September 2017 • Volume 24, Number 9

Identifying
and Preventing
DAMAGE TO
AIR HEATERS

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 SEPTEMBER 2017 Volume 24 • Number 9

16
Features
12 Heaters Online Exclusives
Identifying and Preventing Physical Damage to Heat Tracing Glossary of Terms
Tubular Air Heaters To help avoid miscommunications when talking with prospective heat trace
Tubular air heater damage and leakage can affect system partners, a glossary of commonly used industry terms may be helpful.
performance and increase costs. Learn how erosion, corrosion,
plugging and exceeding operational limits could be robbing
your plant of capacity. A Used Boiler Selection Guide
When considering a used boiler and used boiler supplier, evaluate factors
16 Boilers such as supplier recommendation, delivery lead time, warranty offered and
5 Questions to Ask Before Selecting a Used Boiler installation and setup support.
Purchasing a used industrial boiler may make sense for your
plant. Before you buy, ask these questions to help ensure you’re
buying a system that will operate effectively for your application. Powder Coating, Curing Seminar Includes Hands-On Lab
A day-and-a-half seminar in Atlanta offers classroom instruction detailing
20 Heat Tracing the basics of powder coating and curing processes as well as hands-on
10 Ways to Ensure a Winning Heat Trace demonstrations in a laboratory.
Partnership
Before teaming up with a heat tracing supplier, compare and
contrast the contenders to identify those with the experience Always Online
you need. ■ Archives ■ Energy Notes column ■ Digital Editions
23 Dryers ■ Calendar of Events ■ Equipment Overviews ■ Buyers Guide
5 Considerations When Recycling Air and Material ■ Drying Files columns ■ Heating Highlights ■ Archived Webinars
■ New Products ■ Industry News
in Fluid-Bed Drying
Although a fluid-bed dryer may be right for your product, it may Check out our redesigned site with more frequent updates and web exclusives!
not make sense to invest in heat recovery from your dryer. Does
recycling the exhaust air makes sense for your process? Quick links point the way:
26 Burners www.process-heating.com/connect
6 Benefits of Upgrading Your Process Heater
A burner-management system helps heater applications run Go Mobile
safely and efficiently. Use your smart phone to read Process Heating, wherever you are! Point
your phone or tablet’s camera at the image
30 Equipment Overview at right to scan the QR code with your mobile
Infrared Heaters phone or tablet. Your device will display the
Infrared heaters are used to transfer heat through a process mobile version of the current issue of Process
or to a product via radiation. Our Equipment Overview on Heating instantly!
Infrared Heaters provides an apples-to-apples comparison of Your mobile service provide may charge for
the capabilities of a range of radiant heater makers. data transmission usage. Contact your mobile
provider for details on your data plan and limits.
34 Water Treatment
Evaluating Alternative Cooling Tower Makeup
Water Options
One approach that facilities can adopt to reduce their draw
from fresh-water supplies — thus reducing stress on drinking
water reserves — is to use alternative makeup water sources. About the Cover
Learn how to evaluate the options for your plant objectively. Air heater tube erosion, corrosion and September
2017 • Volume
24, Number 9

plugging, and exceeding the operational

Columns & Departments limits of the heater, could be robbing your
plant of capacity. Such physical damage
4 Commentary 45 Advertiser Index mechanisms affect tubular air heater
Identi
and Prevenfying

6 45 DAMAG ting
Inner Workings Classified Directory performance, according to Corrosion AIR HEATEERTO
10 Calendar 46 Places & Faces Monitoring Services (www.cmsinc.us).
S
40 Product Highlights 46 Contact Us Learn more on page 12.
43
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www.process-heating.com SEPTEMBER 2017  3

Commentary
Lessons from the ’70s
As I prepared this column, the 40th anni-
versary of the death of Elvis Presley was
approaching. I’ve loved Elvis as long as I
can remember, and his RCA 2-LP album
from the early ’70s serves as the soundtrack
for my childhood. (You can take the girl
out of the Midwest, but you can’t take the
Midwest out of the girl.) By Linda Becker
So, it should come as no surprise that
“Elvis Presley’s Death — What Really Killed the
King?” from HuffPost grabbed my attention when
originally published in 2016, or that I’ve occasion-
ally returned to it. The author, Garry Rodgers, cites
a study by Dr. Forest Torrent that puts forth his case
for repeated traumatic brain injuries and a subsequent
autoimmune disorder as the causes of Elvis’ decline.
(You can read Dr. Torrent’s paper on www.practical-
painmanagement.com.) Certainly, no one can argue:
the change from the 33-year-old Elvis in his 1968
television special to his health and appearance at the
time of his death, at age 42, is striking.
In many ways, we cannot ever be sure that Dr.
Torrent’s diagnosis — that repeated traumatic brain
injuries (TBIs) and resulting autoimmune disease
contributed to Elvis’ death — is anything more than
a theory. At the same time, we do know, thanks to
research into the effects of TBIs on former National
Football League players, that such injuries have been
linked to cognitive disorders as well as radical changes
in behavior for those suspected or known to be afflict-
ed. While the research is continuing, already the NFL
has made changes intended to improve player safety
and protect them from unnecessary injury.
What lingers in my mind — for Elvis and the
former NFL players suspected of having chronic
traumatic encephalopathy (CTE) due to TBIs — is if
we had known then what we know now, could things
have been different? The research into the effects of
TBIs comes too late to help many football greats
and the King of Rock and Roll, but perhaps the next
generation will be safer.
The ’70s offers other lessons for today. One came
P.S.
In honor of the 40th anniversary, and in the spirit of our September issue, which
is our annual tips issue, I have compiled my list of the 10 most influential Elvis
songs. You can view it on our website at www.process-heating.com/Elvis40.
4  SEPTEMBER 2017 Process Heating
Heat
Processing
Technologies
for these
to the forefront in “5 Considerations When
Recycling Air and Material in Fluid-Bed
9 Industries
Drying,” an article by Larry Stoma of Witte
Co. Stoma notes that the energy crisis of
the 1970s taught some hard lessons to Chemicals/
manufacturers. Long used to abundant, low Petrochemicals
cost fuels, manufacturers gave little thought
to energy efficiency or heat recovery from
thermal processes. With the energy crisis,
quickly rising energy costs drove many products’ Food Processing
manufacturing costs to levels that reduced profit or, at
times, left no profit at all. Savvy process manufacturers
responded by looking for ways to capture and reuse
the thermal energy produced by the heat process- Finishing
ing equipment as much as possible. As Stoma notes,
“Energy efficiency, conservation, recycling and saving
on energy costs became the new normal.”
While the equipment and general methods used
Plastics/Rubber
for heat recovery — for instance, air preheating via
heat exchangers — remain the same, the drivers
for heat recovery and other process heating equip-
ment have changed. Influencing factors include the
desire of companies to be perceived as “green” in an Pharmaceuticals
energy-conscious era. Of course, federal, state and
local rules and regulations also dictate the changes
as well. Likewise, such rules and safety regula-
Pulp/Paper/
tions dictate other thermal processing improvements
Wood/Converting
such as burner-management systems. (For more on
burner-management systems, check out “6 Benefits
of Upgrading Your Process Heater” by Eve Hunter of
ProFire Inc. in this issue.) Ethanol/
As safety standards such as NFPA 87 and NFPA Biodiesel
87 evolve, they drive the development of safer thermal
processing equipment designs. Likely, there will come
a day when others will look back on 2017 and think, Packaging/
if only they had known what we know now. Printing
Electronics
Linda Becker, Associate Publisher and Editor,
BeckerL@bnpmedia.com
Visit www.process-heating.com
to read industry-focused content
as well as thousands of articles
covering industrial heat
processing equipment.
 Learn from two high-profile Keynotes and over
a dozen subject matter experts about industry

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Inner Workings
Service Tips for Hygienic Equipment
Servicing valves and pumps will help prevent problems such as dry running and failed seals.
Even though wear and tear is natural,
preventive maintenance can reduce
unplanned stops, increase equipment
lifetime and reduce workplace
accidents. In a tips bulletin, Alfa Laval,
a provider of engineering solutions
for heat transfer, separation and fluid
handling, offers advice on servicing
hygienic equipment.
• For valves, make regular service and
maintenance checks for them to be
able to perform optimally. Follow
a simple preventive maintenance
program to prolong their lifespan.
• For rotary lobe pumps, check the oil
level in the gearbox regularly and
refill when necessary.
• For centrifugal pumps, check to
make sure water has been connect-
ed so that the shaft seal does not
run dry. Dry running will damage
the shaft seal and could lead to a
damaged pump.
• Regularly maintain your tank equip-
ment following scheduled service
intervals. This will always keep your
tank equipment in good condition.
For more servicing advice from Alfa
Laval, visit www.alfalaval.com.
6  SEPTEMBER 2017 Process Heating
Industrial-Scale Boilers themselves (step-fired), maintaining
Improve Hospital’s Steam pressure as needed and rotating so
Output, Energy Efficiency that all boilers run about the same
Industrial-scale steam boilers will help number of hours.
one Wisconsin hospital reduce fuel
consumption, lower emissions and Foundry Using Batch Ovens
improve steam output. UnityPoint to Dry Sand Cores
Health-Meriter in Madison installed
five Miura EX-300 SGO gas/oil high
pressure boilers for its hot water,
sterilization, humidification, heat and
other facility needs.
“With Miura’s low water-content
design, they start up within a few
minutes and begin producing steam,”
says Ryan Unzicker, Meriter’s facilities
manager. “We have been able to
put at least 60 pounds of steam [per
square inch] in the entire hospital
system within about 15 minutes or so,
where it used to take the old boilers A company in the foundry industry
hours to recover.” will use two natural gas-fired walk-
The boilers also gave Meriter, in ovens to dry sand cores used in
which has been recognized three the casting process of a variety of
times as a “100 Top Hospitals,” the parts. The equipment, which was
capacity it needed while using less manufactured and shipped by
fuel and producing fewer emissions Wisconsin Oven, has a maximum
than the boilers they replaced. The temperature rating of 500°F (260°C).
steam boilers were engineered to fire Guaranteed temperature uniformity
automatically with Miura’s advanced of ±10°F at 500°F was documented
control system. The controls modulate with a nine-point temperature survey.

The oven bodies were constructed
with tongue-and-groove panel
assemblies using the company’s panel
seams, which reportedly provide
improved insulating efficiency.
The sand core dryers have the
capability to dry water and resin from
6,000 lb of sand cores and a 600 lb
steel load car from 70 to 450°F within
two hours.
Steam Boiler
Company Attains
Lowest Possible EMR
Nationwide Boiler Inc. achieved
the lowest possible Experience
Modification Rate (EMR) of 0.61. The
industry benchmark EMR is 1.0.
A company’s EMR is a numeric
representation of its safety record,
taking into account the number
of claims or injuries a company
has had in the past year and the
corresponding costs. A low EMR
indicates a company with a good
safety track record and high standards
in employee safety and training.
Nationwide Boilers’ low EMR
has been attained due to a
comprehensive safety and training
program led by Holly Lepo, the
company’s health, safety and
environmental manager. Lepo said,
“Nationwide Boiler has a well-rounded
health, safety and environmental
program that has been fine-tuned by
our membership in the ISNetworld
and Avetta contractor qualification
programs. We currently have over
60 individual safety modules, from
abrasive wheel grinding to workplace
violence. Employee education,
involvement and compliance are
the keys to having a successful
HS&E program.”
Furnace Brazing School
Scheduled for October
Brazing design and operation,
atmosphere and equipment, material
selection and applications, and
quality control are among the topics
of a three-day course. Wall Colmonoy
will host a fall session of its Modern
Inner Workings
managers and production managers.
Visit www.wallcolmonoy.com for more
information or to register.
Shell Chemical Site
On Track to be Largest
AO Producer
When construction of Shell Chemical
LP’s fourth linear alpha olefins (AO)
unit at its chemicals manufacturing
site in Geismar, La., is complete, the
resulting 425,000-metric-ton-per-year
Furnace Brazing School on October capacity increase will make the site
10-12 at the Aerobraze Brazing the largest AO producer in the world.
Engineering Center in Cincinnati. Shell started construction in
In addition to classroom training, January 2016 and has safely placed
attendees will tour the facility and large process equipment like
see the actual brazing application on reactors, columns and vessels. It
the shop floor. They also will have the has preassembled modules that will
opportunity to apply different forms form the core of the new AO unit
of filler metal to supplied samples, at Geismar. Shell has also finished
have them vacuum brazed and building a cooling tower for the new
discuss the outcomes. AO unit and two new storage areas
The course is intended for (one for rail and one for the AO unit’s
engineers, technicians, quality high-purity butane).
CATALYTIC INFRARED CURING
See the newest, best cure technology
At CIS, FABTECH #A5918
Catalytic infrared delivers perfect, uniform cure for paint or powder.
CIS, world leader in catalytic infrared, can show how retrofitting your sysytem will
save you dollars, re-work and cycle time, from the first day.
• Catalytic infrared cure ovens
• Booster (“gel”) ovens for powder coating
• Combination infrared/convection systems
• Convection retrofits
• Batch Ovens
• Expansions to boost output, or accommodate new product
Visit Booth A5918 at Fabtech, or, for immediate information,
contact Don Smith at (800) 835-0557
Catalytic Industrial Systems
713 N. 20th Street sales@catalyticirovens.com
PO Box 827 (800) 835-0557
Independence, KS 67301 MADETHEIN 2USA
www.process-heating.com SEPTEMBER 2017  7
Inner Workings
The new capacity brings the total
AO production at Shell’s Geismar site
to more than 1.3 million metric tons
per year.
Ammo Manufacturer Adds
Annealing Conveyor Oven
A conveyor oven will be used to
anneal and stress relieve brass
castings by an ammunition
manufacturer. Thermal Product
Solutions, White Deer, Pa., shipped
the Gruenberg conveyor oven, which
has a maximum temperature rating of
850°F (455°C).
A variable-speed conveyor
system provides the operator with
precise process control. The single
oven module is constructed from a
structural steel frame that supports
the chamber liner and the exterior
sheet metal. All interconnecting
struts are non-continuous to keep the
exterior cool.
The oven includes plug-style
circulation and heating equipment.
Three identical plugs on the unit allow
the replacement of heaters away from
the unit by removal of the plug as well
8  SEPTEMBER 2017 Process Heating
as quick interchange if an extra plug
is available.
Technology Could
Transform Microalgae to
Bio-Based Chemicals
A process that could extract the
different chemical components from
microalgae in order to convert them
into bio-based chemicals, biofuels
and bioplastics is under development.
When brought to market, the
technology could provide the means
for waste processors to reap greater
profits from spent algae.
West LaFayette, Ind.-based Gen3Bio
Inc., a Purdue Foundry-affiliated
company, is seeking funding to
further develop the technology.
“Companies use algae for things
such as wastewater treatment or
flue-gas remediation. Additionally,
there are algae producers and
harvesters who clean up fish farms or
natural waters,” said Kelvin Okamoto,
founder of Gen3Bio. “Usually after
the algae has been used for its
initial purpose, it’s disposed of in
landfills or converted into animal
feed supplements or field nutrition
supplements. While the last two are
great uses, companies do not receive
much money from these options.
It’s more profitable to convert the
byproduct algae to high value bio-
based chemicals.”
“There’s been a huge movement
toward greener, renewable products
for the sake of the environment,
and that includes biofuels and
biochemicals,” Okamoto added.
“Conventional biofuels are derived
from sugars of crops, which can take
a considerable amount of land and
water to produce. Algae has a low
carbon footprint, is renewable and
can be accessed in large quantities,
so overall it is very environmentally
friendly. It’s a great alternative to meet
the expected demand for bio-based
products in the future.”
Industrial Automation
Guide Offers Advice
on Calibration, Data
Verification
A new book seeks to help operators
involved in verifying and calibrating
measuring instruments. Published
by ISA, the guide addresses
verification and calibration of
measuring instruments used in
industrial automation and processes
to meet standards such as ISO 9001
quality management systems, ISO
14001 environmental management
systems, ISO 16949 automotive
quality management systems, and
AS/EN 9100 aviation series quality
management systems.
The Calibration Handbook of
Measuring Instruments by Alessandro
Brunelli helps manage industrial
process measurement, specifically
addressing:
• The general concepts for managing
measurement equipment according
to the ISO 10012 management
system of instruments and
measurements.
• An instrument’s suitability to per-
form accurate measurements and
 Inner Workings

control the drift to maintain the

quality of the measurement process.
• The criteria and procedures for
accepting, managing and verifying
the calibration of the main industrial
measuring instruments.
• The provisions of law and regulations
for production and European mark-
ing CE of metrological instruments
used in commercial transactions and
for their periodic verification.

Report templates useful for

recording both instrument data
and experimental calibration data
and for evaluating the conformity
of instruments are included on an
attached CD. The CD also contains
various spreadsheets — in Excel
and calibration reports — that
automatically calculate errors and the
relative measurement uncertainty for
determining a calibrated instrument’s
compliance. To purchase a copy, visit
www.isa.org.
Spanish Paper
Manufacturer Orders
Tissue Production Line
Valmet will supply a complete tissue
production line to Sofidel's Ibertissue
mill in Spain.
The delivery includes an Advantage
NTT 200 tissue production line, stock
preparation equipment and the
automation system. Startup of the
new line is scheduled for the third
quarter of 2018. The tissue machine
will have a design speed of 1,800 m/
min in textured mode and 2,000 m/
min in plain mode. It is designed to
save energy and fiber as well as add
possibilities for product differentiation
and increased capacity.
Sofidel previously purchased an
NTT machine for its Delitissue mill in
Poland and two NTT machines for its
site in Circleville, Ohio.

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Available in stainless steel. www.MultiThermCoils.com
Heat Transfer Fluids • Industrial Coils • HVAC Equipment
www.process-heating.com SEPTEMBER 2017  9
Calendar Events
September
18-19 — Process Burners
Fundamentals Course, Tulsa, Okla.
Presented by John Zink Institute.
Call 918-234-5710 or visit
www.johnzinkinstitute.edu.
18-20 — Process Burner Operator
Training Course, Tulsa, Okla.
Presented by John Zink Institute.
Call 918-234-5710 or visit
www.johnzinkinstitute.edu.
19 — Induction Heating Seminar,
Greenville, S.C. Presented by
Industrial Heating Equipment
Association. Call 859-356-1575 or
visit www.ihea.org.
19-20 — Safety Standards
Seminar, Greenville, S.C. Presented
by Industrial Heating Equipment
Association. Call 859-356-1575 or
visit www.ihea.org.
10  SEPTEMBER 2017 Process Heating
19-20 — Industrial Combustion
Seminar, Greenville, S.C. Presented
by Industrial Heating Equipment
Association. Call 859-356-1575 or
visit www.ihea.org.
20-21 — IHEA Fall Business
Conference, Greenville, S.C.
Presented by Industrial Heating
Equipment Association. Call 859-
356-1575 or visit www.ihea.org.
19-22 — Process Expo, McCormick
Place, Chicago. Hosted by Food
Processing Suppliers Association
(FPSA). Call 703-761-2600 or visit
www.myprocessexpo.com.
19-22 — InterBev: The Beverage
Process Show, McCormick Place,
Chicago. Call 770-618-5842 or visit
www.interbev.com/process.
20-21 — Advanced Process
Burners Course, Tulsa, Okla.
Presented by John Zink Institute.
Call 918-234-5710 or visit
www.johnzinkinstitute.edu.
22 — Fired Heater Reliability
Management Course, Tulsa, Okla.
Presented by John Zink Institute.
Call 918-234-5710 or visit
www.johnzinkinstitute.edu.
28-29 — Thermal Oxidizers
Course, Tulsa, Okla. Presented by
John Zink Institute.
Call 918-234-5710 or visit
www.johnzinkinstitute.edu.
October
3-5 — Industrial Combustion
Workshop, Rockford, Ill. Presented
by Honeywell Combustion Safety.
Call 216-749-2992 or visit
www.combustionsafety.com.
8-11 — ASTM Committee C16 on
 Calendar Events

Thermal Insulation Fall Meeting,
Sheraton New Orleans. Call 610-832-
9678 or visit www.astm.org.
10-12 — Vapor Control Course,
Tulsa, Okla. Presented by John Zink
Institute. Call 918-234-5710 or visit
www.johnzinkinstitute.edu.
27-29 — Drying Theory Put to
Practice Seminar, Raleigh, N.C.
Presented by Bühler Aeroglide.
Call 919-278-2864 or visit
www.buhlergroup.com/drying.
27-29 — Boiler and Pressure Vessel
Repair Seminar (RO), Columbus.
Presented by National Board of Boiler
and Pressure Vessel Inspectors.
Call 614-888-8320 or visit
www.nationalboard.org.
23-24 — Hydraulic Institute
Fall Conference, Renaissance
Worthington, Fort Worth, Texas.
Produced by the Hydraulic Institute
(HI). Call 973-267-9700 or visit
www.pumps.org.
24-26 — The Quality Show, Donald
E. Stephens Convention Center,
Rosemont, Ill. Call 844-644-7449 or
visit www.qualityshow.com.
30 — Fundamentals of Industrial
Process Heating Online Course
(course begins; continues for six
weeks). Presented by Industrial
Heating Equipment Association.
Visit www.ihea.org.
31-Nov. 2 — Chem Show,
Javits Center, New York.
Call 203-221-9232 or visit
www.chemshow.com.
November
6-9 — ISA Process Control and
Safety Symposium and Exhibition,
Houston Marriott Westchase,
Houston. Presented by International
Society of Automation. Call 919-549-
8411 or visit www.isa.org.
6-9 — International
Instrumentation Symposium
(IIS), co-located with ISA Process
Control and Safety Symposium and
Exhibition, Houston. Presented by
International Society of Automation.
Call 919-549-8411 or visit
www.isa.org.
6-9 — Fabtech Expo, McCormick
Place, Chicago. Cosponsored by AWS,
FMA, SME, PMA and CCAI.
Call 888-394-4362 or visit
www.fabtechexpo.com.
7-9 — Drying Theory Put to
Practice Seminar, Joinville, Brazil.
Presented by Bühler Aeroglide.
Call 919-278-2864 or visit
www.buhlergroup.com/drying.

Infrared Systems
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Paterson, NJ. 07501 USA Web: www.glenro.com

www.process-heating.com SEPTEMBER 2017  11

 Heaters

FIGURE 1. Erosion damage can

be seen on tubes. The image on
the left shows erosion from the
inside out while that on the right
shows erosion of the sleeving at
the tube inlets.

Identifying and Preventing

PHYSICAL DAMAGE TO
TUBULAR AIR HEATERS
Tubular air heater damage and leakage can affect system performance and
increase costs. Learn how erosion, corrosion, plugging and exceeding operational
limits could be robbing your plant of capacity.

By Alex Turner, As a result, tubular air heater performance
is not recognized as critical until high lev-
Lonnie Coffey and
el operational goals are affected or at risk.
Shawn Goedeke, Tubular air heater damage and leakage
Corrosion Monitoring Services (CMS) can affect many systems and cost centers.
These include auxiliary loads, fuel con-
• Tube internal surface.
• Tube external surface.
• Tubesheets.
In many cases, fuels burned may have
high ash content. Typically, 90 percent

W
hat is critical to opera-
tors of thermal plants?
Of primary importance
is the delivery of process
steam and electric power within the estab-
lished environmental limits for the site. As
long as the operator can meet those goals
safely, subtle losses of efficiency are often
ignored or not recognized as significant.
sumption, emission control, consumables
and, eventually, steam production. This
article describes several physical damage
mechanisms that can affect tubular air
heater performance.
Heater Failure Causes: Erosion
Tubular air heater erosion primarily occurs
in three locations:
of the ash in the fuel is carried in the
flue gas. Depending on the configura-
tion of the tubular air heater, this fly ash
may be on the inside or outside of the
tube, and it can erode the tube material
(figure 1). This causes the wall to be-
come thinner, increasing the probability
of leakage from the higher pressure air
to the flue gas.

12  SEPTEMBER 2017 Process Heating


The air side is not immune to erosion
either. Air may pick up dirt and even air-
borne fuel particles, depending on the lo-
cation of the forced-draft fan inlet. Dam-
age to the tubesheets provides another area
for the air and flue gas to mix. Mixing of
the hot and cold streams through leakage
affects the plant performance in the sev-
eral ways: reduced exit gas temperature, re-
duced temperature of combustion air, and
increased load on the forced- and induced-
draft fans.
Heater Failure Causes:
Corrosion
Like erosion, corrosion attacks the tube
surface and eventually leads to leakage.
Corrosion develops because of chemi-
cal reactions of the flue-gas constituents.
These reactions can generate acids in the
flue gas. They can include:
• Sulfuric acid (H2SO4).
• Sulfurous acid (H2SO3).
• Hydrochloric acid (HCl).
• Nitric acid (HNO3).
FIGURE 2. Cold areas in the tubes cause the acids to condense and can lead to corrosion. Typical sites include
external corrosion near the tubesheet (left); corrosion holes near the tubesheet (center) and corrosion from the acids
along the tube length (right).
These acids have a limited effect as long
as the surface temperature remains above
the acid dewpoint (ADP).
Unfortunately, leakage or gas distribu-
tion lowers operating temperature and cre-
ates cold areas where acids can condense.
This initiates a reaction with the tube ma-
terials, causing corrosion similar to what is
seen in figure 2.
Additionally, in many cases, the tubular
air heater was designed prior to emissions
limitations and installation of emission
controls such as selective catalytic reduc-
tion (SCR) systems. The SCR may add
chemicals into the flue gas not accounted
for in the original design, and this can
increase the acid production in the flue-
gas stream. These changes all increase the
probability of tube corrosion and, ulti-
mately, leakage.
In some cases, the construction of the
tubes themselves can add to the possibility
of the corrosion. Seam-welded tubes (SWT)
may be attacked by the acids preferentially
along the weld. This can lead to a split along
the seam and another leakage source.
www.process-heating.com SEPTEMBER 2017
Heaters
Heater Failure Causes:
Plugging
Like erosion, plugging can be caused by
fly ash in the flue gas. When the fly ash
mixes with moisture in the flue gas and
condenses on tube surfaces, it becomes
sticky. Once it becomes sticky, it can fill
either the internal diameter of the tube or
the spacing between the tubes, depending
on the tubular air heater configuration.
Two extreme cases of plugging are shown
in figure 3. In both cases, this hinders the
heat transfer by:
• Reducing the surface area.
• Altering the flow distribution.
• Increasing the pressure drop on the tu-
bular air heater.
Another source of plugging comes in
the form of a temporary repair to a tubu-
lar air heater. Often, erosion and corrosion
can cause such extensive damage to tubes
that they are rendered useless. Short of
replacing the damaged section, the only
way to try and minimize further damage
 13
 Heaters

on the outside of the tubes. Bending or

denting of tubes changes the flow profile
inside the tube and the heat transfer char-
acteristics. These physical limitations lead
to stress points in the metal that weaken
the tube walls. This eventually leads to
splits and holes that allow leakage to occur
(figure 4).
Increased vibration in a tubular air heat-
er can be caused by changes in the air- and
flue-gas flows that generate turbulence.
FIGURE 3. Extreme fly ash fouling of a tubular air heater can occur in areas
Operation of the forced- or induced-draft
such as the external flue gas path (left) or plugging of the internal diameter
of the tubes (right). fans also can cause increased vibration. The
resulting stresses in the tubes may not have
been accounted for in the original design.
Because of fuel costs and load require-
ments, plants that were once designed to
operate consistently are now forced to load
cycle much more often. The load cycling
forces the units to go through the low load
turndown, resulting in acid dewpoint cor-
rosion conditions almost daily. The cycling
also makes it more difficult for the opera-
tor to observe subtle performance changes.
In addition, the use of emissions equip-
ment encourages use of lower quality fuels
— with higher sulfur and ash content —
to reduce operating cost. The resulting im-
pacts on the operating conditions are sig-
FIGURE 4. Any limitation to the tubesheet motion can increase internal
nificant when air heater design parameters
stresses that are seen along the length of the tube. For instance, the
motion can create split seams (left). Notice that ash is leaking from the split no longer cover the new operating profile.
(shown with blue arrow). Other failures include tube bulging (center), and Ultimately, any outside force that weak-
the tube appears to show signs of hole development (near the blue arrow). ens the air heater tubes leads to leakage
Bent tubes can be seen between the two red lines (right). and performance degradations. Adding
to the complexity, none of these damage
mechanisms work alone. Erosion and cor-
is to physically plug the tube entrance and tion limitations are caused by limited rosion can work together to thin the tube
exit at the tubesheets. This provides a cost- tubesheet expansion, increased vibration walls — in some cases, from both the in-
effective repair and works well if the dam- and thermal cycling. ner and outer surfaces. The operating pro-
age is in a limited area. However, as the The design of the tubular air heater al- file of the plant and the tubular air heater
damage spreads and the number of plugs lows for the tube to grow in length with can accelerate the wall thinning that leads
increases, it becomes financially feasible to temperature increases. Often, this is ac- to leakage. Increased ash and sulfur con-
have a longer outage and repair the dam- complished by having one tubesheet fixed tent in the fuel accelerate the erosion and
aged tube sections. and allowing the second to float. Any limi- corrosion. Swings in the load can lead to
tation to the tubesheet motion can increase operation below the acid dewpoint on
Heater Has internal stresses that are seen along the nearly daily basis.
Operational Limitations length of the tube. This can cause bulging, A tubular air heater that is not moni-
Similar to other plant equipment, the bending, denting or splitting of the tubes. tored and maintained can be a silent thief
tubular air heater has a design opera- Eventually, each of these damages will that slips in the back door of almost all
tional lifespan. Normal operation results result in tube failures and — in different types of thermal plants. With no moving
in changes that will eventually create ways — limit the performance of the tu- parts, power or water consumption, and no
defects. Each defect — if not monitored bular air heater. For instance, bulging tubes unusual sound alerting of problems, it has
and controlled — has the potential to reduce the separation between the tubes the capability to empty your bank account
accelerate other issues. Common opera- and increase the velocity and pressure drop or shut you down.

14  SEPTEMBER 2017 Process Heating

 Heaters

Poor air heater performance can affect impacts. Tracking this information allows Dr. Shawn M. Goedeke and Lonnie Coffey are
almost every process in a plant whether the for the design and implementation of solu- also with Corrosion Monitoring Services, a
facility is a paper mill, biofuel or coal plant, tions that reduce damage mechanisms and company that provides inspection and repair
or even a refuse processor. Most air heaters financial impacts. of tubular air preheaters, heat exchangers
are designed for a specific, narrow operat- and clinker coolers. For more information
ing range for both physical and chemical Alex Turner is the president of Corrosion from CMS, call 630-762- 9300 or visit
properties. The tubular air heater inlet and Monitoring Services (CMS), St. Charles, Ill. www.cmsinc.us.
outlet temperature of combustion gas and
air are important. Yet, it is the chemical
composition of the gas entering the air
heater that is the conduit for delivery of
207 Thermal Liquid Heaters
destructive mechanisms. Anything that al- Direct Fired
126,000 to 6,250,000 BTU Input
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The first step to minimizing the tubu- Distribution/Air Separation Thermal Liquid Heater
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lar air heater performance impacts is to Air-Cooled 400°F Pumps
schedule regular inspections. These in- Custom Skid Mounts
spections can be performed to suit opera- Natural Gas
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tional schedule requirements. The inspec- Combination Fired
tions are focused entirely on the condition Low NOx
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of the tubular air heater and include spe-
cific technical documentation of damage. 25 Year Guarantee
They may require or include some minor Against Thermal Shock!
emergency repairs.
As a part of the inspection process, it We’re asked by many new and existing customers, what is the projected life
also is recommended to include a ther- expectancy of our products, which is over 50 years with normal use and care.
moeconomic analysis. This requires collec- We’re not always the lowest initial price but know we have one of the lowest
5930 Bandini Blvd. cost of ownership of any boiler manufactured in North America. Facts based on
tion of operational data around the boiler Los Angeles, CA 90040 our 98 plus years of boiler manufacturing, feedback and experiences! From our
and tubular air heater as well as selected Tel: 323-727-9800 end users, service departments, all of our representatives and dealers worldwide.
www.parkerboiler.com
auxiliaries. With this data, it is possible
to evaluate the condition of tubular air
heater and its impact on boiler efficiency.
It also allows you to quantify the financial

www.process-heating.com SEPTEMBER 2017  15

 Boilers Five used and reconditioned mobile
boiler rooms, each rated at 650 hp,
found a second life in the Midwest.

5
Selecting a Used Boiler
QUESTIONS
to Ask Before

Purchasing a used industrial boiler may make sense for your plant. Before you
buy, ask these questions to help ensure you’re buying a system that will operate
effectively for your application.

By Chelsey Ryker, • How much do you want to spend? • A reconditioned boiler typically is 60 to
Nationwide Boiler Inc. • Do you want to test drive the equipment 70 percent of the cost of a new boiler.
before making your decision? • Most manufacturers do not offer the

W
hen it comes time to re-
place an industrial boil-
er, or the need for ad-
ditional capacity arises,
boiler owners have options: They can buy
new, or they can buy used. Just as the adage
“Age is just a number” applies to anyone
young at heart, industrial boilers that are
maintained properly have a life expectancy
of 25 years or more.
To aid in the decision-making process
when determining whether to buy a new
or used boiler, ask yourself:
• When do you need the boiler?
• What type of warranty do you expect?
Your answers to those questions may
direct you to consider used industrial
boilers. It may come as a surprise coming
from an industrial boiler manufacturer, but
purchasing a good quality used or recon-
ditioned boiler can be more advantageous
than buying new. Take a look at the follow-
ing statistics:
• Used boilers generally are in stock and
available for immediate delivery. New
boilers can take between 12 and 36
weeks to build.
ability to test drive new equipment.
However, a reconditioned boiler from
some equipment providers can be leased
with an option to buy at the end of the
rental period.
• Used boilers often are sold with similar
guarantees as a new boiler and can be
warranted for 6 to 12 months.
Given these factors, and the specific
project requirements, a used boiler may
well be the right choice for the application.
Considering five key questions will aid in
the search for a good condition, used boiler
that will provide the plant with a reliable

16  SEPTEMBER 2017 Process Heating


and efficient source of steam production
for many years.
1. Has the Boiler Been
Reconditioned?
With a reconditioned boiler, inspec-
tions, electrical and combustion testing,
hydrostatic pressure test, tube repairs or
replacement, and any other integrity or
cosmetic issues should be taken care of by
the company selling the boiler. As always,
you want to make sure to choose a used
boiler supplier and inspect the equipment
with your own eyes. Or, hire a third-party
inspection service to ensure that the integ-
rity of the equipment matches the buyer’s
scope of supply.
Shown before reconditioning, this used 82,500 lb/hr boiler was built in 1993.
If the boiler is not already recondi-
tioned by a reputable used boiler dealer,
and you are looking at purchasing equip-
ment in an as-is, where-is condition, you
will want to ensure the next items are
checked prior to buying.
2. Has the Boiler Been
Inspected and Tested?
It is important that used boilers are in-
spected and tested by a reliable service
company or inspection agency for any tube
leaks or cracked surfaces. It also should be
confirmed that there are no signs of over-
heating, corrosion or erosion. Tube bulges
and scaling, hot spots, plugged tubes and
other deformities can indicate poor main-
www.process-heating.com SEPTEMBER 2017
Boilers
tenance and inadequate water treatment.
A hydrostatic test should be performed,
which will check for tightness of all valves,
gaskets, boiler fittings and flanged, rolled
and welded joints. This is the most com-
mon method employed for testing pres-
sure vessels.
Additionally, the boiler should be tested
for proper functioning of all boiler con-
trols, including the pressure gauges, low
water cut-off devices, flame scanner, fuel
train, gauge glass and pressure-relief valves.
3. Are the Tubes and Internals
in Good Condition?
A boiler that is properly maintained and
supplied with treated and conditioned
 17
 Boilers
This is the same 82,500 lb/hr boiler after a full reconditioning. The boiler was inspected and tested, and any necessary repairs
and replacements were made.
feedwater can last a lifetime. Tube damage,
however, will occur if the proper main-
tenance is not performed. Therefore, it is
imperative that tubes and internals are ex-
amined thoroughly.
The most common, most reliable and
simplest inspection method is a visual
check. Just by looking at the tubes, you can
typically determine and identify any areas
of fouling, erosion, corrosion or localized
overheating issues. Borescopes also can be
utilized for chemistry-related issues such
as pitting or restrictions internal to the
tubes. Other tests common to internal in-
spections include magnetic particle exami-
18  SEPTEMBER 2017 Process Heating
nation and liquid penetrant examination.
Both of these tests identify external crack-
ing and thermal fatigue. Ultrasonic testing
also determines tube thickness.
Tube repairs and replacements are com-
mon to extend the life of an older boiler
with tube leaks or scaling. A 10-year-old
boiler with brand new tubes is almost like
a new boiler — for half the cost.
4. Have the Controls and
Safety Devices Been Checked
and Upgraded?
Once you have tested the controls and
safety devices and confirmed that they are
in working order, they should be upgraded
as necessary.
Often times, components become obso-
lete, and improvements in design and con-
trol systems make newer devices safer and
more efficient. You also will want to make
sure that all controls and safety devices
meet current standards such as CSD-1 or
NFPA 8501.
Upgrading older controls and devices
may allow for a smoother, more profi-
cient operation. Safety valves, in particular,
should always be replaced on used boilers.
They are the most important safety device
on a boiler.
 Boilers

5. Have You Done

Your Homework?
You cannot rely on a piece of paper and a
photo when buying used equipment. It is
important to go out and examine the boiler
with your eyes. Feel it, touch it and make
sure it is in the condition that you are ex-
pecting. Do your own visual inspections
and, if you have the ability, physically test
the boiler.

It may seem
surprising, coming from
an industrial boiler
manufacturer, but
purchasing a good
quality used or
reconditioned boiler
can be more
advantageous than
buying new.

Some equipment providers have a fully

operational test pit at their facilities. These
companies can fire their used equipment
for customers to assess before they buy. It
is just like buying a used car — you want
to test drive the equipment before you
make the decision to buy.
A reconditioned 70,000 lb/hr boiler with SCR was sold to a customer in California
In addition to going out and seeing the
and installed on-site.
equipment in person, research the compa-
ny from which you are buying the equip-
ment. Be sure that they are a reliable and
reputable used boiler dealer so you know obtaining a good quality boiler by buying Chelsey Ryker is marketing manager and part
they will stand behind their product. used equipment. Do your due diligence of the sales team at Nationwide Boiler Inc.,
when searching for a used boiler for a sys- Fremont, Calif. For more information from
In conclusion, boiler owners and plant tem that will deliver what you need reliably Nationwide, call 800-227-1966 or visit
operators can save time and money while and for some time to come. www.nationwideboiler.com.

www.process-heating.com SEPTEMBER 2017  19

 Heat Tracing
10
WAYS TO ENSURE
A WINNING HEAT
TRACE PARTNERSHIP
Before teaming up with a heat tracing supplier, compare and contrast the
contenders to identify those with the experience you need.
By Kathy Eber,
Delta-Therm Corp.
S
taying competitive and profit-
able is a balancing act for in-
dustrial processing companies.
Meeting market demand and
shareholder expectation keeps the pressure
for well-executed heat tracing systems on
high boil. This makes choosing the right
partner or provider for the job more criti-
cal than ever. Fortunately, it is not difficult.
The elements that make some heat trace
companies great partners are simple. But,
overlooking any one of them can jeopar-
dize production quality, throughput, safety
and profitability. It can damage relation-
ships with customers, suppliers, distribu-
tors and investors and hurt your reputa-
20  SEPTEMBER 2017 Process Heating
tion. Problems caused by providers are your
problems if you picked them for the job.
But, you can prepare yourself for better
outcomes by doing a little up-front dig-
ging. A simple spreadsheet will help you
compare heat trace partners based on your
qualifiers. Compare potential suppliers by
asking these 10 questions.
1. CAD Drawings:
Are They Done In-House?
Because the installation drawings for
your project are the blueprint from which
your system will be built, it is impera-
tive that they be complete and accurate.
They also need to include any revisions
made during the drawing process. Will
the manufacturer provide drawings for
your heat trace project? If so, will they
be created in-house or by a third party?
An advantage of in-house engineering is
that the partner can make revisions in real
time. This helps ensure the system is cor-
rect before the order is placed. Being able
to have all participants meet spontaneously
may help to expedite resolving issues and
revising drawings.
How important is this criterion? Ask
yourself: How critical is your project time-
line? Can you afford a delay for revisions?
2. Customer Service:
Is It Live and Responsive?
Any project manager or system installer
who has spent an inordinate amount of
time waiting on hold or, worse yet, had no
access to a live person for help during an
installation, knows that customer service
 Heat Tracing

representatives are important at all stages

of a project. They help expedite drawing
changes, BOMs and shipping of parts.
They can quickly clear up billing, inspec-
tion and warranty issues.
Check out company policies for returns
and restocks of both standard and custom
products. Emergencies happen. Live access
to quick technical answers means a crew
will not be standing around on the clock
waiting for instructions. Industrial giants
like food manufacturers, oil-and-gas or
nuclear power plants rely on swift resolu-
tions to problems. If a potential partner
cannot provide this, it is worth your time
to keep looking.

3. Reputation:
Theirs Can Become Yours
You may be saving money on the front
end. But what is the cost per day of a pro-
duction shutdown at a pharmaceutical or
Should a problem arise during installation, making on-site troubleshooting
food processing operation? What war- personnel available can make a difference in ease of deployment.
ranty does your heat trace provider offer?

www.process-heating.com SEPTEMBER 2017  21

 Heat Tracing
When seeking out a heat trace
system, it is important to find a
partner that is committed to the
system success before, during and
after installation.
What does the warranty actually cover?
Does the company have a reputation for
solid performance and standing behind its
products? What happens to your reputa-
tion and your bottom line when the com-
pany you chose to design the system fails
to meet the needs of the customer?
4. Does Closer to Home Equal
Closer to Budget?
Having a local provider can save time and
money, especially for ongoing expansion
projects close to home. How much time
and angst can you save with a trusted pro-
vider located close by? If you anticipate the
need for technical site visits during the in-
stallation, a local heat trace partner offers
advantages. For instance, same-day pickup
and shipping help keep labor from waiting
on the clock for parts or direction. Con-
venient product training is another advan-
tage for both you and your customer.
Not every local heat trace will be a fit for
your project. But if other criteria are met,
22  SEPTEMBER 2017 Process Heating
proximity can bring a higher level of support
and comfort to both you and your customer.
5. Define Experience
When you talk to prospective heat trace
partners, dig deeper than their date of in-
corporation. A long history is good. Also,
ask for currently operating examples of so-
lutions they have created for applications
like yours. Though they may have been
around for decades, they may be new to
your type of project.
Look at breadth of experience too. Does
the company have a track record in all the
applications it offers?
6. Design Assistance: Is It
One-on-One?
Industrial heat tracing systems are not
one design fits all. Every project starts
with the needs of the end user. Even when
goals are clear, there may be more than
one way to accomplish them. Drawings
and specifications evolve through discus-
sion until the right solution is reached.
Working with a manufacturer that fully
understands the capability of each system
component is both efficient and conve-
nient and makes communication and
document integrity easier.
Ask about design assistance. If you
prefer to do the initial drawing, find out
if they will assist you or bring in another
party for the project.
7. Lead Time Is Money
Lead time is also productivity and reputa-
tion. It is good to ask about it. What does
it depend on? Will components be coming
from a number of locations to be assem-
bled? Does the company keep an adequate
inventory on hand? Does it manufacture
its own components?
8. Consider Complete
Systems
There are advantages to using a heat trace
partner that offers complete systems. Be-
cause the project is coming from one
source, there is better visibility between
engineering, manufacturing and shipping.
And, often, team members share a com-
mon goal — the timely installation and
success of the system.
Also, companies that produce complete
heat trace systems have built-in component
compatibility. They have experience with
all aspects of the system: cables, controls,
panels, accessories and the requirements of
multiple production environments.
9. Is There a Sufficient
Product Offering?
Good heat trace system partners will of-
fer choices and configurations that fit your
needs because they are interested in de-
signing the best way to achieve the goal.
You’ll recognize them by the number of
questions they ask before they offer a solu-
tion. Rather than trying to shoehorn your
system into their product offering, they will
honestly assess the situation, suggest alter-
natives and then recommend a solution.
10. Is Installation
Support Available?
By offering pre-installation consulting at
the site of the upcoming project, a heat
trace partner can answer any installation
questions and demonstrate kits and con-
trols. And, should a problem arise during
installation, making on-site troubleshoot-
ing personnel available can make a big dif-
ference in ease of deployment.
Hourly and travel fees notwithstanding,
a site visit can still be a bargain if it keeps
the project on track. However, it is good
to know in advance what you’re paying for.
Will the technical advisor look at the sys-
tem as a whole to locate the problem or
simply check to see that his company or
product is not the problem and walk away?
In conclusion, the true cost of a project
will ultimately be determined long after
installation. While the proposal cost is an
important consideration in industrial heat
tracing, it is not the only consideration. The
best scenario is a partner that is committed
to the system success before, during and
after installation. By taking time to find
that heat trace partner, you can rest assured
things will flow smoothly.
Kathy Eber is the marketing manager at
Delta-Therm Corp., Crystal Lake, Ill. For more
information from Delta-Therm, call 800-526-
7887 or visit www.delta-therm.com.
 Dryers

A vibrating fluid-bed dryer designed to

capture and recycle the process air is shown in
production with its ductwork and filter system.
Recovering and reusing heated process air offers
significant savings in energy and costs.

5
CONSIDERATIONS
When Recycling Air and
Material in Fluid-Bed Drying
Does recycling the exhaust air makes sense for your process?

By Larry Stoma, vironmental goals. It allows executives to where it mixes with the material to be
Witte Co. position their companies as sustainable dried and suspends it in the airstream. The
organizations that will be around far into fluidized particles behave like a liquid, al-

I
t is no coincidence that the energy-
cost-reducing technology used to re-
cover and reuse heated process air in
fluid-bed drying systems was devel-
oped during the energy crisis of the 1970s.
As the cost of energy sharply increased, so
did the cost to run and operate a fluid-bed
dryer. Capturing and reusing as much heat
as possible — to take full advantage of ev-
ery unit of energy — became a logical goal
to offset rising costs.
Saving energy also advances worthy en-
the future. If the environmental impact is
the only criteria at your company, then the
decision to recycle is easy. If there may be a
potential cost savings to realize, then con-
sider the following key points to determine
if recycling the exhaust air makes sense for
your process.
1. Product Drying
Temperature
In a fluid-bed dryer, heated air is directed
upward through an air-distribution deck,
lowing the air to surround each individual
particle with the continuous, intimate
contact needed for highly efficient energy
transfer. Because this energy transfer does
not rely on direct contact with heated sur-
faces, the drying occurs gently and without
product degradation. This is why the pro-
cess often is specified for a wide range of
products from delicate, frangible foods to
coarse mineral products.
Although a fluid-bed dryer may be
right for your product, it may not make

www.process-heating.com SEPTEMBER 2017  23

 Dryers
Calculating Returns with
Fluid-Bed Dryers
Whether heating the process air using
natural gas, electricity or steam, this
cost is typically the largest cost in
any drying system. And while the
warm air flows inside the system, it
is an asset. But once exhausted, it is
gone forever. Therefore, determining
the ideal drying system for the
application and whether to recycle
requires a significant commitment
of time, expertise and an extensive
series of calculations.
Educated assumptions regarding
energy costs and ambient
temperatures are made to arrive at
an approximate amount of operating
costs on a yearly basis. Often, two or
three potential systems are compared
by looking at the upfront cost relative
to projected cost savings over a span
of two to five years of operation.
Slightly higher maintenance costs are
also addressed in systems that recycle
due to the need for dust-collection
equipment required for the exhaust air.
Consider this sample process where
a fluid-bed dryer requires 10,000 scfm
of air heated to 500°F (260°C).
This system would require $33 of
natural gas per hour, assuming an
ambient temperature of 65°F (18°C)
and a natural gas cost of $7 per unit.
By recycling 50 percent of the air at a
recycled air temperature of 150°F, the
natural gas cost may be reduced to
$29.80 per hour. This savings equates
to a potential savings of $23,200 per
year in gas alone. Given this type of
drying system would likely require
a baghouse dust collector at a cost
of an additional $35,000 for the dust
collector and ductwork required
to recycle the air effectively, the
recycling system would pay for itself
in energy savings after two years
of operation.
24  SEPTEMBER 2017 Process Heating
sense to invest in recovering the air for
your process.
Materials such as salt and sand offer
high temperature limits and allow the use
of high process air temperatures — up-
wards of 500°F. Given that the exhaust
air generated from such a process may
approach 250°F, capturing and returning
this heated air into the process reduces
the burden on the air heaters. It is far less
costly to raise 250°F air to 500°F (121 to
260°C) than it is to raise ambient air all
the way up to 500°F.
Those delicate, frangible cereals, seeds
and some plastics, by contrast, burn or
melt even at low temperatures. Given that
these products typically require process-
ing at temperatures from 100 to 200°F
(37 to 93°C), the spread between the
process air temperature and the exhaust
air temperature may not be wide enough
to warrant the investment in the heat
recovery equipment. Further, the cost of
heating the ambient air to the process air
temperature — relative to the cost to heat
the exhaust air up to the process air tem-
perature — may be considered insignifi-
cant, depending on the cost of energy and
size of the equipment.
2. Product Drying
Characteristics
Because vibrating fluid-bed dryers ac-
commodate a range of products with par-
ticle sizes ranging from 1” down to 25 mi-
crons, there can be significant differences
in the rate at which drying occurs, and in
how efficiently it occurs. These differences
may be due to particle size or shape, or
to the inherent properties of the material.
For most materials, the smaller the
particle size, the more surface area avail-
able for direct contact with the drying air.
Large, heavy particles require high air ve-
locities and have less surface area to come
in contact with the air. Subsequently, this
reduces the energy transfer efficiency.
Some materials such as vegetables have
a membrane-like outer surface that pre-
vents internal moisture from escaping as
readily — again, reducing the drying ef-
ficiency. By contrast, some porous materi-
als such as carbon black release their in-
ternal moisture easily. Because materials
that dry less efficiently leave more heat in
the airstream, their drying systems often
make fine candidates for air recirculation.
3. Process Requirements
In many applications, the fluid-bed dryer
also is used for a second or third purpose
beyond drying — for instance, dedusting,
cooling or screening. Sometimes, prod-
ucts need to remain heated for a specific
amount of time for heat treatment or
crystallization. In these cases, the exhaust
air temperature will be significantly high-
er than the exhaust air temperature of a
typical drying application.
With this high heat available for cap-
ture, these cases present a perfect fit for
air recirculation. In systems where the
material is cooled directly after drying,
both the heat energy originally generated
for the drying zone, and the dry, exhaust
air from the cooling zone, may be recy-
cled. These special process requirements
need to be evaluated when considering
recycling fluid bed process air.
4. Cleaning the Exhaust Air
To return any of the exhaust air to the
process, entrained particles first must be
removed from the airstream. Recycling
dirty air contaminated with entrained
particles will eventually cause blockages
in the heat transfer coils or gas furnace.
It also can cause product to accumulate in
the underside of the fluid bed.
Achieving this clean air typically de-
mands the air be passed first through a
filtering stage. In some cases, a cyclone
dust collector may be used to remove the
particulates. Most frequently, a reverse-
pulse baghouse filter is used for its greater
dust-collection capacity. It is a wise idea
to put some type of monitoring device on
this filter to alert operators of a possible
filtration failure. The cleaned, heated air
then is directed back to the supply-side
equipment, where it is heated to the final
processing temperature.
As a side benefit, recirculating air
in this fashion also cuts down on the
amount of exhaust air being released to
the atmosphere. This can be important
when applying for air permits under en-
vironmental regulations.
 Dryers

5. How Much Air to Recycle

When designing an air-recycled fluid bed,
determining exactly how much of the to-
tal supplied air to recycle is critical. To the
uninitiated, 100 percent may be desired.
But drying a product releases water vapor
into the exhaust airstream. It is not wise to
recycle this water vapor back to the prod-
uct, which would defeat the original pur-
pose. Most commonly, 50 percent of the
supplied air is recycled. This allows the air
to be recycled once before it is exhausted
to the atmosphere.
Typically, the dryer discharge-end air
will be recycled back to the inlet end be-
fore being exhausted to the atmosphere.
The scenario that would result in the most
heat energy recovered at the highest op-
erating efficiency involves capturing heat
energy from the first drying zone exhaust
air by employing a heat exchanger before
the air is exhausted. This captured energy
then can be used to preheat the air going
to the second zone of the fluid bed.
In conclusion, the 1970s sounded
quite the alarm for manufacturers run-
ning equipment as if energy was freely
available, in nearly infinite supply, at a
consistently low cost. The era of unfet-
tered energy use was over, and in its place
rose the beginning of the environmental
movement. Energy efficiency, conserva-
tion, recycling and saving on energy costs
became the new normal.
While a combination of regulation and
innovation contributed to the clearer skies
of today, the public outcry has continued
to intensify. Manufacturers today face a
maze of federal, state and local rules and
regulations. Failure to comply can carry
penalties that cost far more than the cost
of the equipment needed to capture and
recover process air. Many of today’s busi-
ness leaders understand the basic sensibili-
ties involved in reusing the process air. A
green solution that reduces waste and con-
serves energy, recycled air also more often
than not translates directly into tangible
financial returns.

Larry Stoma is a senior sales and design
engineer at Witte Co., Washington, N.J. For
information from Witte Co., call 908-689-6500
or visit www.witte.com.
This vibrating fluid-bed dryer has a dust-collection system above the drying zone
that allows fine particles to be captured and returned to the process as saleable
product. Recovering and reusing the heated airstream and material supports
green initiatives and often makes sense financially.

www.process-heating.com SEPTEMBER 2017  25

 Burners
Upgrading outdated combustion
control systems with a burner-
management system (BMS) allows a
significant improvement in both the
safety and efficiency.
6
BENEFITS
of Upgrading Your Process Heater
A burner-management system helps heater applications run safely and efficiently.
By Eve M. Hunter,
ProFire Energy
T
he days of using a rag and stick
to light a burner have thankfully
faded into the not-so-distant
past. Technology has evolved
and continues to do so at a rapid rate. Yet,
the truth is that a vast majority of the pro-
cess heaters in operation today are run us-
ing older, less user-friendly — and often
unsafe — systems. Upgrading these out-
dated systems with a burner-management
system (BMS) has become a common
trend in the industry. As a result, there has
been a significant improvement in both the
safety and efficiency of updated systems
and applications.
As with any improvement, issues arise
when upgrading older systems. Upgrad-
ing can involve disruptions in operations
26  SEPTEMBER 2017 Process Heating
and often require the retraining of staff.
It can become difficult to determine when
the benefits of upgrading really outweigh
the extra costs and inconvenience. So,
why bother with a comprehensive burner-
management system? Here are the top six
benefits to upgrading your process heater.
1. Improve Plant and
Personnel Safety
It is no secret that incidents and near miss-
es can tarnish safety records in industries
like oil and gas and chemical processing.
Excellent safety records have become a
large selling point for many companies. It
is not uncommon for safety to be one of
the top core values or strategic imperatives
of any given company. Implementation of
specific goals concerning safety helps many
businesses to maintain and even increase
their safety ratings. Direct-fired heating is
intrinsically dangerous, and it can become
more so when the processing of flammable
fluids and chemicals is not monitored and
controlled correctly.
The implementation of a burner-man-
agement system ensures that safety stan-
dards are not simply met. Instead, in some
cases, they are exceeded. Burner-manage-
ment systems enable the safe startup, oper-
ation and shutdown of a process heater. A
BMS monitors and controls ignition and
main burners as well as valves, pressures,
temperatures and flow, and valve positions.
This built-in functionality allows the safe
operation of crucial equipment in the field
and helps to ensure compliance with ap-
plicable codes and standards.
2. Increase Reliability
If a process heater unexpectedly shuts
down, it is imperative that action is imme-

diately taken to identify the cause and get
the equipment up and running as quickly
as possible. A system that provides a quick
and reliable way to identify shutdowns is
essential to minimizing downtime and
maximizing application uptime efficiency.
Some burner-management controllers
provide intuitive and user-friendly displays
that provide detailed information to the
operators regarding the current status of
the system and allow them to safely per-
form startup and shutdown functions.
Devices that are customizable or mod-
ular are preferable because they permit
greater flexibility within the system. They
often have expansion capabilities that can
accommodate a variety of needs. Custom-
izable or modular systems also can be more
easily upgraded for future application de-
velopmental requirements.
A burner-management system is comprised of an approved and certified burner management controller and a properly
designed and fully compliant fuel gas train that is properly installed, commissioned and configured by a company that provides
expert training and technical support.
3. Enable Automation
Automated features are essential to the
functionality of a burner-management
system, and they can provide many helpful
benefits. Automation allows remote-access
capabilities and helps to reduce both risk
and complexity for operators through the
remote monitoring of critical system pres-
sures, temperatures and levels. Monitor-
ing ensures that the system automatically
responds to the conditions of the process
heater and helps reduce — and sometimes
eliminate — downtime.
Automation can allow user-friendly in-
teraction and improves the overall conve-
nience of a system. It also enhances safety
and system availability and increases com-
pliance to industry standards and codes.
It helps maintain critical aspects of the
system and ensures a rapid response to
www.process-heating.com SEPTEMBER 2017
Burners
changing processes. Increasing the level of
automation of various aspects of the sys-
tem is an expected result as greater changes
to workforce demographics and training
are constantly evolving and developing.
To that effect, automation also allows for
significant efficiency gains in manpower
planning. With technology advancing at
an ever-increasing rate, possibilities in-
crease as well.
4. Enhance Communication
and Reporting Capabilities
Burner-management systems also can of-
fer enhanced communication and report-
ing capabilities. This means that interface
between operators and the BMS is uncom-
plicated and convenient. Some BMS de-
signs incorporate heightened communica-
tion between different areas of the system,
 27
 Burners

allowing for detailed diagnostic reports

and the provision of comprehensive infor-
mation regarding temperatures, pressures
and various other settings that are essential
for the optimal operation of the required
equipment and processes.

5. Ensure Standard and Code

Compliance
Recommendations, guidelines and even
internal standard operating procedures
have existed for many years. Codes driven
by legislation, and the need to adopt and
adhere to these codes, have become an im-
portant necessity within the last decade.
Legislation and regulations are continually
morphing and expanding. The occurrence
of incidents resulting in lawsuits — often
with detrimental consequences — high-
lights the need for approved and certified
The days of using a rag and stick to light a burner are gone, but the truth is that burner-management systems.
a vast majority of the process heaters in operation today are run using older, less The most recognizable codes and stan-
user-friendly and, at times, unsafe systems. dards include CSA-B149.3, NFPA 86 and
NFPA 87. These standards and codes all

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start browsing today at www.process-heating.com/books

28  SEPTEMBER 2017 Process Heating

 Burners

serve the same purpose: they tell the pro-
cess manufacturer how to avoid situations
where dangerous failures could occur, and
they describe what to do when any of these
situations are detected. The main function
of a burner-management system is to keep
the equipment and the personnel safe. Ad-
herence to codes and standards amplifies
this basic functionality by ensuring that
safety requirements and expectations are
adequately met.
6. Allow Standardization
Many companies have implemented de-
tailed standard operating procedures and
workflow processes that revolve around
the operation of their process heating
equipment. Procedures and workflow may
vary — not only from company to com-
pany but from location to location or even
from shift to shift. The implementation of
a proper burner-management system is
essential to the workflow and procedures
surrounding plants, operations and facili-
ties. It can add an extra layer of standard-
ization and consistency that can greatly
improve the safety and operational sophis-
tication of a company.
In conclusion, upgrading your process
heater’s burner-management system is
both advantageous and beneficial on many
levels. The six benefits listed above are a
great place to start; however, these are only
a few of the numerous reasons it should be
seriously considered.
A burner-management system is com-
posed of an approved and certified burner
management controller and a properly de-
signed and fully compliant fuel gas train
that is properly installed, commissioned
and configured by a company that provides
expert training and technical support. Fol-
lowing these guidelines and remaining
cognizant of the many benefits that come
with a proper system will allow your heater
applications to run in a safe, user-friendly
way while becoming optimized, efficient
and compliant.
Eve M. Hunter is a technical writer with
Profire Energy. The Lindon, Utah-based
company can be reached at 801-796-5127 or
visit www.profireenergy.com.

y
Specif
Aitk en Process Modules

Aitken offers a variety

of infra-red metal sheath heaters
for virtually any drying application. They
feature heavy-duty elements designed for contin-
uous operation at ambient temperatures up to 350 o F.
They afford high shock resistance - both physical and thermal -
and there are no ceramic parts to deteriorate or break. Most units can
be shipped within 24 hours. Visit our website at www.aitkenproducts.com.

1-800-569-9341
www.process-heating.com SEPTEMBER 2017  29
Equipment Overview Infrared Heaters

Infrared heaters are used to transfer heat through a process or to
a product via radiation. Our Equipment Overview on Infrared
Heaters, an apples-to-apples comparison of the capabilities of a
range of radiant heater makers, will help you narrow the field of
potential suppliers to those that can satisfy your process needs.
Our Equipment Overview on Infrared Heaters — in print and
online at www.process-heating.com — offers a side-by-side
comparison of industrial infrared heaters manufacturers 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
companies that offer aftermarket parts for their equipment.
Online, we’ve streamlined the process for narrowing your

HEATER TYPE WAVE- MANUFACTURING

LENGTH PROCESS
GAS FIRED ELECTRICALLY POWERED

Porous Ceramic Fiber Matrix

Porous Metal Fiber Matrix
You also can conduct your

Coiled Metal Sheath

Ceramic Fiberboard

Ceramic Generator
Ceramic Element

Ceramic Element
supplier search online!

Halogen Lamp

Medium Wave
Sinuated Wire
Metal Ribbon

Radiant Tube
Radiant Wall
Ceramic Tile

Dehydrating
Quartz Tube

Evaporating
Short Wave
Long Wave

Embossing
Panel Type
www.process-heating.com/buyersguide

Annealing
Catalytic

Bonding
Cooking
Baking

Drying
Curing
Companies

Aitken Products Inc.

www.aitkenproducts.com • • •• • •• • • • •
Catalytic Industrial Systems
www.catalyticirovens.com • • • ••
••
Fostoria Process Equipment Div.
www.fostoriaprocessequipment.com •• • • • • •• ••• •• •• • •• ••• ••
Glenro Inc.
www.glenro.com • • • ••
•• • ••
••• • •
••• • ••
• • • • • ••
•
Anderson Thermal Devices • • • • • • • • • • • • • • •
BGK Finishing Systems • • • • •
Blasdel Enterprises • • • • • • • • • • • • • • •
C. A. Litzler Co. Inc. • • • • • • • • • •
Casso-Solar Technologies LLC • • • • • • • • • • • • • • • • • • • • • • •
CCI Thermal Technologies Inc. •
Chromalox • • • • • • • • • • • • • • • • •
Compact Engineering Ltd. • • • • • • • • • • •
David Weisman LLC • • • • • • • • • • • • • • • • • • • •
Davidon Industries Inc. • •
Detroit Radiant Products • • • • • •
Emitted Energy Corp. • • • • • • • • • • • • •
Eraser Co. Inc. • • • • • •
Fannon Products LLC • • • • • • • • • • • • • • •
General Thermal Corp. • • • • • • • • • • • • • • •
Glo-Quartz Electric Heater Co. Inc. • • • • • • • • • • • • • • • • •
Heatrex • • • • • • •

Manufacturers listed in this Equipment Overview responded to a special mailing by Process Heating and do not necessarily represent the entire industrial
infrared heater market. To be included in future listings, contact Linda Becker or e-mail BeckerL@bnpmedia.com.

30  SEPTEMBER 2017 Process Heating

 search results based on the criteria you choose.
If you need more information than what we have specified
here and on our website, and you would like to talk to a manu-
facturer immediately, complete contact information is included
with each manufacturer’s listing in the online Equipment
Overview at www.process-heating.com/buyersguide.
Simply look in the lower right corner for complete information.

MANUFACTURING INDUSTRIES SERVED

PROCESS

We manufacturer aftermarket parts/supplies

Ethanol/Biodiesel/Oil & Gas
Chemicals/Petrochemicals

Paper/Pulp/Converting

for our infrared heaters.

Packaging/Printing

Pharmaceuticals
Thermoforming

Plastics/Rubber
Heat Shrinking
Heat Setting

Pre-Heating
Laminating

Electronics
Pre-Drying

Tempering
Sterilizing
Extruding

Soldering

Finishing
Fusing

Other

Food

• •• • • 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 SEPTEMBER 2017  31

Equipment Overview Infrared Heaters

HEATER TYPE WAVE- MANUFACTURING

LENGTH PROCESS
GAS FIRED ELECTRICALLY POWERED

Porous Ceramic Fiber Matrix

Porous Metal Fiber Matrix
You also can conduct your

Coiled Metal Sheath

Ceramic Fiberboard

Ceramic Generator
Ceramic Element

Ceramic Element
supplier search online!

Halogen Lamp

Medium Wave
Sinuated Wire
Metal Ribbon

Radiant Tube
Radiant Wall
Ceramic Tile

Dehydrating
Quartz Tube

Evaporating
Short Wave
Long Wave

Embossing
Panel Type
www.process-heating.com/buyersguide

Annealing
Catalytic

Bonding
Cooking
Baking

Drying
Curing
Companies

Heraeus Noblelight America LLC • • • • • • • • • • • • • • • • •

Herr Industrial Inc. • • • • • • • • • • • •
Higuchi Inc. USA • • • • • • • • • • •
Hix Corp. • •
Indeeco • •
Indesco • • • • • • • •
Infrared Solutions & Technologies • • • • • • • • • • • • • • • • • • • •
Intek Corp. • • • • • • • • • • • • • • • • • • • • • •
ITW EAE - Despatch • • • • • • • • • • •
Innovative Industries LLC • • • • • • • • • •
Marsden Inc. • • • • • • • • • • • •
Micropyretics Heaters International • • • • • • • • •
Omega Engineering Inc. • • • • • • • • • • • • •
Osram Process Heat • • • • • • • • • • •
Process Technology • • • • •
Process Thermal Dynamics • • • • • • • • • • • • • • • • • •
Quartz Infrared Inc. • • • • • • • •
Radiant Energy Systems Inc. • • • • • • • •
Research Inc./Precision Control Systems Inc. • • • • •
Scott Can Industries Ltd. • • • • • • • • •
Selas Heat Technology Co., Red-Ray Brand • • • • • • • • • • • • •
Solar Products Inc. • • • • • • • • • • •
Solaronics Inc. • • • • •
Solaronics S.A, Bekaert • • • • • •
Soneko USA Inc. • • • • • • • • • • • • • • • •
SSHC Inc. • • • •
Superior Radiant Products Ltd. • • • • • • •
Tempco Electric Heater Corp. • • • • • • • • • • • • • • •
Thermal Engineering Corp. • • • • • • • • • • • •
Thermal Innovations Corp. • • • • • • • • • • • • • • • • • • • • • •
Trent Inc. • • • • • • • • • •
Trimac Industrial Systems LLC • • • • • • • • • •
Vulcan Catalytic Infrared Oven Systems • • • • • • • • • • • • •
Watlow • • • • • • • • • • • •
Wisconsin Oven • • • • • • • • • • • • • • • • • • • • • •
Wattco • • • • • • • • • • • • •
Zircar Ceramics Inc. • • • • • • • • • • • •
Manufacturers listed in this Equipment Overview responded to a special mailing by Process Heating and do not necessarily represent the entire industrial
infrared heater market. To be included in future listings, contact Linda Becker or email BeckerL@bnpmedia.com.

32  SEPTEMBER 2017 Process Heating

 MANUFACTURING INDUSTRIES SERVED
PROCESS

We manufacturer aftermarket parts/supplies

Ethanol/Biodiesel/Oil & Gas
Chemicals/Petrochemicals

Paper/Pulp/Converting

for our infrared heaters.

Packaging/Printing

Pharmaceuticals
Thermoforming

Plastics/Rubber
Heat Shrinking
Heat Setting

Pre-Heating
Laminating

Electronics
Pre-Drying

Tempering
Sterilizing
Extruding

Soldering

Finishing
Fusing

Other

Food

• • • • • • • • • • • • • • • • • • 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 SEPTEMBER 2017 33

 Water Treatment
Evaluating Alternative
COOLING TOWER
MAKEUP WATER
A best practices approach to comparing four alternative approaches.
By Pete Elliot,
GE Power, Water &
Process Technologies
A
s water resources become in-
creasingly stressed by drought
and intensifying demand from
competing uses, industries that
use significant quantities of water will face
greater pressure to adopt water-efficiency
strategies that can decrease fresh-water
withdrawals. In industrial operations, cool-
ing towers present a viable opportunity for
water conservation. Traditionally, the vast
majority of industrial plants that operate
open evaporative, recirculating cooling
34  SEPTEMBER 2017 Process Heating
Options
systems rely on municipally supplied wa-
ter of potable quality, on-site well water
or locally available surface water (adja-
cent rivers/lakes) as the principal makeup
water source. One approach that facilities
can adopt to reduce their draw from these
supplies — thus reducing stress on drink-
ing water reserves — is to use alternative
makeup water sources.
This analysis focuses on the evaluation
and best practices application of four ma-
jor alternative source options: sodium zeo-
lite softened water, reverse osmosis (RO)
permeate, high phosphate gray water and
municipally treated wastewater. The con-
cept of mitigating fresh-water usage by
Analysis is necessary to evaluate options
for cooling tower makeup water.
utilizing a nontraditional makeup water
supply is readily welcomed at many U.S.
facilities. However, difficulties emerge
when performing a cost/benefit analysis
of a selected option and, subsequently, the
implementation of a project in terms of
defining the practical method of applica-
tion to an existing open evaporative cool-
ing system.
Herein, an approach is presented which
analyzes the key elements that best define
whether an alternative is suitable for an
application. It includes how that alterna-
tive can fit within the scope of the water-
conservation goals determined by a facility
or external jurisdiction.
 Water Treatment

Evaluation Framework Total System Volume Evaporation Load Factor

In assessing each makeup water source 12,000 Gallon 27.0 gpm 100 Percent
option, a case study approach analyzing
operational and performance data, based Recirculation Rate Blowdown
upon an actual site application, was em- 3000 gpm 5.4 gpm
ployed. The goal was to present a clear,
Cycles Target Hottest Outlet Bulk Temp
nonbiased comparison, enabling others to Makeup 6.0 120 °F
adopt a similar process and, ultimately, to 32.4 gpm
make an informed choice among makeup
water source options when faced with that Chemistry Makeup Chemistry Cycled
highly consequential task. pH 8.3 pH 9.6
It should be emphasized that no single m-alk 186 m-alk 1004
Ca 0 Ca 2
nontraditional makeup water option will Cond. 3720
Cond. 620
always present itself as the best solution. SiO 41
SiO 7 2

The benefits, limitations and total cost of

2
Cl 264
Cl 44 SO 210
implementation associated with each al-
4

SO4
35 LSI 1.58
ternative must be objectively evaluated on
a case-by-case basis with respect to site-
specific conditions and the unique cool- FIGURE 1. A formula for cooling tower material balance when evaluating
sodium zeolite softened makeup water demonstrates how softening locally
ing system under consideration. Trade-offs
supplied city water, in lieu of using that same city water in its raw form, can
will certainly factor into the overall analy- decrease the amount of makeup water supply required and blowdown to the
sis and, in many cases, the indirect costs of municipal sewer.
each option cannot be fully anticipated.

Alternative Water Total System Volume Evaporation Load Factor

Source Drivers 20,000 Gallon 15.5 gpm 50 Percent
Beyond the water-conservation benefits,
inherent drivers are present for encourag- Recirculation Rate Blowdown
4300 gpm 1.1 gpm
ing cooling tower system owners/operators
to consider nontraditional makeup water Cycles Target Hottest Outlet Bulk Temp
sources. With municipally supplied po- Makeup
15.0 95 °F
16.6 gpm
table water, prices have risen substantially
in recent years, especially in water-stressed
Chemistry Makeup Chemistry Cycled
regions, making this option increasingly
pH 7.6 pH 9.5
cost-prohibitive in those particular regions. m-alk 844
m-alk 63
Well water, depending on the geographical Ca 74
Ca 5
location, can present performance chal- Cond. 2625
Cond. 175
SiO 28
lenges related to mineral scaling or iron- SiO 2
2 Cl
2

related fouling.
Additionally, locally sourced surface wa-
ter contains a high degree of variability and
poses key risks related to higher silt and
turbidity potential. Surface water sources
also impose higher microbiological/organ-
ic loading demand on recirculating cool-
ing water, requiring additional biological
monitoring and treatment.
Case 1: Sodium Zeolite
Softened Makeup Water
The main purpose of analyzing this op-
tion is to demonstrate how softening lo-
cally supplied city water — in lieu of using
that same city water in its raw form — can
187
Cl 12 SO 4
374
SO 4
25 LSI 2.64
FIGURE 2. Perform a cooling tower material balance analysis when
evaluating reverse osmosis permeate makeup water.
drastically decrease the amount of makeup (salt, extra regeneration water supply and
water supply required and blowdown to sewerage).
the municipal sewer (figure 1). Hypothetically, if this cooling tower
With this example, the cost of softened system were to run on raw city water
water at the facility is $3.54/1,000 gal. The without softening, the cycles of concentra-
base city water cost is $2.17/1,000 gal, and tion would be restricted to 2.0. By utiliz-
the cost of sewerage is $5.68/1,000 gal. The ing softening, the facility can achieve 6.0
difference of $1.37/1,000 gal is reflective cycles of concentration — the optimum
of the annualized softener operating costs number of cycles based on a mass balance

www.process-heating.com SEPTEMBER 2017  35

 Water Treatment

Table 1. Using Raw City Water Without and With Softening

Without Softening — 2.0 Cycles of Concentration
Blowdown: 10,643,400 gpy x $5.68/1,000 gal = $60,454.51/yr
Makeup: 21,286,800 gpy x $2.17/1,000 gal = $46,192.36/yr
Total Annual Water Cost: $106,646.87

With Softening — 6.0 Cycles of Concentration

Blowdown: 1,971,000 gpy x $5.68/1,000 gal = $11,195.28/yr
Makeup: 12,614,400 gpy x $3.54/1,000 gal = $44,654.98/yr (softened)
Total Annual Water Cost with Softener in Use: $55,850.26

Table 2. Total Annual Makeup Water Cost at 15 Cycles of Concentration

Annual Usage Makeup Source Net Annual Usage Net Annual Cost
Water Component
(1,000s gallons) Percentage (%) (1,000 gallons) ($/Year)

Reverse Osmosis Permeate 8,935.20 85 7,594.92 $81,797.29

Softened City 8,935.20 10 893.52 $5,539.82
City (straight) 8,935.20 5 446.76 $2,314.22
Subtotal 8,935.20 100 8,935.20 $89,651.33
Blowdown
- - - $5,787.38
(578,160 gallons annually)
Total $95,438.71

Table 3. Total Annual Water Cost at 2 Cycles of Concentration Water

Annual Usage Net Annual Cost
Water Component Cost $/1,000 gallons
(1,000s gallons) ($/Year)

City Makeup 16,293.60 $5.18 84,400.85

Blowdown 7,884.00 $10.01 78918.84
Total - - 163319.69

curve analysis. Based on brief cost analysis
of this comparison (table 1), the net yearly
savings for using 100 percent sodium zeo-
lite softened city water at this facility is
$50,796.61.
At 6.0 cycles of concentration, highly
alkaline conditions with essentially no
calcium or magnesium hardness are pres-
ent at this facility. But even with elevated
pH (theoretically at 9.6), the potential
still exists for low carbon steel corrosion
to occur. Another factor is the elevated
temperature of the heat exchanger skin/
surface, which contributes to an even
higher potential for corrosion.
Because of the corrosion-related risks,
the benefits are counterbalanced against
the requirement to maintain robust con-
centrations of corrosion inhibitors and dis-
persants. With softening, it also is impera-
tive that tight monitoring and control of
pH and conductivity are maintained.
Case 2:
RO Permeate Makeup Water
In this case study, RO permeate was cho-
sen as the primary makeup water source to
the cooling tower (figure 2). The extremely
high concentration of total alkalinity pres-
ent in the local city-supplied water source

36  SEPTEMBER 2017 Process Heating

 Water Treatment

would essentially limit the cooling tower

cycles of concentration to 2.0 if no treat- Total System Volume Evaporation Load Factor
ment was used. By blending city water (5 30,000 Gallon 29.8 gpm 40 Percent
percent) with softened city water (10 per-
cent) and RO permeate (85 percent), this Recirculation Rate Blowdown
facility produces makeup water that is vir- 8280 gpm 9.9 gpm
tually free of all ionic species, including po-
Cycles Target Hottest Outlet Bulk Temp
tentially corrosive monovalent anions such Makeup
4.0 100 °F
as chlorides. Thus, operation of the cool- 39.7 gpm
ing tower at 15 cycles of concentration is
achieved, dramatically reducing the overall Chemistry Makeup Chemistry Cycled
makeup water usage and blowdown to the pH 8.3 pH 7.4
m-alk 204 m-alk 63
city sanitary sewer. The cooling tower also Ca 820
Ca 205
can act to “use up” excess RO machine ca- Cond. 3612
Cond. 903
pacity if need be. SiO2 56
SiO2 14 Cl 500
At $10.77/1,000 gal, the cost to produce Cl 125 SO4 824
RO permeate makeup water is significant. SO4 53 LSI 0.54
However, in a hypothetical sense, the total
overall cost of this option was still deter-
mined to be significantly lower than uti- FIGURE 3. The cooling tower material balance when evaluating high
lizing municipal potable water priced at phosphate gray water usually reveals a significant cost savings. Most
facilities that adopt this strategy have access to an on-site source
$5.18/1,000 gal (assuming 2.0 cycles of
of process wastewater that inherently contains a high phosphate
concentration). A comparison is provided concentration.
in tables 2 and 3.
Based on a corrosion study of this cool-
ing tower system, an elevated corrosion
9.902

Cooling Tower: pH Ana.-(pH)

potential with low carbon steel and cast
iron is present, necessitating robust levels 9.104
of corrosion-inhibitor components be ap-
plied. Additionally, the facility must man- 8.306

age the RO reject stream as part of the 7.508

overall discharge flow. It should also ad-
minister RO membrane pretreatment re- 6.710
quirements such as softeners or use chemi-
5.912
cal anti-scalant agents, which increases the 25-Jan-16 08-Feb-16 22-Feb-16 07-Mar-16 21-Mar-16 04-Apr-16
total cost of operation.

Case 3: FIGURE 4. In systems using gray water, pH control is critical.

High Phosphate Gray Water
The principal reason for using high phos-
phate gray water as a makeup water source 24.41 5.000
Cooling Tower: Delta PO4- (ppm)

is the significant cost savings associated

18.66 3.690
Cooling Tower: STP- (ppm)

with its use (figure 3). Most facilities that

adopt this strategy have access to an on- 12.92 2.382
site source of process wastewater that
inherently contains a high phosphate 7.167 1.074
concentration. In these cases, the need to
1.419 -0.2340
purchase municipal water is removed, and
the wastewater that would otherwise have -4.329 -1.542
to be managed upstream in the process also 25-Jan-16 08-Feb-16 22-Feb-16 07-Mar-16 21-Mar-16 04-Apr-16
is eliminated.
Another benefit is the relatively high
FIGURE 5. Proper cooling tower dispersant concentration can help
levels of phosphate realized, which act as
maintain the system.
an excellent corrosion inhibitor for the

www.process-heating.com SEPTEMBER 2017  37

 Water Treatment

As with other makeup water alterna-

Total System Volume Evaporation Load Factor
tives, however, several built-in challenges
800, 000 Gallon 1213.8 gpm 100 Percent
exist. Municipally treated wastewater may
contain elevated phosphate concentra-
Recirculation Rate Blowdown
269.7 gpm
tions, which, in turn, drive robust poly-
68000 gpm
meric dispersant demand. This option also
Cycles Target Hottest Outlet Bulk Temp typically carries high water conductivity.
Makeup 5.5 120 °F
1483.5 gpm
Also, due to the potentially high chlo-
ride strength, cycles of concentration can
Chemistry Makeup Chemistry Cycled be limited if high percentages of stainless
pH 8.3 pH 7.5 steel alloy-containing components are
m-alk 48 m-alk 72 present in the cooling water system com-
Ca 90 Ca 495 ponents or heat exchangers.
Cond. 1200 Cond. 6600
SiO2 28 Reliable control of pH is critical when
SiO2 5 dealing with elevated phosphate concen-
Cl 952
Cl 173 SO4 920
SO4 140
trations in the cycled cooling water. In the
LSI 0.63
case study, which operates at 5.5 cycles of
concentration, a significant quantity of sul-
FIGURE 6. The mass balance analysis for municipally treated wastewater is furic acid is fed on a continuous basis to
shown. maintain a 7.50 pH target, promoting the
solubility of the cycled phosphates. Cor-
low carbon steel piping and components the cooling tower system. Most impor- rosion monitoring was the key feedback
in the cooling tower system. Additionally, tantly, the system pH must be monitored provider with this cooling tower. Increased
a facility that utilizes gray water as one and controlled closely to ensure that cal- dosage rates of copper corrosion inhibitor
of its primary makeup water sources is cium phosphate solubility is controlled. are required to reduce copper corrosion
demonstrating measurable environmental This most frequently involves some form rates, which can be potentially higher at
responsibility. of external pH/alkalinity reduction agent neutral or near-neutral pH control ranges.
such as sulfuric acid, hydrochloric acid or,
in some cases, carbon dioxide. Template for Decision
The cooling tower system in the case As demonstrated with each of these case
No single nontraditional study is equipped with an automated mon- studies, specific factors and challenges
makeup water option itoring/control system (figures 4 and 5). will come into play when evaluating non-
will always present The pH control range is set at 7.30 to 7.50, traditional makeup water source options.
itself as the best utilizing sulfuric acid as the pH control/ Armed with an objective, data-driven ap-
alkalinity reduction agent. Phosphate solu- proach, however, facilities can objectively
solution. The benefits, bility also is effectively maintained with weigh the risks and benefits of each poten-
limitations and total proper polymeric dispersant dosage and tial makeup water alternative in reaching
cost of implementation residual monitoring, thus enhancing corro- a decision.
associated with each sion-inhibition properties and minimizing Inevitably, a series of associated costs is
phosphate-related fouling potential. required for inclusion with the analysis of
alternative must be each alternative with respect to the steps
objectively evaluated. Case 4: Municipally Treated required to keep the cooling tower sys-
Wastewater tem under control from a water treatment
Like high phosphate gray water, munici- perspective. It is how well these tangible
However, this option also presents mul- pally treated wastewater offers benefits and intangible costs are managed that ul-
tiple inherent challenges. First, high phos- related to reduced water costs and envi- timately determines the degree of success
phate gray water brings the possibility of ronmentally responsible practices (figure or failure linked with the type of makeup
phosphate-related fouling, ushering in 6). This strategy also permits facilities to co water selected.
the need for high concentrations of poly- mply with local and state regulations that
meric dispersant chemistry to maintain mandate the use of municipally treated Pete Elliott is a senior product applications
the higher cycled phosphate concentra- wastewater, a benefit realized in this case engineer with GE Power, Water & Process
tions in a soluble state. This is especially study where the facility can meet reclaim Technologies. The Trevose, Pa.-based
true where the calcium hardness also criteria under Title 22 of the California company can be reached at 866-439-2837 or
cycles up to an elevated concentration in Administrative Code. visit the website at www.gewater.com.

38  SEPTEMBER 2017 Process Heating

DOWNLOAD FREE TODAY
Your industry
information where
and when you want it.

Mobile App
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.

Grieve Corp. Pepperl+Fuchs

Top-Loading Oven Used for Drying Electrical Explosion Protection Equipment
The 500°F (260°C),
top-loading oven
can be used for
applications such
as drying water
from racks of piston
rings. Workspace
dimensions of this
oven measure 48
x 48 x 36", and 40
KW are installed in Electrical explosion-protection equipment is tailored to
Incoloy-sheathed meet the multifarious requirements of process automation.
tubular heating elements. A 4,200-cfm, 3-hp recirculating Product line includes basic terminal boxes, control units and
blower provides horizontal airflow to the workload. The oven stations, and complex control solutions. Utilization of various
has 4" insulated walls; an aluminized steel exterior; and Type types of explosion protection as well as a large quantity of
304, 2B finish stainless steel interior with continuously back enclosure styles facilitate the design of efficient solutions
welded seams. Additional features include an air-operated for each application and environment. The enclosures are
rear sliding door; reinforced 0.25" steel plate top; and wear available in various sizes and materials. Customized solu-
bars at sides of workspace. The floor of the workspace is tions come in explosion-protection types: intrinsic safety Ex
reinforced for 1000-lb loading at removable subway grate. i, increased safety Ex e, flameproof Ex d and pressurized Ex p,
Controls include a digital temperature controller and manual- depending on the specific application’s requirements.
reset excess-temperature controller with separate contactors 330-425-3555
and a recirculating blower airflow safety switch. www.pepperl-fuchs.us
847-546-8225
www.grievecorp.com Conair
Portable Chillers with Variable-Speed
Eurotherm USA, Schneider Electric Compressors Offer Energy Savings
Precision Controller with Robust The 10-ton and 20-ton EP2 Series can handle low, partial
Cybersecurity Strategy and full chilling loads. In head-to-head tests against 10- and
With a high level of func- 20-ton chillers equipped with fixed-speed and digital scroll
tionality and configurabil- compressors, the company says, the portable chillers with
ity, EPC3000 offer ease of variable-speed compressors provided energy savings of
installation, commissioning 20 to 50 percent in a range of realistic and low-load condi-
and replacement. The pre- tions. This option is
cision controllers achieve available on both
the required stability, water-cooled and air-
accuracy and repeatability cooled models from
and provides real-time indi- the company. All
cators for efficient monitor- portable chillers with
ing of process equipment the variable-speed
effectiveness. The Eurotherm brand programmable precision compressor option
controller with Ethernet communications helps deliver an from this com-
efficient and secure process, maintaining high standards pany also include a
of production and helping to ease cybersecurity concerns. touchscreen control-
According to the manufacturer, it offers particular benefits in ler with easy-to-use
heat treatment for aerospace and automotive, life sciences, operational and
semiconductor, glass and food and beverage applications. diagnostic screens.
703-724-7300 724-584-5500
www.schneider-electric.com www.conairgroup.com

40  SEPTEMBER 2017 Process Heating

 Product Highlights

ThermoElectric Cooling America Corp. Graco Inc.

Thermoelectric Air Conditioner with Stainless Steel Flange Connections on
Universal Input Air-Operated Double-Diaphragm Pumps
The AHP-2259 Series Line of corrosion-resistant stainless steel air-operated
automatically double-diaphragm (AODD) pumps includes stainless steel
accepts 90 to 264 ANSI/DIN welded flanges. The flanges are available in vertical
VRMS input. No and forward-facing orientations and have a rotatable design
adjustments are that simplifies connection to process piping. The Husky brand
required to be made pumps range from 0.25 to 3" connections and produce flow
by the end user. The rates up to 300
enclosure cooler has gal/min. Configu-
a universal input power rable in a range of
supply. The portable air condition- pump body mate-
ers can meet a range of input volt- rials and wetted
ages, making them suitable for worldwide operation. Other elastomers, the
versions include high capacity for more cooling and high AODD pumps are
efficiency for power saving. Either includes an energy-saving engineered to be
ECO-Mode temperature control feature for passive cooling compatible with
during lower demand times. Cooling capacity is 1300 to 1800 challenging fluid
BTU/hr, depending on configuration. Heat/cool or cool-only characteristics
configurations are available. End users can specify NEMA 12, such as low and high temperatures, high levels of abrasives,
NEMA 4 or NEMA 4X as well as temperature control options. and caustic and corrosive materials.
773-342-4900 866-348-3188
www.thermoelectric.com www.graco.com

WE KNOW ELECTRICITY
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www.process-heating.com SEPTEMBER 2017  41

Product Highlights

Quantech Vortec
Air-Cooled Variable-Speed Screw Chillers to Electric Cabinet and Enclosure Cooler
360 tons Prewired to ease installation, Vortex AC
The QTC4 line in- can be operational in minutes to
cludes 21 models quickly cool sensitive electronics
ranging from 150 and controls. Cooling capaci-
to 360 tons. The ties of 900, 1500 or 2500
line of air-cooled BTU/hr allow users to
variable-speed- select a model to opti-
drive screw chill- mize performance and
ers includes hybrid operating cost. The ther-
falling-filling-type mostatically controlled
evaporators and devices maintain
microchannel- enclosure tempera-
type condensers to optimize heat transfer and minimize the tures at user-defined
refrigerant charge.To minimize pump energy consumption, setpoints. Electric
chillers can be utilized in variable primary flow (VPF) systems, Vortex AC models
which reduce the chiller flow to match the load. Options in- operate in environ-
clude variable-speed-drive (VSD) condenser fans to enhance ments up to 175°F (79°C) and
part-load efficiency and reduce part-load sound. Native com- produce only 62 dBA, making
munications capability supports BACnet (MS/TP), Modbus them well suited for many industrial
and N2 with optional support for LON communications. environments.
414-524-6170 513-686-8200
www.quantech-hvac.com www.vortec.com

Mettler-Toledo Process Analytics

Multi-Parameter Transmitters

Model M400 has a combined touchscreen and tactile softkey

user interface. The high contrast screen permits viewing in
all light conditions, and the softkeys allow operation even
if protective gloves are being worn. Parameters covered
address the needs of the process industries from chemical ap-
plications to pharmaceutical production. The transmitters are
compatible with analog sensors and the company’s digital
Intelligent Sensor Management (ISM) probes. A software
For over
For 6050
over years, wewe
years, havehaveprovided
providedElectrical Safety
Electrical Equipment
Safety for for the
Equipment
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Industry. complete
For completeinfo,
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email@protectioncontrolsinc.com. tool supplied with the transmitter enables configuration of a
Visit our website at www.protectioncontrolsinc.com.
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transmitter via PC and USB stick and shared with similar trans-
mitters, simplifying setup and batch configuration efficiency.
800-352-8763
www.mt.com

42  SEPTEMBER 2017 Process Heating

Free Literature To request any of these free brochures, use the contact information in the literature item in which you
are interested, or consult our ad index for the company's phone, fax and website.

New electric heaters from Heatec Versatile MTH Series Burners

Catalytic Industrial Systems
Catalytic Industrial Systems is industry’s infrared
authority, offering advanced IR technology for
every cure requirement.
C.I.S. manufactures curing systems that meet
the needs of industry worldwide. Our mission
is to understand your process and to engineer
the most efficient, cost effective way to achieve
your process goals.
Catalytic Industrial Systems,
www.catalyticirovens.com
Heatec, Inc., Chattanooga, Tennessee, has
introduced a new line of electric circula-
tion heaters. They provide heat for a wide
variety of manufacturing and processing
operations. The heaters are used to heat
liquids or gases for industrial applications
such as chemicals, oil, water, air, nitrogen,
steam, etc.
Heatec Electric
Process Heaters,
heatec.com
Designed for longevity and trouble-free oper-
ation, Industrial Combustion’s MTH Series
burners are ideal for process heating applica-
tions.
These burners feature:
• Swing-away air housing for easy access to
internal components
• Low NOx/CO emissions without FGR
• Up to 5:1 turndown capability
• Firing rates available from 2.5 to 71.0 MM
BTU/hr
Industrial Combustion,
ind-comb.com

Vertical Water Wall Design MultiTherm Coils Paratherm

Low NOx Steam Boilers
Shown on is a 9.5LWW (Low NOx) 9.5 hp,
150 psi Steam Boiler. Standard heavy-duty
1” tubes are used with a 0.12” wall thickness.
The tubes are bent around the flame, creat-
ing a water wall furnace. A large 0.5” thick
seamless horizontal steam drum is used for
a steady water line and clean dry steam pro-
duction. Footprint similar to vertical tubeless
boiler. The sealed combustion design raises
efficiency with lower excess air. Units avail-
able 9.6 to 24 hp.
Parker Boiler Co.,
www.parkerboiler.com
Whether it's new, retrofit or replacement
coils, MultiTherm Coils can successfully and
economically accommodate a customer's
heating or cooling requirement.. We build
HVAC Coils of all types, Industrial Coils,
Tube bundles, Heat Exchangers. We spe-
cialize in quick ship and are capable of 3, 5 or
10 days on most coils.
MultiTherm,
www.multithermcoils.com
Paratherm's User's Guide to Heat Transfer
Fluids and Hot-Oil Systems is a web site with
links to over 30 documents containing valu-
able instructions, insights, and advisories. For
users of heat transfer fluids, this essential refer-
ence includes detailed specifications for rec-
ommended system components, fluid analysis
and system troubleshooting.
Paratherm,
http://www.paratherm.com/users-guide

www.process-heating.com SEPTEMBER 2017  43

Free Literature To request any of these free brochures, use the contact information in the literature item in which you
are interested, or consult our ad index for the company's phone, fax and website.

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ACS
The K Series 2’ NPSH Pump, Used on
Condensate Return and Boiler Feed Units for
condensate temperatures up to 212 ° F. Pump
can operate in Low NPSH conditions con-
trolling damaging cavitation and providing TM

steady flow. Efficient design provides maxi-

mum capacity, minimum motor load, and the
ability to operate in low NPSH conditions.
ACS,
www.acscorporate.com

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44  SEPTEMBER 2017 Process Heating

PH Classifieds Display Classified Rates:
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ADVERTISING INDEX
21 ACS Group 262-641-3808 www.sterlco.com

29 Aitken Products, Inc. 440-466-5711 www.aitkenproducts.com

7 Catalytic Industrial Systems 800-835-0557 sales@catalyticirovens.com

10 Fostoria 800-495-4525 www.fostoria-tpi.com

11 Glenro, Inc. 973-279-5900 www.glenro.com

48 Heatec, Inc. 423-821-5200 www.heatec.com

2 Industrial Combustion 608-329-3131 www.ind-comb.com

9 MultiTherm LLC 800-339-7549 www.multitherm.com

15 Parker Boiler 323-727-9800 www.parkerboiler.com

41 Payne Controls 304-757-7353 www.payneng.com

42 Protection Controls 847-674-7676 www.protectioncontrolsinc.com

www.process-heating.com SEPTEMBER 2017  45

Places Faces
Javier Jimena was
named president and
general manager of
Spirax Sarco Inc.,
Blythewood, S.C.
He assumed his role
Jimena on July 17 and is
responsible for the U.S. business. He
previously served as regional general
manager for Spirax Sarco Argentina,
leading Argentina, Chile, Peru and
Latin America. Before joining Spirax
Sarco, he held a number of general
and strategic management positions in
Argentina and Brazil.
Fulton Thermal Corp., Pulaski, N.Y.,
a manufacturer of thermal fluid heat
transfer products, added a used stock
heater program. The refurbished
thermal fluid heaters are suited for
customers in need of quick-ship order
fulfillment. The used heaters offer the
same capabilities as standard coil heat-
ers from the company. They include a
90-day warranty and standard Fulton
factory and engineering support.
Bruce Nelson, president of Colmac
Coil, Colville, Wash., was awarded a
new patent for a plate freezer innova-
tion. Nelson's innovation uses a wick-
ing structure and internal passageways
to ensure the uniformity of the refriger-
ant. The design also reduces health
hazards should a leak occur. A bime-
tallic coupling used at the connection
of the conduit to the freezing plates
eliminates the risk of refrigerant leaks
over multiple freezing cycles. Read the
patent at www.colmaccoil.com.
Columbus, Ohio-based BriskHeat, a
provider of flexible heating solutions
46  SEPTEMBER 2017 Process Heating
used for flow viscosity control, vacuum
bake-out, composite curing, tempera-
ture process control, freeze protection
and condensation prevention, hired
Hampton Brown to fill the newly cre-
ated role of international director of
composite sales. BriskHeat seeks to
expand its footprint in the $8 billion
industry, building on its experience
with composite curing and processing
equipment such as hot bonders, heat-
ing blankets and other devices.
Yokogawa Electric Corp. acquired
TechInvent2 AS, a Norwegian enter-
prise that holds the rights to FluidCom,
a chemical-injection metering valve
(CIMV) that prevents blockages and
corrosion in oil wells, pipelines and
other facilities. The valve employs a
patented technology for thermal con-
trol and incorporates the functions of
a mass flow meter, control valve and
valve controller.
Fluke Process Instruments, Santa
Cruz, Calif., launched a new website
combining its industrial temperature
measurement solutions. Fluke
Process Instruments was formed by
joining three brands — Raytek,
Ircon and Datapaq — and offers a
complete line of infrared sensors,
linescanners, thermal imagers and
profiling systems. View the new site at
www.flukeprocessinstruments.com.
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Contributing Editor • JOY LEPREE ANDERSON
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LIST RENTAL
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