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Tag Archive: Heat Exchanger Solutions

  1. Process Cooling: The Salsa Cooling Challenge

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    A custom heat exchanger design allows a salsa manufacturer to effectively complete process cooling of the product and expeditiously clean-in-place between batches and shifts.

    California-based Southwest Thermal Technology was approached by one of its OEM customers to provide a shell-and-tube cooler to chill a client’s salsa prior to bottling. The request was more challenging than it sounds.

    The Challenge

    Because of the viscosity of the salsa — around 2,000 cP while warm and much thicker at 9,165 cP when cooled — turbulent flow was extremely difficult to achieve in the tubes of a shell-and-tube heat exchanger. The viscous salsa hindered efficient heat transfer. Typically, this situation is addressed by using a heat exchanger with more surface area while using a high volume of cooling water on the shell side of the heat exchanger. Such a design could achieve process cooling from 200 to 120°F (93 to 49°C).

    Southwest Thermal Technology wondered whether a more compact solution was possible. That’s when they reached out to Enerquip.

    After reviewing the problem, the engineers at Enerquip first considered a single, large heat exchanger that would perform well thermally. But the single large exchanger would be difficult to clean with the salsa maker’s clean-in-place (CIP) system. Typically, CIP works best when the cleaning solution can be circulated at 5 ft/sec or more. In a single, large exchanger, this would not be achievable.

    Of course, in food production environments, it is crucial to keep process equipment like shell-and-tube heat exchangers clean and sanitary. Regular CIP cleaning takes place between batches or shifts. This prevents cross-contamination of different products between batches and prevents unwanted bacterial growth that could contaminate food products.

    A New Approach

    The design team at Enerquip then developed a new approach. Process cooling of the salsa would occur by flowing through three smaller heat exchangers stacked in series. The salsa would pass from one heat exchanger to the next traveling through a sanitary jumper, which connected the outlet of the first exchanger to the inlet of the second exchanger, and likewise for the second-to-third exchanger connection. Meanwhile, the cooling water would flow counter-current from shell to shell, starting in the third exchanger, flowing through the second exchanger, and finally through the shell of the first unit.

    To realize this process cooling solution, three unique shell designs were created. They allowed the connecting flanges between each shell to be bolted together for the chilled water flow. Tube-side connections included an additional CIP connection on the first bonnet for the inlet and on the last bonnet for the outlet. CIP flow through the other bonnets used the jumper connections for the salsa to further reduce the piping costs and complexity.

    Enerquip Salsa Coolers – Stacked Set

    This design allowed for more efficient process cooling. In addition, the reduced exchanger size allowed the units to be cleaned effectively using the customer’s CIP system at 5 ft/sec flow through the tubes.

    Enerquip Salsa Cooler Enerquip Salsa Cooler

    Because of the acidity of the salsa, the salsa maker opted to use a higher stainless alloy for the tubes and other product-contact surfaces of the exchangers. While more expensive, super-austenitic stainless steel is more resistant to corrosion from acids and cleaning solutions.

    Another benefit of the three smaller, stacked exchangers over one larger exchanger was risk avoidance. If there was ever a tube failure in the single large exchanger, the customer would potentially be shut down completely during a repair, and the entire tube chest would need to be replaced. This would take months to achieve due to the lead-time on super-austenitic tubing. By using three smaller shell-and-tube heat exchangers in series, the salsa maker has equipment redundancy. Any of the units can be temporarily bypassed if there were a tube failure. Replacement of a smaller tube chest would be less than the cost of a single, larger one.

    Through this approach, the salsa maker was able to get more consistent process cooling and meet all the sanitary requirements for cleaning their equipment. As an added benefit, the company gained flexibility and redundancy while minimizing the risk of costly downtime.

    Article published in Process Cooling magazine: July 2019.

    Jim Peterson, Enerquip Sales Engineer

    Article Author: Jim Peterson, Enerquip Sales Engineer

    sales@enerquip.com

  2. Heat Exchanger Helps Aloe Processor Improve Quality

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    Enerquip Tank The aloe producer found that if they could cool the product below 40°F (4.4°C) before packaging it, there was a significant improvement in quality.

    In 2012, a producer of pure aloe for medicinal and nutritional products approached Enerquip, a manufacturer of shell-and-tube heat exchangers, with a unique cooling problem. In the tropical region where aloe is harvested, the ambient temperatures hover near 95° F (35°C) most of the time. This tropical climate was accelerating bacterial growth in the product, which was lowering its value and shelf life. Enerquip worked with the producer to develop a solution using a heat exchanger.

    Ideal conditions for the product were discovered after performing some testing. The aloe producer found that if they could cool the product below 40°F (4.4°C) before packaging it, there was a significant improvement in quality.

    However, the customer’s lack of utilities at the packaging site led to complications in the cooling process. They had electricity, but the cooling water system already in place did not supply water that was cold enough to provide the low temperatures necessary to impede bacterial growth. Also, the staff using the equipment was not technically inclined, so any solution needed to be easy to control and understand. Because the aloe processor only packed the product several times per season, the equipment needed to be easy to clean, move and store during the off-season.

    After reviewing the process and existing equipment, the thermal team at Enerquip realized that a heat exchanger was required for the application. Heat exchangers are built for efficient heat transfer from one medium to another. There are multiple types of heat exchangers that offer the ability to either separate the media or, for them, to be in direct contact.

    Shell-and-tube heat exchangers consist of a series of tubes inside a larger pipe. The tubes contain the product, which is the fluid being heated or cooled. The second fluid – a heating or cooling medium – fills the larger pipe around the outside of the tubes, with the heat transferring between the product and the medium through the tube walls.

    During the heat exchanger sizing and selection process, several factors are taken into account:

    • The product specifics
    • Temperature (in/out)
    • Flow Rate (product quantity in/out)
    • Cooling medium
    • Temperature and size limitations

    The ability to easily clean the equipment played a major role in this application. Aloe is a very viscous product, and due to the frequency of use, it became evident that a shell-and-tube heat exchanger would best fit this application. The exchanger was designed in a straight-tube, multi-pass configuration, which allowed the product to travel back and forth through the exchanger several times before heading to the packaging line. The straight tube exchanger option with removable bonnets allowed for easier mechanical cleaning than other designs.

    Due to ground water availability and temperature at the plant location, a chiller was added to complete the process for this application. The air-cooled chiller was installed and utilized to provide enough cold glycol and water to cool the aloe product in a single pass through the exchanger. Once filled with glycol and water, the chiller only needed plant electricity to run. The chiller supplier installed simple pushbutton procedures that were easy for the plant staff to follow. Independent shut-off valves and removable hoses between the chiller and exchanger also allowed for easy tear down and cleaning following production.

    The end results of this process provided the aloe producer with an efficient system and cleaner, colder and more valuable aloe products.

    Click hereto read more about the Aloe Vera processing.

    Contact the helpful heat exchanger expertsat Enerquip today!

  3. Condensing Economizers Can Help Operations Reclaim Latent Heat

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    Condensing economizers can help recover latent heat.
    Condensing economizers can help recover latent heat.

    Boilers involve a lot of energy and heat, much of which can be wasted if a system isn’t designed to prevent this. One way to capture and reuse lost heat is through installing a condensing economizer. This item captures water vapor and heat, turning it into usable energy.

    Condensing economizers have a place in virtually every industry. Food processing plants, greenhouses, pulp and paper mills, hospitals and even district heating systems all utilize boilers and have the potential to use economizers. Investing in one can reduce energy requirements and cut operational costs.

    However, condensing economizers typically don’t come in a one-size-fits-all format. They often require highly specialized design and are fabricated to meet the specific needs of one facility’s operations.

    How Condensing Economizers Work

    In most natural gas-fired boilers, it’s tough to cool flue gas much lower than 250 degrees Fahrenheit, according to the U.S. Department of Energy. Beyond this point, the gas can begin to condense, and the resulting vapor can become corrosive, posing a threat to the integrity of the stack or stack liner. However, for the flue gas to be captured and used as boiler feedwater, it needs to be cooled below its natural dew point of 135 degrees Fahrenheit.

    Condensing economizers collect flue gas and cool it to the appropriate temperature, allowing the economizer to reclaim sensible heat (in the form of flue gas) and latent heat (in the form of flue gas water vapor). The amount of latent heat that’s recoverable depends on the type of fuel used, the style of condensing economizer used and other factors.

    Types of Condensing Economizers

    There are two types of condensing economizers that plant managers or other decision makers can choose from: direct and indirect.

    A direct contact condensing economizer includes a vapor-conditioning chamber that’s connected to a countercurrent spray chamber, the Department of Energy explained. Inside the spray chamber, droplets of cool fluid come into contact with the hot gas to facilitate the heat exchange. The droplets cool the stack gas. This option provides a high heat transfer rate and allows for relatively easy water recovery, though this method can only heat water to about 140 degrees Fahrenheit. This style requires a mist eliminator, which prevents droplet carryover.

    An indirect contact condensing economizer utilizes a shell and tube heat exchanger to capture the flue gas. This style offers greater heating and cooling capacity; water can be heated to as much as 200 degrees Fahrenheit and cooled to as low as 75 degrees Fahrenheit.

    One example of an indirect contact condensing economizer successfully helping reduce costs and energy requirements was detailed by the Department of Energy. A food processing facility wanted to reduce its deaerator steam requirements, which were 5,000 lbs per hour. The company installed the economizer, which served to lower flue gas temperatures from 300 degrees Fahrenheit to 120 degrees Fahrenheit. The process allowed them to capture 2 million British Thermal Units per hour, and effectively cut its deaerator steam requirements down to 1,500 pounds per hour.

    Considerations for Condensing Economizers

    For both direct and indirect contact condensing economizers, the water exiting the system is usually very acidic and should be neutralized before being used as process water or directed to a sewage system. External heat exchangers, membranes or pH control systems are all viable options for this.

    Choosing the right materials of construction is an important aspect of designing a heat recovery system with an economizer. Because the water vapor can be highly acidic or otherwise corrosive, the fabrication materials should be resistant to wear. Stainless steel and similar alloys typically hold up well when exposed to water vapor that comes as a result of hydrocarbon fuel combustion, which is the case with natural gas-fueled boilers.

    The space in which the economizer will be used should also be carefully analyzed. For operations where most of the deaerator steam comes from blowdown heat recovery, there is limited potential for cost savings with an economizer. Additionally, operations where there isn’t much need for cold or low-temperature water, a direct contact condensing economizer won’t be especially helpful.

    Working with heat exchanger experts such as those at Enerquip can help you determine your needs and the potential for heat recovery at your facility. Further, Enerquip’s engineers will help you design a shell and tube heat exchanger that suits your specific operation.

    Request a quote, today.

  4. Exchanger System Helps Food Packager Put the Soup On

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    A mechanical contractor for a Chicago-based liquid-foods packager had an interesting and challenging cooling application. An important client planned to award the foods packager a large contract for packaging soup if they could satisfy one stipulation: The company had to guarantee that the product would be cooled from 198°F (92°C) to precisely 77°F (25°C) before packaging.

    In addition to the tight temperature requirements, process flexibility was required. The contract was for various types of soups, so the packager had to be able to cool products having different thermal properties. At the same time, the packager needed to be able to clean the system easily between batches to avoid any carry-over from different soup types. The cooling point had to be met precisely. If the soups were too warm when packaged, spoilage potentially could occur. If they were too cool during packaging, the containers could sweat, and the labels would not properly adhere to the packages.

    In addition, the packager had to accomplish this within a physical area with space limitations. The entire cooling system had to fit within a 14-by-6’ footprint and fit under a 12’ ceiling. Additionally, in order to minimize utility costs, the packager wanted to take advantage of ambient water from their cooling tower to perform the bulk of the cooling. A glycol/water mix through a chiller would be used for final cooling. Another factor considered in the design was the requirement for a sanitary food-grade system that met the 3-A sanitary standards for polished surface finishes and cleanability.

    Dual-Stage Heat Exchanger Design Selected

    After exploring the options, the food packager selected a designer of shell-and-tube heat exchanger systems. Often when designing shell-and-tube heat exchangers, multiple configurations can perform the duty requested. The best design is selected based on surface area, utility service provided, regulatory preferences and customer priorities. Working together in a collaborative process, the heat exchanger designer and food packager pursued the best option balancing all of the conditions.

    In order to provide a fairly simple solution, the first design presented was for a pair of 24” by 10’ long BEM-style straight tube exchangers in series. The soup product would flow through the tubes of the first exchanger while being cooled by cooling tower water in the shell. After the first exchanger, the soup would flow through the tubes of the second exchanger while being cooled by 45°F (7°C) glycol/water mix in the second shell. Both exchangers were inclined to allow the units to drain out when not in use between batches. The two heat exchangers were designed with davit swing-arm assemblies to help facilitate removal of the bonnets for periodic inspection and manual cleaning when needed.

    This dual exchanger approach, despite the advantage of simplicity, had several drawbacks. First, the cooling performed in the first exchanger was limited to the temperature that the cooling tower water was being heated to on the shell side. In other words, when the soup entering the exchanger at 198°F (92°C) met the cooling tower water entering the shell at 70°F (21°C), it heated up the cooling tower water to around 120°F (49°C). The soup could not be cooled below this level of 120°F (49°C), which is known as the temperature cross or temperature pinch. This would then put most of the burden on the glycol/water chiller to perform the bulk of the cooling, requiring a larger and more expensive chiller unit.

    The other issue that presented itself was the ability to completely clean the unit between batches of product. Although the exchanger could be cleaned by backflushing the tubes with water and cleaning solution, there was no way to accelerate the wash water to the preferred velocity (5 ft/sec) needed for adequate cleaning. This was limited by the size of the onsite cleaning clean-in-place (CIP) system (200 gal/min). With the sheer size of the exchangers and number of tubes, it would have taken a CIP system using 1,500 gal/min to reach the proper cleaning velocity. These factors led to a redesign to a more complex yet more effective solution.

    In order to allow for a smaller tube field that would provide the 5 ft/sec velocity for cleaning, the exchanger diameter was reduced from 24” to 6”. Because of the reduction in surface area per heat exchanger, it was necessary to add more exchangers to the set. The first, large unit being cooled by the cooling tower water was replaced by six smaller exchangers. For the final cooling utilizing the chiller, the larger exchanger was replaced by two of the smaller units.

    As the design simulations unfolded, other benefits started to show themselves. By restricting the flow of the product to a smaller number of tubes, the velocity of the product also increased. This improved the heat transfer when cooling the soup product. It also allowed the cooling tower water to be split into a fresh stream flowing into each of the six shells, avoiding the temperature cross experienced in the larger unit. During winter months, when their cooling water was colder than 70°F (21°C), it was possible to shut down the glycol/water chiller and perform all of the cooling with just cooling tower water, saving utility costs.

    The smaller diameter exchangers were easier to construct and polish to meet the 3-A sanitary requirements. They were efficient to clean using the onsite CIP system, and they were simpler to take apart to inspect due to the smaller, lighter bonnets on each exchanger.

    The eight exchangers were stacked on a custom rack with all of the interconnecting product jumpers, utility piping and the contractor’s manual valves. During design, it was decided to leave enough space to mount two more of the same size exchangers on the rack, allowing for future growth in batch size, or for tough-to-cool products requiring more surface area. The units were all pitched slightly to allow for full draining of the product and cleaning fluids from the tubes. Another advantage was that spare parts like gaskets and tri-clamps were less expensive and more readily available for the smaller exchangers than with the two original, large exchangers. An added bonus is that the parts are interchangeable between the eight exchangers in the set.

    The new system of stacked heat exchangers in series still fit within the packager’s space limitations, and it ended up costing about the same as the two larger custom units. This allowed the food package to stay within the budget and timeline for the project. The stacked set approach of smaller heat exchangers in series performed consistently. This allowed the packager to win the contract while enjoying the benefits of lower utility costs, increased regulatory compliance and automation of the maintenance process for the system.

  5. Enerquip Helps Design a Fountain that Flows During Freezing Temperatures

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    Enerquip’s shell and tube heat exchanger solution keeps this fountain working well all year round.
    Enerquip’s shell and tube heat exchanger solution keeps this fountain working well all year round.

    Signature Fountains, a national fountain installation company, works to ensure each project they complete looks great, benefits its clients and functions well. Sometimes, that means overcoming obstacles that make pumping water difficult.

    Ascend Federal Credit Union came to Signature Fountains for help designing a fountain to place outside its corporate headquarters in Tullahoma, Tennessee. They wanted the fountain to flow as much as possible, even when temperatures drop.

    Tennessee has mild winters, with average January temperatures ranging from 36 to 40 degrees Fahrenheit, according to the University of Tennessee’s Institute of Agriculture. However, there are times when the mercury can dip below freezing. When that happens, outdoor fountains can’t function properly and can be at risk of damage due to ice.

    To solve this issue, Signature Fountains wanted to create a way to heat the water under certain circumstances. They turned to Enerquip’s heat exchanger experts for help. They had a few requirements:

    • The heat exchanger needed to be very compact, able to fit inside a small utility pit designed for the fountain’s equipment and controls.
    • It needed to source hot water from a nearby location.
    • It needed to activate based on environmental conditions.

    Signature Fountains and the credit union weren’t sure how much heat was lost through the fountain. Without this information, the project was more complex. Further, both companies were working with tight deadlines, and the installation needed to be completed quickly.

    Enerquip worked with Signature Fountains to design the perfect heat exchanger and control for the fountain. When the temperature dropped below 45 degrees, it would turn on. A pump sourced hot water from the credit union’s nearby office building to circulate through the exchanger. It has a multi-pass design, which efficiently directs the hot water to flow through the exchanger several times.

    “The design worked beyond our best expectations,” wrote Gary Boeyer of Signature Fountains.

    Both Signature Fountains and Ascend Federal Credit Union were impressed with the design and how well the fountain runs. Additionally, they were pleased that Enerquip made an effort to help them stay on schedule. By working quickly yet intelligently, Enerquip created a long-lasting solution for the credit union.

    “Recently, Tullahoma experienced cold overnight temperatures,” Boeyer noted. “The system turned on, the heat exchanger very effectively heated the water and the fountain was kept in operation.”

  6. 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.”

    Meet the Enerquip Sales Team for yourself.

  7. Lamberti Employs Enerquip Bayonet Heaters to Maximize Efficiency

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    Introduction

    Lambertiprovides specialty chemicals to a wide variety of industries. From ceramics to agrochemical to PVC additives, 14 different industries rely on Lamberti for necessary chemicals to enhance product quality for their customers. Located in 17 different countries allows Lamberti to work with a diverse group of clients.

    Bill Ruder is a product manager at Lamberti Systems USA, a division of Lamberti, in Chattanooga, Tennessee. The Tennessee facility specializes in ethoxylation and propoxylation technology. It produces such chemicals as surfactants, polyols and block copolymers, as well as combinations of these.

    Companies in the textile, oil, cosmetic, agrochemical and ceramic industries utilize these products. The facility needed a way to heat large storage tanks without altering their complex system already in place. Many of the chemicals are produced in batches to ensure accuracy and quality. It is essential that the chemicals are able to heat and cool properly to the necessary temperatures to maintain their quality before being distributed to clients. However, installing large equipment could hold up production and alter the workflow of the production area.

    Reaching Out To A Trusted Company

    Mr. Ruder decided to contact a company Lamberti had done business with before, Enerquip. For the past three years, Lamberti has worked with Enerquip to customize shell and tube heat exchangers for its operations. Ruder has always been impressed with Enerquip’s ability to provide affordable, high-quality exchangers to its facilities in Tennessee and Texas. Even though Enerquip is located in Wisconsin, more than 900 miles north of Chattanooga, the exchangers have always arrived quickly and safely at Lamberti’s various locations.

    Lamberti has purchased 11 shell and tube heat exchangers from Enerquip. The engineers at Lamberti have always been impressed with the exchangers bought from Enerquip. Ruder also appreciates the extent of knowledge everyone at Enerquip displays about Lamberti’s needs and of the chemical processing industry in general. The person he regularly speaks with, Ron Herman, Enerquip’s director of sales and marketing, has always been able to answer his questions about the equipment Enerquip provides.

    “Ron was more knowledgeable on the technical side than most marketing professionals,” he explained.

    This is why Ruder thought of them first when he decided to invest in an immersion heater. He learned that Enerquip had a new line of bayonet heaters, so he decided to ask Enerquip about them.

    The liquid that Lamberti needed to heat was being stored in vessels. After talking to Enerquip, Ruder learned that the manways located at the top of the vessels were perfect for Enerquip’s bayonet heaters. The bayonet heater could be attached at the manways, which would allow for easy removal when needed. Ruder explained this is necessary because Lamberti’s policy states that equipment must be inspected periodically

    A Solution Is Found

    Ruder and others at Lamberti liked the bayonet heater because it has direct contact the fluid in the vessel. Because of this, there is no need for extra piping or an external loop. No existing equipment needed to be moved or altered to accommodate the new heater, because it goes right into the vessel itself. This saved Lamberti money and time in the long run.

    The raw material can also be heated before being fed into the unit. Once inside, the material needs to be heated to high temperatures. When the fluid is heated before entering the unit, the machine performs less work and the liquid reaches the desired temperature faster. This saves reaction time as well as the energy it would take to heat the material from a lower initial temperature.

    Lamberti has been using the bayonet heater for several months now and has enjoyed its space-and cost-saving properties. It is easy to use and simply removed from the vessel for inspection and cleaning purposes. It has been able to heat the necessary liquids to the correct temperature without any problems.

    Ruder says he would recommend other companies work with Enerquip because they are fast, reliable and willing to help clients customize their exchangers to provide the best solution to meet their unique needs.

    Meet the teamandrequest a quote, today!

  8. Enerquip Introduces New Product Line – Compact Heat Exchangers

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    MEDFORD – Enerquip, a Wisconsin company that specializes in a wide variety of shell and tube heat exchangers, recently added a new line of compact heat exchangers to meet the growing demand from customers with low flow-rate applications.

    Enerquip has been one of the leading providers of heating and cooling equipment for production plants and the OEM’s and system integrators that support them. The company crafts stainless steel and high alloy shell and tube heat exchangers of the highest quality, with delivery lead-times that are half of the industry standard. The size of Enerquip heat exchangers can range from the size of a loaf of bread up to 10 tons.

    “Until now, we haven’t had an efficient solution for product flow rates from 1 to 10 gallons per minute,” explained Ron Herman, Director of Sales & Marketing. “These scaled down versions of our exchangers utilize smaller tubes that increase tube side velocities and turbulence, while avoiding problems with bypass seen in larger exchangers when they are used at low flow rates.”

    Available in both U-tube and straight tube designs, these space-saving exchangers are easy to clean, are high quality and built to last. Enerquip’s compact exchangers are also ASME code stamped, to provide customers with peace of mind that their product and their people will be safe during production.

    This new product line is perfect for small batch processes, point-of-use streams, or R&D or pilot scale applications where a smaller compact exchanger would be an advantage.

  9. Waste heat recovery systems reduce operational expenses in cement plants

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    Concrete is the most widely utilized construction material on the planet, and has been so for centuries. The advantages of including it in building projects are well-known and simple: It’s strong and highly durable, and the ingredients – gravel, sand and water – are found just about anywhere.

    Cement and concrete’s carbon emissions

    Despite the obvious benefits of using concrete in construction projects, there’s one major downside to the concrete and cement industries: Their carbon footprint is enormous. In fact, cement production is thought to contribute as much as 5 percent of global CO2 emissions, according to the Cement Sustainability Initiative.

    A large part of these emissions is unavoidable. When limestone – a critical component of cement – is heated up, it converts to calcium oxide and releases carbon dioxide. This transformation accounts for about half of the CO2 emissions released during cement production, according to the Cement Industry Federation. Another 35 percent of the emissions created is a byproduct of burning fuels to keep the cement plant operable. The remaining 15 percent is due to electricity used throughout the plant.

    Although cement creation contributes to global pollution in a major way, the need for concrete outweighs any notions that production should be cut back. Relying on alternative construction materials has not yet proven to be more environmentally friendly, according to Cement Science. Additionally, transporting alternative materials to certain construction sites is far more complicated than logistics to do with concrete.

    Compared to the production of steel and other materials, cement and concrete use relatively low levels of energy, Cement Science pointed out. The biggest reason the cement industry contributes such a large portion of CO2 emissions is its popularity. In 2016, 4,200 million metric tons of cement was produced globally, with 85.9 million metric tons being made in the U.S., according to Statista.

    Waste heat recovery systems market increases

    Growing concerns about climate change and the negative impact of carbon emissions have encouraged many companies to develop ways to lower their carbon footprints. Various governments’ dedication to green production practices have led to tighter regulations. And more consumers voicing their support for companies that make an effort to lower their own emissions has motivated production plants to explore new ways to make their operations more environmentally friendly.

    These trends have fuelled the growth of the waste heat recovery system market, which is expected to grow 6.9 percent annually between 2016 and 2021, according to a report from MarketsandMarkets. By 2021 the market is expected to be valued at $65.87 billion.

    MarketsandMarkets found that the largest driver of this growth is the cement sector. The global cement industry is projected to grow 9 percent a year until 2021. Massive construction efforts around the world, particularly in Indonesia, India and China, are some of the biggest reason for this.

    As the need to reduce carbon emissions becomes more pertinent to the cement industry, and as the need for cement in global construction projects continues to be at a high level, it’ll become more important for manufacturers to invest in waste heat recovery systems.

    Waste heat recovery in the cement making process

    The first time a cement producer employed a heat recovery system to reduce operation costs was Japan’s Kawasaki Heavy Industries, which outfitted its Sumitomo Osaka Cement plant with a waste heat recovery system in 1980, according to a report from the International Finance Corporation. Since that time, more cement companies have enjoyed the benefits of waste heat recovery. “Up to 30 percent of a cement plant’s electricity needs can be generated using waste heat recovery systems.”

    The typical process by which cement is made includes raw materials (usually limestone, sand, shale or chalk) being collected in a rotary kiln, which heats the materials to around 2,640 degrees Fahrenheit. At this temperature, the materials undergo chemical reactions that result in a product called clinker, which looks like small dark rocks. After the clinker is cooled, it’s ground to a fine powder along with additives like gypsum. This powder is the final product – cement.

    Reaching 2,640 degrees requires a lot of energy. Kilns are powered by heat sources like coal or natural gas. Rock and sand can be preheated prior to moving into the kiln, which cuts down on the energy required to heat up the materials. The hotter the shale, chalk and other materials can get prior to entering the kiln, the faster the cement-making process will be and the more energy efficient the plant runs.

    Preheaters in cement operations are typically systems of large cyclones that utilize exhaust gas leaving the kiln. Some systems have as many as six cyclones. Materials successively pass through each one, getting hotter as they go before finally reaching the kiln. Each cyclone takes advantage of heat escaping the kiln.

    Using heat from the kiln to prepare raw materials for production is an excellent way to increase energy efficiency, but it’s not the only method of utilizing waste heat in a cement operation. Aside from the kiln, heat escapes from the preheating cyclones as well as the system used to cool the clinker before it’s ground into cement. These sources of heat can be directed to other parts of the plant where heat is needed, including the general HVAC system. It can also be used to generate electricity to decrease the plant’s reliance on the grid and lower utility costs. Nearly one-third of a plant’s electricity needs can be generated using waste heat recovery systems, the IFC explained.

    A high-quality heat exchanger is the key to an effective waste heat recovery system in a cement plant. If you’re seeking out new ways to reduce your operational expenses, investing in a shell and tube heat exchanger to begin recovering otherwise wasted heat is an excellent place to start. To learn about the best way to incorporate a waste heat recovery system in your plant, reach out to the engineers at Enerquip.

  10. Maple syrup producers use shell and tube heat exchangers and membranes to improve production

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    Maple syrup is a beloved topping many people reach for when diving into a plate of pancakes or waffles. Though you’d be hard-pressed to find a person who doesn’t love this sticky-sweet condiment, syrup makers only have a short window of opportunity every year to produce this favorite flavor.

    The fleeting sugaring season

    Sugaring season begins with winter waning into spring, when the days get warm, but the nights still sink below freezing. The daily freeze-thaw cycle is what pushes sweet sap out of the trees from which the syrup is made. As soon as nighttime temperatures rise above freezing and buds begin to grow on the trees, the sap becomes bitter and unusable, thus ending sugaring season as swiftly as it began.

    Typically, sugaring season only lasts a few weeks or months, according to Discover New England. Every year is different, though. If winter should recede early, the season may begin early; if the weather warms up quickly, the season is cut short, Farming Magazine reported.

    “We’re hoping for another good season [in 2017] where we get 3 weeks or a month of good cool sugar weather,” explained Burr Morse of Morse Farm Maple Sugarworks in Montpelier, Vermont, to Farming Magazine. “We had a season back in 2012 where we had a great week of sugaring around the first part of March. Then it turned to summer for 10 days and we lost our sugaring right there. That can happen and it’s nothing anyone can predict.”

    Speeding up the sap production process

    Given the unpredictability of springtime weather, it’s crucial that maple syrup producers make every moment count during sugaring season. Different producers approach this dilemma differently. One Vermont company, The Maple Guild, invented a steam-craft system that allows the company to produce 55 gallons of syrup in just three minutes using indirect heat, as opposed to the industry standard of an hour using direct heat, according to FoodNavigator-USA.

    “Essentially, we pre-boil the syrup before it hits the main evaporators, and we do that with steam that was generated at the bottom evaporator – and we shoot air in to the top evaporator which makes the concentrate float in the steam,” explained Mike Argyelan, the CEO of The Maple Guild.

    Other companies use sanitary shell and tube heat exchangers to both pasteurize the syrup and make it less viscous and easier to bottle. Putting the product through this process also removes any insects or other contaminants that have a way of getting stuck in the sticky sap.

    Another technique is reverse osmosis, a process by which maple sap is concentrated before entering the evaporator where it becomes syrup. A research paper detailing experiments with RO on maple sap conducted at the University of Vermont Proctor Maple Research Center stated that this method can decrease the amount of time syrup spends in the evaporator, increasing both productivity and energy efficiency. Researchers compared the effects of concentrating the sap to 2, 8, 12, 15 and 21.5 percent sugar concentration and found that flavor, color and other characteristics were generally consistent across the board. ONMapleSyrup noted that by using RO, producers can reduce the number of taps needed to manufacture their syrup.

    In addition to saving time and taps, RO also reduces the need for fuel, making the syrup production process more environmentally friendly.

    Saving energy during syrup production

    Since syrup production is consolidated into a several-week-long sprint, condensed operations demand high energy spend. While more syrup producers are utilizing RO technology, there are other ways producers can save energy.

    A large amount of water needs to be removed from sap to make syrup. Because of this, the syrup-making process gives off incredible amounts of steam. The steam released provides a convenient and free heat source that producers are beginning to take advantage of.

    “Syrup manufacturers can capture the heat lost to rising steam.”

    A Forest Service Research Paper explained that by installing a shell and tube heat exchanger syrup manufacturers can capture the heat lost to rising steam and use it to preheat the sap before it reaches the evaporator. Like RO, this process will reduce the amount of time the sap needs to spend in the evaporator before it reaches the desired consistency.

    This mechanism was perfected in 1974 by George Raithby of the University of Waterloo in Ontario. Prior to Raithby’s development, the use of any equipment above the evaporator would compromise the final product because rising steam would condense on the metal surface and drip back into the open pans of syrup. Raithby used a shell and tube heat exchanger with a drip pan installed beneath it to collect the condensate. Inside the tubes, the sap could be heated from a starting temperature of about 40 degrees Fahrenheit to around 190 degrees Fahrenheit before it reaches the evaporator.

    The Forest Service conducted experiments to determine whether using a shell and tube heat exchanger to preheat the product would have any effect on the quality of the final bottle of syrup. The researchers found it did not, but pondered whether utilizing copper tubing instead of stainless steel would leave behind remnants of copper in the syrup. The researchers determined it did not after analyzing the ultimate product, though if producers are concerned about this effect, investing in a stainless steel shell and tube heat exchanger may be a smart move. Not only will it lend to consistent materials being used throughout the process, but it is also highly durable and long lasting.

    Sugaring season, short and sweet though it may be, is an important time of year for maple syrup producers and, whether they realize it or not, breakfast lovers everywhere. If you’re wondering how a new shell and tube heat exchanger or a membrane can improve your operation, reach out to the engineers at Enerquip.