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Category Archive: Chemical Heat Exchangers

Tag Archive: Chemical Heat Exchangers

  1. How Almost Any Industry Can Benefit from Waste Heat Recovery

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    In a world where energy costs keep rising and sustainability expectations are higher than ever, waste heat recovery has become a smart — and surprisingly simple — way for facilities of all types to lower operating expenses, boost efficiency, and shrink their environmental footprint.

    What is Waste Heat Recovery?

    Waste heat recovery is the process of capturing heat that would otherwise escape into the air or environment and putting it to good use elsewhere — whether it’s preheating water, powering additional processes, or even generating electricity. It’s like giving your energy a second life instead of letting it slip away.

    While nearly any large-scale operation can benefit, certain sectors are leading the charge by investing heavily in waste heat recovery systems. Let’s take a closer look at where these systems are making a serious impact — and why your facility might be next.

    Industries Benefiting from Waste Heat Recovery

    1. Oil, Gas, and Fuel Refining

    Refining crude oil into fuel is one of the most energy-hungry industrial processes out there. Operations like distillation, cracking, and treatment generate intense amounts of heat. Waste heat recovery systems help refiners reuse that energy — reducing fuel consumption, cutting emissions, and improving overall plant efficiency.

    2. Cement and Building Materials

    The cement industry, famous for its massive kilns operating at up to 400°C, has seen a sharp rise in waste heat recovery adoption. Capturing heat from kiln exhaust not only slashes energy costs but also helps facilities meet tightening emissions regulations — a win-win for both profits and the planet.

    3. Food and Beverage Production

    Whether it’s cooking, pasteurization, or bottling, food and beverage plants generate plenty of excess heat. Many smart food processors have embraced waste heat recovery, using systems like Enerquip shell and tube heat exchangers to reroute and reuse energy throughout their facilities — improving sustainability and cutting costs along the way.

    4. Colleges, Universities, and Large Campuses

    Higher education institutions aren’t just teaching sustainability — they’re practicing it. Universities are installing heat exchangers and economizers to recover wasted energy from campus utilities, saving tens of thousands in energy bills and millions of gallons of water annually.

    5. Chemical and Pharmaceutical Manufacturing

    Precise temperature control is essential in chemical and pharma production. Waste heat recovery systems not only stabilize processes but also lower utility costs by capturing and reusing heat that would otherwise be lost in reactors, dryers, and condensers.

    6. Data Centers and Technology Hubs

    Those racks of servers aren’t just producing information — they’re generating a ton of heat. Forward-thinking data centers are now using waste heat recovery to heat office spaces, nearby buildings, or even entire city blocks, turning a liability into an asset.

    7. Pulp, Paper, and Packaging Industries

    Steam is king in pulp and paper plants. Capturing waste heat from steam vents and dryers can provide significant energy savings and help offset the high energy demands of paper production.

    Why Waste Heat Recovery Matters More Than Ever

    No matter the industry, one fact is clear: making the most of the energy you already produce is a powerful way to stay competitive. Waste heat recovery can:

    • Cut fuel and utility costs significantly
    • Boost overall energy efficiency
    • Reduce greenhouse gas emissions
    • Extend the life of existing equipment
    • Support corporate sustainability initiatives

    Ready to Put Your Waste Heat to Work?

    If you think your facility might be leaking valuable heat (hint: it probably is), the experienced engineers at Enerquip are ready to help. We’ll work with you to design the right shell and tube heat exchanger or waste heat economizer solution to capture, redirect, and reuse your energy for maximum efficiency.

    Reach out today — because saving money (and the planet) never goes out of style.

  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. 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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  4. Enerquip Helps Generon Provide State-of-the-Art Systems

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    GENERON is the world leader in the design and manufacture of custom process air and gas separation systems including nitrogen generators for onshore and offshore platforms, floating production, storage and offloading units and transport tankers for the oil & gas market. GENERON has an expanded product base which includes primary compression, instrument air and post compression packages.

    GENERON can design and manufacture standard systems or custom engineered packages. For over 40 years, GENERON has provided thousands of systems worldwide to the oil and gas, marine, and industrial service industries that meet stringent customer and third-party society specifications. GENERON® systems are designed for all areas of classification, from Safe to Hazardous Areas, Class I Division 2, Zone 1 and 2, potentially explosive atmospheres, CE / PED, as well as other European standards.

    GENERON has a wide variety of clients that require nitrogen generation systems, including drilling and service contractors like Schlumberger, Weatherford, and Halliburton; engineering companies like Alliance Engineering, Wood Group, McDermott, Fluor, and Petrofac; and major oil companies like Exxon-Mobil, Shell, Chevron, Total, and British Petroleum.

    High Expectations

    GENERON’S dedicated research and development team in California is constantly working to improve product offerings.

    Most recently, the GENERON® Dehydration Hollow Fiber Membrane, was re-developed to reduce the weight and size of overall systems, while maintaining instrument quality air. Innovations like this, along with the complete GENERON® product line, continue to elevate the standards and expectations of clients.

    GENERON’s facilities in Houston, Texas and Pittsburg, California allow the hands-on monitoring of quality control while delivering the most cost effective products. Both are certified by certified by DNV to ISO-9000 standards, the American Society of Mechanical Engineers, the Pressure Equipment Directive, GOST, and Underwriters Laboratories and the Canadian Standards Association. High quality and high standards are expected from not only their company, but the companies they partner with.

    For nearly a decade, GENERON has trusted Enerquip to provide stainless steel shell and tube heat exchangers for these systems. GENERON turns to Enerquip multiple times a year to fulfill the needs and expectations of a growing customer base. The shell and tube heat exchangers Enerquip develops are integral in the nitrogen generation and natural gas compression and processing packages. GENERON relies on the high standards and integrity of Enerquip’s products and services to fulfill this need.

    Industry Standards

    GENERON relies on Enerquip’s commitment to meet all necessary compliance standards. Enerquip produces shell and tube heat exchangers that are code compliant and follow the regulations set by the Tubular Exchanger Manufacturers Association (TEMA’s) Classes B, C and R; the American Society of Mechanical Engineers (ASME); the Pressure Equipment Directive; the Ministry of Manpower; 3-A; as well as the codes set forth by the American National Standards Institute. Enerquip also fabricates to American Petroleum Institute (API) and Canadian Standards Association (CSA) standards. Enerquip is able to produce heat exchangers that are customized to GENERON customers’ specific needs. Many have unique requirements for various sizes, models and capacities. While many other shell and tube heat exchanger suppliers provide standard pieces of equipment, Enerquip is able to tailor each product to the unique applications for which it will be used. This is because Enerquip has in-house engineers who develop solutions for GENERON’s clients’ needs.

    “We often require more customized equipment,” explained Sergio Gonzalez, the Americas Sales Director at GENERON.

    “That’s why we turn to Enerquip. They have the engineering and manufacturing capabilities and facilities.”

    Enerquip can produce shell and tube heat exchangers ranging from two inches to four feet in diameter, and it has access to a variety of alloys with which to create the equipment. Using the right material is important to GENERON’s clients to ensure the longest lifespan of the equipment as possible. Using the wrong metal can cause corrosion or won’t be able to withstand the pressure or other conditions of the operations.

    Quick Turn-Around and On-Time Delivery

    Delivery time is another key factor GENERON appreciates. Enerquip prides itself on providing fast deliveries to clients for whom time is a critical factor. GENERON clients sometimes need to put in rushed deliveries for various systems that GENERON provides. However, the company cannot deliver unless it works with a supplier that can provide them with the necessary equipment in a short period of time. Gonzalez explained that even when GENERON clients need a system to be expedited, Enerquip is eager to accommodate the short time frame whenever possible.

    GENERON also values the time Enerquip takes to answer questions and give feedback about various products and orders. Gonzalez explained the contact person he has at Enerquip, Shane Viergutz, is always available to talk and is helpful.

    “Every time I call them, even if it’s after hours, he answers the phone or returns my calls,” Gonzalez said.

    Sometimes GENERON’s customers need a heat exchanger but don’t need a full system for gas compression, production or processing. Other times, they’ll indicate they need an exchanger or system for an application that GENERON doesn’t specialize in. In these instances, Gonzalez explained, he steers them directly to Enerquip. This is because he knows Enerquip’s engineers will be able to work with them to create the right solution for their needs.

    “I’ve recommended Enerquip to some of my clients when they only need the heat exchanger, or when it’s not our market,” he said. “When they are working on a different application that we are not directly involved with, I send them directly to Enerquip.”

    In getting connected with GENERON’s trusted supplier, the clients know GENERON is looking out for their best interests and will help them succeed in the future.

    GENERON plans to continue working with Enerquip for years to come. The company knows Enerquip and its engineers are dependable, efficient, and will work hard to create the best solution for the many systems GENERON provides to its clients.

    Simply put, said Gonzalez, “Overall, Enerquip gives good service to us, good products, and good quality.”

    We invite you to meet the team, contact us, or request a quote today.

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  6. Controlling Temperatures in Chemical Processing Plants

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    Editor’s note: This content was last updated 3/13/24.

    The Importance of Temperature Control

    Temperature control is pivotal in chemical processing, serving as the cornerstone of operational efficiency and product quality. Even minor adjustments in temperature can instigate significant transformations in the product.

    Throughout various stages of chemical processing, temperature management via heating or cooling is indispensable. This spans from initial processing through intermediate steps to the production of final products. Essential equipment includes shell and tube heat exchangers, crucial for regulating temperatures in processes such as:

    • Cooling high-viscosity products like latex.
    • Heating, cooling, and reheating solvents such as toluene, commonly found in paint thinners.
    • Maintaining temperatures of solutions, acids, and bases like sodium hydroxide.
    • Preventing contamination between different solutions or solvents.

     Enhancing Heat Transfer Efficiency

    Efficient heat transfer, as highlighted by the Rensselaer Polytechnic Institute, depends on the interplay of heat transfer from temperature gradients and fluid flow velocity through heat exchangers. Heat exchangers are also vital for boiling or condensing specific solutions or acids to precise levels. Augmenting the heat transfer area, often through fin additions, can boost transfer rates, although this may lead to increased fouling, especially in bio-processes.

    Considerations for Reactor Temperature Control

    Reactor temperature control is equally critical for process stability and product quality. Temperature fluctuations can affect production rate, operating costs, and final product quality. Continuous reactors rely on heat exchangers to regulate jacket temperature, ensuring steady operation. Batch reactors require swift heat-up or cool-down processes to manage load disturbances effectively.

    The National Renewable Energy Laboratory emphasizes the use of heat exchangers in batch reactors, employing pump-around loops to control temperature and agitate the process. This underscores the indispensable role of temperature control in chemical processing.

    Meticulous Temperature Control

    Meticulous temperature control is not merely a technicality but a fundamental aspect of chemical processing. From managing heat exchangers to overseeing reactor temperatures, every adjustment influences the final product’s quality and operational efficiency.

    Are you in the market for a custom exchanger for your unique process conditions? We invite you to contact us or request a quote to get the process started.

     

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