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  1. Which Brewery Heat Exchanger Is Right For You?

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    Which Brewery Heat Exchanger Is Right For You?

    Across the United States, the craft brewery industry is experiencing a boom. As production increases, heat exchangers are increasingly in demand, as they are essential pieces of equipment in any brewery. Composed of multiple stainless steel plates mounted on support shafts, brewery heat exchangers play a key role in quickly cooling wort as it is moved from kettle to fermenter. When properly selected and used, heat exchangers preserve the beer’s taste and increase production speeds.

    Why Should a Brewery Invest in a Heat Exchanger?

    Wort must be cooled quickly to prevent bacteria and dimethyl sulfide (DMS) from tainting the initial brew. Brewery heat exchangers accomplish this goal by reducing cooling time to as little as 45 minutes. Proper control of heat is essential to any brewing process for the following reasons:

    • Temperature control. By cooling wort quickly, heat exchangers in breweries prevent contamination and preserve flavor.
    • Reusing heat. Brewing heat exchangers can also collect the heat and apply it to other parts of your brewing facility, such as the hot water system.
    • Growing your brewery business. Speeding the cooling process and recycling heat greatly increases production and cuts costs.

    Types of Heat Exchangers Available on the Market

    Selecting the right brewery heat exchanger requires knowledge of the different types available.

    Plate Heat Exchanger

    Several metal plates are placed in direct contact with the brewing tank, transferring heat from one fluid to another. The cooling medium and beer flow through the plates in opposite directions on separate flow paths.

    Plate heat exchangers have a wide range of applications, such as:

    • Water heaters
    • Cooling tower isolation
    • Free cooling
    • Waste heat recovery
    • Heat pump isolation
    • Thermal (ice) storage systems

    This translates to major benefits for the brewery, such as:

    • Energy efficiency
    • Emission reduction
    • Recovery of waste and water
    • Reduced operating costs

    Shell and Tube Heat Exchanger

    A series of parallel tubes send the wort and the cooling medium past each other in opposite directions. Heat exchange takes place between the tube walls. In addition to beer brewing, shell and tube heat exchangers have a vast range of possible applications in these industries:

    • Power Generation
    • HVAC
    • Marine
    • Pulp & Paper
    • Refrigeration
    • Pharmaceutical
    • Food & Beverage
    • Air Processing & Compressor Cooling

    Due to their simple, flexible design, shell and tube heat exchangers are the more cost-effective option for most breweries. Other benefits include:

    • Handles extremely high pressures with minimal pressure loss
    • Tolerates high and low temperatures
    • Resistant to thermal shock
    • Easy assembly and disassembly
    • Easy repair and maintenance
    • Customizable size

    Heat Exchanger Design Characteristics

    To choose the best type of brewing heat exchanger for your facility, consider these design characteristics.

    Flow Configuration

    Flow configuration will influence the efficiency of your overall system:

    • Cocurrent flow brewery heat exchangers move fluids parallel to each other and in the same direction, which provides the highest level of thermal uniformity but less efficiency than a countercurrent system.
    • Countercurrent flow systems move fluids antiparallel to each other (opposite directions through parallel tubes), resulting in greater heat transfer efficiency between the two liquids.
    • Crossflow heat exchanger tubes are routed perpendicular to each other and are less efficient than countercurrent systems but more efficient than cocurrent systems.
    • Hybrid flow heat exchangers use any combination of the above three flow configurations.

    Construction Method

    The types of materials used to construct heat exchangers range from various metals to ceramic, graphite, or composite materials, each with its own advantages and disadvantages. There are also different build methods, such as:

    • Recuperative vs. regenerative: Recuperative heat exchangers house each liquid in its own tube, while regenerative heat exchangers use one tube to transfer cool and warm fluids at alternating times.
    • Direct vs. indirect: Recuperative heat exchangers can transfer heat either directly or indirectly. Direct contact heat exchangers do not separate fluids within the device, so heat transfers through direct contact. Indirect contact heat exchangers separate and transfer heat between fluids using thermally conductive materials, such as tubes or plates.
    • Static vs. dynamic: Regenerative heat exchangers can either be static or dynamic. Static regenerators feature materials and components that stay in place while fluids flow through them. Dynamic regenerators have components and materials that move during heat transfer.

    Heat Transfer Mechanism

    Heat exchangers use either a single-phase or two-phase heat transfer mechanism. Single-phase heat exchangers process fluids that remain the same state of matter throughout the heat transfer process. Two-phase heat exchangers change either one or both liquids to a gas, or vice versa.

    What to Consider Before You Choose

    Before investing in a brewery heat exchanger for your operation, consider these factors:

    • Cost
    • Energy consumption
    • Space consumption
    • Maintenance needs and costs
    • Scalability

    Brewery Heat Exchangers From Enerquip

    Since 1985, Enerquip has been an industry leader in fabricating industrial heating and cooling equipment. Our technicians are standing by to help you select the right brewery heat exchanger according to your exact needs. If you have any questions, please contact us or request a quote.

  2. The Best Types of Shell and Tube Heat Exchangers

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    A heat exchanger is a system that transfers heat between two media of different starting temperatures. Used in both heating and cooling processes, they have a broad range of industrial applications, such as refrigeration, space heating, and air conditioning.

    Shell and tube heat exchangers are the most typical type of heat exchangers used in oil processing facilities, large-scale chemical operations, and high-pressure applications. Here you’ll learn about the different types of shell and tube heat exchangers, as well as their individual components and benefits.
     

    Shell and Tube Heat Exchangers

    Every type of shell and tube heat exchanger is made of a large cylindrical enclosure called a shell, which contains bundles of precisely spaced tubing. The shell is made of corrosion-resistant metal plates or pipes that can withstand extreme temperatures. The tubes are made of extruded or welded stainless steel, carbon steel, titanium, copper, or Inconel.

    Other components include:

    • Tube sheet: The tube sheet is a plate containing holes for inserting the pipes. Its design supports the tubes on both ends of the shell. 
    • Channels: Also called heads, channels contain fluid in the tubes and can have either bonnet-type heads for infrequent removal or removable covers for frequent removal. Channel covers are removed for inspection and maintenance purposes.
    • Baffles: Baffles guide the flow within the shell to boost fluid velocity, increasing the heat transfer coefficient and reducing fouling—the accumulation of materials on the heat transfer surface. Fouling can increase heat transfer resistance, thus decreasing heat exchange efficiency.
    • Tie rods and spacers: Tie rods and spacers maintain space between baffles while holding them in place. The appropriate number of tie rods and spacers to use depends on the shell’s diameter and the number of baffles.
    • Expansion joint: When transferring heat from one side of the exchanger to the other, heat exchangers are exposed to a wide range of temperatures. Expansion joints are necessary because heat exchanger materials expand when heated and contract when cooled. They prevent buckling of the tubes or shell and distortion of the nozzle connections. 

     

    How Do Shell and Tube Heat Exchangers Work?

    All types of shell and tube heat exchangers work via the same basic mechanism. A hot fluid flows in the shell and transfers heat to a cold fluid contained in the tubes. The two fluids exchange or transfer heat based on the direction of flow and thermal contact through the heat exchanger’s conductive materials.
     

    Types of Shell and Tube Heat Exchangers

    The classification of a shell and tube heat exchanger is determined by the construction and structure of the shell as well as the type of service the unit provides.
     

    Fixed Tube Sheet Exchanger

    Two stationary tube sheets are welded directly to the shell. It is easy to clean and maintain but cannot withstand extreme temperature fluctuations without the addition of an expansion joint. 

    Enerquip Thermal Solutions carries Tubular Exchanger Manufacturers Association (TEMA) Type L, M, and N fixed tube sheet exchangers. 
     

    U-Tube Heat Exchanger

    The U-tube heat exchanger is the most cost-effective version of the shell and tube design. U-tube shell and tube heat exchangers feature a tube bundle made of continuous tubes that bend into a U shape. The bundle is secured to the shell using a tube plate. The bends enable thermal expansion without the use of expansion joints, making these excellent for high-temperature fluctuations. The bent tube bundle is removable but difficult to clean mechanically.

    Enerquip stocks several sanitary U tube heat exchangers per TEMA standards.  
     

    Floating Head Heat Exchanger

    The tube sheet in the floating head heat exchanger is permitted to move or float rather than being welded to the shell at the rear header end. This allows for thermal expansion and removal of the tube bundle for cleaning. This type of shell and tube heat exchanger is suitable for processes involving high temperatures and pressures, but it is more expensive than fixed tube sheet heat exchangers.  

    Enerquip carries TEMA Type W, P, S, and T floating head heat exchangers.
     

    General Benefits of Shell and Tube Heat Exchangers

    Used in a variety of industries and applications, shell and tube heat exchangers are highly versatile pieces of equipment. Benefits include:

    • Cost-effective
    • Handles a wide range of temperatures and pressures
    • Adjustable design allows for thermal expansion
    • Minimal pressure loss
    • Handles flammable or toxic fluids

     

    Shell and Tube Heat Exchangers From Enerquip

    Given the wide range of applications and types of shell and tube heat exchangers, selecting the right model for your application is key to reaping every possible benefit. Your specific technical requirements determine the ideal type of shell and tube heat exchanger for your application. Enerquip is a leading shell and tube heat exchanger manufacturer with over 35 years of extensive industry experience. 

    Request a quote or contact us today for more information.

  3. Tips for Increasing Asphalt Plant Efficiency

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    Asphalt plants can consume a ton of energy through their everyday operations. With energy costs on the rise, many facilities are looking for ways to reduce their energy consumption in order to reduce costs and increase overall efficiency.

    Fortunately for plant managers, there are a number of strategies that can be implemented in order to accomplish this.

    Here, we’ll review a number of tips for increasing asphalt plant efficiency, both in terms of reducing energy usage and otherwise, to keep your plant functioning at maximum capacity.

    9 Strategies for Improving Asphalt Plant Efficiency

    While some of these tips may be more feasible than others for your specific plant to implement, all will contribute to improving your facility’s level of efficiency.

    1. Perform an Audit

    A good first step to take if you’re looking to improve the efficiency of your plant’s systems and processes is to invest in an audit. Audits can be really valuable, and will review systems, processes, and system components to look for any areas where efficiency could be improved.

    Hiring a professional outside agency to perform the audit (with the help of your internal staff) can be really valuable, as it will give you a new and unbiased perspective about what’s going in within your facility. It can also help you to identify areas of weakness that may have otherwise been overlooked, and point you in the right direction in terms of what you can feasibly upgrade to increase efficiency.

    2. Talk to Staff Members

    The people working with the equipment and in the midst of the processes on a daily basis are a great resource for insider information about how things are going in your plant. They can offer first hand feedback on processes that aren’t working, communication lines that could be cleared up, systems that break down frequently, and so on.

    Taking their feedback into earnest consideration could ultimately save your facility thousands. One of your most valuable resources and sources of information about increasing efficiency could be right under your nose.

    3. Invest in Equipment Maintenance

    Believe it or not, regular maintenance is actually a great way to increase plant efficiency. Though it may seem like consistently dedicating resources to maintenance might reduce efficiency, in the long run it can save you from equipment breakdowns, plant shutdowns and more, which can ultimately be more devastating in terms of efficiency.

    Don’t have a maintenance program in place? There’s no better time than now to implement one.

    4. Invest in Regular Training for Employees

    Having all hands on deck at all times may seem like the way to get work done efficiently, but the truth is that regularly setting aside time for routine training for your team members is a great way to both invest in your employees and increase efficiency.

    Scheduling time for employees to engage in ongoing education, whether to review common best practices or to learn about new strategies, can help, in turn, to enhance efficiency in a few ways. Your team will be able to improve processes and identify areas for improvement on a more regular basis when provided with the knowledge and information necessary to do so. In addition to keeping your facility on the cutting edge, dedication to employee training initiatives can help to improve employee morale, which in itself can have a positive impact on the overall effectiveness of your team and the efficiency of the work they do.

    5. Keep Your Facility Clean

    Systems that have grime, dust, dirt, and oil buildup plaguing them can run less efficiently even if their components still seem to be in good working order. As a result, it’s important to make an effort to perform routine maintenance and cleaning on a regular basis – even if that means shutting your systems down periodically.

    Your systems and equipment may be up to date, but if they’re not running clean, they’re probably not operating as efficiently as they could be – which is likely taking a toll on your asphalt plant’s overall efficiency.

    6. Invest in New Equipment to Decrease Energy Consumption

    Try to keep a finger on the pulse of your systems and processes and determine where excess energy is being consumed and where energy use can be reduced, if possible. An audit can be helpful with this.

    It may also be well worth it to actively seek out system components or an entirely new system that offers higher efficiency and more longevity. Outdated systems tend to operate less efficiently.

    While adapting to alternative forms of energy or investing in systems that operate more efficiently may be costly up front, it can save you thousands in the long term.

    Learn more about why it’s well worth it to invest in efficient industrial heating equipment.

    7. Insulate

    Ensuring that your facility and its equipment is properly insulated is key, especially for asphalt plants where the process of drying materials tends to drive efficiency down and energy costs up. You’ll want to be sure you’re capitalizing on the heat and energy that your systems are producing.

    If you haven’t reviewed the state of your facility’s insulation in a while and you’re concerned about increasing energy costs, this may be a good place to start.

    8. Make Safety a Priority

    Keeping your employees safe and your equipment in good working order can do wonders for increasing efficiency. It may seem obvious but taking the time and investing the necessary resources in safety measures can keep your plant running smoothly and efficiently.

    Find some helpful tips for reducing hazards and keeping your employees and equipment safe here.

    9. Schedule Strategically and Communicate Effectively

    Depending on how your asphalt plant operates, you may be working with various crews on various mixes and projects at one time. Be sure that the lines of communication with each of the groups you are working with remain open so you are sure to produce the right mix on the right day.

    This is something that must be focused on day in and day out, but it can go a long way when it comes to increasing productivity both in your plant and in the field where your asphalt is being used.

    Strategic scheduling and effectively communicating can help to reduce wasted materials and time, and will help to keep projects on schedule while earning you a reputation as a reliable and trusted asphalt producer.

    Take Your Asphalt Plant to the Next Level by Increasing Efficiency

    Putting some or all of these strategies into action can make a significant impact when it comes to improving your plant’s overall efficiency.

    Additionally, increasing efficiency can in turn increase profitability, so if you’re looking to improve your bottom line investing in efficiency is a great option.

    Ready to take your asphalt plant to the next level? At Enerquip, formerly American Heating Company, we specialize in designing and manufacturing highly efficient industrial heating equipment. Made right here in the USA, our industrial heating systems are durable, reliable, and energy efficient options that have helped organizations in various industries – including asphalt plants – take their business to the next level.

    Our team of designers and engineers can devise a custom solution for your plant, and our industry-leading serpentine coil technology can help you enhance your efficiency on numerous levels, from operation to maintenance and beyond.

    Interested in learning more about how we can help your facility improve its efficiency? Give us a call today at (715) 748-5888 or contact us online to get the conversation started.

    Editor’s note: This content was originally published in 2018 but was updated in May 2021 and October of 2022.

  4. Enerquip’s Employee Match Supports Local Cancer Patients

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    Enerquip has proudly donated $500 to the P-Town Cancer Battle benefit. In its second year, the P-Town Cancer Battle raises funds that support those locally undergoing cancer treatment.

    This year’s event, held on Saturday, August 20, included a mini-triathlon, fish boil, and smokin’ BBQ cook-off. Raising nearly $16,000, the funds will be used to purchase gas cards, gift cards, and cover other expenses for the benefit of local patients.

    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 from Enerquip’s Director of Business Development Ron Herman includes his own contributions to the benefit.

  5. Enerquip’s Employee Match Supports Ss. Peter & Paul Parish

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    As part of its employee match program, Enerquip has proudly donated $500 to Ss. Peter & Paul Catholic Church in Gilman. The donation was presented at the church’s annual Bazaar and will be used for ongoing outreach and service expenses related to the dedicated work of the church.

    Enerquip is committed to supporting and encouraging its employees to lift others through giving and servicing. 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 from Enerquip Design Engineer Linda Olejnichak includes her volunteer hours as the church’s Bazaar Chairperson, along with other volunteer activities.

  6. Enerquip’s Employee Match Supports Rhino’s Foundation

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    Enerquip has proudly donated $500 to Rhino’s Foundation in River Falls, WI, as part of its employee match program. The funds will help support patients in western Wisconsin currently undergoing cancer treatments.

    Rhino’s Foundation was established in 1991 to support the fight against cancer and those affected by the disease. They provide patients with direct cash donations, grocery and gas gift cards, and other support.

    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 from Enerquip Welder Ivan Hubbard includes his own contributions to the Foundation. A supporter for many years, he’s provided handcrafted stainless steel artwork and fire rings for raffle, along with monetary support and fundraising event participation.

  7. Key Features and Benefits of Enerquip’s Thermal Fluid Heaters

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    If you’re in the market for a thermal fluid heater, there are many important factors to consider before deciding on a product and making the purchase.

    From shopping industrial heating system providers to find a partner you can truly rely on to considering your heater options and selecting the one best suited for your applications and facility, there’s a lot to contemplate throughout the purchase process.

  8. Enerquip Promotes Diedrich to Design Engineering Manager

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    Enerquip is excited to announce the promotion of Cameron Diedrich to Design Engineering Manager. In this role, Diedrich will oversee Enerquip’s talented Design team, push the limits of innovation, create direction for the department’s future, and be a valuable technical resource for customers.

    Diedrich’s management responsibilities were previously split between Operations & Facilities Manager Tim Strebig and Process Manager Tom Steen. “Enerquip is seeing rapid growth,” says Steen. “Cam’s promotion gives us a talented designer to lead the team while also allowing the Enerquip team to continue its focus on what’s next in the industry.”

    “With the purchase of American Heating Company last year, our products, designs, and fabrication have greatly expanded,” says Strebig. “Cam’s skills and passion for innovation will help drive our designs forward.”

    Diedrich earned his bachelor’s degree in mechanical engineering from UW-Platteville and is currently working toward his Professional Engineering (PE) license. Before coming to Enerquip in 2018, he worked as a designer and project manager for a local contracting firm.

    “I enjoy seeing projects come to life,” says Diedrich. “From the digital design to steel fabrication, I just love the process.”

    Natives of Athens, WI, Diedrich and his wife volunteer as first responders in the Athens community. They have one child and two more on the way, along with a house full of animals. Outside of work, Diedrich enjoys coaching football, hunting, fishing, camping, and just about anything else outdoors.

  9. Helical Coil Thermal Fluid Heaters from Enerquip [Video]

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    Enerquip Helical Coil Heater Skid

    The Enerquip helical coil skid is a complete system, which includes a high-efficiency burner, recirculating pump, control panel, safety alarms, burner shell, range fly, and exhaust stack. Low NOx burners are also available for required applications.

    With some simple wiring and attachment of the gas supply, it’s ready for production.

    Made in the USA

    Made right here in the USA, our ASME code stamped systems are fabricated by our team of ASME code welders. Our high-quality heaters are made to run for 20-30 years, and even longer.

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    Helical Coil Heater
  10. Engineering & Fabrication Advancements [Video]

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    Enerquip Thermal Solutions

    Enerquip Thermal Solutions is the joining of Enerquip and the former American Heating Company. This union of manufacturing leaders, has provided customers with a variety of product advancements and process enhancements. Watch the video to learn more.

    New Website is Coming

    Enerquip will be rolling out a new website late summer of 2022. It will be a merger of both Enerquip.com and AmericanHeatingCo.com.

    Planned for an August roll-out, the new site will include Enerquip’s expanded product offering which includes a variety of sanitary and industrial heating and cooling solutions, from shell and tube heat exchangers to industrial thermal fluid heaters and tank heating coils.
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    Engineering & Fabrication Advancements