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  1. 3 Shell & Tube Heat Exchanger Features That Affect Shell-Side Pressure Drop

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    Managing Pressure Drop in Shell and Tube Heat Exchanger Design

    When designing a shell and tube heat exchanger, one of the most critical considerations is pressure drop. Each heat exchanger has a maximum allowable pressure drop, which is influenced by several factors, including the specific application, the type of fluid, and operating conditions.

    The goal of the designer is to approach—but not exceed—the maximum allowable pressure drop. Exceeding this threshold can lead to operational inefficiencies and even equipment damage, as excessive pressure can disrupt flow rates and reduce performance. On the other hand, a pressure drop significantly below the maximum limit may indicate suboptimal fluid velocity, which could also impact heat transfer efficiency.

    Typically, pressure drop problems arise when the flow rate is too high, resulting in excessive pressure. In such cases, engineers need to implement effective strategies to control pressure while maintaining process efficiency.

    There are several approaches to reduce shell-side pressure drop, all of which are tied to key components in shell and tube heat exchanger design: the shell, the tubes, and the baffles.

    Limiting Pressure Drop: Shell Design

    The shell is a primary factor in controlling pressure drop. The most commonly used shell design is the E-type shell, which features a single inlet and outlet valve and allows the shell-side fluid to make a single pass. While the E-type shell is widely used, it can sometimes result in a pressure drop that exceeds the allowable limit. In these cases, designers may consider alternative shell types, such as the J-type shell, which incorporates two outlet valves to split the flow and reduce pressure drop.

    Shell designs that limit shell-side pressure drop

    In some configurations, the J-type shell may be modified to include one outlet valve and two inlet valves, sometimes referred to as the I-type shell. Though less common, this design can also help manage pressure drop by allowing for more balanced flow.

    Shell designs that limit shell-side pressure drop

    For situations where flow splitting isn’t sufficient to control pressure drop, designers might opt for the X-type shell. Like the E-type, the X-type shell has a single inlet and outlet valve. However, the valves are positioned directly opposite each other, which improves flow distribution and can help reduce pressure drop. X-type shells are typically used in shell-side condensers and gas coolers.

    Shell designs that limit shell-side pressure drop

    If the shell style must remain unchanged but pressure drop still needs to be controlled, increasing the shell diameter can be an effective strategy. A larger diameter reduces flow velocity by shortening the length of the tubes, which can lower the pressure drop. However, this comes with trade-offs, including increased material costs due to the thicker shell wall and a higher tube count. Additionally, shorter tubes can lower tube-side velocity, potentially reducing heat transfer efficiency.

    Limiting Pressure Drop: Tube Configurations

    The arrangement of tubes also plays a significant role in managing shell-side pressure drop. For example, tubes arranged in a square pattern can reduce pressure drop and facilitate easier tube cleaning. However, a square arrangement tends to accommodate fewer tubes, which can limit heat transfer capacity.

    To balance this, designers may opt for a rotated square (or diamond) tube pattern, which can improve heat transfer by increasing flow turbulence, though it may still lead to a higher pressure drop in some cases.

    Tube pitch—the distance between adjacent tubes—also impacts pressure drop. A tighter tube pitch increases the number of tubes within the shell, maximizing heat transfer but also increasing shell-side pressure drop. Conversely, increasing the tube pitch can reduce pressure drop by allowing the fluid to flow more slowly, which can be particularly effective when combined with an X-type shell.

    Limiting Pressure Drop: Baffle Design

    Baffles, the metal plates that direct the flow of shell-side fluid, are another critical element in pressure drop management. The size, shape, and placement of baffles influence the flow pattern, velocity, and ultimately, the pressure drop.

    The most common baffle design is the single segmental baffle, which is nearly a full circle with one-third of the circumference cut away to allow fluid to flow around it. This pattern repeats along the length of the shell. While effective, the single segmental baffle can result in higher-than-desirable pressure drops, especially at high flow rates.

    To mitigate this, engineers may opt for a double segmental baffle, where the cutout is centered rather than positioned at the sides. This design divides the flow into two separate streams, helping to lower pressure drop by reducing the flow velocity while still maintaining effective fluid circulation.

    Enerquip Heat Exchanger Baffles
    Baffles arranged along the tube bundle help direct the flow of shell side fluid. 

    Limiting Pressure Drop: Baffle Spacing and Cut

    The spacing between baffles can be adjusted to control pressure drop. Increasing the gap between baffles allows for greater cross-flow, which reduces the pressure drop. However, there are design limits—baffles must be spaced far enough apart to prevent tube vibration or damage, as they also serve as support for the tube bundle.

    Baffle cut, or the percentage of the shell diameter removed from each baffle, also plays a role. A larger baffle cut (i.e., a larger opening) reduces flow resistance, lowering the pressure drop. However, this reduces baffle support, which can compromise tube stability and heat exchanger performance. Designers must strike a balance between reducing pressure drop and ensuring adequate tube support.

    Another baffle design option to reduce pressure drop is the no-tubes-in-window design. In this configuration, the baffles do not interact with the tubes, allowing for wider spacing between baffles. While this reduces pressure drop, it limits the space available for tubes, thus reducing heat transfer capacity.

    Finding the Optimal Solution

    Reducing pressure drop in a shell and tube heat exchanger requires a careful balance of design factors, and there’s no one-size-fits-all solution. Each design decision—from shell type to tube arrangement to baffle placement—impacts pressure drop, flow rates, and heat transfer efficiency. Experienced engineers understand how to navigate these trade-offs to meet the specific needs of your operation.

    At Enerquip, we specialize in designing and manufacturing shell and tube heat exchangers that optimize performance, including managing pressure drop. Our team can work with you to create a solution tailored to your requirements. Ready to discuss your project? Request a quote today!

     

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  2. Hastelloy C-276 Resists Corrosion in Harsh Environments

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    When selecting a shell and tube heat exchanger, understanding the strengths and limitations of different alloy options is key. Every application has unique demands—whether it’s resistance to corrosion, high temperatures, or pressure tolerance. Familiarizing yourself with these characteristics can help ensure you select an alloy that will deliver the performance your operation requires.

    Alloy Composition and Properties

    Alloys are created by combining specific metals to form a new material with unique properties. For example, nickel is a common choice to boost strength and hardenability while preserving ductility. Nickel-based alloys are highly resistant to stress corrosion cracking, making them ideal for challenging industrial environments.

    Among the popular options for durability and corrosion resistance is Hastelloy C-276, composed of:

    • Nickel for overall strength
    • Molybdenum to reduce brittleness
    • Chromium for improved ductility and wear resistance
    • Tungsten to enhance corrosion resistance

    The regulatory landscape emphasizes materials that meet stringent industry standards, such as those outlined by the International Organization for Standardization (ISO). For instance, ISO 15156 provides guidance specific to the petroleum and natural gas industries, outlining suitable materials for corrosive environments rich in hydrogen sulfide. Nickel-based alloys, including Hastelloy C-276, are recommended for these high-risk conditions due to their robust chemical composition and manufacturing process.

    How Hastelloy C-276 is Made

    Solution annealing and cold-working are two key methods used to manufacture alloys. Solution annealing involves heating the metal to a set temperature to enhance workability and reduce hardness. Cold working, in contrast, strengthens the alloy by manipulating it below its recrystallization point, although this can increase hardness, making periodic annealing beneficial for achieving optimal characteristics in tubular structures.

    Resisting Hydrogen Sulfide Corrosion

    Hydrogen sulfide (H₂S), common in natural gas and crude oil extraction, is a highly corrosive agent that poses safety risks if materials fail. ISO 15156 suggests that nickel alloys such as Hastelloy 825, 625, and C-276 are effective for high-hydrogen sulfide environments. Among these, Hastelloy C-276 is particularly well-suited for high-pressure H₂S exposure.

    Hastelloy C-276 also offers resilience against a variety of acids and corrosive compounds, including hydrochloric acid, sulfuric acid, acid chlorides, phosphoric acid, acetic and formic acids, hypochlorite, wet chlorine gas, and acetic anhydride.

    While it doesn’t perform well against nitric acid, its resistance to other corrosive agents makes it a popular corrosion-resistant material.

    High-Temperature Tolerance

    Nickel-based alloys like Hastelloy C-276 have impressive heat resistance, making them suitable for operations with fluctuating or extreme temperatures. This alloy remains stable at temperatures as high as 2,500°F, offering:

    • Oxidation resistance at 2,000°F
    • Corrosion and cracking resistance up to 1,900°F
    • Load-bearing capacity at 1,600°F
    • Thermal conductivity of 11 Btu/ft•h•°F at 1,000°F

    Finding the Right Fit for Your Heat Exchanger

    Choosing the best alloy for your shell and tube heat exchanger means evaluating environmental factors and operational requirements. In many cases, Hastelloy C-276 stands out as a durable and highly corrosion-resistant option, ideal for harsh environments. However, consulting with an experienced metallurgist is crucial for making an informed decision.

    If you’re considering a nickel-based alloy for its durability and resistance, Enerquip’s engineers bring unique expertise in integrating Hastelloy C-276 into custom process equipment. Contact us for guidance on maximizing efficiency and lifespan in your next heat exchanger investment.

     

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  3. Are Outdated Heating Systems Costing Your Plant Thousands? Here’s Why Efficiency Matters

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    We all know energy efficiency is important. From high-efficiency light bulbs and heating systems to fuel-efficient cars, efforts to increase efficiency are all around us.

    But if you’re a plant manager or facility owner, you may be overlooking one major source of inefficiency: the industrial heating equipment powering your facility. Relying on outdated equipment might seem cost-effective in the short term, but keeping old systems can cost your plant a significant amount over time in both money and environmental impact.

    Here’s why investing in modern, efficient industrial heating equipment should be a top priority for your facility.

    Lower Costs, Higher Efficiency: The Financial Case for Upgrading

    Switching to a high-efficiency industrial heating system is more than just an investment—it’s a way to save money year over year. Here are a few reasons upgrading makes financial sense:

    Decreased Energy Costs: New, high-efficiency heating systems use significantly less energy than older models, which means lower utility bills.

    Lower Operating Costs: Aside from saving energy, new systems generally cost much less to operate than the older equipment found in many plants and facilities.

    Fewer Repairs: Efficient systems are built to last, often requiring fewer repairs than older equipment. Many plants find that investing in new systems reduces downtime and minimizes disruption.

    By upgrading, you’re not just avoiding high operating costs—you’re also ensuring a steady, reliable heat source without the frequent headaches of repairs and maintenance.

    Green Gains: How Efficient Heating Systems Benefit the Environment

    Industrial facilities can make a big environmental impact by switching to efficient equipment. Here’s how:

    Less Energy Consumption: Efficient heating systems use less fuel, meaning your plant reduces its carbon footprint and conserves resources. Since these systems operate on a large scale, even one industrial heating system’s energy efficiency can have a significant impact on resource consumption.

    Less Waste: Efficiency doesn’t just mean lower energy use; it also reduces waste. High-efficiency systems create less operational waste and fewer emissions, and they’re built to last, cutting down on the need to replace parts frequently.

    Choosing green equipment for your facility is a practical way to contribute to a sustainable future while also benefiting your bottom line.

    Invest in Efficient Industrial Heating Equipment

    If you’re considering updating your facility’s heating equipment, remember: investing in a highly efficient system can positively impact your facility’s profitability and environmental footprint. It’s a responsible choice that could save your company thousands, all while reducing your impact on the environment.

    At Enerquip Thermal Solutions, we specialize in highly efficient, USA-made thermal fluid heating systems. Whether you’re looking for custom plant heating solutions, standard heating systems, or waste heat economizers, our systems are among the most advanced and durable available.

    Want to know how much you could save by upgrading? Reach out to our team for a free efficiency assessment! With decades of experience, Enerquip is proud to offer solutions that not only save energy but also support a sustainable future. Contact us today to learn more.

     

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  4. Enerquip Expands Team with Industry Expert Glenn Borthwick

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    Enerquip Thermal Solutions is thrilled to announce the appointment of Glenn Borthwick as its new Business Development Manager. With 27 years of sales management experience and a strong background in technical heat transfer, Borthwick is a key resource for customers seeking innovative heating and cooling solutions for both sanitary and industrial applications.

    As Business Development Manager at Enerquip, Glenn designs custom heat transfer solutions, navigates complex thermal calculations, and provides comprehensive project management support for clients across the globe.

    Borthwick is an experienced business development leader specializing in sales growth and technical solutions in heat transfer, mechanical power transmission, automotive, and contract manufacturing. He brings a wealth of experience from previous strategic roles with industry leaders such as Paul Mueller and Timken. Borthwick holds a bachelor’s degree in business administration and operations behaviors from Western Illinois University and is a Six Sigma Black Belt. His expertise includes technical sales, project estimation, root cause analysis, and account management, with a focus on continuous improvement and lean practices.

    “Glenn’s extensive experience and innovative problem-solving abilities will enhance our capacity to address the complex needs of our customers,” said Ron Herman, Director of Business Development. “We’re thrilled to have him join our team.”

    Outside of work, he enjoys classic cars and life in the Midwest, where he makes the most of outdoor activities like hunting and fishing.

    Ready to leverage Glenn Borthwick’s expertise for your next project? Contact Enerquip at sales@enerquip.com or call 833-516-6888 today.

    Meet the rest of the Enerquip sales team.

  5. Strategize Your Orders to Prepare for Long Lead-Times

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    Creating a high-quality product requires more than luck—it demands careful planning and the right tools. Every component, from the raw materials to the equipment used, plays a critical role in ensuring success. It starts with selecting the best materials, building an efficient facility, and utilizing top-tier equipment.

    But even the best equipment won’t last forever. Over time, wear and tear take their toll, which makes it essential to monitor and maintain machinery to avoid disruptions in your operation.

    Replacing or upgrading equipment, however, isn’t always a simple task. Large, specialized machinery, like shell and tube heat exchangers, can have long lead times. Waiting for essential equipment can cause significant delays, making proactive planning essential. Here are a few strategies to help streamline the process and minimize downtime.

    Know When You’ll Need Replacements

    You don’t need to be a fortune teller to predict when equipment might need replacing. Keeping track of the age, condition, and expected lifespan of your machinery will give you a solid idea of when to plan for upgrades or replacements. While it’s important to know the average lifespan of your equipment, remember that factors like usage, environment, and build quality can affect performance, so regular inspections are key. The older your equipment, the more frequently you should inspect it to catch signs of wear early.

    Develop an Ordering Schedule

    Once you have a general idea of when your equipment may need replacing, it’s smart to create a schedule for ordering new parts or machinery. This allows you to budget accordingly and plan ahead, so you can place orders well before equipment failures occur. By staying proactive, you’ll minimize downtime and avoid the costly delays that come with waiting for critical parts to arrive.

    Communicating your needs with your equipment supplier is also essential. By keeping them informed, they can provide you with accurate lead times and production schedules, ensuring that you’re never caught off guard.

    Plan for the Unexpected

    While planning can help avoid many issues, unexpected problems can still arise. Equipment can fail suddenly, and when it does, quick action is necessary to minimize downtime. Having an emergency budget in place and spare parts on hand will help you recover faster. Additionally, working with a reliable equipment manufacturer who can respond quickly in an emergency can make all the difference.

    Build Strong Partnerships

    In any industry, strong relationships with trusted suppliers are invaluable. Over time, a reliable partner will gain a deep understanding of your specific needs and processes, making collaboration smoother and more efficient. When it comes to ordering specialized equipment like shell and tube heat exchangers, having a dependable partner ensures that you’re well-supported throughout the process.

    If you’re unsure of how to plan for future equipment needs or want advice on reducing lead times, the engineers at Enerquip are ready to help. Contact us today to streamline your operations and stay ahead of the curve.

     

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  6. Duplex Stainless Steel Makes an Excellent Choice for Manufacturers

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    Designing a shell and tube heat exchanger involves making several important decisions, with one of the most critical being the selection of the right material. The material choice directly impacts the exchanger’s performance, durability, and overall cost.

    Material Selection for Heat Exchangers

    Engineers have a wide range of materials to choose from when building a shell and tube heat exchanger. Steels and alloys come in different compositions, each offering unique properties that come with distinct advantages and disadvantages. Selecting the right material depends on how the exchanger will be used — factors such as the type of chemicals it will encounter, the operating temperature and pressure, and the environment it will be placed in all play significant roles. Additionally, the chosen material must be both cost-effective and readily available to manufacturers.

    Why Duplex Stainless Steel is a Popular Choice

    One material that stands out for many industries, including pharmaceuticals, oil and gas, and biotechnology, is duplex stainless steel. Known for its ability to handle high-stress applications, duplex stainless steel is composed of a combination of ferrite and austenite, offering both strength and corrosion resistance.

    Stainless steel is categorized into different types based on its composition. Austenitic stainless steels are the most commonly used because of their versatility and ease of welding. However, they can crack under excessive heat or pressure.

    Ferritic stainless steels, on the other hand, while not as durable as austenitic varieties, are highly resistant to corrosion and relatively easy to form. By combining both austenite and ferrite into duplex stainless steel, you get the best of both worlds: the strength of austenite and the corrosion resistance of ferrite.

    Strength and Efficiency of Duplex Stainless Steel

    Due to the strength of duplex stainless steel, engineers can design thinner-walled heat exchangers without sacrificing durability or corrosion resistance. Duplex stainless steel is typically twice as strong as austenitic stainless steel. Thinner walls reduce the amount of material needed, cutting manufacturing costs, while the lower weight can improve the exchanger’s efficiency.

    Resistance to Corrosion and Chlorine

    Corrosion resistance is another key factor in selecting materials for heat exchangers. Tubes that become corroded or pitted over time can eventually spring leaks, leading to problems such as:

    • Fouling
    • Cross-contamination
    • Damage to tube sheets, shells, or other critical components

    Not only are damaged tubes costly to replace, but they can also lead to equipment downtime, negatively impacting productivity.

    Corrosion can occur when the material of the exchanger reacts with substances introduced during operation. For example, chlorine is a common cause of pitting corrosion, which can significantly weaken austenitic stainless steels in chlorine-heavy environments. Duplex stainless steel, however, offers superior resistance to the damaging effects of chlorine, making it ideal for industries that frequently work with this chemical.

    High-Temperature Tolerance

    Duplex stainless steels also tolerate high-temperature applications. While austenitic stainless steels begin to degrade at around 150°F when exposed to chloride and tensile stresses, duplex stainless steel can handle temperatures up to approximately 250°F without risk.

    Tackling Rouging

    Some industries, such as pharmaceuticals and biotechnology, must contend with rouging, a form of discoloration caused by oxygen exposure. This discoloration can lead to contamination if left unchecked. Cleaning rouging from equipment can be time-consuming and expensive, so selecting a rouging-resistant material is critical. While 316L austenitic stainless steel is popular in these industries for its resistance to rouging, duplex stainless steel has been found to offer even greater protection.

    Cost Benefits of Duplex Stainless Steel

    In addition to its performance advantages, duplex stainless steel also provides cost benefits. It contains lower levels of nickel and molybdenum compared to austenitic stainless steel, reducing its price and making it less vulnerable to price swings in the raw materials market.

    Since duplex stainless steel is stronger, less material is needed to achieve the same durability as with austenitic or ferritic steels, further lowering costs. Over time, the reduced need for maintenance and replacement, thanks to the material’s strength and resistance to corrosion, can result in significant long-term savings.

    Choosing the right materials for your shell and tube heat exchanger is critical to the performance and longevity of your system. For a durable, cost-effective, and corrosion-resistant solution, duplex stainless steel offers many advantages. At Enerquip, our team of expert engineers is ready to help you select the best materials and configuration to meet your unique operational needs. Contact us today to learn more about how we can help you increase the efficiency and longevity of your heat exchanger.

     

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  7. Is Landfill Gas a Renewable Energy Source?

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    Landfill gas, or LFG, comes from decomposing solid waste. Often considered a foul-smelling hazard and source of air pollution, it can also be captured, refined, and reused for energy production. Shell and tube heat exchangers are critical throughout the processing stages that convert LFG to fuels and other energy sources.

    Keep reading to learn more about landfill gas, how it can be reused to benefit the environment, and the role shell and tube heat exchangers play in the process.

    What Is Landfill Gas?

    When trash is added to a landfill, it decomposes over time. Initially, decomposition is aerobic (i.e., in the presence of oxygen); however, after several months, the decomposition becomes anaerobic (i.e., without oxygen). This anaerobic decomposition results in LFG.

    LFG is composed of many different gases, but primarily methane and carbon dioxide, approximately 45-60% and 40-60% respectively. It also contains small amounts of carbon monoxide, hydrogen, sulfides, ammonia, oxygen, nitrogen, and nonmethane organic compounds, including vinyl chloride, benzene, and trichloroethylene.

    Is Landfill Gas a Renewable Energy Source?

    As a byproduct of decomposition, LFG is naturally released into the surrounding environment, generating odors and air pollution. Instead of allowing the gas to escape, many landfills recapture or extract it for processing. This converts it into fuel that can be used directly for medium-BTU applications or used to power turbines to generate electricity. It can also be further processed for use as vehicle fuel or added to gas pipelines.

    LFG also stands out among renewable resources like wind and solar because it is constantly being produced. While wind speeds vary and the sun sets each night, trash never stops decomposing and generating LFG.

    According to the EPA, landfill gas offers many environmental benefits:

    • It is a renewable and safe energy resource.
    • It reduces reliance on using other polluting forms of energy.
    • It reduces air pollution and other risks to health and the community.

    The EPA also notes several economic advantages of LFG:

    • LFG is a ubiquitous and consistent local resource and recycling it is cost-effective.
    • Reusing LFG can generate economic advantages for the local community.
    • LFG energy projects can create local jobs.
    • Landfill energy sources have the potential to attract businesses to the area.

    Landfill Gas Coolers from Enerquip
    Landfill Gas Coolers, Heat Exchangers, from Enerquip 

    How Shell and Tube Heat Exchangers Assist in Recycling and Recovering LFG

    LFG recovery and processing involves many steps. Shell and tube heat exchangers are an important part of the process.

    LFG Collection and Processing
    • Collection. Escaping LFG is collected through a network of pipes and wells.
    • Processing. Moisture is removed from the LFG so that siloxane and sulfur can be removed to create fuel for electricity production or medium-BTU applications.
    • Advanced processing. Removing carbon dioxide, nitrogen, oxygen, and VOCs creates fuel for vehicles or to be added to gas pipelines.
    The Role of Shell and Tube Heat Exchangers
    • Cooling and Condensation. Shell and tube heat exchangers help cool raw LFG, condensing the moisture to separate it. This prevents corrosion of equipment due to moisture.
    • Heating for Siloxane Removal. Shell and tube heat exchangers heat LFG to separate siloxanes. This protects downstream equipment and improves gas quality.
    • Heat Recovery. Shell and tube heat exchangers help recover heat from combusting purified LFG. The recovered heat can be reused in other processes to improve efficiency.
    Energy Production
    • Fuel for Engines or Turbines. Purified LFG can be used to power turbines or reciprocating engines to generate electricity. Heat exchangers assist in maintaining ideal operating temperatures.
    Environmental Benefits
    • Reduced Emissions. Heat exchangers assist in efficient cooling and purification of landfill gas, reducing harmful emissions.
    • Energy Efficiency. Incorporating heat exchangers allows for the recovery and use of waste heat.
    Challenges and Considerations
    • Corrosion and Fouling. Heat exchangers require protection from corrosion and fouling from gas impurities.
    • Maintenance. Regular maintenance is required for efficiency and optimal performance in extreme operating conditions.

    Heat Exchangers From Enerquip for Landfill Gas Applications

    As the world moves towards renewable energy sources, biofuels like LFG are an ideal solution for powering equipment that generates electricity and in other applications. Shell and tube heat exchangers are a critical part of the LFG capture and refining process.

    Enerquip’s high-quality equipment helps you meet landfill gas renewable energy demands. Contact us or request a quote to get started.

     

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  8. Plastic Pyrolysis: Transforming Waste into Resources

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    As the world faces growing challenges from plastic waste, innovative technologies like plastic pyrolysis offer promising solutions. Plastic pyrolysis transforms discarded plastic into useful fuels, chemicals, and materials, helping to reduce landfill waste and support a circular economy. Enerquip is providing thermal solutions to serve the emerging plastic pyrolysis industry.

    What is Plastic Pyrolysis? 

    Plastic pyrolysis is an advanced recycling process that heats plastic waste in the absence of oxygen, breaking it down into valuable liquid and gas products without burning it. This process, known as thermal decomposition, takes place at high temperatures—around 932 °F (500 °C)—and produces fuels like pyrolysis oil and gas. These fuels can be used in a variety of applications, including energy production and chemical manufacturing.

    Unlike traditional incineration, pyrolysis reforms plastic into useful substances instead of turning it into ash or releasing harmful emissions into the atmosphere. This makes it a more sustainable option for recycling plastic waste.

    The Plastic Pyrolysis Process

    The plastic pyrolysis process involves several key steps:

    • Shredding and Drying: Plastic waste is shredded and dried to prepare it for the pyrolysis reactor.
    • Feedstock Separation: Non-plastic materials are removed to ensure pure feedstock for efficient processing.
    • Thermal Decomposition: The plastic is heated in a reactor, where it vaporizes and breaks down into pyrolysis oil and gases.
    • Oil Distillation and Purification: The liquid fuel produced is distilled and purified for further use.
    • Storage and Dispatch: The final product is stored for distribution or immediate use.

    Catalysts for Improved Efficiency

    Certain catalysts can enhance the efficiency of the plastic pyrolysis process by speeding up chemical reactions and improving fuel quality. Common catalysts include:

    • ZSM-5
    • FCC
    • MCM-41
    • Zeolite

    Benefits of Plastic Pyrolysis

    Plastic pyrolysis offers several advantages that make it an attractive option for plastic recycling:

    • Relatively Eco-Friendly: Studies show pyrolysis is more environmentally sustainable than landfilling or incinerating mixed plastic waste. The oil produced through pyrolysis replaces the need for new commercial diesel, reducing environmental impact.
    • Combustion-Free: Since oxygen is absent in the pyrolysis process, no greenhouse gases are emitted from combustion. The only emissions come from the fossil fuels used to heat the reactor, which can be reduced by using the fuel produced during pyrolysis.
    • Cost-Effective: The gas produced can be reused to heat the reactor, saving significant costs on external fuel.

    Importance of Plastic Waste Recycling in the Chemical Industry

    Plastics are not a renewable fuel source. Producing plastics and converting them into fuel releases a considerable amount of pollution that can put the health of nearby residents at risk and accelerate climate change.

    However, plastic recycling reuses processed plastics, reducing the need to extract raw, new materials from the earth and preserving natural resources. In recycling applications, plastic pyrolysis can also help minimize the emission of heat-trapping gases into the atmosphere.

    Properly recycling plastic waste can help prevent it from entering rivers, oceans, and ecosystems, where it can contribute to the degradation of the environment and harm wildlife. Recycling gives plastics a second purpose, preventing it from becoming a recurring pollutant.

    Types of Equipment Used in the Plastic Pyrolysis Process

    Shell and Tube Heat Exchangers

    A shell and tube heat exchanger plays a crucial role in the pyrolysis process by managing the heat transfer between different fluids or gases. Here’s how it fits into the plastic pyrolysis system:

    • Preheating the feedstock to reduce energy consumption in the reactor.
    • Cooling pyrolysis vapors to condense them into liquid products like pyrolysis oil.
    • Recovering heat to increase energy efficiency.
    • Stabilizing reactor temperature for optimal performance.

    Enerquip Heat Exchanger for a Pyrolysis application
    Enerquip Heat Exchangers for a Pyrolysis Application

    Pyrolysis Oil Burners

    While an industrial pyrolysis oil burner is considered optional, the equipment is typically necessary since the pyrolysis oil can be used as fuel to heat the pyrolysis reactor. This eliminates the need to purchase fuel from other sources, resulting in convenience and cost-saving benefits.

    Carbon Black Screw Conveyors

    Following discharge from the pyrolysis reactor, carbon black must be carried away by screw conveyors. These specialized conveyors help save time and labor.

    Environmental Protection Devices

    A tail gas purification system is used to purify the tail gas produced during the pyrolysis process. Most pyrolysis plants also maintain a flue gas desulfurization tower as part of their standard flue gas purification system. If there is a greater need for environmental protection, custom configurations are available to meet those needs.

    Auto-Feeders

    An auto-feeder improves the efficiency of feeding plastic into a pyrolysis reactor. By automatically pressing the plastics into the reactor at high pressures, auto-feeders can significantly reduce the amount of time and effort needed for feeding compared to manual labor.

    Vacuum Systems

    Once the plastic pyrolysis process is complete, a vacuum system extracts the remaining oil from the reactor to prevent the oil from causing a fire when the reactor door opens.

    Plastic Pyrolysis vs. Mechanical Recycling

    Chemical Recycling

    Chemical recycling encompasses reprocessing technologies, such as industrial pyrolysis, that directly affect the formulation of the polymer or the polymeric waste. Chemical recycling converts the polymer into chemical substances or products for either its original purpose or other purposes, except for energy recovery.

    Mechanical Recycling

    Also known as physical recycling, mechanical recycling involves processing plastic materials without altering their original chemical structure. The plastics are subject to various processes, such as melting and grinding, that alter the materials’ physical form. Without breaking any polymeric chains, these steps aim to purify the material for reuse.

    Enerquip: Your Partner in Plastic Pyrolysis Solutions

    Since 1985, Enerquip has been a leader in providing industrial heating and cooling solutions. All of our products are manufactured in the U.S. from our carbon-neutral facilities in Wisconsin and Oklahoma. We continuously explore new and emerging technologies to enhance sustainability, from biofuel blending to landfill gas recycling—and now, plastic pyrolysis.

    Request a quote today to see how our equipment can serve your process application.

     

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  9. Exploring Electrolysis as a Leading Hydrogen Production Process

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    Electrolysis is a method that produces carbon-free hydrogen from nuclear and renewable resources. The process uses electricity to split water into oxygen and hydrogen molecules in the electrolyzer unit. Electrolyzers come in a range of sizes, from small appliance-sized units for small-scale hydrogen production to large-scale units for production facilities in the renewable energy production sector.

    Learn more about the main types of electrolysis and how Enerquip’s solutions serve this market.

    Types of Electrolysis Processes for Hydrogen Production

    Electrolyzers are made of a cathode and anode with an electrolyte separating them, similar to a fuel cell. There are several types of electrolyzers, each with different functions based on the material of the electrolyte and the ionic species it conducts.

    Polymer Electrolyte Membrane Electrolyzers

    A polymer electrolyte membrane (PEM) electrolyzer has an electrolyte made of a specialty plastic. When water is introduced to the anode, it reacts to form oxygen and hydrogen ions with a positive charge. The electrons move through an external circuit system, and the hydrogen ions are drawn across the PEM to the cathode. There, the hydrogen ions and electrons combine to form hydrogen gas. The reactions are as follows:

    • Anode: 2H2O → O2 + 4H+ + 4e-
    • Cathode: 4H+ + 4e- → 2H2

    Alkaline Electrolyzers

    In alkaline electrolyzers, hydroxide ions (OH-) in the cathode move through the electrolyte to the anode, and hydrogen gas is generated in the cathode. Alkaline electrolyzers typically use a liquid alkaline electrolyte solution of potassium or sodium hydroxide. However, newer alkaline electrolyzers that use electrolytes made of solid alkaline exchange membranes (AEMs) are being developed and show promising results in lab environments.

    Solid Oxide Electrolyzers

    A solid oxide electrolyzer uses a solid ceramic electrolyte to conduct oxygen ions (O2-) selectively under elevated temperatures to produce hydrogen. Steam in the cathode and electrons from the external circuit combine to create hydrogen gas and oxygen ions with a negative charge. These oxygen ions transfer through the ceramic membrane, reacting at the anode to generate oxygen gas and electrons for the external circuit.

    The Role of Thermal Process Equipment in Electrolysis

    Electrolysis offers a unique opportunity to align hydrogen production with renewable energy sources, like wind power, by using excess electricity for hydrogen generation when energy supply exceeds demand. This process provides operational flexibility that enhances the overall efficiency of renewable energy systems.

    Enerquip supports hydrogen production by designing and fabricating industrial heating and cooling equipment essential for electrolysis processes. All our products are made in the U.S. and play a crucial role in hydrogen generation. Our heat exchangers and heaters—such as shell and tube heat exchangers, waste heat economizers, and thermal fluid heaters—are vital in these applications.

    Heat exchangers are critical in hydrogen production as they recover and recycle heat from the process, improving overall energy efficiency. For instance, in high-temperature electrolysis, heat exchangers capture waste heat and transfer it back to preheat incoming water or steam, reducing energy consumption. This heat recovery system is essential for optimizing the cost-effectiveness and sustainability of hydrogen production.

    Additional applications for Enerquip’s heat exchangers include:

    • HVAC systems
    • Chemical processing
    • Ethanol production
    • Feedwater heaters
    • Fuel gas heaters
    • Suction heaters
    • Oil coolers
    • Kettle reboilers
    • General service condensers

    Partner With Enerquip

    Due to its ability to produce carbon-free hydrogen, electrolysis will continue to grow in popularity to support worldwide sustainability goals. There are several types of hydrogen production electrolysis systems available to meet the needs of your operation. Enerquip offers a variety of heat exchangers and other temperature control solutions for hydrogen production.

    Enerquip has delivered industrial heating, cooling, and sanitary solutions made in the USA since 1985. Contact us or request a quote to get started with your unique solution today.

     

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  10. How High-Efficiency Industrial Heating Equipment Can Save Your Facility Money

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    In any production or manufacturing facility, efficiency and profitability are paramount. The more effectively you streamline your processes, the more competitive and profitable your organization becomes.

    While cost-effectiveness is often top of mind when choosing materials and vendors, it’s equally important to focus on the industrial equipment and systems your plant depends on. After all, the right equipment can dramatically reduce operational costs over time.

    At Enerquip, we specialize in the design and manufacture of highly efficient thermal fluid heating systems, serving a wide range of industries. We’re proud to offer American-made industrial heating equipment that can save facilities thousands of dollars annually.

    But what sets our equipment apart in terms of efficiency and savings? Let’s take a look at the key features of our industrial heaters and heating systems that can help reduce costs at your facility.

    Key Features of Enerquip’s High-Efficiency Industrial Heating Equipment

    1. Serpentine Coil Heater Design

    Most industrial thermal fluid heaters feature a helical coil design, which typically provides about 77% efficiency. While we build helical coil for customers who require it, our unique and innovative serpentine coil thermal fluid heater design is more efficient at about 88%. This boost in efficiency can save your facility thousands of dollars each year, making it an investment that often pays for itself in just a few years.

    2. Minimal Maintenance

    Enerquip’s industrial heating equipment is engineered for longevity and minimal upkeep. In most cases, a simple annual burner tune-up is all that’s required. With fewer replacements and repairs needed, our systems keep maintenance costs low—saving you money in both the short and long term.

    3. Exceptional Durability

    Built to last, Enerquip’s thermal fluid heaters are among the most durable on the market. With decades of reliable service, our heaters eliminate the need for frequent replacements, ensuring that your facility can operate smoothly without the constant worry of new equipment investments.

    4. Low Flow Rates

    Our advanced thermal fluid heater design allows for lower flow rates compared to most market alternatives, which leads to significant savings. Lower flow rates reduce the size of the pipes and valves required throughout your system. Smaller components like bends, elbow joints, and piping are more affordable, lowering the overall cost of your heating system.

    Additionally, heaters with lower flow rates require pumps with lower horsepower, which consume less electricity. By operating on less power, Enerquip heaters reduce your facility’s energy costs, providing long-term savings on operational expenses.

    Invest in Industrial Heating Equipment You Can Rely On

    Enerquip is a trusted source for high-quality, energy-efficient industrial heating equipment, proudly made in the USA. Our heaters are ideal for use across multiple industries, including asphalt, refineries, tank terminals, and more.

    All our heaters are ASME code stamped and built to last. Whether you need custom heating solutions or standard heating systems, Enerquip has the expertise to deliver.

    Interested in learning how our equipment can help your facility save money and boost efficiency? Contact us at (833) 516-6888 or online here for more information.

     

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