of catastrophic
damage include fire and explosion.
A closer look at the reasons for poor
oven performance will help processors un-
derstand what to look for. Following that
review, this article will review three case
histories to demonstrate how other pro-
cessors updated poorly performing ovens
for renewed life.
Physical Damage
Physical damage to an oven can be consid-
ered catastrophic or non-catastrophic. Cat-
astrophic damage means the equipment is
no longer usable. With non-catastrophic
damage, you can limp along for weeks,
months or even years and still get by.
Examples of catastrophic damage in-
clude fire and explosion. When this type
of damage occurs, nearly everyone notices,
including employees, facility neighbors,
the local fire department, the insurance
company, OSHA, etc. Even if less severe,
the processor often cannot use the oven
until a full investigation is completed by
the authorities having jurisdiction. And,
most of the time, the equipment will have
to be repaired or rebuilt before it is re-
turned to service.
Non-catastrophic damage includes
abuse that does not put an oven out of
commission. Examples are damage during
loading or unloading, or a collision with
a forklift truck. Ovens typically are made
out of sheet metal. Inattentiveness during
loading can result in baskets crashing into
ductwork or parts jamming on a conveyor
belt. General inattentiveness around the
oven can lead to someone poking through
the oven wall with the tines of forklift. (For
a variety of reasons, this type of incident
seems only to happen on second or third
shift.) Depending on the extent of the
physical damage, fixing the oven would be
considered a repair or a rebuild.
Old Age/Wear and Tear
Everything has a life cycle. For an indus-
trial oven, the expected useful life is 20 to
30 years, assuming some minimal amount
of maintenance has been performed. It is
not surprising to hear, “Worked fine for
the last 35 years. I don’t know why we are
having problems now.”
Industrial ovens have limited moving
parts: fans, combustion blowers, conveyor
drives, conveyor belts, conveyor slide beds,
etc. That said, these parts wear out over
time and need to be replaced.
But, there are also longer-term issues
seen with older equipment. Metal fatigue
(caused by long-term vibration) and insu-
lation degradation can be seen at the end
of the life of an oven. If the top of an oven
side wall is significantly hotter to the touch
than the bottom, it is a good indication
that the insulation binders no longer func-
tion, and the insulation is settling.
Industrial ovens also are rebuilt to bring
them into compliance with current stan-
dards and safety codes. Existing equip-
ment is grandfathered in (exempt from
being required to meet new regulations)
— as long as it meets the safety standards
that were in force when the equipment was
built. Insurance companies, however, will
caution processors that even if old equip-
ment is grandfathered in as it relates to
compliance issues, manufacturing compa-
nies should maintain a uniform standard of
care among all of its industrial facilities. In
other words, if a processor repairs one oven
and it meets current standards and safety
codes, the processor should strongly con-
sider a program of repairing the ovens in its
other facilities to avoid liability issues. The
standard of care issue becomes more acute
when manufacturers’ have more than one
facility, where the actions of management
in one facility may be unknown by the
management team at the other facilities.
Work of this sort performed on an
old oven would be considered a repair
or rebuild.
Relocation
Industrial ovens are moved for many rea-
sons. Examples include optimizing a plant
layout, a building expansion, or adhering
to lean manufacturing principles or specif-
ic Kaizen events such as reducing work-in-
process inventory. Equipment relocation
often prompts an opportunity to give the
equipment a facelift and address the small
issues that have accumulated over time.
Depending on the length of the to-do list,
work done in association with relocation
would be considered a repair or a rebuild.
Product Changes
Products and product lines can evolve over
time. Expanded product offerings can be
larger than originally contemplated. When
the mass of the parts increases, those parts
may need to remain in the oven for a
longer period of time to achieve the same
process time. In order to maintain the
same product rate with larger parts, you
may need a longer, wider or higher oven.
It also is possible the oven may need larger
burners or additional fan capacity. This
type of modification would be considered
a retrofit.
Process Changes
Like products, the process may evolve and
change. These changes can be internally
www.process-heating.com OCTOBER 2018  15
 Ovens

or externally driven. Perhaps there is a

coating that performs better that needs
a longer cure cycle. Perhaps related pro-
cesses were always marginal, and now
rejects are manifesting themselves in the
oven. Perhaps the customer’s specifications
have been modified to require better tem-
perature uniformity or longer dwell times.
Maybe the time has come to incorporate
some factory automation, and batch pro-
cesses need to conveyorized or loading/
unloading needs to be automated. Perhaps
new statistical process controls are being
implemented, and you need to add data
acquisition. This type of upgrade would be
considered a retrofit.

Production Rate Changes

Production rates increase over time.
When customer demand goes up, man-
agement needs to increase throughput.
The high performance job shop provides powder coating and other services.

The initial inspection of the oven at the job shop coater revealed sagging ductwork and wall panels deteriorated beyond use.

16  OCTOBER 2018 Process Heating

 Ovens

When customer demand goes down,
management wants to improve the effi-
ciency of existing equipment by cutting
back on personnel or the number of
shifts. An analysis of cyclical and seasonal
demands may draw attention to the pro-
duction equipment.
The same is true when it comes time to
look at overall cost and productivity. The
competition can drive you to improve ef-
ficiency. Having to bid against other busi-
ness units within your organization when
it comes time to add or move product lines
also can drive efficiency improvements.
Increased production and throughput can
influence size, conveyor speeds, material
handling, etc. This type of upgrade would
be considered a retrofit.
Never Really Worked
from the Start
Industrial ovens are designed to be used
every day and should last for decades (with
preventive maintenance). Occasionally,
processors have equipment that has been
in place for years, but it is rarely or never
used. When asked about it, the reply is
too often: “That equipment never really
worked since day one.” These are usually
inherited problems. There are several pos-
sible reasons:
• Incorrectly specified.
• Lower expectations at time of purchase.
• Marginal acceptance.
•
•
Homemade equipment.
Used equipment that was cheap and
available.
Everything has a life cycle.
For an industrial oven,
the expected useful life is
20 to 30 years, assuming
maintenance is performed.
Case Study: Oven Rebuild
In this application, a high performance
coating job shop provided a range of
services such as PTFE, thermal spray
and powder coating. The oven, which
was originally purchased for a facility in
Michigan in 1989, was moved to Texas
around 2008. Once at the new plant, the
oven was modified by a local contractor
with changes to ductwork.
Approximately 10 years later, the fin-
ishing company wanted to move the oven
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again to a location two miles away. Prob-
lems were encountered when disman-
tling started.
The initial conditions observed included:
• Inside dimensions of 15 x 15 x 60’.
• Oven design temperature of 800°F
(427°C).
• 6” thick walls.
• Two burner zones at 2 million BTU/hr.
• Four recirculation fans, and each pro-
vided 25,000 cfm.
As noted, the supply duct had been
modified from the original. Both sides of
the ducts had slots, and the ductwork was
sagging and ready to fall down. In addi-
tion, the wall panels were deteriorated
beyond use, and the oven had cold spots
where the temperature dropped 150°F just
inside each door.
To meet the oven design specifications
needed at the new plant, the oven was
modified and upgraded. Oven modifica-
tions included:

With industrial ovens, as with many

things, you usually get what you pay for. If
someone in your organization was trying
to save money, do something on the cheap
or did not know what they were doing,
you may have to live with those decisions
for years. This oven issue is resolved by a
retrofit or a complete replacement.
The following case studies are three
recent real-world examples where a re-
pair, rebuild or retrofit saved significant
time or money on an oven project. Each
case resulted in a high performance in-
dustrial oven with years of additional
PROCESS-HEATING.COM/CONNECT
useful life.

www.process-heating.com OCTOBER 2018  17

 Ovens

The manufacturer of aerospace vehicles needed an oven large enough to hold fuselage or wing sections. The oven was used
for composite curing of vacuum-bagged sections and components.

18  OCTOBER 2018 Process Heating


TABLE 1. Coating Job Shop Oven Rebuild
New Oven Estimated Cost and Timing
Oven Demolition
Replacement Oven
New Oven Install
Total Replacement
Oven Demolition
New Oven Delivery
New Oven Install
Total Downtime
• Replacing all roof and wall panels.
• Providing new ductwork designed to the
manufacturer’s original configuration.
• Replacing one fan and two burners.
• Updating the control system to current
NFPA 86 requirements.
As a result of the rebuild, the oven now
provides temperature uniformity mea-
sured at ±10°F at 800°F (±5.6°C at 427°C)
throughout the oven.
Table 1 compares the cost of the oven
rebuild vs. the cost of a new oven. The re-
build saved $287,000 and eight weeks. The
processor did not have use of the oven for
five weeks because they elected to move
the salvageable parts and demolish the rest.
Case Study 2:
Rebuild and Retrofit
In this application, a manufacturer of
aerospace vehicles required a rebuild and
retrofit on a large oven capable of holding
fuselage or wing sections. Purchased used
in 2013, the oven was used for composite
curing of vacuum-bagged sections and
components. The required process time
varied based on part size, and the maxi-
mum temperature was 392°F (200°C).
The initial conditions observed included:
• Inside dimensions of 27 x 10 x 40’.
Rebuild Oven Cost and Timing
$18,000 Oven Relocation/Demo
$377,100 Materials
$109,300 Field Labor
$504,400 Total Rebuild
After Relocation Oven Relocation
20 weeks PO to Oven Retrofit
5 weeks
None Total Downtime
• 4” thick walls.
• Twelve indirect-fired burners at 400,000
BTU/hr.
• Five burner tubes were ruptured.
• Twelve recirculation fans, each provid-
ing 20,000 cfm.
• Six recirculation fans were spinning
backwards.
• Both sides of the supply duct had slots.
• A wide-open return was positioned over
exposed (and burned-out) burner tubes.
• Temperature uniformity was recorded
to be ±65°F (±36°C).
• Only the middle 15’ of the oven could be
used.
To meet the oven design specifications
needed for the composite curing opera-
tions, the oven was modified and upgrad-
ed. Oven modifications included:
• Replacing all 12 burner tubes.
• Upgrading each recirculation fan with
variable-frequency drives (VFDs).
• Control system improvements.
• Adding return ductwork with adjustable
louvers under the burner tubes.
As a result of the rebuild, the oven now
provides temperature uniformity measured
at ±3°F (±1.7°C) throughout the oven.
Table 2 compares the cost of the oven
www.process-heating.com OCTOBER 2018
Ovens
$21,100
$82,200
$113,900
$217,200
1 weeks
12 weeks
5 weeks
rebuild/retrofit vs. the cost of a new oven.
In summation, the rebuild/retrofit saved
$677,000 and 16 weeks, and the processor
continued to use the old oven for four ad-
ditional weeks.
Case Study 3: Retrofit
In this application, a manufacturer of
capacitor vertical transformers (CVT)
needed to retrofit an oven first built in
2008 to meet the design conditions of a
two-part heating process.
With CVTs, the capacitor stack works
as a voltage divider. Individual capacitors
are separated by dielectric spacers made
from plastic film and paper. Oil is added as
a thermal insulator. The two-part heating
process involved both moisture removal
(vacuum) and oil impregnation. The re-
quired process time was seven days with a
maximum temperature of 300°F (150°C).
The initial conditions observed included:
• Inside dimensions of 10 x 9 x 24’.
• Maximum design temperature of 265°F
(130°C).
• 2” thick walls and 4” thick roof.
• Recirculation fan capacity of 5,900 cfm.
• Heating capacity 90 kW.
• The supply duct had a single opening in
the ceiling.
• The return duct had two openings in the
 19
 Ovens

TABLE 2. Aerospace Manufacturer Oven Rebuild and Retrofit

New Oven Estimated Cost and Timing Rebuild/Retrofit Oven Cost and Timing
Oven Demolition $11,000 Oven Demolition Not Required

Replacement Oven $730,000 Materials $64,000

Oven Install $68,300 Field Labor $67,700

Total Replacement $809,000 Total Rebuild $131,700

Oven Demolition 2 weeks

New Oven Delivery 20 weeks PO to Oven Retrofit 8 weeks

New Oven Install 6 weeks

Total Downtime 8 weeks Total Downtime 4 weeks

TABLE 3. Transformer Manufacturer Oven Retrofit

New Oven Estimated Cost and Timing Retrofit Oven Cost and Timing
Oven Demolition $7,800 Oven Demolition Not Required

Replacement Oven $158,500 Materials $35,200

Oven Install $15,300 Field Labor $20,600

Total Replacement $181,600 Total Rebuild $55,800

Oven Demolition 1 week

New Oven Delivery 14 weeks PO to Oven Retrofit 6 weeks

New Oven Install 6 weeks

Total Downtime 7 weeks Total Downtime 2 weeks

lower rear of oven.
• The cooling fan had a capacity of 3,200
cfm, but the fan was disconnected.
• Temperature uniformity was reported to
be ±27°F (±15°C).
• Reject rate was reported at 58 percent.
The oven retrofit included the following
modifications:
• Added 2” thick wall panels.
• Nearly tripled recirculation fan capacity.
• Added a supply duct covering the entire
ceiling of the oven.
• Added return ductwork with adjustable
louvers under conveyors, front to back.
• Increased cooling fan to 8,000 cfm.
• Control changes, including one new
VFD.
Table 3 compares the cost of the oven
retrofit vs. the cost of a new oven. As a
result of the retrofit, the temperature uni-
formity is ±5°F (3°C). The reject rate was
reduced from 58 percent to 3 percent, and
the total cycle time was reduced from 7 to
3 days. In total, the retrofit saved $126,000
and 12 weeks. The transformer manufac-
turer continued to use the old oven for five

20  OCTOBER 2018 Process Heating

 Ovens

additional weeks. Pleased with the results,

the CVT manufacturer commissioned ret-
rofits on four more ovens.

In conclusion, the benefits of exploring

the repair, rebuild or retrofit of an existing
industrial oven include reduced capital cost
and a shorter schedule. Processors need to
pay for the parts that are replaced, and they
can save significant cost on demolition,
rigging and transportation. In addition,
the modified oven will offer better perfor-
mance and operating efficiency.

Steven Onsager is vice president of sales and

applications and John Hober is vice president
of technical services with Precision Quincy,
South Beloit, Ill., a manufacturer of industrial
ovens. For more information from Precision
With CVTs, the capacitor stack works as a voltage divider. Individual capacitors are
Quincy, call 302-408-0269 or visit
separated by dielectric spacers made from plastic film and paper. Oil is added as a
www.pqovens.com.
thermal insulator.

A retrofit for a manufacturer of CVTs allowed the company to reduce its reject rate from 58 percent to 3 percent.

www.process-heating.com OCTOBER 2018  21

 Combustible Dust

Understanding Your
POWDER’S
SELF-HEATING
HAZARDS
Ensuring safety from fires and explosions in drying operations first requires the
proper understanding of the thermal instability properties of the powder present
in the plant. Four testing methods can effectively determine the powder’s thermal
instability hazards and allow evaluation of the self-heating hazards.

By Vahid Ebadat, Ph.D., tion or exothermic oxidation) can result in heating include powder drying/heating
Stonehouse Process Safety Inc. smoldering, fire and production of hot or and their subsequent processing, handling,
incandescent particles that can travel along packaging, storage and transportation.

I
gnition sources for dust fires and ex-
plosions can take many forms. When
powders are heated, however, new
subtle sources of ignition hazards are
revealed: Those associated with the inher-
ent thermal instability properties of the
powder being heated or dried, and the na-
ture of the drying process.
Self-heating of powders due to exo-
thermic reaction (exothermic decomposi-
conveying equipment and act as an igni-
tion source to dust clouds in downstream
process equipment. Sometimes, exother-
mic decomposition causes rapid evolution
of large quantities of toxic or flammable
gases. Even if there is no smoldering or
fire, self-heating can at times compromise
product quality (charred particles).
Industrial operations that are prone to
fires and possibly explosions due to self-
Dry, bulk powder functions as a thermal
insulator, preventing cooling and promot-
ing the generation and buildup of heat en-
ergy from its core. At a temperature called
the onset temperature, an exothermic re-
action process (self-heating) starts some-
where within the powder accumulation.
This reaction can continue to grow even
if no more heat is applied to the powder
from the dryer.

22  OCTOBER 2018 Process Heating


Self-heating is a complicated phenom-
enon consisting of both an exothermic
chemical reaction and a heat-loss process.
Simply, when the rate of heat generation
exceeds the rate of heat loss, temperatures
can rise at an accelerating rate and can re-
sult in smoldering, fire and, sometimes, ex-
plosion. Many factors can affect the onset
temperature of self-heating, including:
• Powder composition.
• Presence of impurities.
• Geometry and size of the accumulated
powder.
• Air availability.
• Duration of the powder exposure to a
given temperature.
This article discusses some well-
established methods for evaluating the
thermal instability properties of powders,
taking into account the actual powder
conditions in dryers and downstream
equipment, with the objective of ensur-
ing the safety of operators, community
and business.
Evaluation of Self-Heating
Hazards of Powders
Ensuring safety from fires and explosions
in drying operations first requires the
proper understanding of the thermal insta-
bility properties of the powder, including
its potential for gas generation and dust-
cloud explosibility. In this article, I will
focus on the powder’s thermal instability
hazards and an evaluation of the self-heat-
ing hazards of powders[1]. Any discussion
of dust-cloud explosibility and vapor flam-
mability is beyond this article’s scope.
Powder self-heating hazards can occur
when the temperature of the powder in
bulk or layer is raised to a level at which
the heat-generation rate by the exother-
mic reaction exceeds the rate of heat lost
to the surroundings. Temperature increase
follows, which frequently results in smol-
dering and, eventually, fire. One of the
www.process-heating.com OCTOBER 2018
Combustible Dust
factors that can affect the onset tempera-
ture for self-heating is the geometry and
size of the accumulated powder. The on-
set temperature for self-heating of a pow-
der in bulk is expected to be lower than
the same quantity of powder spread into
a layer. This is simply because the surface
area per unit mass and, therefore, the rate
of heat loss per unit mass, will be lower for
bulked powder. Other variables such as air-
flow through the bulk powder or over the
powder surface also have influence on the
transition from smoldering to glowing and
flaming as well as the onset temperature
for self-heating.
For laboratory testing to provide useable
indication of the hazards, a representative
powder sample must be selected for testing.
Also, the tests must reasonably simulate
the conditions that the powder experiences
during drying and subsequent downstream
processes. Often, a number of different
tests may need to be considered to obtain
all the necessary data for proper evaluation
 23
 Combustible Dust
of the self-heating hazards during all pro-
cess stages. This is particularly important if
the initial screening test results suggest an
onset temperature for self-heating that is
close to the drying temperature.
The results of the tests that I will be dis-
cussing in this section provide useful data
to assess your powder’s potential for self-
heating. Knowing your powder’s potential
for self-heating will allow you to specify
operating, storage, packaging and trans-
portation conditions that will reduce the
risk of self-heating.
Isothermal Basket Test.[2,3] Measure-
ment of exothermic activity involves heat-
ing the sample under controlled conditions
to determine the point at which its tem-
perature starts to increase independently of
the external heat source.
Isothermal basket testing is performed
by heating the powder samples in cubi-
cal wire baskets of varying sizes (typically,
three sizes) to determine the minimum
temperature at which each sample size
self-heats. During each trial, a stainless-
steel mesh basket filled with the powder
sample is placed in an oven. The oven is
heated and maintained at a preselected
temperature until self-heating is detected,
or for a duration of 24 hours (or longer,
24  OCTOBER 2018 Process Heating
depending on the actual heating or storage
cycle under study), whichever occurs first.
The trials are repeated at various tempera-
tures and basket sizes until the sample’s
minimum-onset temperature for self-
heating is determined for each basket size.
A plot of the onset temperature for self-
heating as a function of basket dimensions
will allow for the extrapolation to either
the maximum safe material temperature
for a given-size container, or the maxi-
mum safe container size for a given mate-
rial temperature.
As you can appreciate, the isothermal
basket test produces fundamental informa-
tion with wide application. However, this
method is time consuming and, therefore,
can be relatively expensive. Although it has
some limitations, the bulk powder test may
offer a simpler option.
Bulk Powder Test.[4] The bulk powder
test is used to evaluate self-heating prop-
erties of bulk powder in quantities not
exceeding one ton. Examples of where it
might be used include powder accumula-
tions in bulk in some dryers, hoppers, silos
or packaging.
A glass cylinder with a height of ~3.15”
(80 mm) and diameter of ~1.97” (50 mm)
is used. The cylinder is closed at the base by
sintered glass and filled with the test pow-
der. Then, the cylinder is placed in an oven,
and the powder temperature is monitored.
Normally, a screening test is first per-
formed during which the oven temperature
is raised at a rate of 0.9°F/min (0.5°C/min)
for a 14-hour period. If the results of the
screening tests indicate a temperature dif-
ference higher than 90°F (50°C) between
the onset temperature for self-heating and
the intended drying temperature, hazard-
ous exothermic reaction is unlikely to occur.
However, additional testing will be required
if any of the following conditions exist:
1. The temperature difference between the
onset temperature for self-heating and
the dryer operating temperature is less
than 90°F.
2. The operating cycle is longer than
the test period above the process
temperature.
3. The onset temperature for self-heating
is less than 392°F (200°C).
If any one of the above conditions ex-
ists, then an isothermal bulk powder test is
conducted at 90°F above the intended dry-
ing temperature for a duration longer than
the maximum drying or heated storage
 Specifying Solenoid
Valves for Process
time. Alternatively, an isothermal basket test may be conducted.
Aerated Powder Test.[4] An aerated powder test simulates con- Heating Applications?
ditions during heating operations of powder in quantities not ex-
ceeding one ton. During the test, a hot airstream diffuses through
the powder — for example at the end of a fluid-bed drying cycle,
when the dryer fan is off but induced airflow is still present. Magnatrol high quality two-way Bronze
This test is identical to the bulk powder test except that in the and Stainless Steel valves are ideally
aerated powder test, an airstream at the same temperature as the suited for steam, boiler water feed, fuel oil,
oven temperature flows at a rate of 0.1585 gal/min (0.61 liter/min)
gas, heat transfer/exchange,
through the sample during the entire test cycle. The sample tem-
perature is measured at several locations in the cell to detect the
and many other process
onset temperature for any exothermic activity. heating requirements.
Normally, testing starts with a screening test. Additional iso-
thermal testing at 90°F above the intended drying temperature — Full Port Steam Valves
for a duration longer than the maximum drying or heated storage • 1/2ʺ – 3ʺ pipe sizes
time — will be required if any of the following conditions exist: • Pressure ratings to
180 PSIG
1. The temperature difference between the onset temperature for • Temps ranging to
self-heating and the dryer operating temperature is less than 400ºF
90°F. • Available Normally Open
2. The operating cycle is longer than the test period above the pro- or Normally Closed
cess temperature. • NPT threaded or
3. The onset temperature for self-heating is less than 392°F. flanged ends

Powder Layer Test.[4] Also called the air-over-layer test, the Full Port Liquid and
Gas Valves
powder layer test simulates the conditions in which hot air passes
• 1/2ʺ – 3ʺ pipe sizes Typical Type K or W
above a layer or deposit of powder in a dryer. Examples include
tray dryers and powder deposits on the internal surfaces of all dryer • Pressure ratings from
types. 0-500 PSIG
A metal tray with dimensions 3 by 1.6 by 0.6” (75 by 40 by • Temps ranging from
15 mm) is filled with the test powder. The tray and powder are -350° to 400ºF
heated by air passing at a velocity of 14 ft/min (4.3 m/min). The • Available Normally Open
temperature in the powder bed and around the outside of the tray or Normally Closed
is monitored. • NPT threaded or
Normally, a screening test is first performed. Additional isother- flanged ends
mal testing at 90°F above the intended drying temperature — for a Valves Feature...
duration longer than the maximum drying or heated storage time • Continuous duty coils
— will be required if any of the following conditions exist: for all AC/DC voltages
• Wide range of options
1. The temperature difference between the onset temperature for such as manual
self-heating and the dryer operating temperature is less than override, position
90°F. indication, NEMA 4X,
2. The operating cycle is longer than the test period above the explosion-proof
process temperature. …and more
3. The onset temperature for self-heating is less than 392°F. Typical Type L or S
Scan for more information,
Such tests can effectively determine the powder’s thermal insta- call 973-427-4341, E-mail:
bility hazards and allow evaluation of the self-heating hazards. info@magnatrol.com or visit
magnatrol.com.
Avoiding Self-Heating Hazards
Preventing self-heating hazards in drying operations requires
proper understanding of the thermal instability properties of the Magnatrol Valve Corporation
powder through laboratory tests. Such tests reasonably simulate the 67 Fifth Avenue • Hawthorne, NJ 07507
conditions experienced by the powder during the drying and subse-

www.process-heating.com OCTOBER 2018  25

 Combustible Dust

quent downstream storage, packaging and
transportation stages. The tests discussed
in this article form an important route to
achieving safe powder drying.
Precautions for avoiding smoldering,
fires and explosions caused by powder self-
heating include:
• Keeping the powder temperature at a
safe margin below the temperature for
the onset for self-heating, obtained by
appropriate test methods.
• Employing facility and equipment de-
signs to avoid ledges, corners, dead
zones, etc., where powder could inadver-
tently build up inside process equipment.
• Avoiding the accumulation of hazard-
ous levels of powder deposits on the in-
side surfaces of process equipment.
Additionally, each plant working with
bulk powders should:
• Identify and control other ignition sourc-
es that might be present during normal
and foreseeable abnormal conditions.
• Consider fire- and explosion-protection
measures when preventive measures alone
may not ensure acceptable level of safety.
In conclusion, self-heating occurs
when the powder temperature is raised to
a level at which the heat generated by an
exothermic reaction exceeds the heat lost
to surroundings, resulting in a thermal
runaway.
Preventing thermal runaway and sub-
sequent fires and explosions in drying
operations requires proper understanding
of the self-heating properties of the power
through specific and tailored laboratory
tests that reasonably simulate the condi-
tions experienced by the powder during
the drying and subsequent downstream
storage, packaging and transportation
stages.
Vahid Ebadat, Ph.D., is CEO of Stonehouse
Process Safety Inc., Princeton, N.J., a company
that provides expert consulting, laboratory
testing, training and incident investigation
in the specialist fields of dust and gas/
vapor explosions, thermal instability, static
electricity, process hazard analysis (PHA)
and process safety management (PSM). For
more information from Stonehouse Process
Safety Inc., call 609-455-0001 or visit
www.stonehousesafety.com.

References
1. John Abbott, Prevention of Fires and Explosions in Dryers, 2nd Edition, The Institution of Chemical Engineers, 1990.
2. P. C. Bowes, “Self-Heating: Evaluating and Controlling the Hazards,” Building Research Establishment, HMSO.
3. P. F. Beever and P. F. Thorne, “Isothermal Methods for Assessing Combustible Powders – Theoretical and Experimental Approach,” Symposium Series No. 68, Institution
of Chemical Engineers, 1981.

GROW
4. N. Gibson, D. J. Harper and R. L. Rogers, “Evaluation of the Fire and Explosion Risk in Drying Powders,” Plant/Operations Progress, Vol. 4, No. 3, July 1985, pp. 181-189.

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26  OCTOBER 2018 Process Heating

Drying with
IIOT AND
CLOUD-BASED
Data Management
Access to more and better information about the drying process can improve
your operations.
By Paul McKeithan,
Bühler Aeroglide
A
smarter world has emerged
around us. The Industrial
Internet of Things (IIoT)
revolution is changing the
way companies are doing business much
as the Internet of Things is changing ev-
eryday life. Crosscutting technology ad-
vancements such wide device availability,
coupled applications and increased op-
portunities for constant connections allow
processors to harness the power of digita-
lization to more safely and efficiently pro-
duce products, goods or services.
No more is the industrial processing sec-
tor lagging behind the consumer market in
computing technology. Here are 10 ways
the new frontier is changing the old mod-
els of dryer operations as we know them.
1. Maintain a Constant
Connection with Solution
Providers
A digital relationship adds value to a
single-point-in-time contact. When com-
panies work with vendors and machine
manufacturers, they do it in a linear way.
Yet, to get the most out of a drying
equipment purchase, manufacturers in the
process industries need access to drying
www.process-heating.com OCTOBER 2018
Dryers
process expertise. They can get this by
attending drying seminars, requesting site
visits and field engineering evaluations,
and simply by calling. These interactions
— based on single-point-in-time interac-
tions — flow in one direction, however.
This is the lone-business model, where the
processor requests support from the dryer
manufacturer “as needed.” The dryer man-
ufacturer does not have access to processor
data because it is generally stored in silos.
The new frontier is a model of collabo-
ration. A processor can be constantly con-
nected to a solution provider, with access to
enterprise expertise. Processors already have
the sensors in place, collecting data. Cloud-
 27
 Dryers
based management, or the digital relation-
ship, can enable a back-and-forth flow of
information analytics between the processor
and the equipment provider. Both can see a
dashboard that centralizes and synthesizes
data in real time for meaningful insights.
IIoT data management interconnects infor-
mation to help processors realize new busi-
ness models, optimize internal processes
and achieve cost savings. It allows compa-
nies to take advantage of the supplier’s pro-
cess knowledge, full time and sustainably.
28  OCTOBER 2018 Process Heating
2. Gain Access to Better
Customer Service
The digital intimacy of cloud-based man-
agement is designed for long-term opera-
tional success.
With information displayed on a web-
based dashboard, a user can pinpoint at-
risk parts and components before they fail.
Service records can be viewed on a time-
stamped basis, and reports generate data
that can show how much money was saved
or how much more could be with preven-
tive maintenance.
Yet, it is not just maintenance that can
improve; the thermal process can improve
as well. The processor and solution pro-
vider can work together to make sure the
processor is getting the most from the dry-
er. This works because the service model is
based on the facts. Unlike the single-point
model, the constant connection in the col-
laborative model can help drive a proces-
sor’s competitive strategy, its culture and
organizational design.
 Dryers

Being able to monitor critical

processing parameters in real time
means you will not have to wonder
if your process is producing a safe
product.

3. Achieve Sustainable
Processing Through
Connectivity
Like a Fitbit watch that never stops offer-
ing insights, IIoT enables an organic, con-
tinuous, real-time connection to optimize
processing. After all, it does not make
sense to monitor and collect dryer data —
energy usage, for instance — unless it can
be put to good use.
Two field evaluations can illustrate how
IIoT improves processing. In any thermal
process, when upstream operations change,
product entering the dryer can have a
higher moisture content. As a result, more
energy may be required to dry the entering
product to the process specifications.
Such was the case at one processor,
where product entering the dryer had
varying moisture content. The processor
reached out to the dryer manufacturer, and
drying engineers address the problem by
optimizing bed depth to ensure optimal
product retention. The changes saved the
processor 12 percent in energy costs.
They did not last, however. Five months
later, the company requested another evalu-
ation. When the field engineers returned,
they recommended the same changes. The
drying engineers explained to the processor
that the same adjustments had been made
during the previous evaluation. The proces-
sor’s varying infeed conditions were push-
ing the drying process out of specification.
This became a turning point for the pro-
cessor. The company realized the value of

www.process-heating.com OCTOBER 2018  29

 Dryers
being connected continuously to process-
ing expertise. By trusting the data, those
energy savings will not disappear again.
4. Use Existing Data to Drive
Business Decisions
From paper reports generated by chart
recorders to Excel spreadsheets from pro-
grammable logic controls (PLCs), pro-
cessors have long had access to critical
information. Often, however, it was buried
in volumes of emails, exchanged through
private discussions, hidden within spread-
sheets and housed on laptops. With IIoT
management, it is possible to pair one
chart with another, to analyze the data to
gain insights that were not possible before,
and to ask questions and find answers that
can affect management decisions, staff-
ing and operating conditions. Simply put,
IIoT makes data relevant.
Over time, changes in recipes and oper-
ating parameters — whether due to opera-
tor preferences, turnover or process con-
straints — can lead to significant losses in
energy efficiency. For instance, one proces-
sor added cloud-based data management
and discovered that nearly 20 percent of
the time a dryer was energized, it con-
tained no product. By tracking energy use
and the time during which the dryer was
energized, by day and by shift, manage-
ment was able to pinpoint inconsistencies
in the operations. A review of the entire
process allowed the processor to reduce en-
ergized time without affecting product and
prevented this waste of energy.
5. Manage the Human
Element More Effectively
When a dryer operator is asked to get as
close to the target moisture point as pos-
sible, there is a natural tendency to overdry.
Overdrying is a common practice, and
one processing deviation can dramatically
affect batch results and yield. When feed
is overdried, too much water is evaporated,
which has to be replaced with raw ingre-
dients. Access to continuous, real-time
monitoring with hardware, software and
ongoing process expertise, combined with
technical support, enables the operator to
consistently reach the desired moisture
target without overdrying.
30  OCTOBER 2018 Process Heating
An example can illustrate potential im-
provements. Suppose a dryer operator tra-
ditionally collects samples and measures
the moisture content level in a labora-
tory. Then, the operator returns to adjust
the dryer controls as needed. The process
is slow: dryer retention time can be 25 to
30 minutes, combined with time to ana-
lyze the product in the laboratory. All the
while, production time and product can be
wasted. Moreover, if testing suggests that
the product is too dry, the process must
be repeated. Without continuously auto-
mated data monitoring, the operator must
take measurements and make adjustments.
When the operator uses cloud-based
tools that reduce time-based moisture de-
viation, a reading can be captured every
second. As the inline moisture sensor takes
a reading, an algorithm written to control
the dryer can manage the temperature set-
ting to consistently achieve the desired
output. This digital relationship gives the
operator confidence that systems are cali-
brated and that processing is efficient.
6. Discover Hidden
Opportunities for
Improved Efficiency
IIoT enables processors to ask questions
they did not know needed to be asked.
With continuous online access to exper-
tise and data on the cloud, an expert can
view and interpret the dryer processing
data. Service records can be viewed and
data interpreted on a time-stamped basis.
This provides insights processors might
not otherwise have and allows them to
investigate anomalies (like why was the
dryer energized 30 percent on Wednesday
when it averages 8 percent on other days).
Time-stamped data allows the processor
to see the big picture and take action based
on history.
Here is another example. In the old
models of production, it was difficult to
manage from behind. Suppose the plant
manager sees the dryer was energized two
hours out of an eight-hour shift. He asks
what happened and suggests adjustments
to reduce that time. The next day, the data
shows the dryer was energized only one
hour. The plant manager can acknowl-
edge the energized reduction but also ask
 Specifying Solenoid
Valves for Process
what was done differently. With IIoT, the opportunity to con-
tinuously ask questions, based on data, keeps production striving Heating Applications?
toward efficiency.

7. Achieve Better Asset Utilization

Every piece of equipment on a plant floor contributes to the Magnatrol high quality two-way Bronze
effectiveness of the total plant production process. Each and every and Stainless Steel valves are ideally
moment the dryer is not working — planned or unplanned, for suited for steam, boiler water feed, fuel oil,
product changeover or maintenance — can negatively affect overall
gas, heat transfer/exchange,
effectiveness. Therefore, the fewer the stops, the better for overall
results. IIoT capacity metrics can demonstrate how much a dryer
and many other process
is down due to maintenance, and the insights can enable new busi- heating requirements.
ness decisions. For example, if a dryer is down 60 percent of time,
then there is 40 percent more capacity available for running more Full Port Steam Valves
product or selling more contracts. Such data could even justify • 1/2ʺ – 3ʺ pipe sizes
investment in a new production line. Data gained from IIoT can • Pressure ratings to
help the plant manager have a better view of the entire production 180 PSIG
for better asset utilization. • Temps ranging to
400ºF
8. Connect Data with People to Improve • Available Normally Open
Performance or Normally Closed
IIoT can drive competitive insights based on facts to better • NPT threaded or
integrate an organizational structure and its capabilities. Such flanged ends
insights create trusted, human-connected solutions that improve
businesses. For instance, if a conscientious dryer operator is mak- Full Port Liquid and
Gas Valves
ing good decisions for his shift, controlling moisture according
• 1/2ʺ – 3ʺ pipe sizes Typical Type K or W
to specifications and saving money, the plant manager will have
access to this information and be able to champion him. By inte- • Pressure ratings from
grating the human instinct to connect with people and expertise, 0-500 PSIG
IIoT can eliminate information silos, bring full employee engage- • Temps ranging from
ment into any business process and help solve problems quickly -350° to 400ºF
to improve performance. • Available Normally Open
or Normally Closed
9. Verify Processing Parameters • NPT threaded or
Validation ensures that pathogens such as Salmonella and Listeria flanged ends
are controlled when producing food for human consumption. In Valves Feature...
nut roasting, for instance, log reduction is based on defined pa- • Continuous duty coils
rameters such as retention time, product temperature, process air for all AC/DC voltages
temperature, air velocity, product moisture content and process air • Wide range of options
humidity, with sensors correlated to a known validation. Being able such as manual
to monitor critical processing parameters in real time means you override, position
will not have to wonder if your process is producing a safe product. indication, NEMA 4X,
IIoT enables processors to validate that a roaster is delivering the explosion-proof
desired kill step every time. …and more
If a process interruption occurs, an IIoT-connected tool in Typical Type L or S
cloud-based management services can warn the operator. This
Scan for more information,
might happen because of a change in temperature, moisture or call 973-427-4341, E-mail:
time retention. Or, perhaps a burner goes out. An alert gives the info@magnatrol.com or visit
operator an opportunity to do something about it, have the product magnatrol.com.
closely checked or keep it from being shipped. This ensures food
safety for the consumer as well as protecting the brand. It also can
save product that would potentially have to be discarded. Being Magnatrol Valve Corporation
able to reduce the amount of waste that a facility produces means 67 Fifth Avenue • Hawthorne, NJ 07507
there is more sellable product.

www.process-heating.com OCTOBER 2018  31

 Dryers
10. Recognize New Insights
to Ensure Continuous
Improvement
Being able to ask the hidden questions and
discover new efficiencies is part of the cul-
ture of IIoT. It can change behaviors that
people begin to see. An IIoT cloud-based
Conveyor Ovens that Offer
Premium Quality & Performance
• 3 year warranty on most models
• Heavy duty construction with
quality components
• Temperatures to 1400° F (760° C)
• High efficiency design that reduces
operating costs
• High volume airflow provides
excellent
uniformity and heating rates
• Unlimited custom configurations
• Available in all fuel types and
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• Fully adjusted and factory tested
PRIOR to shipment to reduce
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2675 Main Street • PO Box 873 • East Troy, WI 53120 USA
www.wisoven.com • sales@wisoven.com • 262-642-3938
Wisconsin Oven is a brand of
Thermal Product Solutions, LLC
32  OCTOBER 2018 Process Heating
service can nurture and develop the right
enabling patterns of behavior and cultural
attributes of excellence. The information
that has been buried in spreadsheets is
synthesized in meaningful ways that are
transparent, so that the human element
can become vested in the process, to con-
A Variety of Conveyor Designs
Available
• Mesh & Flat Wire Belts
• Overhead Trolley
• Powered Rollers
• Chain Conveyors
• Spindle (Chain on Edge),
Spiral, Indexing, Vertical,
Rotary and Others
tinuously aim for efficiency.
In conclusion, as the old models of
production change, there is an increas-
ing opportunity to harness the power of
digitalization to more safely and efficiently
produce products sustainably. By 2050, the
needs of approximately nine billion people
will require approximately three times our
current resources. At this time, challenges
will accelerate for the deficiencies of re-
sources and the enormous production of
current waste.
IIoT enables an organic,
continuous, real-time
connection to optimize
processing. After all, it
does not make sense to
monitor and collect dryer
data — energy usage, for
instance — unless it can
be put to good use.
Sustainable business models will help
processors get there, focused on safe and
efficient feed processing that saves en-
ergy, and with digitalization that provides
integrated operational connectivity. Sus-
tainable processing must meet present
needs without compromising future vi-
ability. It is not just a corporate respon-
sibility: Sustainability directly relates to
maximizing efficiency, minimizing waste,
finding cost savings and discovering in-
creased profitability.
Paul McKeithan is head of digital services at
Bühler Aeroglide, Cary, N.C., a manufacturer
of thermal processing technologies such as
dryers, roasters, toasters, ovens and coolers.
For more information from Bühler Aeroglide,
call 919-851-2000 or visit
www.buhlergroup.com/drying.
 Heat Exchangers
Some pasteurization systems allow
the heating-holding-cooling cycle to
be adjusted.

Heat-Exchange
Technologies for Effective
FOOD PASTEURIZATION
Pasteurization is not the same as sterilization. Pasteurization methods such as high
temperature, short time (HTST) and low temperature, long time (LTLT) have little or
no impact on quality or taste, and they can extend the shelf life of food products.

By Matt Hale, was used to keep wine fresh and drinkable. ers from using pasteurization technologies
HRS Heat Exchangers Since these early beginnings, both the sci- or getting the most out of them.
entific understanding and the technical Pasteurization is not the same as steril-

T
he development of pasteuri-
zation as a method to destroy
pathogenic bacteria in food
and drink and, therefore, aid in
food safety, dates back to the 19th century.
However, the origins of heating (rather
than cooking) food and drink for the pur-
poses of preservation go back to China
in the 12th century, where the technique
uses of pasteurization have improved as
longer and more complex food chains have
become the norm.
Developments in the equipment used
for the primary methods of pasteurization
mean that more products can be pasteur-
ized with little or no impact on quality or
taste. Yet, commonly held misconceptions
may play a part in preventing food produc-
ization. While this may seem obvious, the
differences between the two processes are
not always fully understood. It is, there-
fore, worthwhile to consider the differenc-
es at the outset to ensure you choose the
right process for your requirements. Two
common methods of food pasteurization
are high temperature, short time (HTST)
and low temperature, long time (LTLT).

www.process-heating.com OCTOBER 2018  33

 Heat Exchangers

as any process that eliminates, removes, Salmonella — resulted in the destruction of

Pasteurization can be used for
viscous fluids such as soup.
Unlike sterilization, pasteurization does
not completely eliminate micro-organisms
that may be present in the foodstuffs. Pas-
teurization reduces the microbial load by a
significant factor (for example, by 5-logs).
In other words, in normal circumstances,
pasteurization reduces contaminating
pathogens to a level at which they do not
pose a hazard.
In contrast, sterilization can be defined
kills or deactivates all forms of life or bio-
logical agent present in a material or on a
surface. There are, therefore, many ways to
sterilize, including the use of heat, chemi-
cals or radiation. As it relates to food and
drink products, sterilization aims to have a
much bigger effect on the microbial load of
the product. It also is more likely to have
unwanted effects on quality parameters
such as taste and texture.
The exact costs of pasteurization equip-
ment vary according to the requirements
of each installation. In all applications, as
with any other food processing activity,
there is an initial capital cost together with
ongoing costs associated with energy use,
service and maintenance.
Food products recalls in the United
States alone cost as much as $10 million
each year, and that cost does not include
the potential impact or damage to the
brand. In 2017, 24 different food recalls
— due to E. coli, Listeria monocytogenes and
some 700,000 pounds of products.
When these negatives are considered,
the capital costs of pasteurization systems
such as corrugated-tube heat exchanger
systems appreciate. Some heat exchangers
and pasteurization units are designed to
reduce fouling and maintenance require-
ments to minimize ongoing operating
costs. Furthermore, using systems that re-
cover heat means that the energy costs re-
quired for pasteurization heating are kept
to a minimum.
Pasteurization is a simple process: It re-
quires that a material be held for a certain
time at a certain temperature in order to
kill micro-organisms. Additional com-
plexity comes from the design factors ap-
plied to commercial pasteurization such as
maintaining product output and quality.
There is no doubt that pasteurization is
an additional step in the overall manufac-
turing process. If well designed, however,
it should not slow down throughput or

Design and Fabrication

of Heat Exchangers Markets
• Oil & Gas • Pharmaceutical
for Industrial Application • HVAC • Tobacco
since 1959 • Food • Nonwovens
• Energy • Paper
Working as
Air Heaters and Coolers
Steam Condensers
Fluid Coolers

Certifications
• ISO 9001:2015
• P.E.D. 2014/68/EU Module H
• ASME ‘U’ stamp

DECA Srl
20090 Segrate (Milan) Italy
info@deca.com - www.deca.com

34  OCTOBER 2018 Process Heating

 Heat Exchangers

place additional management burdens on

the plant. The use of continuous pasteuri-
zation systems means that the process is
simple, and the potential for product dam-
age or changes in quality is minimized.

Pasteurization Is Suitable for

a Range of Materials
One misconception is that pasteurization
only can be used with relatively simple
fluids such as milk or fruit juice. With
careful equipment selection, it can be used
successfully with many liquid and semi-
liquid materials.
Simple Newtonian fluids are the easi-
est to work with and often can be ef-
fectively pasteurized with a simple plate
heat exchanger. Solutions exist for almost
any material, however. Corrugated-tube
and scraped-surface heat exchangers can
deal with viscous fluids requiring gentle
handling or with low rates of heat trans-
fer. Such technologies also can be used
with complex mixtures such as curd
cheese, which could otherwise foul the
heat exchanger.
Many plant managers in the food indus-
try know that subjecting viscous or non-
Newtonian fluids such as cooking sauces to
shear stress during the manufacturing pro-
cess can damage the quality and texture.
This limitation prevents the use of certain
designs of heat exchangers. Using a system
such as a scraped-surface heat exchanger
prevents fouling while maintaining rela-
tively low pressure, so such unwanted ef-
fects can be overcome.
Energy and Maintenance
Requirements
The amount of energy required for effec-
tive food pasteurization will vary consider-
ably depending on:
• The type of pasteurization used (for ex-
ample, HTST or LTLT).
• The type of material being treated.
• The type and design of heat exchanger
used.
The bulk energy requirement is needed
to raise the temperature of the foodstuff.
Traditionally, many units have simply
dumped this heat once the product has
Pasteurization often is used with relatively simple fluids such as milk or fruit
juice, but it also appropriate for many other liquid and semi-liquid materials. This
pasteurization system is used in a tomato processing plant.
been pasteurized, resulting in a wasteful negative effect on line or plant through-
and inefficient process. put or efficiency. A well-designed sys-
The solution is to recapture the re- tem incorporating heat regeneration and
maining heat after pasteurization and use corrugated tubes should enhance the
it again to either to reduce the amount overall facility, helping to add flexibility
of initial heat required or to provide heat to your business.
Pasteurization is a simple process:
It requires that a material be held for a certain time
at a certain temperature in order to
kill micro-organisms.
elsewhere in the process such as heating Food processors should consider wheth-
cleaning water. This makes heat exchang- er adding pasteurization technology — to
ers up to 70 percent more efficient than existing equipment or when a new line is
some traditional designs. specified — can improve or upgrade cur-
The use of corrugated tubes, together rent processing capabilities. Bearing the
with integrated cleaning-in-process (CIP), above points in mind when talking to
minimizes the amount of fouling and, potential equipment suppliers can help
therefore, the amount of cleaning neces- ensure you achieve efficient, cost-effective
sary to maintain the efficiency of pasteuri- food preservation.
zation systems. The careful design of static
tubes also helps to keep down production Matt Hale is the international sales
(and purchase) costs. and marketing director with HRS Heat
In conclusion, carrying out pasteuri- Exchangers, Atlanta, a manufacturer of
zation need not be overly onerous or thermal processing technologies for the
detrimental to the quality of the product. food and beverage industries. For more
With the appropriate equipment choice, information from HRS, call 770-726-3540 or
pasteurization does not need to have a visit www.hrs-heatexchangers.com.

www.process-heating.com OCTOBER 2018  35

Equipment Overview Heat Exchangers

W hen selecting the type of heat exchanger to use, construction

materials, heat transfer medium, flow arrangement and heat
transfer method are all factors to consider, making the selection
process a difficult job. But, Process Heating has something to help
you out: Our Equipment Overview on Heat Exchangers will
allow you find a few potential suppliers that can provide just what
you need.
Our Equipment Overview on Heat Exchangers — in print and
online at www.process-heating.com/exchangers-chart — offers
a side-by-side comparison of industrial heat exchanger manufac-
turers to show you which companies manufacture the types you
want. Cross-check multiple headings by skimming down specific
columns to find those manufacturers that have experience with the
type of equipment you want. We’ve even identified those compa-

CONSTRUCTION
https://www.process-heating.com/exchangers-chart

Tubular, Shell-and-Tube, Plate Baffle

Tubular, Shell-and-Tube, Rod Baffle
Extended Surface, Plate-Fin
Extended Surface, Tube-Fin

Tubular, Double-Pipe

Tubular, Spiral Tube

Plate, Gasketed
Plate, Lamella

Plate, Welded
Plate, Brazed

Plate, Spiral
Companies

Other
Advanced Coil Technology LLC
507-451-0130, www.advancedcoiltechnology.com
••
DECA Srl
0039 022169581, www.deca.com
••
Heatec Inc.
423-821-5200, www.heatec.com
Heresite Protective Coatings LLC
920-684-6646, www.heresite.com
ProXES Inc., Terlet
847-247-0182, www.proxes-group.com
••• •
Aaron Equipment | 630-350-2200, www.aaronequipment.com • • • •
Advanced Heat Recovery, Div. Aqua Innovations Inc. | 410-421-9180, www.advancedheatrecovery.com • • • • • • • • • • •
Adwest Technologies Inc., CECO Environmental | 714-632-9801, www.adwestusa.com • •
AEC | 262-641-8600, www.aecinternet.com • •
Affiliated Steam Equipment Co. | 800-424-5392, www.affiliatedsteam.com • • • • • • • • •
AGC Heat Transfer Inc. | 703-257-1660, www.agcheattransfer.com •
Alfa Laval Inc. | 866-253-2528, www.alfalaval.us • • • • • •
Allegheny Bradford Corp. | 814-362-2590, www.alleghenybradford.com •
American Industrial Heat Transfer | 434-757-1800, www.aihti.com • •
Ametek Chemical Products | 570-645-6917, www.ametekfpp.com • •
Ametek Fluoropolymer Products | 570-645-6917, www.ametekfpp.com • • •
Anguil Environmental Systems Inc. | 414-365-6400, www.anguil.com •
API Heat Transfer | 716-684-6700, www.apiheattransfer.com • • • • • • •
APV, An SPX Brand | 262-728-1900, www.spx.com • • • • •
Baelz North America | 844-223-5962, www.baelzna.com • • • • • • • • •
Bell & Gossett | 847-966-3700, www.bellgossett.com • • • •
Cast Aluminum Solutions | 630-879-2696, www.castaluminumsolutions.com • • •
CCI Thermal Technologies Inc. | 780-466-3178, www.ccithermal.com •
Chemineer, a brand of NOV | 832-424-7300, www.nov.com •
Chester-Jensen | 610-876-6276, www.chester-jensen.com •
Chromalox | 800-443-2640, www.chromalox.com • • • • • • • •
Colmac Coil Mfg. Inc. | 509-684-2595, www.colmaccoil.com • •
DDI Heat Exchangers Inc. | 514-696-7961, www.ddi-heatexchangers.com • • • • • •
Delta Tee International | 817-466-9991, www.delta-tee.com • • • • •
Diversified Heat Transfer | 800-221-1522, www.dhtnet.com • • • • • • •
DME Co. | 248-398-6000, www.dme.net • • •
Doucette Industries Inc. | 800-445-7511, www.doucetteindustries.com • • •
DRS Marlo Coil, Leondardo DRS | 636-677-6600, www.marlocoil.com • • • • •
Enerquip LLC | 715-748-5888, www.enerquip.com • •
Epcon Industrial Systems LP | 936-273-3300, www.epconlp.com • •
ES Thermal Inc., Super-trol Div. | 440-323-4080, www.es-thermal.com •
Exergy LLC | 516-832-9300, www.exergyllc.com • •
Feldmeier Equipment Inc. | 315-454-8608, www.feldmeier.com •
Fin Tube Products Inc. | 330-334-3736, www.fintube.com •
Fluorotherm Polymers Inc. | 973-575-0760
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.
36  OCTOBER 2018 Process Heating
 nies that offer aftermarket parts for their equipment.
Visit www.process-heating.com/exchangers-chart and select
the Equipment Overview on Heat Exchangers to use our RFP
Builder and request information via a single form. On any page in
the Equipment Overview, click the plus sign next to those suppliers
you wish to add to your distribution list. Once you've selected the
companies you are interested, click on the Submit An Info Request
button to create a prepopulated form. Fill in your contact informa-
tion and send it. If you realize you want to add more companies,
just click on the Add Suppliers button in the contact form. All
responses from suppliers will be sent directly to you or the contacts
you designate.
If you need more information than what we have specified here
and on our website, www.process-heating.com/exchangers-chart.

MATERIALS OF CONSTRUCTION FLOW ARRANGEMENT MEDIUM PROCESSED METHOD OF HEAT MANUFACTURING PROCESS INDUSTRIES SERVED
TRANSFER

parts/supplies for our heat exchangers.

Multi-Pass, Parallel Plate Multi-Pass

Ethanol/Biodiesel Fuels/Oil & Gas

Multi-Pass, Parallel Counterflow
Multi-Pass, Cross Parallel Flow
Multi-Pass, Cross Counterflow

We manufacture aftermarket
Evaporation/Condensation

Chemicals/Petrochemicals
Single Pass, Parallel Flow
Single Pass, Counterflow
Multi-Pass, Divided Flow

Pulp/Paper/Converting
Single Pass, Crossflow

Plastics/Rubber/Vinyl
Multi-Pass, Split Flow

Packaging/Printing
Heat Transfer Fluid

Fibrous Effluent
Steam to Liquid

Pharmaceutical
Fluoropolymers

Liquid to Liquid

Vapor Recovery
Feed Preheater

Pasteurization
Stainless Steel

Heat Recovery

Reactor Slurry
Heat Transfer
Exotic Metals

Interchanger
Gas to Liquid
Carbon Steel

Steam to Air
Air to Liquid
Refrigerant

Distillation

Electronics
Aluminum

Gas to Air

Finishing
Titanium
Graphite

Air to Air

Reboiler
Ceramic

Cooling
Copper

Steam
Nickel

Water
Glycol
Other

Other

Other

Other
Brass

Glass

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

www.process-heating.com OCTOBER 2018  37

Equipment Overview Heat Exchangers
CONSTRUCTION
https://www.process-heating.com/exchangers-chart

Tubular, Shell-and-Tube, Plate Baffle

Tubular, Shell-and-Tube, Rod Baffle
Extended Surface, Plate-Fin
Extended Surface, Tube-Fin

Tubular, Double-Pipe

Tubular, Spiral Tube

Plate, Gasketed
Plate, Lamella

Plate, Welded
Plate, Brazed

Plate, Spiral
Companies

Other
Advanced Coil Technology LLC
507-451-0130, www.advancedcoiltechnology.com
••
DECA Srl
0039 022169581, www.deca.com
••
Heatec Inc.
423-821-5200, www.heatec.com
Heresite Protective Coatings LLC
920-684-6646, www.heresite.com
ProXES Inc., Terlet
847-247-0182, www.proxes-group.com
••• •
Gasmaster Industries | 604-523-0600, www.gasmaster.ca •
GF Piping Systems | 714-731-8800, www.gfpiping.com •
Gooch Thermal Systems Inc. | 908-236-9350, www.goochthermal.com • • •
Graham Corp. | 585-343-2216, www.graham-mfg.com • • •
Greenwood Engineering Inc. | 952-474-0415, www.greenwoodengineering.com • •
Harbridge Systems LLC | 262-966-2712, www.harbridge.com • • •
Heat and Control Inc. | 800-227-5980, www.heatandcontrol.com • • •
Heat Transfer Systems Inc. | 314-631-3311, www.heattransfersys.com • •
HomeWiz | 844-746-4949, www.yourhomewiz.com •
Honeywell Thermal Solutions (HTS) | 765-284-3304, www.thermalsolutions.honeywell.com • • •
Hydro-Thermal Corp. | 800-952-0121, www.hydro-thermal.com •
Industrial Heat Transfer | 608-452-3103, www.iht-inc.com • • •
Isotherm Inc. | 817-472-9922, www.iso-therm.com • • •
JLS International | 704-679-9575, www.jlsintl.com • • • • • •
Kelvion | 717-268-6200, www.kelvion.com • • •
Koch Heat Transfer Co. | 713-466-3535, www.kochheattransfer.com • • •
Komline-Sanderson | 908-234-1000, www.komline.com •
Lytron Inc. | 781-933-7300, www.lytron.com • • •
Madden Manufacturing | 800-369-6233, www.maddenmfg.com
Manning & Lewis Engineering Co. | 908-687-2400, www.manninglewis.com •
Metso Minerals Industries Inc., Pyro Processing Div. | 717-843-8671, www.metso.com •
Modine CIS | 800-225-4328, www.modine.com • •
Mokon | 716-876-9951, www.mokon.com • • • • •
Multitherm | 800-225-7440, www.multitherm.com •
Munters Corp. | 540-291-1111, www.munters.com • •
Parker Boiler Co. | 323-727-9800, www.parkerboiler.com • • •
Paul Mueller Co. | 800-683-5537, www.paulmueller.com • • •
Pick Heaters Inc. | 262-338-1191, www.pickheaters.com •
Plate Concepts Inc. | 908-236-9570, www.plateconcepts.com • • •
Polaris Heat Exchangers LLC | 732-544-8800, www.polarisphe.com • • •
Process Heating Co. | 206-682-3414, www.processheating.com •
Process Technology | 440-974-1300, www.processtechnology.com •
ProSonix Corp. | 800-849-1130, www.pro-sonix.com •
R.P. Adams, Subsidiary of Service Filtration Corp. | 716-877-2608 x302, www.rpadams.com • •
RAS Process Equipment | 609-371-1000, www.ras-inc.com •
Robson Industries Inc. | 610-692-9952, www.robsonind.com • •
Rubicon Industries | 718-434-4700, www.rubiconhx.com •
Sentry Equipment Corp. | 262-567-7256, www.sentry-equip.com • •
Smithco Engineering | 918-446-4406, www.smithco-eng.com •
Standard Exchange | 716-862-4061, www.ittstandard.com • • • • • •
Sterling Products Inc. | 262-641-8600, www.sterlco.com • •
Super Radiator Coils | 804-794-2887, www.superradiatorcoils.com • • • • •
Swep North America Inc. | 770-923-7444, www.swep.net •
Tek-Temp Instruments Inc. | 215-788-5528, www.tek-tempinstruments.com • • • • • • •
Thermal Transfer Systems Inc. | 972-242-9600, www.thermaltransfersystems.com/index.html • • • • • • • • • •
ThermTech Inc. | 800-752-6917, www.thermtech.net •
Tranter Inc. | 940-723-7125, www.tranter.com • • • •

38  OCTOBER 2018 Process Heating

 MATERIALS OF CONSTRUCTION FLOW ARRANGEMENT MEDIUM PROCESSED METHOD OF HEAT MANUFACTURING PROCESS INDUSTRIES SERVED
TRANSFER

parts/supplies for our heat exchangers.

Multi-Pass, Parallel Plate Multi-Pass

Ethanol/Biodiesel Fuels/Oil & Gas

Multi-Pass, Parallel Counterflow
Multi-Pass, Cross Parallel Flow
Multi-Pass, Cross Counterflow

We manufacture aftermarket
Evaporation/Condensation

Chemicals/Petrochemicals
Single Pass, Parallel Flow
Single Pass, Counterflow
Multi-Pass, Divided Flow

Pulp/Paper/Converting
Single Pass, Crossflow

Plastics/Rubber/Vinyl
Multi-Pass, Split Flow

Packaging/Printing
Heat Transfer Fluid

Fibrous Effluent
Steam to Liquid

Pharmaceutical
Fluoropolymers

Liquid to Liquid

Vapor Recovery
Feed Preheater

Pasteurization
Stainless Steel

Heat Recovery

Reactor Slurry
Heat Transfer
Exotic Metals

Interchanger
Gas to Liquid
Carbon Steel

Steam to Air
Air to Liquid
Refrigerant

Distillation

Electronics
Aluminum

Gas to Air

Finishing
Titanium
Graphite

Air to Air

Reboiler
Ceramic

Cooling
Copper

Steam
Nickel

Water
Glycol
Other

Other

Other

Other
Brass

Glass

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

www.process-heating.com OCTOBER 2018  39

Equipment Overview Heat Exchangers
CONSTRUCTION
https://www.process-heating.com/exchangers-chart

Tubular, Shell-and-Tube, Plate Baffle

Tubular, Shell-and-Tube, Rod Baffle
Extended Surface, Plate-Fin
Extended Surface, Tube-Fin

Tubular, Double-Pipe

Tubular, Spiral Tube

Plate, Gasketed
Plate, Lamella

Plate, Welded
Plate, Brazed

Plate, Spiral
Companies

Other
Advanced Coil Technology LLC
507-451-0130, www.advancedcoiltechnology.com
••
DECA Srl
0039 022169581, www.deca.com
••
Heatec Inc.
423-821-5200, www.heatec.com
Heresite Protective Coatings LLC
920-684-6646, www.heresite.com
ProXES Inc., Terlet
847-247-0182, www.proxes-group.com
••• •
Trent Inc. | 800-544-8736, www.trentheat.com • • •
Vilter Manufacturing LLC | 414-744-0111, www.vilter.com • •
Watlow | 800-928-5692, www.watlow.com •
Waukesha Cherry-Burrell, An SPX Brand | 262-728-1900, www.spx.com • • •
WCR Inc. | 937-223-0703, www.wcrhx.com • • •
Webco Industries Inc. | 918-245-2211
Wessels Co. | 317-888-9800, westank.com • • •
Xchanger Inc. | 952-933-2559, www.xchanger.com • • •

For over 60 years, we have provided Electrical Safety Equipment for

Industry. For complete info, contact us at email@protectioncontrolsinc.com.
Visit our website at www.protectioncontrolsinc.com.

40  OCTOBER 2018 Process Heating

 Aluminum
Brass

• • •
• •
• •
•
•
•
Carbon Steel

• • •
Ceramic

•
••• •
Copper

• •
• •
•
• • ••
Exotic Metals
Fluoropolymers
Glass
Graphite

•
•

•
•
Nickel

•
•

•
•
•
•
•
•
•
••
Stainless Steel

•
•
•
•
••
Titanium

•
Other

• • •
Multi-Pass, Cross Counterflow

• •
Multi-Pass, Cross Parallel Flow
Multi-Pass, Divided Flow

• • • • • •
• • •
Multi-Pass, Parallel Counterflow

• •
Multi-Pass, Parallel Plate Multi-Pass
Multi-Pass, Split Flow

•
•
Single Pass, Counterflow
Single Pass, Crossflow
MATERIALS OF CONSTRUCTION FLOW ARRANGEMENT

• •
Single Pass, Parallel Flow
Air
Gas

• •
• •
Glycol

• •
•
• • • • • •
Heat Transfer Fluid

•
Oil

• •
•
Refrigerant
Steam

•• •••
••••• ••
Water
MEDIUM PROCESSED

• • • • • • •
• • • • •
• • • • •
• • •
Other
Air to Air
Air to Liquid
• • • • •
Gas to Air

• • • • • • • • • • • • • • • • •
• • • •
Gas to Liquid

•
•
•
Liquid to Liquid
••••••••• •••• •
••••••••• ••••••••• • • •
TRANSFER

Steam to Air
•
• Steam to Liquid
METHOD OF HEAT

Other
•
•• • •

Cooling
•

• • • • Distillation
•

• • • • • • Evaporation/Condensation
• • • •
•

Feed Preheater
• •

Fibrous Effluent
•
•
•
•

Heat Recovery
•
•
•
••
••

Heat Transfer
• • •
• • •
•
• ••••••

Interchanger
•
• •

Pasteurization
Reactor Slurry
•

Reboiler
MANUFACTURING PROCESS

Vapor Recovery
• • • • • • •

Other
•

Chemicals/Petrochemicals
Electronics
• •

• •
• •
• •
• •

Ethanol/Biodiesel Fuels/Oil & Gas

• • • • •

Finishing
• • • •
•

•
•
•
•

Food
Packaging/Printing

www.process-heating.com OCTOBER 2018

• • • • • • • • •
• •
•
•
• •

Pulp/Paper/Converting
•

Pharmaceutical
INDUSTRIES SERVED

Plastics/Rubber/Vinyl

 41
We manufacture aftermarket
• *
• *
*
*
•• ••••••••• *
• ••••••• *
• • ••••••• *

• • Yes
• • Yes
• • Yes
• • Yes

parts/supplies for our heat exchangers.

• 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.

Cleaver-Brooks Grieve Corp.

Skid Solutions for Boilers Electrically Heated Oven
Line of preengineered, skid- Dries Parts on Trays
mounted boilers provide the A 250°F (121°C)
system as prepiped and electrically
ready for startup. heated oven,
The company No. 861 is used
offers boiler to dry small
skids for its parts in a tray
full line of at the user’s
hot water facility. A 300-
boilers. cfm, 0.33-hp
Every skid recirculating
system includes the boiler, system pumps, air separator blower provides
and expansion tank. Optional items include a chemical vertical airflow
pot feeder and glycol fill station. Preengineered skids are upward
available for gas-fired, condensing boiler systems ranging through tray to
in size from 500 to 12,000 MBH capacity. Up to six boilers the workload
can be combined in a skid, and additional boilers can be while 3 KW
added as a custom-engineered solution. are installed
800-250-5883 in Incoloy-
www.cleaverbrooks.com sheathed
tubular heating
Witte Co. elements. The
Vibrating Fluid Bed Dryers and Coolers oven holds one
Process heating equipment skids include standard unitary stainless steel tray 6 x 18 x 6" with a perforated bottom.
steel bases that allow cover-lift hoists, process The tray sits on drip trap/air diffuser, which is removable for
air ductwork, control panels, monitoring cleaning. Features include 2" insulated walls and Type 304,
instrumentation 2B finish stainless steel interior. Controls include a digital-
and other auxiliary indicating temperature controller, manual-reset excess-
equipment to temperature controller with separate contactors and an
be attached to airflow safety switch.
the system as 847-546-8225
a single unit. www.grievecorp.com
Providing a
dedicated, Honeywell Process Solutions
non-moving Managed Security Services Help Protect
foundation, the Against Industrial Cybersecurity Threats
bases ease process integration, CyberVantage Managed Security Services help users
add flexibility in installation and enhance industrial control system (ICS) capabilities and
ensure ancillary support systems may be increase protection against cybersecurity attacks. Industrial
installed on the same footprint, rather than set separately companies in particular require specialized capabilities
or left unspecified. The bases are designed for use with to secure sensitive environments such as live production
the company’s vibrating fluidized bed drying and cooling plants and utility networks. This becomes even more
systems, which are used to process foods, chemicals, important as industrial sites become more connected. The
pharmaceuticals, minerals, plastics and other products. The security service provides threat detection and vulnerability
support bases are weighted to minimize vibratory reaction identification; file transfer services; a managed security
forces and permit installation on mezzanines, light steel service center; expanded security device management; and
structures and on other above-grade locations. multi-vendor support.
908-689-6500 800-343-0228
www.witte.com www.honeywellprocess.com

42  OCTOBER 2018 Process Heating


Tempest Engineering
Chiller Equipment
Rejects Heat from
Industrial Processes
E3:ICE is custom engineered to meet
the functional and performance
demands of critical industrial
process applications in chemical,
pharmaceutical, food processing,
oil/gas, rubber and plastics.
The industrial chiller system is
designed to remove heat from an
industrial process efficiently via
optimal load management utilizing
proprietary controls. The system is
environmentally friendly, utilizing
natural refrigerants like ammonia to
achieve a zero global warming rating
and zero ozone depletion.
216-347-6806
www.tempest-eng.com
Advanced Thermal Solutions
(ATS) Inc.
Flat and Round Heat Pipes
Line of flat and round heat pipes
includes round heat pipes in lengths
Product Highlights
of ~2.76 to 23.6" (70 to 600 mm) and performance copper heat pipes have
diameters of ~0.15 to 0.4" (4 to 10 grooved or sintered, copper-powder
mm). Flat heat pipes are available in wick structures. They are suited for
lengths of ~2.76 to 19.7" (70 to 500 cooling applications in electronics
mm), widths of 0.19 to 0.45" (4.83 and HVAC, among others.
to 11.41 mm), and heights of ~0.08 781-769-2800
to 0.26" (2 to 6.5 mm). The high www.qats.com
Thermal Fluids that
go beyond precise
temperature control
Working closely with equipment manufacturers and our customers, we’ve
gained an intimate and unrivaled understanding of real-world concerns for
heat transfer fluids. Our full range of environmentally responsible thermal
fluids and unique and innovative system cleaners make Duratherm a single
source for all aspects of heat transfer fluid applications.
• Operating range -84ºC to 338ºC (-120ºF to 640ºF)
• Non-toxic/non-hazardous
• Complete engineering data
• OEM system design collaboration
• Online thermal fluid calculators
• 24/7 technical support
• Free fluid analysis
• Fast response to all inquires
1 800 446 4910
www.durathermfluids.com
© 2016 Duratherm.
www.process-heating.com OCTOBER 2018  43
 Product Highlights

Omega Engineering, Delta T Systems

part of Spectris plc High Capacity,

bad Polyimide Heater Kit

Polyimide heater kit
contains thin
Variable-Speed Industrial
Process Chiller
Designed to complement the
corrosion? and flexible
heaters with
company’s line of 1 to 30 ton chillers,
VS Series is supplied with four
adhesive variable-speed compressors that
backing to operate effectively between
conform to 10 percent and 100 percent of rated
most flat or capacity. Available as air- or water-
curved surfaces. cooled models, the variable-speed
With 15 different shapes, the kit can chiller utilizes compressor technology
suit almost any application. Heater from the HVAC industry to produce
configurations are outlined on a 1 x 1' energy savings over traditional hot
(0.3 x 0.3 m) sheet with line markings gas bypass regulation. Other features
to ease selection and cutout. When include the elimination of vintage
used in combination, the heaters can limit switches and capillary tubes
provide a number of resistances and to optimize reliability. Also, VFD
wattages. Leads can be soldered on or technology allows for soft starts and
connected with alligator clips. less compressor cycling, and adaptive
888-826-6342 controls help ensure that the chiller
www.omega.com system will continue to operate in the
event of a problem and will not shut
Riello UPS down completely.

GREAT Single Phase Uninterruptible

Power Supply for
800-733-4204
www.deltatsys.com

PROTECTION.
Proven protection for
heat exchangers and
systems against the
most extreme marine,
coastal and industrial
environments.
www.heresite.com
Critical Applications
The Sentinel
RT single-
phase UPS
line offers
true online,
double
conversion
technology
for maximum
power
protection
and a clean sine wave output. Rated
for 115/120/127 VAC, the 60 Hz models
have capacities of 1, 1.5, 2, 3, 6 and
10 KVA. The interruptible power
supply protects equipment against a
full range of disturbances, including
outages, sags, surges and noise.
It also improves energy efficiency
and minimizes power losses due to
the power factor equal to 1. Several
function modes like online, smart
active and standby off help ensure
energy efficiency and full protection.
513-282-3777
www.rielloupsamerica.com
Bacharach Inc.
Hand-Held Combustion
and Emissions Analyzer
PCA 400 provides on-demand
or semi-continuous sampling in
light industrial applications where
furnaces, boilers, compressors
and generators are present.
The hand-held combustion and
emissions analyzer includes
features such as sensor protection,
low NOX measurement, near-field
communications (NFC) and the ability
to connect/control the analyzer with
a mobile app. With the user-defined
sensor protection for CO, NO, NO2
and SO2 sensors, the analyzer will
automatically engage the dilution
pump for high concentration gas
samples to prolong sensor life.
Precalibrated sensors can be added or
replaced in the combustion analyzer
with a simple scanning process using
near-field communications.
800-736-4666
www.mybacharach.com

44  OCTOBER 2018 Process Heating

PH Classifieds Display Classified Rates:
1X $130 • 3X $125 • 6X $120 • 12X $110
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

SEE
For $30 Liquid Cooled

▼
we will
YOUR AD post & link
HERE 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
Page Company Phone Website

8 Advanced Coil Technology 507-451-0130 www.advancecoiltechnology.com

13 & 34 DECA SrI info@deca.com www.deca.com
7 & 43 Duratherm 800-446-4910 www.durathermfluids.com
2 FABTECH 888-394-4362 www.fabtechexpo.com
41 Fostoria 800-495-4525 www.fostoriaprocessequipment.com
48 Heatec 423-821-5200 www.heatec.com
10 & 44 Heresite Protective Coatings, LLC 920-684-6646 www.heresite.com
12 & 40 International Thermal Systems LLC 414-672-7700 www.internationalthermalsystems.com
9 Isel 800-503-9533 www.calderafluids.com
25 & 31 Magnatrol Valve Corporation 973-427-4341 www.magnatrol.com
15 & 30 ProXES Group 847-247-0182 www.proxes-group.com
12 & 40 Protection Controls 847-674-7676 www.protectioncontrolsinc.com
11 Thermal Product Solutions 570-538-7200 www.themalproductsolutions.com
32 Wisconsin Oven 262-642-3938 www.wisoven.com

www.process-heating.com OCTOBER 2018  45

Places Faces
Charles Sears, the
president of Dri-Air
Industries Inc.,
East Windsor, Conn.,
passed away on
August 5 after a recent
Sears
battle with cancer.
Sears founded Dri-Air Industries
in 1985 to provide drying systems for
the plastics industry. He was a noted
authority on the science of drying
technology and applications and held
several patents.
Jason Sears, who has been with
the company 27 years, is managing the
company operations.
Curran Group Inc., Crystal Lake, Ill.,
is celebrating its 100-year anniversary
in 2018. A family-owned, privately
held corporation, Curran owns Global
Finishing Solutions, Osseo, Wis.,
a manufacturer of paint booth and
finishing systems, among other
companies. Curran has a series of
events planned to mark the milestone
with its employees across North
America. In addition, the company
developed an anniversary video.
View it at www.currangroup.com.
St. Louis-based Watlow released
a new heater catalog, “Heating
Solutions: Thermal Systems for
Every Application,” in print and
online versions. The online version is
touchscreen-enabled for access via
tablets and smart phones. It contains
embedded videos for additional product
explanation. It can be downloaded from
www.watlow.com.
Seattle based Seeq Corp., a provider
of manufacturing and Industrial Internet
of Things (IIoT) analytics software,
secured $23 million in funding to
46  OCTOBER 2018 Process Heating
expand its development, sales and
marketing resources. The funding
was led by the Altira Group with
participation by Chevron Technology
Ventures, next47, the Siemens-
backed global venture firm, Second
Avenue Partners and other existing
investors.
Seeq’s software applications help
manufacturing organizations analyze,
predict, collaborate and distribute
insights to improve production
outcomes.
During the 2018 CCAI annual meet-
ing in Sarasota, Fla., the Chemical
Coaters Association International
recognized chapter users and suppli-
ers for contributions to the organiza-
tion. CCAI also installed its 2018-19
national board of directors and offi-
cers. It includes Bill Oney, Therma-
Tron-X Inc., president; Duane Fudge,
Chemetall, vice president; Tony
Sclafani, AR Iron LLC, treasurer; and
Ron Lum, Coral Chemical Co., recent
past president. The board also includes
Kevin Coursin, George Koch Sons
LLC; Shivie Dhillon, SunDial Powder
Coatings; Jim Gallagher, Harley-
Davidson Motor Co.; Loren Keene,
Pneu-Mech Systems Mfg. LLC;
Dan Labrecque, Tiger Drylac USA
Inc.; Jim Malloy, Kolene Corp.; Tim
Milner, J.I.T. Powder Coating Co.;
Mark Walsworth, Nordic Ware Inc.;
Bob Warren; Jeff Watson, Custom
Chemicals of Texas; and Sam
Woehler, George Koch Sons LLC.
Vermilion, Ohio-based
CSV Marketing Inc.,
a manufacturers’
representative agency
offering industrial
products, named
Oberholtzer
Beck Oberholtzer as
regional and marketing manager.
SUBSCRIPTIONS
For subscription information or service, please contact
Customer Service at:
Phone: 800-952-6643 or Fax: 847-763-9538
Email: processheating@omeda.com
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847-405-4044 • dalpozzod@bnpmedia.com
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262-564-0074 • BeckerL@bnpmedia.com
Technical Editor • REED MILLER
412-306-4360 • reed@process-heating.com
Associate Editor • BILL MAYER
412-306-4350 • bill@process-heating.com
Contributing Editor • JOY LEPREE ANDERSON
856-582-9554 • joylepree@gmail.com
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248-786-1700 • AzarS@bnpmedia.com
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412-306-4355 • McClellandB@bnpmedia.com
ADVERTISING SALES
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412-306-4352 • FAX 248-502-1046 • HeinauerS@bnpmedia.com
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 WEBINAR
How to Select and Operate Fluids Heaters
for Efficiency, Quality and Safety
September 27, 2018 2 PM ET or On Demand

Explosions and fires in fuel-fired and electric fluid heaters due to overheating or the release of flammable or
combustible fluids from the heater tubing can cause loss of life, property and production. In industrial fluid
heaters, where heated fluid may flow under pressure, most causes of failures can be traced to human error.

Updated for 2018, NFPA 87: Standard for Fluid Heaters defines the requirements for process fluid heaters to
minimize fire and explosion hazards. During this one-hour webinar, you will gain insights about key points of
NFPA 87 and notable revisions in the most recent edition.

You will also learn about:

• Types of process heating solutions and their applications

• Tips for selection and sizing fluid heaters and load-delivery heat exchangers

• Other standards and regulations such as OSHA PHA that affect owners and operators of fluid heaters

• Step-by-step on how to:

Commission and startup

Operate the heater and perform routine and preventative maintenance
Testing and troubleshooting
Emergency shutdown, fire and explosion protection
Interlocks and emergency procedures

• New content anticipated for NFPA 87 for 2021 edition

Speaker:
Rick Martin
President & Principal Engineer
Martin Thermal Engineering Inc.

CHEM
GROUP

Process-Heating.com/webinars
• Bath Heaters
• Glycol Heaters
• Electric Heaters
• Regen Gas Heaters
• Waste Heat Recovery
• Fuel Gas Conditioning
• Thermal Fluid Heaters

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
to meet your specifications. When you need a
process heating system for your plant, talk to a
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