Enerquip Thermal Solutions in Medford, Wisconsin, is proud to announce a $500 donation to the Athens High School Track & Field program. This contribution will help support the program’s ongoing expenses including competition expenses, student transportation, and more.
Enerquip is dedicated to supporting its community, with a unique program that matches employee donations and volunteer hours up to $500 per employee annually. Lance Bloch, an Enerquip Assembler and Athens Track & Field Coach, chose the Athens Track & Field program as the beneficiary of his employee match.
In 2024, two athletes coached by Bloch medaled at the Wisconsin State Track & Field Championships. “Coaching these young athletes and seeing their hard work culminate in success, from the very first practice to the state podium, is incredibly rewarding,” says Coach Bloch. “On behalf of the entire program, I’m truly grateful for Enerquip’s financial support.”
For more information about Enerquip’s community giving programs and culture, visit www.enerquip.com.
Lance Bloch (left) and Athens High School Sophomore Sy’Rih Hartwig (right): Sy’Rih Hartwig, coached by Lance Bloch, took 5th place in shot put (37 feet, 11.5 inches) at the 2024 WIAA Division 3 State Track & Field Championships.
Athens High School Freshman Delaney Beasley (3rd from right): Coached by Lance Bloch, Delaney Beasley placed 3rd in shot put (32 feet, 11 inches) and 9th in discus (93 feet, 7 inches) at the 2024 Freshman State Track & Field Championships.
Enerquip is on the lookout for a talented CNC Machinist to join our team in Medford, WI. If you’re eager to work with a company that values integrity, drive, and quality, this could be the perfect opportunity for you.
Chemical engineers around the world know that the success of chemical processes often hinges on the efficient and reliable performance of the equipment used. Among the most critical components in many chemical plants is the heat exchanger, which plays a vital role in regulating temperature, facilitating reactions, and optimizing energy usage. The shell and tube heat exchanger stands out as a workhorse in the chemical and petrochemical industries, offering a unique combination of efficiency, safety, and versatility.
Understanding the Shell and Tube Heat Exchanger
A shell and tube heat exchanger consists of a shell, or outer casing, and a bundle of tubes housed within it. The two fluids or gases, typically one hot and one cold, flow through the heat exchanger in a counter-current or parallel-flow arrangement, allowing for the efficient transfer of heat between them.
One key advantage of the shell and tube design is its flexibility. The size and configuration of the heat exchanger can be scaled to meet the specific requirements of a chemical process, whether it’s handling large volumes of fluids or dealing with high-pressure or high-temperature conditions. This adaptability makes shell and tube heat exchangers a popular choice for a wide range of chemical applications, from petrochemical refineries to pharmaceutical production facilities.
Shell and Tube Versatility
Shell and tube heat exchangers offer nearly limitless customizations and can optimize almost any process. Common applications include:
Condensing vapors into liquids: Commonly used in power plants, refrigeration systems, and chemical processing industries.
Reboiling: Adding heat to the bottom of a distillation column to boil the liquid, creating vapors that rise up the column.
Preheating fluids: Before they enter process units like reactors or distillation columns, improving efficiency by reducing the energy needed for heating.
Cooling down hot fluids: Using a cooler fluid, often in chemical plants to remove excess heat from reactions or other processes.
Heating a fluid: By transferring heat from a hot fluid to a colder one, used in various chemical processes that require specific temperatures for reactions.
Evaporating liquids: To leave behind concentrated solutions, common in the production of chemicals, pharmaceuticals, and food products.
Recovering waste heat: From industrial processes to improve energy efficiency, with the recovered heat used elsewhere in the plant or for generating power.
Efficiency and Performance
The efficiency of a shell and tube heat exchanger is crucial for its performance and the overall success of a chemical process. The design of the heat exchanger, including the arrangement of the tubes, the flow patterns, and the materials of construction, all contribute to its thermal efficiency.
One factor that enhances the efficiency of shell and tube heat exchangers is the large surface area-to-volume ratio. The multiple tubes within the shell provide a significant surface area for heat transfer, allowing for more effective heat exchange between the two fluid streams. Additionally, the counter-current arrangement ensures that the temperature difference between the hot and cold streams is maximized throughout the length of the exchanger, further improving heat transfer efficiency.
Another aspect that contributes to the efficiency is the ability to optimize fluid flow patterns. The design of the shell and the arrangement of the tubes can be tailored to create optimal flow conditions, minimizing pressure drops and ensuring effective heat transfer.
Safety and Reliability
The design of equipment plays a crucial role in ensuring the safe operation of chemical processes. Shell and tube heat exchangers are renowned for their robust and reliable construction, making them a preferred choice for many chemical applications.
The thick shell and sturdy tube construction of these heat exchangers provide excellent pressure containment, allowing them to withstand high-pressure and high-temperature conditions. This level of structural integrity is particularly important in processes where the fluids involved are hazardous or corrosive.
Additionally, the modular design of shell and tube heat exchangers allows for easy maintenance and inspection, enabling regular checks and preventive measures to ensure continued safe operation. This proactive approach to maintenance helps minimize the risk of unexpected failures and ensures long-term reliability.
High Alloy Materials of Construction
The chemical industry often deals with highly corrosive, abrasive, or aggressive fluids, which can pose a significant challenge to the materials used in heat exchanger construction. Shell and tube heat exchangers are known for their ability to be fabricated from a wide range of high-alloy materials, ensuring compatibility with the specific process requirements.
Stainless steel, Hastelloy, Inconel, and other specialized alloys are commonly used in the construction of shell and tube heat exchangers for chemical applications. These materials are selected for their exceptional resistance to corrosion, erosion, and high-temperature degradation, ensuring the long-term integrity and performance of the heat exchanger.
The use of high-alloy materials also enables shell and tube heat exchangers to be designed for specific process conditions, such as handling highly acidic or alkaline fluids, or operating in extreme temperature ranges. This flexibility in material selection is a key advantage that allows chemical engineers to tailor the heat exchanger to the unique requirements of their processes, further enhancing the overall efficiency and reliability of the system.
The widespread use of shell and tube heat exchangers in the chemical and petrochemical industries has had a significant impact on the efficiency, safety, and overall performance of chemical processes. By providing reliable and efficient heat transfer, these heat exchangers have enabled chemical engineers to optimize process parameters, reduce energy consumption, and ensure the safe operation of their facilities.
One primary impact is the improvement in energy efficiency. By effectively transferring heat between fluid streams, these heat exchangers can reduce the amount of energy required for heating, cooling, or maintaining specific temperature conditions. This translates into lower energy costs and a reduced environmental footprint for chemical plants, making them more sustainable and cost-effective.
Additionally, the safety and reliability of shell and tube heat exchangers have been instrumental in mitigating the risks associated with chemical processes. The robust construction and use of high-alloy materials ensure that these heat exchangers can withstand harsh operating conditions, reducing the likelihood of equipment failures and potential accidents or environmental incidents.
The shell and tube heat exchanger is an indispensable component in the chemical industry, due to its exceptional efficiency, safety, and versatility. By providing reliable and efficient heat transfer, these heat exchangers have enabled chemical engineers to optimize their processes, reduce energy consumption, and ensure the safe operation of their facilities.
Are you looking for a custom process solution? Contact us today.
The Westboro Volunteer Fire Department, committed to enhancing public safety and rescue services for Westboro and neighboring communities, has been actively fundraising to purchase a new fire engine. Enerquip Thermal Solutions has donated $500 to support this critical initiative.
In January 2024, the Westboro Volunteer Fire Department ordered a state-of-the-art fire engine to better serve the 700 residents and 125 square miles of Westboro. This new engine will also bolster the department’s ability to provide mutual aid to the surrounding areas in Taylor and Price counties.
The fundraising efforts, fueled by the community’s dedication, have already enabled a substantial down payment; however, the department still needs to raise an additional $180,000 to fully fund the new fire engine. Enerquip’s contribution marks a step toward reaching this goal.
“We are incredibly grateful for the community’s generous support,” said Captain Bryan Strobach of the Westboro Volunteer Fire Department. “Enerquip’s donation, and others, not only brings us closer to acquiring the new fire engine but also strengthens the safety and well-being of our community and neighboring areas.”
Enerquip Sales Engineer Will McCarron and Enerquip Design Engineering Manager Cam Diedrich, who also volunteer as firefighters for the Stetsonville and Athens Volunteer Fire Departments, respectively, presented the donation to Captain Strobach. Their dual roles highlight the deep commitment and close-knit nature of the community.
This donation exemplifies the power of local businesses in supporting essential community services. The Westboro Volunteer Fire Department encourages other businesses and individuals to contribute to this vital cause, ensuring the safety and protection of all residents and visitors in the area. For more information on how to donate, please contact the Westboro Volunteer Fire Department at (715) 905-0702.
Enerquip Thermal Solutions is proud to announce a $500 donation to the Beggs Lady Warriors Youth Softball team to help purchase new uniforms. This contribution supports Beggs Little League, which provides a nurturing environment for dozens of young athletes each summer, promoting values such as hard work, sportsmanship, and teamwork.
Enerquip is committed to giving back to the community by matching employee donations and volunteer hours up to $500 per employee each year. This year, Enerquip Quality Control Manager Kenny Devilbiss (back right), who also coaches the team, chose the Beggs Lady Warriors as the recipient of his employee match.
One of the most significant sources of energy loss in industrial processes is waste heat – the thermal energy that escapes without being put to productive use. However, there’s a powerful tool at our disposal that can help us recapture this valuable resource: the shell and tube heat exchanger.
Below, we’ll explore five ways that shell and tube heat exchangers can assist in recovering waste heat, ultimately improving your overall process efficiency and bottom line.
1. Reclaiming Heat from Exhaust Streams
One of the primary applications of shell and tube heat exchangers is the recovery of heat from exhaust streams. Whether it’s the flue gas from a boiler, the hot air from a drying process, or the discharge from a compressor, these heat exchangers can be strategically placed to capture the thermal energy that would otherwise be lost to the environment.
By using a shell and tube design, the heat exchanger can effectively transfer this waste heat to a secondary fluid, such as water or a process stream, which can then be used to preheat incoming process materials or generate steam for other applications. This not only reduces the overall energy consumption of the facility but also helps to minimize the environmental impact of the operation.
2. Improving Process Heating Efficiency
In many industrial processes, heat is required to maintain specific temperature setpoints or to raise the temperature of raw materials or intermediates. Conventional heating methods, such as electric heaters or steam boilers, can be energy-intensive and often result in significant heat losses.
Shell and tube heat exchangers can be used to improve the efficiency of these process heating applications. By using the waste heat from one stream to preheat another, the overall energy required for the heating process can be significantly reduced. This can be particularly beneficial in applications where the process stream needs to be heated to a high temperature, as the shell and tube design allows for efficient heat transfer over a wide temperature range.
3. Enabling Cogeneration and Combined Heat and Power (CHP) Systems
Cogeneration and combined heat and power (CHP) systems are powerful tools for improving overall energy efficiency. These systems generate both electricity and useful thermal energy, often by capturing the waste heat from power generation equipment, such as turbines or engines.
Shell and tube heat exchangers play a crucial role in CHP systems by allowing the efficient transfer of this waste heat to a secondary fluid, such as water or steam. This thermal energy can then be used for a variety of applications, such as space heating, process heating, or the generation of additional electricity through a steam turbine.
By implementing a CHP system with shell and tube heat exchangers, facilities can achieve remarkable improvements in energy efficiency, often reaching overall system efficiencies of 80% or higher.
4. Facilitating Heat Integration in Complex Processes
In many industrial processes, there are multiple streams of hot and cold fluids that could potentially be integrated to improve overall efficiency. However, the complexities of these systems can make it challenging to identify and implement effective heat recovery strategies.
Shell and tube heat exchangers are well-suited for these types of complex heat integration projects. Their modular design and flexible configurations allow them to be easily integrated into existing processes, enabling the recovery of waste heat from a wide range of sources and the efficient transfer of this energy to other process streams.
By carefully analyzing the heat and mass balances of the entire process and strategically placing shell and tube heat exchangers, engineers can unlock significant energy savings and improve the overall sustainability of the operation.
5. Enhancing the Reliability and Longevity of Heat Recovery Systems
Effective heat recovery systems are not only about maximizing energy efficiency – they also need to be reliable, durable, and easy to maintain. Shell and tube heat exchangers excel in this regard, thanks to their robust construction and proven track record of long-term performance.
The shell and tube design, with its separate fluid paths and sturdy tube bundle, is inherently less susceptible to fouling and corrosion than other heat exchanger types. This translates into fewer maintenance requirements, longer service life, and a lower risk of unexpected downtime or system failures.
Additionally, shell and tube heat exchangers can be easily inspected, cleaned, and repaired, allowing facility operators to proactively maintain the performance and reliability of their heat recovery systems. This, in turn, helps to ensure a consistent and reliable supply of recovered thermal energy to support the overall process efficiency.
Shell & Tube Heat Exchangers from Enerquip
Most operations are looking to optimize energy efficiency and minimize waste. The shell and tube heat exchanger is a powerful tool that can help achieve these goals, enabling the recovery of waste heat and the implementation of more sustainable and cost-effective operations. By leveraging the benefits of shell and tube, you can unlock significant energy savings and reduce environmental impact.
As we continue to navigate the challenges of today’s energy landscape, the shell and tube heat exchanger will undoubtedly play an increasingly important role in our quest for greater efficiency and sustainability. By embracing this technology and incorporating it into our operations, we can build a brighter, more sustainable future for our industries and our planet.
Enerquip is excited to introduce Emily Schafer as its newest Design Engineer.
As an Enerquip Design Engineer, Schafer crafts detailed fabrication drawings for various equipment, ranging from heat exchangers to condensers and bayonet heaters. Proficient in managing intricate thermal calculations and interpreting blueprints and specifications, she and the rest of Enerquip’s talented designers design thermal process solutions that optimize our clients’ manufacturing processes.
With a strong interest in engineering, Schafer began her journey with Enerquip as a mentorship student back in 2020 as a Medford High School Senior. Throughout her college years, she further developed her skills at Enerquip during winter and summer breaks away from college. Now, as a recent graduate of UW-Stout’s engineering technology program and armed with her completion of the SolidWorks Associate’s Exam, she’s joined Enerquip full-time as a Design Engineer.
Cameron Diedrich, Design Engineering Manager, shares his enthusiasm about Emily Schafer joining the team, stating, “Emily brings a wonderful blend of talent, dedication, and fresh perspective to our design team. Her passion for engineering and commitment to excellence make her a valuable addition to Enerquip.”
A native of Medford, Wisconsin, Schafer is thrilled to kickstart her career at Enerquip. “Returning home to launch my career is incredibly exciting,” remarks Emily Schafer, Enerquip Design Engineer. “I chose Enerquip for its collaborative atmosphere, team of talented colleagues, fantastic work/life balance, and the opportunity to tackle custom projects that push my boundaries.”
Outside of work, Schafer enjoys spending time with family and friends, doing outdoor activities, going for walks, discovering new coffee shops, and nurturing her love for gardening. Schafer is also a lifelong hockey player and was ranked number one in the state of Wisconsin during her senior year of high school.
According to the Bureau of Labor Statistics, the U.S. has approximately 43,000 open welding jobs to fill each year. To help fill these vital roles and open students to the challenging but exciting world of welding, Enerquip has introduced augmented reality welding simulators to its internal and external training programs. With the purchase of the robust AugmentedArc® and the smaller MobileArc™ Augmented Reality Welding Systems from Miller, Enerquip is set to amplify welding education in central Wisconsin by offering safe, life-like, hands-on learning experiences for both student education and internal training.
Both welding systems were developed by Miller and tailored for classroom training. These highly realistic multi-process welding simulators cater to students ranging from beginners to advanced-level welders. By seamlessly blending real-world and computer-generated images into a unique augmented reality environment, these welding systems provide immersive learning experiences. Students can interactively explore the fundamentals of welding, fostering a deeper appreciation for the craft.
“Enerquip has invested in welding simulation tools to help advance welding education and training in Taylor County,” said Tim Strebig, Facilities & Operations Manager of Enerquip. “By leveraging this augmented reality, we empower students with the skills and knowledge they need to succeed in the welding industry within a safe, fun, and stress-free environment.”
While Enerquip opened its doors for student opportunities years ago, using virtual welding simulators has added significant value to its tours and school-to-work student programs. While Enerquip only provides the virtual option for student tours, students in its internship and mentorship programs can work with both simulators and actual welding equipment. This addition of simulators provides students with a virtual hands-on experience before they begin welding real materials. Utilizing simulators helps students familiarize themselves with welding techniques and enables Enerquip to significantly reduce costs associated with stainless steel and other consumables.
This spring, Enerquip began demonstrating these simulators with hundreds of area students at various career fairs and speaking engagements. Students were given a firsthand glimpse into opportunities within the welding industry. By leveraging augmented reality technology, Enerquip and Miller are not only preparing the next generation of welders but also inspiring them to pursue fulfilling careers in welding. Furthermore, with the addition of these simulators, Enerquip is in the process of developing a welding curriculum to collaborate with local schools for the upcoming 2024 – 2025 academic year.
A participant at April’s Homegrown Success Career Fair at the Simek Center shows off her welding skills on the AugmentedArc® Augmented Reality Welding System from Miller. Her welds are mirrored on the TV screen in the background.
Brady Loetscher (right), Enerquip Sales Engineer, tries out the MobileArc™ Augmented Reality Welding System from Miller as he receives guidance from Enerquip Welder Troy Komarek (left).
Enerquip Welder Travis Frost helps a student set their hands before trying out the AugmentedArc® Augmented Reality Welding System from Miller.
Enerquip has proudly donated $500 to the Oklahoma DirtBags Youth Baseball program in Beggs, OK. This contribution will assist with the program’s ongoing expenses, including uniforms, athletic equipment, tournaments, and more.
The Oklahoma DirtBags Youth Baseball program is dedicated to supporting dozens of youth participants each summer. Through this program, youth not only have a great time playing the game but also learn the importance of hard work, good sportsmanship, and teamwork.
Enerquip is committed to supporting and encouraging its employees to lift others through giving and service. Therefore, Enerquip provides gifts to organizations at 100% of the employee’s contribution up to $500 per employee per calendar year, including volunteer hours.
This employee match designation from Enerquip Welder & Safety Coordinator Pat Branson (back, left) includes his own volunteer hours and contributions as a 10U AA Oklahoma DirtBags Youth Baseball Coach.
When it comes to pharmaceutical manufacturing, the integrity of equipment is vital. Among the critical components in this industry are shell and tube heat exchangers. Understanding what sets pharma-grade heat exchangers apart is crucial for ensuring product quality, safety, and compliance with stringent regulations.
Here, we answer common questions about pharma-grade shell and tube heat exchangers, shedding light on their functionality, materials, regulatory requirements, and key considerations in selection and maintenance.
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