www.process-heating.com | February 2011 | Volume 18, Number 2
Control
Tool In print and online, our Equipment Overview brings controls makers into tight focus.
Periodical Class
14 How to Drive Down Drying Costs 17 Boiler Fundamentals 20 Effective Process Management
These heaters will be fully assembled and checked at our factory before delivery.
Get a complete heater package Need a new heater? Get a complete heater package from Heatec. A complete package eliminates hassles, saves you time and saves you money. Our package includes design, manufacturing, factory assembly, on-site setup and startup. We also offer maintenance contracts and provide free phone support. Heaters have many components from a variety of manufacturers. It’s always best to mate these components with the heater and adjust them before the heater is shipped to you. This eliminates most compatibility problems. Our goal is that setup of our heater at your plant will be trouble free, without undue rework. Most setups should only require re-assembly of parts dismantled
for shipping, plus connection of electrical power and piping. Complete factory assembly eliminates last-minute fieldwork that can cause startup delays. It also eliminates buck passing if things don’t go right. Moreover, if a problem develops later, you won’t have to wrangle with a variety of component suppliers to fix it. So, when you buy a new heater, always choose a manufacturer that provides a complete package. Heatec has this capability, which sets us apart from others. Call today and let us answer any questions you have about our heater packages.
HEATEC
( % ! 4 % # DQ$VWHF,QGXVWULHV&RPSDQ\ :,/6215'&+$77$122*$7186$)$;KHDWHFFRP
Full control at your fingertips
s "RIGHT DISPLAY WITH SCROLLING TEXT s 0)$ WITH AUTO TUNE AND FUZZY LOGIC s 0,# LADDER LOGIC CONTROL s -ULTIPLE CONFIGURATION MODES EASY STD PRO ® s #OMMUNICATIONS %THERNET -ODBUS PH02114Yok ® ® $EVICE.ET 0ROFIBUS AND MORE
s )NTUITIVE CONFIGURATION SOFTWARE s YEAR WARRANTY For more information, go to
AD A D21 D2 D 110 102 02
WWWUTADVANCEDCOM 800-258-2552
February 2011 Volume 18 • Number 2
www.process-heating.com WEB EXCLUSIVES: READ MORE AT WWW.PROCESS-HEATING.COM Q Setting Up an RS-485 Network to a PC
page
page
14
20
Although RS-485 communication has been around for a while, one does not set up networks every day. When you do, it is important to remember there are four steps in setting up an RS-485 network to a PC serial interface.
Q Heat Recovery Incentives Besides the return on investment achieved from a properly applied heat recovery system, a number of federal, state, local or utility incentives may be available.
Features 12
Equipment Overview: Temperature Controllers Control Tool You know you need to get control of your process. But, what kind of control does your process need? Process Heating has created this bullet chart to help you figure that out.
Q Technology to Increase Boiler Operating Efficiency Licensed Innovative technology for capturing waste heat and water vapor from exhaust/flue gas for reuse from industrial and commercial boilers and other industrial process equipment will soon be commercially available as a result of a licensing agreement.
UPDATED DAILY Q New Products
Q Industry News
ALWAYS ONLINE
14
Dryers How to Drive Down Drying Costs Although expenditures for dryer energy may be only a small fraction of a product’s cost, reducing energy usage could provide significant bottom-line savings.
17
Boilers Achieving Higher Efficiencies & Lower Emissions More than 24,000 installed boilers operate in the 10 million BTU to 100 million BTU range. What are the trends for this important segment?
20
Process Control Software Automates Pasta-Making Process Integration of panel-mounted process controllers with RS-485 communication and process control software has allowed a small pasta manufacturer upgrade a SCADA-based operation at minimal cost.
Columns & Departments 6
Editor’s Page
24 Classified Directory
7
Inner Workings
25 Advertiser Index
11
Calendar
26 Places & Faces
Q Archives Q Calendar of Events Q Drying Files columns
Q Energy Notes column Q Equipment Overviews Q Heating Highlights
Q Digital Editions Q Buyers Guide Q Archived Webinars
Check out our redesigned site with more frequent updates and web exclusives!
Q Go Mobile Use your smart phone to read Process Heating, wherever you are! Simply visit http://gettag.mobi/ with your phone’s browser to install the Microsoft Tag app. Then, point your phone’s camera at the tag below to be taken to our current issue online — instantly. The reader works on most current smart and advancedd ffeature phones, h includi l d ing Windows Mobile (5.5 and above), iPhone, Blackberry, Symbian and J2ME.
About the Cover On the manufacturing line at Yokogawa Corporation of America, Newnan, Ga., temperature and process controller units are assembled and tested at an automated test station. The Yokogawa controllers have option cards installed into them so that the unit can be configured to the customer’s specifications. To learn more about temperature controllers, see page 12.
22 Products
PROCESS HEATING (ISSN 1077-5870) is published 12 times annually, monthly, by BNP Media, 2401 W. Big Beaver Rd., Suite 700, Troy, MI 48084-3333. Telephone: (248) 362-3700, Fax: (248) 362-0317. No charge for subscriptions to qualified individuals. Annual rate for subscriptions to nonqualified individuals in the U.S.A.: $115.00 USD. Annual rate for subscriptions to nonqualified individuals in Canada: $149.00 USD (includes GST & postage); all other countries: $165.00 (int’l mail) payable in U.S. funds. Printed in the U.S.A. Copyright 2011, by BNP Media. All rights reserved. The contents of this publication may not be reproduced in whole or in part without the consent of the publisher. The publisher is not responsible for product claims and representations. Periodicals Postage Paid at Troy, MI and at additional mailing offices. POSTMASTER: Send address changes to: PROCESS HEATING, P.O. Box 2146, Skokie, IL 60076. Canada Post: Publications Mail Agreement #40612608. GST account: 131263923. Send returns (Canada) to Pitney Bowes, P.O. Box 25542, London, ON, N6C 6B2. Change of address: Send old address label along with new address to PROCESS HEATING, P.O. Box 2146, Skokie, IL 60076. For single copies or back issues: contact Ann Kalb at (248) 244-6499 or
[email protected].
www.process-heating.com • Fe b r u a r y 2 0 1 1
|
5
By Linda Becker
Commentary Tools on CD, Incentives Database, Bioenergy Resources
3 Tools to Check Out Most processors likely are familiar with the Industrial Technologies Program from the Department of Energy’s Office of Energy Efficiency and Renewable Energy. ITP works with industry to develop and promote technologies and tools that industrial processors can use to satisfy energy and environmental performance goals. It is an invaluable resource I have mentioned before, and it has released new tools worth a closer look. • Access Industrial Energy Management Resources and Tools This free CD includes software tools, tip sheets, fact sheets and case studies to help manage process heating, steam and motor-driven systems. Using the CD, you can get information on energy assessments, learn how to partner with the “Save Energy Now” program, and discover energy-saving technologies. To order your copy, contact the EERE Information Center online at www1.eere.energy.gov/ informationcenter or call (877) 337-3463. • Find Incentives for Your Industrial Plant by City or Zip Code ITP’s state incentives and resource database currently contains nearly 3,500 programs that provide energy assessments, grants, rebates,
loans, training and other tools to help manufacturers implement energy-saving projects. Located at www1.eere.energy.gov/industry/ states/state_activities/incentive_search.aspx, the site includes incentives at the state, local, utility and non-profit levels. • Research Bioenergy Online Resource In January, the DOE launched the Bioenergy Knowledge Discovery Framework. It allows simultaneous geographic mapping of complex data sets such as biomass feedstock production, fueling stations and biorefineries on a national, state and county level. Registered users will be able to contribute additional data. For more information, visit www1.eere.energy.gov/biomass. Check out these resources and let me know what you think.
Linda Becker, Associate Publisher and Editor,
[email protected]
Raytek MI3 ®
World Cup Winner for IR process monitoring! The new Raytek MI3 team of infrared sensors wins the World Cup of IR process monitoring by offering industry-leading performance at the lowest installed cost per measurement point. This new generation of infrared thermometers delivers innovative new features for a broad range of OEM and industrial manufacturing processes with pricing that will save you time and money. Team Stats ■ Low cost, fully networkable OEM solution ■ Multi sensor design reduces cost & simplifies installation ■ Field calibration software saves time and money ■ Standard USB digital interface for fast, easy set-up ■ DataTemp® Multidrop Software for remote configuration Want to learn more about what the MI3 team can do for your business? Email us today at
[email protected]
The Worldwide Leader in Noncontact Temperature Measurement 6
|
Fe b r u a r y 2 0 1 1 • Process Heating
www.raytek.com/PH Call 800-227-8074 for application assistance
Inner Workings
Spray Drying Process Creates Aloe Vera Powder Until recently, the therapeutic plant aloe vera has been dried naturally in the sun — a fairly crude process with limited uses — or has undergone an extensive preparation for freeze drying for pharmaceutical use. A new process from GEA Niro bridges the gap between those processes to provide a high quality powder that is suitable for use in personal care, nutraceutical and food products.
As a part of GEA Process Engineering Inc., the Columbia, Md.-based company already supplies freeze drying technology that produces high quality aloe vera powder for use in pharmaceutical products. Spray drying will provide an option for those looking to use the final dried product as a functionalityenhancing agent for yogurts, dressings, drinks, face creams and cosmetics. The process requires the aloe vera cactus leaves to be processed so the moisture-absorbing pulp can be microdisintegrated and spray dried efficiently. First, the leaves are filleted to remove the hard outer shell. What is left — the inner tissue — is made up of 98 percent water and 2 percent tissue matter that behaves like a sponge. This means that when the aloe vera has been spray dried, it will act as a thickening agent and provide texture and volume to the end product without adding calories. In the GEA Niro process, the aloe vera fillet is put through a shredder and a milling machine to create a feed that can be atomized. The feed pulp is heated to less than 122°F (50°C) and
dosed with enzymes that break down the cellulose chain in a reaction tank, reducing viscosity. The fibers then are segregated, and those less than 200 microns continue in the process. Aloin, used as a bittering agent in beverages and as a pharmaceutical laxative, is extracted. The remaining pulp then goes on to be pasteurized, creating a gel. After evaporation to increase the total solids of the gel, it is spray dried into a fine, free-flowing powder. Robert Djernaes, Food Sales Group manager for GEA Niro, explains that the new process will make aloe vera more accessible to a range of industries. “The spray dried powder is ideal for use in all products, and the spray drying process has lower operation costs compared to freeze drying,” he says. For more information, visit www.niroinc.com.
Pass-Through Oven Solves Arterial Stent Challenge Carbolite, a manufacturer of standard laboratory and industrial ovens in Hope Valley, U.K., has developed a solution for a leading producer of arterial stents used by clinicians to treat cardiovascular disease. The stent maker required a custom Class 10,000 clean room oven to meet precise production needs. Although the stents only needed heat treatment to a maximum 752°F (400°C), the oven’s dimensions and temperature uniformity specifications posed a major technical challenge. The solution called for a chamber nearly 5' deep to be heated with a stability of better than ±1.8°F (±1°C) under steady state conditions coupled with temperature uniformity better than ±9°F (±5°C). To ensure good temperature uniformity, the oven is divided into three separately controlled zones. The main program controller links digitally to two slave controllers, which automatically track the program set in the main controller.
INSPIRED INNOVATION
Despatch LAC High Performance Benchtop Ovens The LAC forced convection oven utilizes horizontal airflow for exceptional temperature uniformity and the shortest possible processing time. The result is proven reliability in demanding production and laboratory applications, such as curing, drying, sterilizing, aging, and other process-critical procedures. Temperatures up to 260°C (500°F) Horizontal recirculating airflow Nickel plated shelves
rated to 23kg (50 lbs) 430 polished stainless
steel interior
Thermal Processing Technology
phone: 1-952-469-5424
[email protected] www.despatch.com © 2011 Despatch Industries. All rights reserved.
www.process-heating.com • Fe b r u a r y 2 0 1 1
|
7
Inner Workings The Class 10,000 clean room pass-through oven heat treats arterial stents to a maximum 752°F (400°C). To ensure good temperature uniformity, the oven is divided into three separately controlled zones.
For over 50 years, we have provided Electrical Safety Equipment for the Industry. For complete info, contact us at
[email protected]. Visit our website at www.protectioncontrolsinc.com
A digital time-temperature program controller manages the oven temperature and can store up to 20 programs each with up to 16 segments. A program segment relay can be set to sound an audible alarm at the end of the program. The oven employs forced-air circulation positioned to give optimum zone uniformity. A specially designed load management system also is a key requirement because the stent manufacturer needs to quickly and easily load the untreated arterial stents into the chamber through the “front door” and unload the medical devices through the opposite door within a clean room environment. Carbolite designed and built a loading system that allows the stents to be loaded onto mandrels for easy transport straight from a carrier on a trolley into the oven chamber, ready for the heating process. The loading system has an adjustable support frame that holds 30 shafts.
WE KNOW ELECTRICITY Questions about SCR power control systems? We can help. • Fusing • Cooling • Heatsink Design • Voltage protection • Application assistance For more than 40 years we have been designing and building SCR controls for hundreds of thousands of users like you.
For answers to your solid state control questions
Call 1-800-331-1345 Box 70 Scott Depot, WV 25560-0070 • Fax: 304-757-7305 E-mail:
[email protected] • www.payneng.com 8
|
Fe b r u a r y 2 0 1 1 • Process Heating PH06074Payne01Blue.indd 1
5/21/07 9:53:59 AM
Inner Workings Parker Low NOX Boilers Suit Multiple Applications Four Parker Boiler Co. model G1536RL low NOX Water Wall boilers are part of a multiple-boiler replacement job at a California aerospace plant. Designed to ease service, the units incorporate Parker’s low NOX System 4 with a cylindrical premix metal-fiber burner and a variablefrequency drive blower for additional energy savings. Last year, Parker Boiler, Commerce, Calif., installed Water Wall boilers in several locations. For more information on Parker boilers, go to www.parkerboiler.com.
For more information go to www.carbolite.com.
Finding Temperature Sensor Facts Thermocouple and RTD users interested in knowing the range and accuracy values of the instruments they use or plan to buy can check manufacturers’ sites for great information. One such source is www.nanmac.com. While there, look for a comparison of temperature sensors and their response times. There’s also detail on thermocouple alloy use and characteristics, which includes a chart showing thermocouplewire limits of error. The website, from Nanmac Corp. in Framingham, Mass., carries charts, tables, white papers and links to related sites. Click on “Resources” to access the material.
Preheat Fluid Fast with Direct Injection Heater Understanding the industrial markets that need to rapidly and accurately
heat water and water-based slurries by injecting steam directly into the fluid, Kadant Johnson Inc., Three Rivers, Mich., has introduced a direct steam-injection water heater product line. Direct injection heaters are used in many processing applications, including preheating boiler feedwater, pretreatment of fibrous slurries such as pulp stock, pretreating biomass, paper-starch processing, sanitization, tank cleaning and anaerobic treatment of organic waste. “Direct injection heating uses all the sensible and latent heat of steam to heat the fluid,” says Gregory L. Wedel, Kadant’s president. “It can provide equal heating to that of an indirect heat exchanger process with 20 percent to 30 percent less energy. The improved energy efficiency results in less steam consumption with no reduction in output. This new product line complements our existing steam specialty products to maximize energy efficiency in process industries.”
INSPIRED INNOVATION
Despatch TA/TF Truck-in Ovens The TA truck-in/walk-in oven is designed for industrial process versatility and dependability. Typical applications include aging, bonding, curing, drying, baking, heat treating, annealing and stress-relieving. Despatch’s design, manufacturing, quality and innovation ensures industrial ruggedness, excellent process control and dependable operation. TF Series meets NFPA 86 Class A
for use with flammable solvents Large sizes up to 216 cubic feet Temperatures up to 340°C (650°F) Horizontal recirculating
airflow for uniform heating
Thermal Processing Technology
phone: 1-952-469-5424
[email protected] www.despatch.com © 2011 Despatch Industries. All rights reserved.
www.process-heating.com • Fe b r u a r y 2 0 1 1
|
9
Inner Workings The units come in sizes 1.5 through 6". With the exception of the actuator and modulating spindle, the direct injection heater does not have any moving parts, giving it long service life. For more information, go to www.kadant.com.
SPI Accepting Hall of Fame Nominations Nominations are now open for living individuals to be inducted into the Plastics Hall of Fame. The deadline for submissions is September 30. SPI, the Washington, D.C.-based plastics industry trade association, is administering the nominating process on behalf of The Plastics Academy, whose officials will make up the initial screening committee. The induction ceremony will take place on April 2, 2012, during the NPE 2012 exposition, slated for April 1 through 5 in Orlando. To obtain a nomination form, visit www.plasticsindustry.org and type “hall of fame” in the search box, or call (202) 974-5224.
PH05091Wys.indd 1
10
|
Fe b r u a r y 2 0 1 1 • Process Heating
4/20/09 9:22:58 AM
Calendar of Events February 15-17 — Ipsen-U Vacuum Furnace Technical Training, Rockford, Ill. Call (815) 332-2518 or visit www.ispenusa.com. 17-22 — Hydraulic Institute Annual Meeting, Scottsdale, Ariz. Call (973) 267-9700 or visit www.pumps.org. 22-25 — Infrared Thermography Training Course (Level I), Seattle. Call (978) 901-8405 or visit www.infraredtraining.com. 28-March 3 — Boiler Operator (Level I) Training Seminar, Garden City, Kansas. Call (620) 271-0037 or visit www.boilerlicense.com. 28-March 4 — Infrared Thermography Training Course (Level I), Boston. Call (978) 901-8405 or visit www.infraredtraining.com.
Workshop, Rockford, Ill. Call (815) 8773031 or visit www.eclipsenet.com. 15-17 — Steam System Training (Level III) Training, Las Vegas. Call (888) 6153559 or visit www.swagelokenergy.com. 15-17 — Semicon China, Shanghai, China. Call 86 21 5027 0909 or visit semiconchina.semi.org. 16-17 — Plastec South, Orlando, Fla. Call (310) 445-4200 or visit www.canontradeshows.com/expo/ plastecshows/. 20-23 — SNAXPO, Grande Lakes, Fla. Call (800) 628-1334 or visit www.snaxpo.com. 21-24 — Infrared Thermography Training Course (Level I), Dallas. Call (978) 901-8405 or visit www.infraredtraining.com.
March 1-4 — Infrared Thermography Training Course (Level I), Dover, Del. Call (978) 901-8405 or visit www.infraredtraining.com. 7-8 — IHEA Safety Standards Seminar for Industrial Ovens and Furnaces, Rosemont, Ill. Call (859) 356-1575 or visit www.ihea.org. 7-10 — Boiler Operator (Level II) Training Seminar, Garden City, Kansas. Call (620) 271-0037 or visit www.boilerlicense.com. 8-11 — Aquatech USA Conference and Exhibition, San Antonio. Call (630) 5050160 or visit www.wqa-aquatech.com. 8-11 — Infrared Thermography Training Course (Level II), Las Vegas. Call (978) 901-8405 or visit www.infraredtraining.com. 13-18 — Pittcon Conference and Expo, Atlanta. Call (412) 825-3220 or visit www.pittcon.org. 15-17 — Eclipse Combustion
INSPIRED INNOVATION
22-26 — IFPE, Las Vegas. Call (800) 8676060 or visit www.ifpe.com. 29-31 — Interphex Trade Show and Conference, New York. Call (888) 3348704 or visit www.interphex.com.
April 4-5 — Hauck Mfg. Combustion Seminar (2 Day Version), Lebanon, Pa. Call (717) 272-3051 or visit www.hauckburner.com.
Despatch Custom Solutions: A LowRisk Choice to Your Complex Challenges Despatch has over 100 years of proven success in partnering with customers to deliver complex thermal processing solutions. We are committed to working with you to learn the details of your unique process in order to design and engineer a custom piece of equipment that will meet your specific requirements. Over 100 years of thermal
processing experience Continous processing
and automation Inert environment control
5-7 — International Wood Composites Symposium, Bell Harbor Convention Center, Seattle. Call (509) 335-2262 or visit www.woodsymposium.wsu.edu. 5-6 — Web Coating and Drying Seminar (Europe), Brussels. Hosted by AIMCAL. Call (803) 802-7820 or visit www.convertingschool.com. 5-7 — John Zink Co. Vapor Control Systems Seminar, Tulsa, Okla. Call (918) 234-5710 or visit www.johnzink.com.
Particulate measurement
and control
Thermal Processing Technology
phone: 1-952-469-5424
[email protected] www.despatch.com © 2011 Despatch Industries. All rights reserved.
6-8 — Hauck Mfg. Combustion Seminar (3-Day Version), Lebanon, Pa. Call (717) 272-3051 or visit www.hauckburner.com. www.process-heating.com • Fe b r u a r y 2 0 1 1
|
11
Equipment Overview Temperature Controllers
Y
Photo courtesy of Yokogawa
ou know you need to get control of your process. But, what kind of control does your process need? Process Heating has created this bullet chart to help you figure that out. This chart allows you to cross check control-
ler types and features with those companies that manufacture them. You also can conduct your search online at www.process-heating.com. Online, you decide how picky the search engine is and
INPUTS
CONTROL MODES
Sensors
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Cristal Controls Ltd.
•
Electronic Development Labs Inc.
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Gain Scheduling
•
•
•
•
Fuzzy Logic
•
•
•
•
Cascade
•
•
•
•
Auto/Manual
•
•
•
•
Autotuning
•
•
•
•
Adaptive Tuning
•
•
Time Proportioning Triac
•
•
Time Proportioning Relay
•
Chromalox
•
Time Proportioning Logic
Ascon Corp.
•
Dual (Heat/Cool)
•
•
Analog Voltage
•
•
Analog Current
•
•
Universal Thermocouple
•
•
Universal Process
•
•
Type T
•
•
Type S
Yokogawa Corp. of America, Network Solutions www.yokogawa.com/us
•
Type R
•
Type PL2
•
Type N
•
Type K
Type C
•
Type J
Type B
•
Type E
RTD
•
Type D
Relative Humidity
Dwyer Instruments Inc. www.dwyer-inst.com
Thermistor
Pyrometer
Thermocouple
Differential
You also can conduct your supplier search online! www.process-heating.com Click on Equipment Overviews, then on temperature controllers.
OUTPUTS
•
•
Eurotherm/Invensys
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Eustis/Pyrocom Heatcon Inc. Honeywell Process Control/Field Solutions
•
IMC Instruments
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
IMS Industrial Molding Supplies
•
Indeeco Moore Industries Inc.
•
Nanmac Corp.
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
• •
•
•
•
•
•
•
•
•
•
•
Nexthermal Corp. Nextron Ltd.
•
Ogden
•
Omega Engineering Inc.
•
•
•
•
•
•
•
•
•
Oven Industries Inc.
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
PolyScience RKC Instrument
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Siemens Industry Inc. Tempco Electric Heater Corp.
•
•
Tyco Thermal Controls
•
•
•
United Electric Controls Watlow West Control Solutions Zytron Control Products Inc.
12
|
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Companies with an arrow in front of their names have an advertisement in this issue.
Fe b r u a r y 2 0 1 1 • Process Heating
PHYSICAL FEATURES
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Max/Min/Average Statistics
•
Loop Break Alarm
•
CUL Recognized
CE Certification
•
•
•
•
•
•
•
•
•
•
•
•
Plastics/Rubber/Vinyl
•
•
•
•
Pharmaceutical
•
•
•
•
•
Pulp/Paper/Converting
•
•
•
Packaging/Printing
•
•
•
•
Food Processing & Production
•
•
•
•
Finishing
•
•
•
Electronics
•
•
•
•
Chemicals/Petrochemicals
•
•
•
Universal Power Input
•
•
•
•
•
Serial Communications
•
•
•
Operator Lockout
•
•
•
Load Current Display
•
•
•
Field Configurable
•
•
Configurable Display
•
•
•
Configurable Alarms
•
•
•
•
INDUSTRIES SERVED
Agency Approval
UL Recognized
•
•
•
DIN Rail
•
•
•
Back Panel
•
•
•
Front Panel
•
•
•
Display, Single
•
•
Display, Dual
•
•
Connection, Plug
•
•
Connection, Hard Wire
•
•
Other
•
1/32 DIN
•
1/16 DIN
•
1/8 DIN
Ramp/Soak Programming
•
1/4 DIN
Proportional with Manual Reset
•
Full DIN
PID
•
Mounting
Valve Positioning
On/Off
•
Ratio Control
Multiple Setpoint
Sizes
ADDITIONAL FEATURES
NEMA 4 Rating
CONTROL MODES
Heating can help you out. If you want to talk to a temperature controller manufacturer immediately, view the Equipment Overview online or send an e-mail to editor Linda Becker at
[email protected].
Load Failure Alarm
how many categories under which you would like to search. Hyperlinks take you directly to selected manufacturers web sites. If you need more information than what we have specified here and on our website, Process
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
• •
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
• •
• •
•
•
•
• •
• •
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
• •
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
• •
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
• •
•
•
•
•
•
•
•
•
•
•
•
• •
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
• •
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Manufacturers listed in this Equipment Overview responded to a special mailing by Process Heating and do not necessarily represent the entire temperature controller market.
•
•
•
•
•
•
• •
•
•
• •
•
•
•
•
•
• •
•
•
•
•
• •
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
www.process-heating.com • Fe b r u a r y 2 0 1 1
|
13
Dryers
How to Drive Down
Drying Costs Although expenditures for dryer energy may be only a small fraction of a product’s cost, reducing energy usage could provide significant bottom-line savings. By Tim Golden, Megtec Systems Inc.
M
any products go through a dryer, an oven or drying process, and fluctuating natural gas prices make it difficult for companies to price products competitively and manage profit margins. There is also increased pressure to reduce greenhouse gases and the products of combustion typical of the drying process. Fortunately, it is possible to drive down dryer energy costs and boost heat recovery
14
|
Fe b r u a r y 2 0 1 1 • Process Heating
return on investment (ROI). For example, dryer energy costs for printing or coating may be only 1 percent of total expense, but they could easily add up to $1 million a year. Reducing usage by 25 percent — often an achievable goal — saves $250,000. Moreover, in many cases, savings could be realized with little or no capital outlay.
Make the Most of What You Have Major heat recovery projects are not always cost effective for all processes. Luckily, several far less extensive steps can yield significant savings. You should benchmark energy usage up front so you can measure progress. Step one is to audit your equipment and make sure routine preventive maintenance procedures are followed. Loose or worn
belts; dirty filters, nozzles or plenums; and leaking gaskets, seals or burners constantly rob energy. Next comes setup and operation of the dryer itself. Creating a “cookbook for success” may be as simple as developing a checklist of optimum parameters, or “recipe,” for each product. Recipe “ingredients” include substrates, coatings and line speed, any or all of which can vary from product to product or shift to shift, even for the same product. A change in substrate thickness may require less tension. A new coating may require less heat or less drying time. The list goes on.
Depending on the size and type of application, preassembled and tested packaged process heat recovery systems can simplify and speed installation while reducing investment costs compared to a custom system. This unit draws heated air from the exhaust duct or stack for energy recovery and draws in fresh outdoor air, which is controlled within the setpoint range of 70 to 125°F (21 to 52°C) for supplemental heating or cooling for the building.
Dryers LFL Control Exhaust Fan
An OEM or qualified service provider can help model your system so you can document parameters along with baseline energy usage. You can use the data to create a roadmap to optimum energy use.
Exhaust To Atmosphere
Exhaust Damper
LFL Monitor
Makeup Air Safety Interlock Makeup Air Damper
LFL Monitor (Redundant)
Burner
Supply Fan
Dryer Controls and Configuration
Recirculation Manual Balancing Dampers
Manual Balancing Dampers
Coated Web Out
Coated Web In
Humidity Control Humidity Monitor
Exhaust Fan
Exhaust To Atmosphere
Exhaust Damper Makeup Air Makeup Air Damper
Burner
Supply Fan
Recirculation Manual Balancing Dampers
Coated Web Out
Manual Balancing Dampers
Coated Web In
Minimizing dryer exhaust safely is the task of this closed-loop system, which monitors the lower flammable limit (LFL) and opens a series of dampers or AC drives to control the exhaust flow.
Many companies “make do” with used or relocated equipment that is working okay, yet wasting energy. Many of these systems can be optimized to run more efficiently. For instance, in a flotation dryer, the air-bar gaps, quantity, widths and center-to-center settings can be adjusted for efficiency, or the air bars can be replaced with different style air bars. Remember, the idea is to apply only as much heat or air as necessary to achieve
the desired speed and product quality. This is especially important if exhaust air is treated by an oxidizer or pollution control device. Process supply air, makeup air and exhaust air flows, temperatures and critical parameters can be “balanced” for each dryer or process. In addition, the flows often can be optimized for each product, plus factors such as ambient conditions, humidity, temperatures or building pressures.
Many vintage dryers have obsolete controls or instruments. Replacing limiting devices for better control could help them run more efficiently, faster — perhaps at 800 ft/min instead of tripping out at 400 ft/ min — and more reliably. System upgrades may require little money or downtime. • Air-to-gas ratio control keeps your burner at stoichiometric combustion throughout the operating ranges, optimizing the amount of combustion air supplied to the burner. • Controls to measure the lower flammable limit (LFL) or humidity are used to monitor the solvent concentration or relative humidity within the dryer in order to control the exhaust rate. They will maintain only the exhaust necessary to safely provide the desired product quality and production speed. • Outdated or problematic PLCs, discrete controllers and other devices can play havoc with your process. Fortunately, OEMs can provide replacement kits that include all parts, programming or other instructions needed for installation. Improper configuration, as noted earlier, robs energy every day. This also can create web-handling problems, reduce product quality and limit production speeds. Here again, a qualified OEM can help model your processes and recommend alternatives.
Dryer Heat Recovery Criteria for Success Before investing in dryer energy recovery, you need to determine a cost-effective, reliable means of collecting and distributing waste energy, along with suitable uses for the energy recovered. While every exhaust stack has a different temperature and flow, to be used efficiently, your waste stream will need to be: www.process-heating.com • Fe b r u a r y 2 0 1 1
|
15
Dryers The air-to-air heat recovery system recovers energy from the exhaust airstream and passes it through a heat exchanger, where ambient air is pulled in and cost-effectively converted to heated makeup air. To Oxidizer Stack
VSD
• Clean. Particulates, condensates or dirt will accumulate and plug up equipment. In some cases, particulate can be filtered. • Reasonably Dry. The proper level can vary, but 25 percent humidity, for instance, may create unmanageable condensation. • Kept at a Temperature Above 250°F (121°C). Unless the volume is substantial, any airstream below 250°F probably will not “pay its way” for heat recovery. Also, a minimum temperature within the heat recovery system must be maintained to prevent dewpoint condensation. Systems that generally provide the most payback deliver heat or energy back to the process for year-round savings. Examples include: • • • •
Combustion air heating. Process makeup air. Building makeup air. Direct building makeup air and space heating. • Building hot water systems (plant boiler loop). • Low temperature steam applications. When considering uses for recovered heat, keep in mind that the need for area or space
WEB EXCLUSIVE Heat Recovery Incentives Besides the return on investment achieved from a properly applied heat recovery system, a number of federal, state, local or utility incentives may be available. READ MORE @ WWW.PROCESS-HEATING.COM
16
|
Fe b r u a r y 2 0 1 1 • Process Heating
Stack
TIC
From Oxidizer
Ambient Air
Oxidizer Exhaust Fan To Makeup Air
TE
VSD
heating can be limited by the local climate. Also, the recovery method, devices and capital expenditure depend on the application and distance between the source and user. Temperatures and flows also may impact technology used. Optional methods include: • Air-to-Air Systems. These systems pass exhaust air through a heat exchanger and return fresh air into the process or building. • Air-to-Water Systems. These are used to preheat water for boilers or other uses. • Air-to-Oil Systems. These systems use high temperature thermal oils for applications above 300°F (149°C) where glycol or water may not work. • Direct Hot Water Systems. Though primarily a pulping industry application, these systems run air through a water mist. • Hybrid and Custom Systems. These systems can be any combination of the above. Many OEMs can customize a system for you. Don’t overlook off-the shelf solutions though — standard packaged system could be used for many applications. A
PIC
PT
local sheet metal company could install the ductwork and you’d be running in a few days. Finally, when projecting payback, don’t overlook incentives in the ROI mix. For any heat recovery system, consider: • Equipment costs (with installation and commissioning). • Current and potential future energy costs and savings. • Maintenance and related upkeep for the expected lifetime of equipment. Improved operating conditions and productivity should be factored as well. Acceptable ROI varies among applications, but projects with a two-year payback typically merit serious consideration. PH Tim Golden is the aftermarket services director for Megtec Systems Inc., De Pere, Wis., a manufacturer of air flotation web dryers, solvent recovery systems, thermal oxidizers, bioreactors, bioscrubbers and energy recovery equipment. For more information, call (920) 336-5715 or www.megtec.com.
Boilers
A
study conducted in 2005 showed that at that time, more than 162,000 industrial and commercial boilers were in operation throughout the United States. Of those boilers, roughly 15 percent were generating steam in the 10 million BTU to 100 million BTU range — many in process applications. Fast forward to 2011. Much of the installed boiler inventory in this particular segment is more than 25 years old. This includes natural circulation firetube boilers — the most prevalent in this category — watertube boilers and forced circulation steam generators. These systems primarily are fired by natural gas although light oil often is used as an alternate or backup fuel. Many boiler designs exist to meet a customer’s needs — insofar as quantity of steam output and pressure, desired fuel and operating characteristics. However, the basic design of these boilers is standardized from the standpoint of: • • • •
The actual combustion process. Heat transfer surface per horsepower. General shell-and-tube configurations. Basic controls and safety features.
These are mostly complete packaged systems, factory assembled and tested, hav-
• Less operator intervention. • Longer useful life. • Best use of available space. In response to this wish list, boiler and auxiliary equipment manufacturers improved existing technologies and developed new ones. Many of these improvements can be applied to a large number of the existing installed boiler base. To take full advantage of these improvements though, in some cases, a complete boiler replacement may make more sense and provide a respectable return on the investment. What can you expect to find in a modern boiler setup? Consider these common boiler design improvements.
Boiler Design Current firetube boiler designs are optimized for peak efficiency vs. cost to manufacture. One improvement has been the use of extended-surface boiler tubes, which are usually internally ribbed. This internal extended surface produces a tube with a heat transfer rate significantly greater than that of a plain tube. The use of this type of tubing reduces the overall size requirement for a boiler and can result in reduced boiler cost. Replacing existing boiler tubes with ribbed tubes can increase the output
Achieving
Higher Efficiencies & Lower Emissions More than 24,000 installed boilers operate in the 10 million BTU to 100 million BTU range. What are the trends for this important segment? By Alan L. Stehman, Cannon Boiler Works Inc.
ing fuel-to-steam efficiencies in the low 80 percent range. While the basic boiler itself has not changed much, there have been a number of technological advances in the overall system over the last 20 years. End-users have asked for — and received: • • • •
Higher efficiencies. Lower emissions. Ease of maintenance. Greater safety.
of existing equipment — without a corresponding increase in fuel cost — or reduce fuel requirements at the current load.
Combustion Controls Excess air is required for the safe, complete combustion of fuels. Too much excess air results in a loss of combustion efficiency while not enough leads to incomplete combustion and safety issues. Proper control of the fuel-to-air ratio is the key to optimizing combustion efficiency. www.process-heating.com • Fe b r u a r y 2 0 1 1
|
17
Boilers The most common system of control has been the use of a single rotating shaft and mechanical linkages operating the fuel valve and combustion air damper in tandem (single-point positioning). This system is set initially at startup and usually is adjusted once or twice a year thereafter. Normally, the setup is performed to reach a 5 percent to 7 percent O2 reading at the stack to compensate for atmospheric changes and mechanical variances in the linkage system that normally occur between tuneups. Although the amount of excess air is higher than what is required for the most efficient combustion, in order to remain at safe levels without constant monitoring and adjustment, there is a built-in efficiency loss. The use of microprocessor-based controls combined with an O2 analyzer and transmitter in the flue gas, individual servo or stepper motors directly controlling the gas valve and air damper (parallel positioning), or a variable-speed drive controlling fan speed, have allowed owners to comfortably run their boilers with as low as a 2 percent O2 reading at the stack. The parallel-positioning setup gives owners confidence that the air-to-fuel ratio is constantly monitored and adjusted for optimum efficiency and safety. By using this method of control to minimize excess air, most users can expect a 2 percent to 3 percent increase in efficiency.
Low NOX Burners To meet the ever-tightening clean air regulations, boiler and burner manufacturers have been required to develop technology that will allow them to provide a package with the lowest NOX emissions possible — without post-combustion treatment. Several generations of low NOX designs — including steam injection, flue gas recirculation, premixing, two-stage combustion and fiber mat combustion head — have allowed manufacturers to now supply equipment with single digit NOX emissions (on natural gas), with some claiming as low as 5 ppm.
Heat Recovery Most new industrial boilers are said to be somewhere in the low 80 percent range in fuel-to steam-efficiency, meaning anywhere 18
|
Fe b r u a r y 2 0 1 1 • Process Heating
from 16 percent to 20 percent of the heat input is lost up the stack. Traditional stack economizers, in various forms, have been installed in boiler stacks almost as long as there have been boilers. Most modern economizers consist of a series of extended surface tubes installed in the boiler flue gas stream. Warm boiler feedwater is circulated through the tubes, where wasted heat is exchanged from the flue gas to the feedwater, which is then fed directly to the boiler. The conventional stack economizer will provide about a 2 percent to 4 percent gain in efficiency. More recently, with improvements in design and materials selection, condensing economizers are more in demand. These units are similar to a conventional economizer; however, by circulating cold water through the tubes, using boiler makeup water, the stack temperature can be lowered enough to condense water vapor in the flue gas. This allows the unit to recover both sensible heat and latent heat. These units are usually only found on natural gas-fired boilers, many times in combination with a conventional economizer in the same housing. They usually require all stainless steel construction to prevent corrosion from the condensate. While the initial investment can be substantially higher than a conventional unit, it is possible to gain up to an additional 10 percent in efficiency. There are many variations of the condensing economizer, particularly in off-boiler applications where cold process water, in much greater volume than boiler makeup, is the heat sink. Typically, these are floor- or skid-mounted units consisting of a singleor multiple-stage economizer and include an induced-draft fan with controls to draw hot flue gas as needed from the boiler stack.
These systems are invisible to the boiler and burner operation and can be turned on and off to meet demand. Generally, with large volumes of very cold water, the recovery rate can be calculated to an equivalent of greater than a 10 percent increase in efficiency. Another development in boiler heat recovery incorporates both conventional and condensing economizers as well as a patented heat exchanger called a Transport Membrane Condenser (TMC). The TMC was invented by Gas Technology Institute, Des Plaines, Ill., as a part of the U.S. Department of Energy’s (DOE) Super Boiler program. In the economizer system that incorporates the TMC technology, the TMC section utilizes porous ceramic tubes coated with selective membranes. When cold makeup water is passed through the tubes, a capillary condensation occurs within the tube wall. The makeup water is kept under negative pressure, allowing this warm condensate to be added to the boiler water stream. With this economizer system, sensible heat, latent heat and water are all recovered. The efficiency gain can be up to 15 percent with as little as 25 percent cold makeup flow. The design allows nearly any boiler system to take the greatest advantage of condensing without the need for a large cold water process flow as a heat sink. TMC technology can be retrofitted on any clean fuel boiler to raise the efficiency to as much as 95 percent fuel-to-steam efficiency while allowing the return clean water to the system.
Modular Systems Currently, there are many oversized boiler systems operating in the United States. Oversized boilers can lead to great operational inefficiencies. Generally, boilers become less efficient when operated at less
Boilers In the economizer system that incorporates the TMC technology, sensible heat, latent heat and water are all recovered. The efficiency gain can be up to 15 percent with as little as 25 percent cold makeup flow.
than their maximum rating. Of particular concern is when a larger boiler that is not designed to cycle is required to turn on and off in response to steam load. The loss of efficiency due to oversizing can make a system using boilers rated at greater than 80 percent efficiency actually produce steam with a system operational fuel-to-steam efficiency as low as 50 percent. Even a “right sized” boiler system will operate at an effi-
ciency less than its rating unless operated at or near its capacity most of the time. Systems utilizing multiples of small footprint, low water content, forced circulation steam generators are gaining in popularity. In this type of system, the boilers are designed to turn on and off, via microprocessor-based control, in response to steam load demand. These boilers are designed to be unaffected by the thermal shock associated with boiler cycling, and because of the small physical size and low water content, normal cycling losses are minimized. When set up properly, a modular system will operate at or near its reported efficiency throughout its operating range.
Some boiler manufacturer offer remote monitoring services, where each installed boiler is connected directly to a computer monitoring system at the manufacturer’s offices. The system sends continuous data on burner history, fault history, fuel consumption, scale buildup, and a number of other items. The manufacturer monitors each boiler and reports to the owner immediately when a caution occurs. This allows the owner to respond to issues before they become major. Also, a monthly report may be submitted, summarizing key boiler operating parameters and offering recommendations to assist the owner in keeping boilers at peak operating condition. PH
Remote Monitoring
Alan L. Stehman is president of Cannon Boiler Works Inc., New Kensington, Pa., a manufacturer of heat recovery systems for steam generation systems. For more information, call (724) 335-8541 or visit www.cannonboilerworks.com.
Reliable performance also is a factor in overall efficiency. Poorly performing equipment not only wastes fuel but impacts maintenance and service budgets as well.
SYSTEM DOWN!
MultiTherm’s Heat Transfer Fluids Keep All Systems
GO! Run your system more efficiently, for longer periods, with less down time. Make System Maintenance a Priority!
1-800-339-7549 www.multitherm.com www.process-heating.com • Fe b r u a r y 2 0 1 1
|
19
Process Control
Software Automates
Pasta-Making Process
Integration of panel-mounted process controllers with RS-485 communication and process control software has allowed a small pasta manufacturer to upgrade a SCADA-based operation at minimal cost. By Jason Dahl, Integrated Pro Left: Strands of spaghetti are visible in the extruder area at the beginning of the pasta process. Below: Spaghetti hangs on bars as it enters the dryer.
D
eseret Pasta in Salt Lake City, Utah, owned by a nonprofit entity, produces pasta products for humanitarian relief efforts. A small staff of full-time workers at the plant is supplemented by volunteers from the community during peak times. When planning an upgrade to its existing SCADA-based operation, cost was a strong issue in choosing a solution. The plant staff desired minimal changes to the current controls but but wanted the benefits of a centralized solution. After considering the alternatives, National Instruments’ LabView was chosen because it offers a graphical environment that can be programmed and customized quickly. The addition of a cabinet-mounted, desktop PC with serial interface and wiring between controllers was the only required hardware to complete the solution. To simplify development for the pasta maker, the program incorporated process controller communication libraries devel-
20
|
Fe b r u a r y 2 0 1 1 • Process Heating
oped for LabView by Integrated Pro, a developer of custom engineering and programming solutions. The libraries support many commonly available DIN-sized process controllers. This permitted faster development and the ability to add or change features in a drag-and-drop programming environment. The pasta-making plant has two productions lines: one for “short goods” such as macaroni and the other for “long goods” such as lasagna, spaghetti and linguini. Pasta is extruded through a die that is supplied with dough from a mixerhopper, where Semolina flour and hot
water are combined. Different dies in the extruder determine the type of product manufactured. After being extruded into the desired shape, the pasta hangs on long bars as it moves through the dryers. At the end of the drying process, the dried pasta strands are carried by a belt through a cutter, cut to packaged length and delivered in chutes to workers who place the pasta in bins until it is packaged. The pasta dryers require control over temperature and humidity in multiple stages as the pasta cools and dries. Each dryer is controlled by two panel-mounted controllers with 4 to 20 mA current loop
Process Control
Oxidizers Ovens Furnaces
Above: Pasta production runs can be compared graphically for training or diagnostics. Right: Process control libraries simplify the development of RS-485 communication-based networks in LabView graphical programming environment.
sensors and voltage-controlled actuators to control temperature and venting. An upgrade to the process, a panel-mounted counter, provides tracking of each bar of pasta through the dryer. The program trends temperature, humidity and dewpoint values at different locations. The operator can control setpoints and recipes, arm and acknowledge alarms, and view both process history and product drying history for each bar of pasta. Data
WEB EXCLUSIVE Setting Up an RS-485 Network to a PC Although RS-485 communication has been around for a while, one does not set up networks every day. When you do, it is important to remember there are four steps in setting up an RS-485 network to a PC serial interface. READ MORE @ WWW.PROCESS-HEATING.COM
¾ Oxidizers RTO Recuperative Catalytic is saved to disk for offline analysis using custom formatted reports in Excel using a reporting toolkit for LabView. “It’s not as simple as Play-Doh,” says one employee. “Pasta drying is a complex process that happens on the molecular level.” Incorrect drying conditions can lead to fractured product or undesirable texture. Having a centralized view of the drying process provides an improved picture of how the product is progressing and allows for better control. New employees can be trained more quickly because they can view the process as a whole. Ultimately, the plant makes better product and reduces waste because of the program. PH
¾ Ovens & Furnaces Conveyorized Low Temp. & High Temp. Batch 936-273-3300
[email protected] www.epconlp.com
Jason Dahl works for Integrated Pro, Lehi, Utah. The company, which is a National Instruments certified partner, can be reached at (801) 768-4606 or www.integratedpro.com. www.process-heating.com • Fe b r u a r y 2 0 1 1
|
21
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’ web sites using the published web addresses.
Hot Water Boilers TC Series is available in sizes from 399,000 to 5,443,000 BTU input with stainless steel construction for resistance to corrosion at low operating temperatures. The condensing hot water boilers utilize a proven European design built for high efficiency. The units are available with conventional gas burners or low NOX power type burners. They are ETL listed as complete gas fired boiler assemblies per UL 795, and models under 2 million BTU/ hr input are completing SCAQMD 1146.2 certification. Parker Boiler Co. • (323) 727-9800 • www.parkerboiler.com
Stainless Steel Sensors The sensors withstand high pressure and high temperature washdowns while offering resistance to corrosion and damage caused by harsh cleansing agents. Allen-Bradley 42CS photoelectric and 871TS inductive sensor families have stain-
less steel construction, extended temperature ratings and IP69K enclosure ratings. IP69K testing replicates the steam-cleaning process typically used in the food and beverage industry, and it requires the sensors to withstand spray pressure up to 1,450 psi and temperatures up to 176°F (80°C). Rockwell Automation Inc. (414) 382-2000 • www.ab.com/sensors/
Vertical Conveyor Oven No. 961 is used for preheating baskets of steel parts and uses 30 KW installed in Incoloy sheathed tubular heating elements. The electrically heated 350°F (~176°C) vertical conveyor oven has 4" insulated walls and an aluminized steel interior and exterior. It also is equipped with a removable top-mounted heat chamber (shown removed) and a motoroperated vertical lift door. A 4,200 cfm, 3-hp recirculating blower provides vertical upward airflow to the workload. Grieve Corp. • (847) 546-8225 • www.grievecorp.com
Low NOX Burner The basis for the MSC2 burner’s operation is multistage combustion (MSC). The staged Q-jet design introduces fuel into primary and secondary airstreams. The primary stream allows for the company’s stable flame technology, ensuring an ultrastrong root flame for extreme stability. The secondary zone stages the flame to mitigate thermal NOX production. It has a firing rate of 20 to 400 million BTU/hr. Hamworthy Peabody Combustion Inc. (203) 922-1199 • www.hamworthy-peabody.com
Combustion Analyzer s &LU s &LUID 0ROCESS (EATING s UID 0ROCESS (EATIN UID NG s s $ESIGN, %NGINEER AND -ANUFACTURE s #ONTACT OUR %NGINEERING 3ALES TEAM DIRECTLY TEL s &AX INFO HUBBELLHEATERSCOM wwwHUBBELLHEATERSCOM
4(% %,%#42)# (%A4%2 #/-0ANY 22
|
Fe b r u a r y 2 0 1 1 • Process Heating
Features of the BTU2200-NOX include a design that is NO/NOX upgradeable; ability to read O2, CO, CO2, NO/NOX; field-replaceable sensors; built-in non-thermal printer; and metal connections. Its robust boiler room design also includes a built-in manometer, thermometer (ambient and flue gas) and carbon monoxide leak detector (safety). E Instruments • (215) 750-1212 • www.e-inst.com
Product Highlights
Free Literature
Open Path Gas Detector
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 phone, fax, web and e-mail information.
Model IR5500 provides continuous monitoring of combustible gas concentrations. The system consists of an infrared source and receiver that continuously monitor for methane in both the 0 to 5,000 ppm-meter and 0 to 5 LEL-meter ranges. Two other scales (0 to 2,000 ppm-meter and 0 to 1 LEL-meter) are available for monitoring propane. The open path gas detector provides two 4 to 20 mA analog signals proportional to the standard ranges in addition to a digital display and relay contacts. It utilizes a single-beam-detection design to improve accuracy and reduce drift. General Monitors • (800) 330-9161 www.generalmonitors.com
AC and DC Output Solid-State Relays SeriesOne DR is intended for use in heating applications where DIN rail mounting is preferred and higher output power ratings are required. Features include a proprietary thermal management design without exposed hot metal surfaces for safety. The line includes AC output ratings at 104°F (40°C) ambient for single-channel models of either 6 or 12 A, and dual AC output models with 6 A per channel, each rated at either 12 to 280 VAC or 24 to 600 VAC. DC output model ratings at 104°F ambient include single-channel versions rated at either 6 or 12 A and 1 to 60 VDC or 1 to 100 VDC. Crydom Inc. (619) 210 1550 • www.crydom.com
Custom Electrical Control Panels This publication illustrates our experience as a UL 508A Certified Panel Shop in designing and building custom electrical control panels. It also presents a user-friendly guide to selecting a temperature control based on the performance required. Tempco Electric Heater Corp., Ph: 800-323-6859. www.tempco.com
Custom driers, ovens, roasters, toasters and coolers www.aeroglide.com/process
Blower with DC Motor Designers of industrial systems need blowers with DC motors that are compact and low weight yet provide good volumetric flow and differential pressure. The CPC blower with DC motor offers volumetric flow of 400 m3 • h-1 and differential pressure of 500 pa. It operates at a speed of 3,700 to 4,200 min-1, and the 24-volt DC electric motor’s direction of rotation is “right.” They are designed for continuous operation and offered with brush-type motors or as brushless drives. Robert Bosch LLC • (708) 865-5286 www.bosch-ibusiness.com
Great is Gr eat. It Doesn’t Matter What You Call Us.
www.process-heating.com • Fe b r u a r y 2 0 1 1
|
23
PH Classifieds
Send advertising copy to: Process Heating/Attn. Becky McClelland Phone: (412) 306-4355 • Fax: (248) 502-1076 E-mail:
[email protected]
Display Classified Rates: 1X $100 • 3X $95 • 6X $90 • 9X $85 • 12X $80
Equipment for Sale Significantly reduce your drying time
CAN-ENG FURNACES INTERNATIONAL LTD. z
LHS 40 Air Heater
z
Rebuilds z Retrofits z Combustion Controls z
Control Panels z Thermal Profiling z Ovens z Burners z Elements z
t: 905-356-1327
f: 905-356-1817
e:
[email protected]
www.can-eng.com
Contact: JOE SALIBA (ext:2058) z KIM IAMARINO (ext:2037) z ANNA ROLFE (ext:2056) Air Radiation Heater
HEAT EXCHANGERS ▼
Combining Leister’s High Quality Air Heaters with Infrared Technology
Contact Becky McClelland
Liquid Cooled
Xchanger.com
Air Cooled FOR
PH02114LeisterClass.indd 1
1/20/11 2:12 PM
to reserve your classified advertising space for 2011!
▼
www.leisterusa.com Toll-free: (855) Leister
GASES & LIQUIDS!
Talk Directly with Design Engineers! Blower Cooling
Vent Condensing
(952) 933-2559
[email protected]
CATALYTIC INFRARED HEATERS 11/24/08 11:34:24 AM New, “As Is” & Factory Refurbished
PH12084XchangerClass.indd 1
Print/online packages are available.
Discount Prices/Many Sizes Available
Phone: 412-306-4355 Fax: 248-502-1076 Email:
[email protected]
800-648-1698 INQUIRE ABOUT OURR ON-SITE REFURBISHING SERVICES
American Catalytic i Technologies T h l i
[email protected] | www.americancatalytic.com
PH01084AmerCatClass.indd 1
12/19/07 8:58:46 AM
Need Thermal Fluid Heaters... To find them, turn here: www.process-heating.com/buyersguide
WWW.PROCESS-HEATING.COM
PH03084DuraliteClass.indd 1
2/19/08 2:47:23 PM
Locate the industrial equipment, components and services specifically used in applying, transferring, measuring, monitoring and controlling heat in the manufacturing operations that you need! • Search by Company Name or Product Category • Downloadable Product Spec Sheets • Alpha Company Listings • Live Web & Email Links • Product Photos
2011 Buyers Guide Start your search today! Watch for expanded - listings! www.process-heating.com/buyersguide
24 | Fe b r u a r y 2 0 1 1 • Process Heating
The South’s Plastics Processing Resource for Project Acceleration
New Location
March 16–17, 2011 Orlando Convention Center Orlando, Florida Sponsored by:
Supported by:
Submit your registration request today at
PLASTECsouth.com
Advertising Index
Please use Promo Code: AB
Page
Company
Phone
Fax
Web
E-Mail
23
Buhler Aeroglide
(919) 851-2000
(919) 851-6029
www.aeroglide.com
[email protected]
7
Despatch Industries
(952) 469-8278
(952) 469-8206
www.despatch.com
[email protected]
9
Despatch Industries
(952) 469-8278
(952) 469-8206
www.despatch.com
[email protected]
11
Despatch Industries
(952) 469-8278
(952) 469-8206
www.despatch.com
[email protected]
10
Dwyer Instruments/Love Controls
(800) 828-4588
(219) 872-9057
www.dwyer-inst.com
[email protected]
21
Epcon Industrial Systems
(936) 273-3300
(936) 273-4600
www.epconlp.com
[email protected]
27
Fives North American Combustion
(216) 271-6000
(216) 641-7852
www.fivesna.com
[email protected]
2
Heatec
(800) 235-5200
(423) 821-7673
www.heatec.com
[email protected]
28
Heatec
(800) 235-5200
(423) 821-7673
www.heatec.com
[email protected]
9
Higuchi USA
(310) 792-7051
(469) 241-1902
www.higuchiusa.com
[email protected]
22
Hubbell Electric Heater Co.
(800) 647-3165
(203) 378-3593
www.hubbellheaters.com
[email protected]
19
MultiTherm LLC
(610) 408-8361
(610) 408-8365
www.multitherm.com
[email protected]
8
Payne Controls
(800) 331-1345
(304) 757-7305
www.payneng.com
[email protected]
25
Plastec
(203) 601-3730
(203) 268-5874
www.plastecsouth.com
[email protected]
8
Protection Controls
(847) 674-7676
(847) 674-7009
www.protectioncontrolsinc.com
[email protected]
6
Red-Ray Manufacturing Inc.
(908) 722-0040
(908) 722-2535
www.red-ray.com
[email protected]
4
Wisconsin Oven
(262) 642-3938
(262) 363-4018
www.wisoven.com
[email protected]
10
Wyssmont
(201) 947-4600
(201) 947-0324
www.wyssmont.com
[email protected]
3
Yokogawa
(770) 251-8700
(281) 340-3838
www.us.yokogawa.com
[email protected]
www.process-heating.com • Fe b r u a r y 2 0 1 1
|
25
®
Places & Faces Hamworthy Peabody Combustion, Shelton, Conn., launched an interactive website at www.hamworthypeabody.com. The website provides information on the company’s expanded line of low emission products, services and efficiency-improving solutions. Stockholm-based
Munters AB announced the retirement of Mike McDonald effective April 1, 2011. Over the past 15 years McDonald Mike has held various management positions in Munters, most recently as group vice president and president of the Munters Dehumidification Division.
Scott Switzer was named industrial sales manager for CPM
Roskamp Champion, Waterloo, Iowa. The company manufactures pelleting and particle size Switzer reduction equipment and automation systems for the animal feed milling and oilseed processing industries as well as food, pharmaceutical, chemical and plastics applications.
Omega Engineering Inc., Stamford, Conn., released “Dilbert ControlCat New Horizons in Temperature, Pressure, Flow and More! Version No. 28.” To request a copy, visit www.omega.com/ literature/controlcat28/.
E Instruments, Langhorne, Pa., released an updated brochure describing its Multical 2500 secondary standard precision calibrator. The temperature, pressure and DC calibrator is intended for research and development, metrology, manufacturing and calibration lab applications. Cherry Valley, Ill.-based Ipsen opened a 26
|
Fe b r u a r y 2 0 1 1 • Process Heating
new sales office in Tokyo, Japan, that will focus on sales and service in the Kanto region. With more than 12 years experience in the Japanese market, Stephan Gagne will head up the new office.
ECD, a maker of thermal profiling tools and software in Milwaukie, Ore., named Iberiana Technical Lda. its distributor in Spain and Portugal. Headquartered in Braga, Portugal, ITEC is certified according to EN ISO 9001:2008 and has been serving the electronics/component assembly, automotive and plastics markets since 2006.
Matt Holland was appointed vice president of operations for the Richmond Division of Super
Radiator Coils (SRC). He will be
Birk responsible for overseeing the division’s sales, engineering and manufacturing operations, according to Rob Holt, president and COO of SRC, which is headquartered in Minneapolis. Holland replaces Ray Birk, who has become SRC’s first vice president of industrial sales. In his new position, Birk will lead the company’s continued expansion in key growth markets, including power generation, wind energy, heavy-duty heat exchanger applications, and waste and solvent recovery.
John Atanasio was appointed president and CEO of Alfa Laval Inc., Richmond, Va., in January. In other company news, Alfa Laval, Atanasio Lund, Sweden, received a $10.2 million order for compact heat exchangers from a refinery in Russia to be used in the distillation process. Michael Hancock assumed the position of training manager for US Water Services, St. Michael, Minn.
PUBLISHING STAFF Senior Group Publisher, Manufacturing Group TOM ESPOSITO • (610) 436-4220 ext. 8530 Group Publisher • DOUG GLENN (412) 306-4351 •
[email protected] Publisher • ANNE ARMEL (847) 405-4043 •
[email protected] Associate Publisher and Editor • LINDA BECKER (630) 694-4332 •
[email protected] Contributing Editor • JOY LEPREE ANDERSON (856) 582-9554 •
[email protected] Art Director • COURTNEY FATHERS (248) 244-1292 •
[email protected] Production Manager • BETH MCCLELLAND (412) 306-4354 •
[email protected] Reprint Sales • JILL DEVRIES (248) 244-1726 •
[email protected] E-Media Sales • SUSAN HEINAUER (412) 306-4352 •
[email protected] Classifieds • BECKY MCCLELLAND (412) 306-4355 •
[email protected] Publishing Director, Manufacturing and Gaming Groups JOHN R. SCHREI • (248) 786-1637 Editorial Office 155 N. Pfingsten Road, Suite 205, Deerfield, IL 60015 (847) 405-4000 • FAX (248) 502-1001
ADVERTISING SALES NORTH AMERICA • Sean Meaney • National Sales Manager 530 Humiston Drive • Bay Village, OH 44140 (440) 895-0919 • FAX (248) 502-1051 •
[email protected] NORTH AMERICA • Anne Armel • Publisher 155 N. Pfingsten Road, Suite 205 • Deerfield, IL 60015 (847) 405-4043 • FAX (248) 786-1441 •
[email protected] EUROPE • Carolyn Eychenne • European Sales Representative 7 rue de Maurepas • 78000 Versailles France tel/fax: 011 33 1 30 21 15 62 •
[email protected]
CORPORATE STAFF BNP Media Corporate Office • (248) 244-6400
SINGLE COPY SALES ANN KALB • (248) 244-6499 •
[email protected]
POSTAL LIST RENTAL ROBERT LISKA • (800) 223-2194 x726
[email protected]
E-MAIL LIST RENTAL SHAWN KINGSTON • (800) 409-4443 x828
[email protected]
AUDIENCE DEVELOPMENT Audience Development Coordinator • HAYAT ALI-GHONEIM Corporate Fulfillment Manager • MEGAN NEEL Corporate Audience Audit Manager • CATHERINE M. RONAN
SUBSCRIPTIONS Contact Customer Service at Tel. (847) 763-9534 or Fax (847) 763-9538 or e-mail
[email protected]. Via Web: to subscribe or submit an address change, visit www.process-heating.com and click on subscribe. Via Mail. Send your old address label along with your new address to Process Heating, PO BOX 2146, Skokie, IL 60076.
GET MORE ONLINE Search and read our archives. Every article and column published in Process Heating since 1998 is available online! • • • •
• •
Get daily updates Read web-exclusive articles, product writeups, news and more Sign up for our weekly eNewsletter Search our Online Buyers Guide, complete with expanded listings, data sheets, and other manufacturer-supplied materials, as well as links to manufacturers’ sites Use our Google-powered search engine to find content on www.process-heating.com or all of BNP Media’s web sites Contact us
WWW.PROCESS-HEATING.COM BNP MEDIA HELPS PEOPLE SUCCEED IN BUSINESS WITH SUPERIOR INFORMATION
Associate Member
Fives North American provides a wide range of systems and services. 185 standard burner models built for fuel efficiency and increased production The best available low NOx technology Comprehensive array of process control products and systems
www.fivesgroup.com/fivesna
TEL 216.271.6000
FAX 216.641.7852
[email protected]
Got Maintenance? Plant operators are finding out the advantages of having their heaters serviced by Heatec on a regular basis. There are important benefits of having a contract for our service technicians to do preventative maintenance once or twice a year. An important benefit is safety. Our technicians make sure all limit devices are working properly. Insurance companies usually prefer that specialists, such as Heatec technicians, perform services related to safety. Fuel savings is another important benefit that results from maintenance that includes tuning the burner. Moreover, preventative maintenance usually eliminates unexpected heater
shutdowns at times that interrupt production. Preventative maintenance can usually be done without adversely affecting production schedules. Another benefit is usually a reduction in costs for each service call. This results from lower travel expenses when our technicians can make service calls at other plants in the same area. Moreover, many of our technicians reside in diverse locations that reduce travel to plant sites. Call today to find out what kind of service contract would work best for you.
HEATEC
( % ! 4 % # DQ$VWHF,QGXVWULHV&RPSDQ\ :,/6215'&+$77$122*$7186$)$;KHDWHFFRP
