Skip to Content
Exit

Category Archive: Heat Exchanger Solutions

Tag Archive: Heat Exchanger Solutions

  1. The causes of overheating and how to avoid them

    Leave a Comment

    After leaks, overheating is the most common concern for people working with hydraulic equipment. An overheated system can reduce the effectiveness and life span of oils in the system, and can degrade important polymer elements, like hoses and seals, Hydraproducts explained.

    While most people who work with hydraulic systems know that overheating is bad, few fully understand the causes of this concern. It can be hard to find a solution to an overheating problem, and even more difficult to uncover the exact cause.

    Defining overheating

    Generally speaking, an overheated system is one that’s running at 180 degrees Fahrenheit or hotter, according to Machinery Lubrication Magazine. However, every system is unique. It’s important to monitor the viscosity of your oil as well as your equipment temperature to determine whether it’s overheating.

    “An overheated system is one that’s running at 180 degrees Fahrenheit or hotter.”

    The ability to identify overheating right away is a crucial skill, but it’s preferable to avoid the issue altogether. The only way to avoid overheating, by definition, is to ensure that the amount of heat your system is generating is less than the amount it’s dissipating.

    Determining your system’s limitations

    The first step in avoiding overheating is knowing your system’s capacity. Machinery Lubrication Magazine explained this can be done with a simple equation using the system’s continuous input power and its efficiency percentage.

    The example provided by the source used a system that has a continuous input power of 100 kilowatts and an efficiency of 80 percent. In this case, the system needs to be able to dissipate at least 20 kilowatts at any given time.

    Any time circumstances reduce the system’s ability to cool or dissipate heat, or increase the heat load above 20 kilowatts, overheating will occur. Given these facts, there are two ways to correct an overheating problem: Decrease the heat load, or increase the heat dissipation.

    Decreasing heat load

    If your system is overheating, there’s an underlying cause that may not always be immediately evident. The best way to avoid increasing heat loads is to ensure that every feature of your system – from the machines to the oil and seals within them – is in top condition.

    Change out parts and fluids when they begin to degrade or otherwise go bad. Perform routine inspections to make sure you catch issues before they become operations-halting problems. Keep a regular maintenance and cleaning schedule as well.

    Sometimes it’s not a buildup of debris or a skipped cleaning that causes overheating. Any leaks in your hydraulic system can have a negative effect on your operation as a whole.

    “If your system is overheating, there’s an underlying cause.”

    The main goal here is to ensure that your equipment is operating efficiently at all times. When your system is operating as it should, there are fewer chances for it to overheat.

    Increasing cooling capacity

    If everything seems to be consistently in order, but you’re still having trouble with overheating, it’s a sign that your system needs an adjustment. Your cooling system could be worn out. Be sure to regularly check all cooling system parts and their functionality so you know when to replace something.

    Sometimes, your cooling system may just not have the right capacity for your hydraulic machinery. Don’t let this problem persist. One way to increase the dissipation rate is to add another oil cooler, Engineering Made Easy pointed out. With an added cooler comes increased ability to cool the system down before the temperature swings too high.

    An overheated hydraulic system won’t do you, your business or your clients any favors. A major part of running an efficient operation is the ability to maintain the right temperature. Be sure you know the maximum heat your system can handle, and take steps to keep it in that range.

    Remember, one important part of maintaining an efficient system is knowing when to replace critical equipment and components. When you need to replace your shell and tube heat exchanger, or add an oil cooler, reach out to the experienced heat exchange engineers at Enerquip

  2. 2 Ways Shell and Tube Heat Exchangers can Reduce Energy in Breweries

    Leave a Comment
    Fortune
    You can read more [ Here ].

    The craft beer industry has taken off in the last few years. Beer drinkers seek out full, unique flavors and variety in their beverages. Craft beer drinkers also like to support local, small and independently owned breweries.

    Fortune reported that the craft brewers increased volume by 13 percent in 2015, making this the eighth year in a row of growth rates of 10 percent or more. There are more breweries than any beer aficionado can keep track of: 4,269 of them, to be exact.

    Another impressive statistic is that, even in a year when the total beer market for the country contracted by 0.2 percent, the craft beer industry managed to grow, now encompassing 12 percent of the market.

    “The figures show there is still strong growing demand for fuller flavored products from small brewers,” Bart Watson, the Brewers Association’s chief economist, explained to Fortune.

    “It shows the premiumization trend that we’ve seen the last few years has room to run,” he continued, referring to consumers’ willingness to pay higher prices for beer that cost more to produce but have fuller flavor.

    Recognizing obstacles in energy efficiency

    As more craft breweries come on the market or expand, owners and operators are beginning to realize some of the obstacles that can come along with beer production. For instance, breweries are extremely energy-intensive operations. Between refrigeration, space heating, packaging and the actual brew house, there are many aspects to a brewery that require either a large amount of electricity, natural gas or both, the Brewer’s Association explained.

    The Daily Energy Report said many breweries have put efforts into reducing their energy use. Anheuser-Busch InBev announced in 2013 it had reduced its energy consumption by 12 percent and carbon emissions by 16 percent in three years. That same year, $100,000 in grants were awarded to five Wisconsin breweries for their efforts to reduce energy use.

    There are many ways to curb energy consumption in a brewery, as with any other entity. The owner can invest in energy-efficient lighting and Energy Star equipment as two surefire ways to begin conserving, Brewers Association explained.

    Reducing energy in wort cooling

    One piece of equipment many breweries have found various uses for is the shell and tube heat exchanger. These are versatile machines with a wide range of applications in the brewery setting.

    “Shell and tube heat exchangers have a wide range of applications in the brewery setting.”

    A sanitary shell and tube heat exchanger can be used in the brewing process for wort cooling. This is a crucial step, and a shell and tube heat exchanger is a great way to achieve this efficiently. According to Craft Beer & Brewing, a shell and tube heat exchanger can cool the wort to the desired temperature in just 10 minutes, and sometimes even quicker. This not only speeds up the brewing process, but it also results in a clearer product in the end. Shell and tube heat exchangers also use less water than some of their counterparts, such as an immersion chiller.

    Reducing energy in wort boiling

    Prior to the process of cooling the wort, there is a significant amount of energy used to heat up the mixture of water and malt. Chris Riphenburg, head brewer at Madison, Wisconsin-based Ale Asylum, told Craft Brewing Business that it’s essential to have the correct heating source for the kettle or hot liquor tank. There are three options brewers can choose from, though there is one clear choice if the brewer is hoping to reduce energy use and operating expenses. Three options are to use:

    1. A burner, which is an older method not used as often anymore.
    2. A steam jacket, a method adopted by many modern breweries today.
    3. A shell and tube heat exchanger, which can significantly reduce energy costs.

    According to Riphenburg, a shell and tube heat exchanger can be as much as 80 percent more efficient than a burner and 50 percent more efficient than a steam jacket.

    In addition to its environmental and financial benefits, a shell and tube heat exchanger also has the advantage of not having any moving parts and is easier to clean than other heating devices. This means brewers can spend more time making beer and less time worrying about equipment issues.

  3. Honey warming prevents crystallization

    Leave a Comment

    Honey is a popular sweetener many people often use while baking, in teas and as a topping on toast or ice cream. When thinking of honey, most envision an amber-colored, sticky liquid that is easily, if slowly, poured from a bottle. This is the most popular form and the state in which honey producers strive to keep their product.

    As many people know, honey is a substance created by bees. The bees extract nectar, or sugars, from flowers to transform into honey in their hives. The substance is therefore essentially a sugar mixture, composed primarily of fructose and glucose, according to Serious Eats. These sugars can cause the honey to crystallize over time, making it appear cloudy and thick.

    “The heating element will evenly warm the honey.”

    How quickly honey crystallizes depends on many things, including how it is stored, what type of flowers the bees took nectar from and how the honey was treated before it went to the store’s shelves.

    Keeping out crystals

    To prevent early crystallization of honey, producers of the sugar alternative might choose to process it through a heating and filtering process. The heating will do several things for the honey, Blue Ridge Honey Company explained. First, it will dissolve sugar crystals to prevent quick crystallization. Second, it will make it thinner, so the honey can be finely strained. When it is strained, particles like pollen and bee parts are taken out of the honey. This will prevent crystallization further, because there are fewer particles to which sugar crystals can bind.

    To be effective, honey should be heated to 160 degrees Fahrenheit for a short period of time. A stainless steel shell and tube heat exchanger works well in this capacity. The heating element, such as water, will evenly warm the honey to the desired temperature, preventing pockets. This is essential if the honey is to be evenly treated to prevent early crystallization.

    For information about how shell and tube heat exchangers can benefit your food production business, contact the experts at Enerquip. Their in-house engineers will be able to help you find a cost-effective solution for your company.

  4. Shell and tube heat exchangers used for waste heat recovery

    Leave a Comment

    Waste heat recovery has been a topic of concern for large-scale industrial companies for several decades. Not only does recovering waste heat make an operation more environmentally friendly, but it also helps to cut costs. Additionally, it can reduce the amount of resources needed to power a facility.

    Many industries and facilities have implemented different methods of waste heat recovery. One popular choice is using a shell and tube heat exchanger. According to the Energy Efficiency Guide for Industry in Asia, these exchangers are best suited for recovery methods dealing with warming liquids with heat recovered from:

    1. Condensates from process steam, distillation processes or refrigeration, or air-conditioning systems
    2. Coolants from engines, lubricants, bearings, air compressors, furnace doors, pipes or grates
    3. Flue gas streams and exhaust streams from furnaces, dryers and exhaust stacks

    The waste heat usually flows shell side, while the liquid is positioned tube side. This is because the higher-pressure liquid or vapor should be in the tube, because the shell is the weaker container. Utility fluids and products being heated can also be kept cleaner on the tube side of a heat exchanger. Waste heat typically produces condensation. Allowing condensates to form on the inside of the tube will typically cause flow irregularities and could lead to problems with the exchanger.

    Vegetable oil processing plant

    One example of a shell and tube heat exchanger put into practice for recovering waste heat is outlined in Energy Mines and Resources Canada’s Energy Management Series for Industry Commerce and Institutions. The paper explained a vegetable oil processing plant hoped to reduce its use of a steam heater in the refining process. The semi-processed oil needs to be heated from 30 degrees Celsius to 80 degrees before heading to the final stage of processing and then storage.

    “A shell and tube heat exchanger for waste heat recovery saved a processing plant $29,570 a year.”

    When the oil is transferred to storage, some heat is expelled that the company wanted to recover. This heat would then be used to warm the oil before going to the steam heater, reducing the amount of energy needed to bring the oil to its optimum temperature. By sending the oil through the heat exchanger prior to going into the steam heater, the oil can be heated to 70 degrees Celsius, requiring the steam heater to only raise the temperature by 10 degrees instead of 50.

    By implementing this practice, it was predicted the processing plant could save $29,570 annually. Taking into consideration the cost of the exchanger and its installation, it would take slightly more than half a year to see financial benefits.

    Diesel engines

    Research done by Saiful Bari, a senior lecturer, and Shekh N. Hossain, a research student at the Barbara Hardy Institute, a division of the School of Engineering at the University of South Australia, showed shell and tube heat exchangers could also provide beneficial heat recovery methods for diesel engines.

    Bari and Hossain explained the exhaust from diesel engines contains 38 percent usable energy. Heat exchangers were fitted to connect to the engine’s exhaust and arranged in parallel and series configurations. The two exchangers had different purposes. One, called the super heater, was used to superheat steam coming from the exhaust, which normally expands in the truck’s turbines. The second, named the vapor generator, was used to generate vapor from a liquid put into the exchanger.

    The researchers found in initial testing that 16 percent of additional power was recovered. Knowing that the heat exchangers used were not built specifically for this application, they decided to customize them to more efficiently recover the heat. After optimization, 23.7 percent additional power was generated. They also found that maximum heat recovery could be achieved with both the series and parallel arrangements when the engine’s pressure is higher, specifically at 30-bar working pressure. With this pressure, up to 9.85 kilowatts of energy could be retrieved. With lower-pressure engines, the parallel configuration is more efficient than the series configuration because it produced a higher mass of steam.

    Bari and Hossain attributed the success of their research partially to the fact that they customized the design of the heat exchangers to the particular engine used. They noted that, by using these shell and tube heat exchangers for heat recovering, the efficiency of the engine rose from 30 percent to 41 percent.

    Both of these examples show that waste heat recovery can be used to save money and resources, as well as make processes more energy efficient. Many different industries can benefit from using shell and tube heat exchangers in this way.

  5. New processing method creates better-tasting tomatoes

    Leave a Comment
    flavor A simple and inexpensive hot water bath could drastically change the flavor.

    If you’ve ever bought regular tomatoes from the grocery store, you might have had a few you’ve considered to be bland or flavorless. This notion is not uncommon in grocery stores since the majority of tomatoes come from the farm not fully ripened and green, which leaves them to turn red once they are already stored.

    This process can have tomatoes tasting boring before you even pick them out of the bin at the supermarket. In fact, chilling tomatoes has been found to degrade the flavor of these fruits and the overall quality, Gizmag reported.

    However, a new discovery from plant physiologist Jinhe Bai​ and a team of scientific researchers, found that better-tasting tomatoes could actually be a very simple fix.

    According to the researchers, adding a hot water treatment to tomatoes before they are chilled for storage and shipment increases the flavor of the fruit, Quartz magazine reported. The researchers tested green tomatoes from Florida by dipping the fruit in hot water – approximately 125 degrees Fahrenheit – for five minutes and by letting them cool at room temperature.

    “To produce a better tasting tomato, we added a hot water pre-treatment step to the usual protocol that growers follow,” Bai said. “We found that this pre-treatment step prevents flavor loss due to chilling.”

    Bai also worked with researchers from the University of Florida and the U.S. Department of Agriculture and the Agricultural Research Service to test the tomatoes.

    Counterbalancing preservatives and chemicals

    To keep tomatoes on the shelves longer, it’s no secret that chemicals are used to help the fruits ripen. However, these chemicals tend to deter the flavor of tomatoes. But the hot bath has proven to enhance flavor compounds.

    The very simple alteration to the tomatoes is completed before they are shipped, which produces more enhanced smells as well. Bai explained that the heat treatment regulates the ripening enzymes in the tomatoes and activates the production of a protein that can help prevent cell decay on the fruit.

    “Chilling suppresses production of oxygen, nitrogen, and sulfur-containing heterocyclic compounds, ketones, alcohols and aldehydes, including 13 important aroma components of tomato flavor,” Bai added. “But hot water-treated fruit actually produced higher concentrations of these important aroma contributors, even with subsequent chilling.”

    Heat exchangers in processing plants

    The team of researchers is still testing different stages of the tomatoes to determine the absolute best timing for the heat treatment process. Bai believes this will be the best method of action before offering these solutions to tomato processing plants. Some of the researchers’ tests used methyl salicylate​, which is wintergreen oil, instead of hot water to treat the tomatoes, Science 2.0, reported.

    The whole purpose is to help enhance the flavor of tomatoes, but to also provide a better solution to shipping the fruits. Since hundreds of thousands of tomatoes are shipped from the farm each day, processors could use the heat treatment to send more reliable products. Bai hopes the heat treatment process will take off and become a standard in tomato processing. The researcher even believes the adaptation could eliminate the need to chill tomatoes to begin with.

    As the heat treatment testing continues, processors should prepare their facilities with the most up to date shell and tube heat exchangers to help with heat treatment. This equipment can treat tomatoes before they are sent out for shipment, which ultimately provides a better product from the farmers.

  6. Sewage provides energy through processing

    Leave a Comment

    Editor’s Note: This content was last updated 4/1/24.

    Innovation in renewable fuels

    In the past decade, nations have sought new renewable fuel sources, including landfill, biodiesel, and even sewage. With an overabundance of sewage, Japan was an early adopter of this technology.

     Japan’s sewage system covers roughly 80 percent of the land area where most people live through approximately 279 miles of pipelines. The Japanese Land, Infrastructure, Transportation and Tourism Ministry said there’s certainly no lack of sewage in the country and that the issue is persistent.

    For that specific reason, the nation’s leaders leaned into the technology to use sewage as renewable energy. For example, a facility in Tokyo, built in 2021, converts sewage sludge into renewable hydrogen gas for fuel-cell vehicles. This one location near Tokyo Bay processes 1 ton of dried sewage sludge daily, generating enough hydrogen to fuel ten passenger vehicles each day.

    In February of 2024, researchers from the University of Cordoba, Spain, announced the development of a sustainable method to convert sewage sludge from wastewater treatment into activated carbon. Activated carbon is used for water and air purification, environmental remediation, gas purification, chemical processing, and in the food, beverage, medical, and pharmaceutical industries for adsorbing impurities and contaminants.

    How the sewage treatment works

    Sewage is processed in various ways for various applications, but it is often pulled into a processing center through a heat pump and given heat treatment via shell and tube heat exchangers. Once complete, the energy produced from the process can be reallocated to heat, cool, generate power, and more.

    In Albany, New York, city officials installed an $8.6 million power generator to turn sewage at the wastewater plant into harnessed energy. The North Wastewater Treatment Plant, located in Menands, New York, said the system saves taxpayers roughly $400,000 a year and can supply approximately 75 percent of the plant’s energy through the disposal process.

    They noted that sewage sludge is renewable energy powered, literally, by the people, and it’s always available. New energy systems like this one not only help cities with daily energy needs but also help in critical times when power surges occur on the grid.

    More from the Enerquip Blog

  7. Why Heat is Vital to Dairy Pasteurization

    Leave a Comment

    Editor’s note: This content was last updated 3/11/24.

    The Need for Pasteurization

    A century ago, the significance and process of pasteurization eluded us, but today we recognize its indispensable role in dairy product handling. Pasteurization not only eliminates harmful organisms but also safeguards product integrity. By heating dairy products just below the boiling point, we effectively eradicate bacteria and organisms, ensuring our safety and preserving the product’s shape and flavor.

    Different dairy products require specific heating temperatures, necessitating tailored equipment like shell and tube heat exchangers. Selecting the appropriate heat exchanger is crucial for achieving the necessary temperature variations. Learn more about designing shell and tube heat exchangers for sanitary dairy applications.

    The primary objectives of pasteurization are twofold: ensuring products are safe for human consumption and enhancing overall product quality. With varying susceptibility to spoilage, pasteurization extends product longevity and freshness, crucial for dairy items with short shelf lives.

    Critical Heat Treatment Methods

    Heat treatment methods are indispensable in preparing dairy products for consumption. While heat treatment reduces bacterial pathogens and spoilage bacteria, it’s essential to maintain product safety even after pasteurization. Prompt packaging minimizes oxygen exposure, reducing the risk of harmful bacteria entering the product.

    Different pasteurization methods, such as vat pasteurization and high-temperature short-time (HTST) processes, serve to eliminate pathogens and enhance product quality. By precisely controlling heat and timing, pasteurization maintains product shape and taste.

    Pasteurization also significantly extends the shelf life of dairy items, ensuring their safety and palatability over an extended period. Without this process, many dairy products would have an impractical short shelf life.

    In essence, pasteurization is the unsung hero of the dairy industry, safeguarding our health and preserving the delicious flavors we associate with dairy products. As consumers, we benefit from the science and care behind this essential process every time we enjoy dairy delights.

    Enerquip’s Dairy Solutions

    Enerquip has been providing sanitary process solutions to the dairy industry since 1985. If you’re in the market for stock or custom sanitary shell and tube heat exchangers, we invite you to contact us or request a quote today.

    More from the Enerquip Blog