March 2018 • Volume 25, Number 3

Optimizing Your
THERMAL
OXIDIZER

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www.process-heating.com
Bringing practical solutions to industry worldwide,
Grieve has manufactured industrial ovens and furnaces since 1949.

Whatever your requirement, a Grieve oven or furnace

is likely the best solution.

We are committed to
continuing the tradition
of personal involvement
and quality products begun
by our fathers.

We welcome your inquiry.

Douglas V. Grieve,
President
Frank P. Calabrese,
Vice President

Jumbo Walk-In Oven

 MARCH 2018 Volume 25 • Number 3

28
Features Online Exclusives
12 Air Heaters Optimizing Exhaust-Air Purification Systems with
Practical Air Heater Performance Evaluations Energy-Efficiency Technology
The ability to interpret air preheater performance and analyze Exhaust-air purification systems offer energy savings, especially for
the results is enhanced with an understanding of the process customers in the chemical industry, says one maker of pollution-control
variability within both the air and gas systems. equipment.

18 Industrial Automation Overview of Data-Analytics Software

Software enables users to get more value out of process data by providing
Applying IIoT for Process Heating Applications
interactive, visual tools to accelerate industrial process analytics.
It is time to move beyond the language and promises of IIoT
to solutions that improve asset availability and production View Thermal Management Webinar On Demand
outcomes. “Thermal Management Solutions for Automotive, Lighting and Industrial
Applications,” a recording of a live webinar produced by Dow, is available
24 Temperature Sensing to view on demand.
Selecting Process Temperature Sensors
Would you like to improve industrial temperature Always Online
measurement performance? Gain and apply a theoretical ■ Archives ■ Energy Notes column ■ Digital Editions
understanding of temperature sensor characteristics to make ■ Calendar of Events ■ Equipment Overviews ■ Buyers Guide
■ Drying Files columns ■ Heating Highlights ■ Archived Webinars
the best choice for your heat processing applications. ■ New Products ■ Industry News
Check out our redesigned site with more frequent updates and web exclusives!
28 Heat Recovery
Optimizing Your Thermal Oxidizer
Quick links point the way:
Optimization saves energy and operating costs through heat www.process-heating.com/connect
recovery. One way to mitigate an oxidizer’s operating costs
and carbon footprint is to consider adding a secondary heat Go Mobile
exchanger as a means to recoup heat from the oxidizer’s Use your smart phone to read Process Heating, wherever you are! Point
your phone or tablet’s camera at the image
exhaust. at right to scan the QR code with your mobile
phone or tablet. Your device will display the
32 Equipment Overview mobile version of the current issue of Process
Industrial Ovens Heating instantly!
Whether you want a booster oven or a completely new Your mobile service provide may charge for
data transmission usage. Contact your mobile
thermal processing system, use Process Heating’s annual
provider for details on your data plan and limits.
Equipment Overview on Ovens to find suppliers and save time
specifying your oven.

About the Cover

Companies with thermal oxidizers may be
able to optimize the facility’s energy cost by
Columns & Departments recovering heat from the existing
March 2018
• Volume
25, Number 3

process, says Durr Systems Inc. Optimizing You

4 Commentary 42 Success Stories (www.durr-cleantechnology.com).
THERMAL
r

OXIDIZER
6 Inner Workings 45 Advertiser Index The recovery of waste heat from an oxidizer
10 Calendar 45 Classified Directory may reduce a plant’s carbon footprint
and improve the bottom line. Learn
38 Product Highlights 46 Places & Faces
about process heat recovery in an article
46
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on:

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eating.c om

PROCESS HEATING (ISSN: Print 1077-5870 and Digital 2328-9996) is published 12 times annually, monthly, by BNP Media, Inc., 2401 W. Big Beaver Rd., Suite 700, Troy, MI 48084-3333. Telephone: (248) 362-3700, Fax: (248) 362-0317. No charge for subscriptions to
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www.process-heating.com MARCH 2018  3

Commentary
Appreciating Transformation
Charmed by the snaggletooth grin of the
beaming Girl Scout on Facebook, I ordered
cookies again this year. There she was, in
all of her prepubescent glory: my friend’s
daughter, a proud Junior Girl Scout, hoping
to sell hundreds of boxes in support of her
troop. Heck, I had been that girl once! My
fingers placed my Tagalong order before I By Linda Becker
had a chance to rethink it.
The regret came moments later when I remembered
the difficulties each year: Finding a time and place to
meet with the scout’s mom to make the payoff. All done
so the poor parents’ wouldn’t get stuck paying for my
cookie order along with cheap Uncle Bob’s and those
neighbors who ordered 10 boxes but now won’t open
the door. My Girl Scout lived a few hours away, further
complicating matters.
Fortune intervened when I realized I’ve moved
into a generation of Girl Scouts’ moms who are more
comfortable with electronic payments that cash or
check. A few clicks on Apple Pay and my cookies
were paid for — and destined for a soldier overseas. I
showed support for a budding entrepreneur, beloved
family friends, our U.S. military (and economy), and
an organization focused on building girls’ courage,
confidence and character — without moving from my
comfy chair.
What could all this have to do with process heating,
you might wonder? The ease of the transaction, and the
contactless way in which it was completed drove home
again the transformative effects of the internet on our
daily lives.
How the internet — and the Industrial Internet of
Things — is transforming industrial processing facilities
is at the forefront “Applying IIoT for Process Heating
Applications” by Michael Risse of Seeq Corp. After
describing the ways in which IIoT technologies are
permeating process plants, Risse illustrates them with
real-world example. A pharmaceutical manufacturer
was experiencing scale-up issues with a new upstream
bioreactor process. A process to analyze, visualize and
report the current inputs online, and a means to combine
that data with information gleaned via laboratory-
scale and pilot-scale experimentation, allowed the
pharmaceutical processor to quickly assess what was
happening at the cell and processes levels for multiple
scales and operating conditions. In particular, Risse
descrives how IIoT and effective data management and
analysis provided key benefits:
4  MARCH 2018 Process Heating
Heat
Processing
Technologies
for these
• Uncovered issues related to bioreactor
scale-up and provided the means to
9 Industries
make quick comparisons of key process
steps across multiple batches.
• Performed calculations and comparisons Chemicals/
of durations of sensitive growth periods Petrochemicals
during an intensive cell-growth phase.
• Enabled analysis of related downstream
process operations.
Food Processing
In effect, the pharmaceutical team was better
positioned to measure, record, adjust and control
key operating parameters throughout the thermal
processing. What process could not benefit from that? Finishing
Elsewhere in this issue, Lonnie Coffey, Shawn
Goedeke and Alex Turner of Corrosion Monitoring
Services show how O2 concentration measurements
in the air and gas flows of air preheaters offer insights
Plastics/Rubber
into the process operation. The CMS team tapped
process data from the process historian for time-based
operational data to perform boiler and air preheater
performance calculations.
Jim Griffin of Durr Systems Inc. tackles technologies Pharmaceuticals
for heat recovery from pollution-control equipment in
“Optimizing Your Thermal Oxidizer.” Though various
oxidizer designs exist to improve on energy efficiency of
Pulp/Paper/
the equipment, thermal oxidizers remain a substantial
Wood/Converting
user of natural gas and electricity. The technologies
used and potential for payback depend on application-
specific variables, including the operation modes of the
installed thermal oxidizer. Use this article to explore
Ethanol/
whether heat recovery is an option for your system.
Biodiesel
Finally, Neil Larson and Todd Olin of Emerson
Automation Solutions compare two mature
temperature-sensing technologies — the thermocouple Packaging/
and the RTD — and highlight the ways in which these Printing
workhorses help provide accurate temperature control
in process applications. Sensors do the “hand-on” work
of gathering in situ data for our data-analysis schemes.
Understanding how to ensure the greatest accuracy
Electronics
within process applications will help ensure that the
decisions based on the data gathered reflect actual
process conditions.
Visit www.process-heating.com
to read industry-focused content
as well as thousands of articles
covering industrial heat
processing equipment.
Linda Becker, Associate Publisher and Editor,
BeckerL@bnpmedia.com
 Webinar
Steam Boiler Safety by Design
March 13, 2018 @ 2 PM ET

Today, there is a commonly accepted belief in the boiler industry that watertube boilers are
intrinsically safer than firetube boilers due to their design. In his book, “Boiler Operator’s
Workbook,” a well-accepted reference tool, the author R. Dean Wilson writes “Why is an
explosion generally less disastrous in a watertube boiler than in a firetube boiler?”

“In a watertube boiler, the large volume of water is distributed into many small tubes,
and the volume of water in the drum is comparatively small. If one water tube bursts, the
pressure in the entire pressure vessel is bled off slowly, and the tendency of the large body
of water to flash into steam is minimized...”

“In a firetube boiler, a sudden crack in the shell or a flue pulled loose at the end causes
the entire body of water to be subjected to a sudden and substantial drop in pressure. The
huge volume of flash steam that results can cause an explosion of tremendous force.”

Since Steam Boiler Safety should never be a variable, but an absolute, this webinar will
explore “Steam Boiler Safety by Design.”

Speaker:
Kyle Richards
West Division Manager

process-heating.com/webinars
Inner Workings
GE to Provide Total Plant Services Solution
for Power Plant
GE’s Power Services will provide
25 years of total plant services
solutions for the 907 MW Norte
III combined-cycle power plant in
the state of Chihuahua, Mexico. GE
Power Services signed the long-term
agreements with a consortium formed
by Macquarie Capital and Techint. The
contracts, valued at approximately
$330 million, include an operation
and maintenance agreement and a
contractual service agreement.
GE will utilize its Fleet360 platform
of total plant solutions for the
facility, which operates on four of
GE’s 7F.04 gas turbines as well as two
Toshiba steam turbines. The platform
also provides digital solutions and
plant-improvement services. GE’s
Predix-based asset-performance
management and operations-
optimization software applications
will be deployed. The software will be
6  MARCH 2018 Process Heating
used to apply advanced data analytics
to predict and eliminate unplanned
downtime and improve productivity.
Norte III is expected to provide
electricity to more than 500,000
houses in Mexico once completed.
Merger Creates Combined
Pump Company
Simmons Pump LLC and Simflo Pumps
Inc. have merged. The combined
company, which will be privately held
and operate under the Simflo name
and brand, will engineer, manufacture,
source and deliver pump products
and technologies for major industrial
users, including manufacturing,
mining, chemicals, hydrocarbons and
saltwater extraction.
The headquarters for the new
company will be located in Lubbock,
Texas, although Simflo will maintain
offices in its former headquarters
in Willcox, Ariz., and in Garden City,
Kan. All 120 employees of Simmons
and Simflo have been retained.
The combined company plans on
increasing its workforce by 10 percent
in 2018 and intends on opening new
locations in other markets in the future.
Victaulic to Build
Manufacturing Facility in
Pennsylvania
Victaulic, a manufacturer of
mechanical pipe-joining solutions,
plans to build an additional
 Inner Workings

manufacturing center in Lehigh Valley, installed above each set of doors. Fans two 50,000-cfm circulating fans to
Pa. The 400,000 ft2 facility is expected over the hoods start automatically to deliver dual airflow throughout the
to break ground later this year and be remove any fumes and heat that exit the workspace. Due to the NFPA Class
fully operational in 2019. workspace when the doors are opened. A rated requirement, a 3,000-cfm
In addition to housing the Both ovens are heated with direct- exhaust fan is included to remove
company's current light-assembly fired natural gas and have a maximum volatiles. Recirculation air filters were
operation, the center will include operating temperature of 500°F provided to maintain a class A finish
several millions of dollars in new (260°C). Each oven is equipped with on the parts.
equipment to modernize its
manufacturing operations. Robotic
and optical technology will advance
the limits of quality control for the
TURN-KEY INDUSTRIAL OVENS
company's castings and finished
products through automated assembly
operations. Use of computerized,
visual inspection systems will allow the
company to identify nonconformities,
preventing them from being shipped
to customers.
Along with the expansion, Victaulic
anticipates adding 40 to 50 new
jobs by the end of 2018. Many of the
new positions – from machining and
lab technicians to assemblers and
production staff – will be filled by local
talent from the area's skilled workforce.

Auto Manufacturer Orders

Ovens for Research Facility

Process Heating Solutions

Global Service, Support & Manufacturing

Ajax TOCCO services & supports numerous makes of ovens including:
Two custom paint-baking ovens will FECO, MOCO, Young Brothers, Coleman Ovens, & Dry System Ovens
be used to cure a powder coating,
z Temper z Metal Decorating
dry paint and preheat automotive
z Preheat z Wicket World Headquarters
components, including complete 1745 Overland Avenue
z Heat Treat z Batch, Continuous & Indexing
bodies and frames. Lewco, Sandusky, Warren, Ohio USA 44483
z Curing / Drying z Parts & Service
Ohio, won the contract to design and z Baking z Install & Construction +1-330-372-8511
build the ovens for an automotive +1-330-372-8608 Fax
manufacturer’s research facility. 24 Hour Customer Service: 800-547-1527
The customer’s application required
bi-parting swing doors at each end
to permit pass-through processing.
To reduce the ovens’ impact on the
surrounding area, exhaust hoods were www.AjaxTocco.com

www.process-heating.com MARCH 2018  7

Inner Workings
Aerospace Company
Orders Temperature-Cycling
Vacuum Chamber
A reach-in temperature-cycling
vacuum chamber will be used for
temperature altitude testing of
aircraft collision avoidance radars.
Manufactured and delivered by
Tenney Environmental, New Columbia,
Pa., the operating temperature range
of the vacuum chamber is -94 to
351°F (-70 to 177°C) with temperature
control of ±1.8°F (±1°C).
The unit has vertical air circulation,
and the refrigeration system utilizes
a customer-requested liquid nitrogen
(LN2) modulating cooling system that
permits extreme low temperatures
to be achieved with rapid pull-down.
The LN2 is routed through an internal
evaporator coil, which allows the
system to control both temperature
and altitude at the same time. The
cycling chamber’s programmable
controller includes RS232 serial
communications and advanced
Ethernet capabilities.
Stone Wool
Manufacturer Rebrands
A global manufacturer of stone wool
products, Roxul Technical Insulation
adopted the name of its global parent
company and is now Rockwool
Technical Insulation in North
America. With five factories and 1,000
employees, Rockwool manufactures
8  MARCH 2018 Process Heating
stone wool insulation for industrial
and technical solutions as well as
building insulation.
The rebrand includes all product
lines of the company’s North American
stone wool insulation business.
Customers of the company’s industrial
(ProRox) as well as marine and offshore
(SeaRox) business segments will notice
a transition to Rockwool branding on
all packaging. The company’s new
website in North America,
www.rockwool.com, launched this
month while the Rockwool Group
corporate site has transitioned to
www.rockwoolgroup.com.
The Rockwool Group has invested
approximately $350 million in three
new North American manufacturing
facilities since 2014, including a stone
wool insulation plant in Ranson, W.V.
Training on Industrial
Instrumentation for Military
Veterans Offered
Over the next decade, the
manufacturing sector is expected
to produce up to 3.5 million highly
skilled, technology-based jobs.
Concurrently, nearly 2.5 million
manufacturing workers will retire
by 2025. The trends will combine
to create up to 2 million positions
unfilled in U.S. manufacturing facilities
and a skills shortage. To address these
shortfalls, Rockwell Automation and
ManpowerGroup have teamed up to
offer 12-week Academy of Advanced
Manufacturing (AAM) programs.
The AAM program celebrated
the graduation of its first veteran
graduates in late 2017. The program
combines classroom learning with
hands-on laboratory experience.
Veterans are trained in Rockwell
Automation’s facility in Mayfield
Heights, Ohio.
In January, professionals from
Endress+Hauser were added to the
AAM curriculum as instructors for
technology and instrumentation
for monitoring and managing
temperature, flow and pressure
for machinery and equipment in
industrial process industries.
CE-, ATEX-Certified Pumps
Available to EU Countries
Dean Pump brand air-cooled, high
temperature RA and RWA heavy-
duty, high temperature R4000
series pumps have achieved CE
and ATEX certifications, says Ceco
Environmental. These certifications
make it possible for original
equipment manufacturers and end
‘Headed Home,’ courtesy of U.S. Army, CC BY 2.0
 Inner Workings

users in the European Union to specify
and purchase Dean pumps.
With these certifications, high
temperature Dean pumps now
comply with ATEX Directive 2014/34/
EU. The pumps can be used in places
where explosive atmospheres may
arise through the mixture of air
and flammable materials such as
gases, vapors, mists and dusts. These
conditions most commonly exist in
chemical plants, refineries, liquid-
storage terminals and latex plants.
All certified and compliant pumps
from Dean will include the CE mark,
which makes them compliant with the
European Union’s Machinery Directive
2006/42/EC in addition to ATEX
Directive 2014/34/EU. According to
Ceco Environmental, Dean pumps are
noted for their ability to move high
temperature liquids in mission-critical
applications.
Batch Oven Ages
Aluminum Components
for Aircraft Engines
sufficient capability to heat 7,000 lb
of aluminum and 15,000 lb of steel
load car and fixturing (including
weight of the multiple-level racks to
support the stacked lip skins) from
70 to 375°F (21 to 190°C) within
a two-hour period. The customer
required a guaranteed temperature
Conveyor Ovens that Offer
Premium Quality & Performance
• 3 year warranty on most models
• Heavy duty construction with
quality components
• Temperatures to 1400° F (760° C)
• High efficiency design that reduces
operating costs
• High volume airflow provides
excellent
uniformity and heating rates
• Unlimited custom configurations
• Available in all fuel types and
electric heated
• Fully adjusted and factory tested
PRIOR to shipment to reduce
installation and start-up times
uniformity of ±5°F at setpoints of
200°F, 375°F and 400°F to ensure the
oven would meet AMS 2750E, Class
1 furnaces and Instrumentation Type
A. The recirculation system utilizes
combination airflow to maximize
heating rates and temperature
uniformity of the product.
A Variety of Conveyor Designs
Available
• Mesh & Flat Wire Belts
• Overhead Trolley
• Powered Rollers
• Chain Conveyors
• Spindle (Chain on Edge),
Spiral, Indexing, Vertical,
Rotary and Others

A batch oven will be used for aging

aluminum exterior components for
aircraft engines. Wisconsin Oven, East 2675 Main Street • PO Box 873 • East Troy, WI 53120 USA
Troy, Wis., manufactured the indirect www.wisoven.com • sales@wisoven.com • 262-642-3938
gas-fired aluminum aging oven for
the automotive and aerospace parts Wisconsin Oven is a brand of
manufacturer. Thermal Product Solutions, LLC
When preheated, the unit has

www.process-heating.com MARCH 2018  9

Calendar Events

March 14-15 — Powder Coating 101: Basic Ammonia Program (GCAP),

Essentials Hands-On Workshop,
5-8 — GFSI Global Food Safety J.W. Marriott, Indianapolis. Produced
Conference, Tokyo. by Powder Coating Institute (PCI).
Call +33 (0)1 41 33 63 69/73, Call 859-525-9988 or visit
send an email to tcgffoodsafety@ www.powdercoating.org.
theconsumergoodsforum.com or
visit www.tcgffoodsafety.com. 14-16 —Semicon China, Shanghai
New International Exhibition Center
11-13 — Seafood Expo North (SNIEC), Shanghai, China. Produced
America/Seafood Processing by Semiconductor Equipment And
North America, Boston Convention Materials International (SEMI).
Center, Boston. Call 207-842-5538 Call 408-943-6982 or visit
or visit www.seafoodexpo.com. semiconchina.org.
12-13 — Powder Coating 2018 18-21 — IIAR Ammonia
Technical Conference, J.W. Marriott, Refrigeration Conference &
Indianapolis. Produced by Powder Exhibition, Broadmoor Hotel and
Coating Institute (PCI). Resort, Colorado Springs, Colo.
Call 859-525-9988 or visit Call 703-312-4200 or visit
www.powdercoating.org. www.iiar.org.
Steam Boiler Div.
Call 620-271-0037 or visit
www.boilerlicense.com or
www.ammoniatraining.com.
26-29 —Aquatech Annual
Convention and Exposition,
Colorado Convention Center,
Denver. Produced by Water Quality
Association (WQA).
Call 630-505-0160 or visit
www.wqa.org/convention.
April
3-5 — Power Boiler Burners
Course, Tulsa, Okla. Presented by
John Zink Institute.
Call 918-234-5710 or visit
www.johnzinkinstitute.edu.

12-14 — SNAXPO, Atlanta. 19-22 — Hands-On Boiler Training 8-11 — ASTM Committee C16
Call -703-836-4500, ext. 201, or Course (Level I), Garden City, on Thermal Insulation Spring
visit www.snaxpo.com. Kansas. Presented by Garden City Meeting, Sheraton San Diego Hotel

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10  MARCH 2018 Process Heating

 Calendar Events

& Marina, San Diego. Call 610-832- www.boilerlicense.com or www.seafoodexpo.com.

9678 or visit www.astm.org.
10-12 — Vapor Controls Systems
Course, Tulsa, Okla. Presented by
John Zink Institute.
Call 918-234-5710 or visit
www.johnzinkinstitute.edu.
15-19 — Corrosion Conference
& Expo 2017, Phoenix Convention
Center, Phoenix. Produced by NACE
International. Call 800-797-6223 or
visit www.nacecorrosion.org.
16-18 — Pack Expo East,
Pennsylvania Convention Center,
Philadelphia. Call 571-612-3200 or
visit www.packexpoeast.com.
16-19 — Hands-On Boiler Training
Course (Level I), Garden City, Kansas.
Presented by Garden City Ammonia
Program (GCAP), Steam Boiler Div.
Call 620-271-0037 or visit
www.ammoniatraining.com.
17-19 — Interphex, Javits Center,
New York. Call 888-334-8704 or
visit www.interphex.com.
18-20— National Insulation
Association Convention, Hyatt
Regency Grand Cypress, Orlando.
Produced by NIA. Call 703-464-6422
or visit www.insulation.org.
23-25 — Industrial Heating
Equipment Association Annual
Meeting, Talking Stick Resort,
Scottsdale, Ariz. Co-located with
annual meeting of Metal Treating
Institute (MTI). Call 859-356-1575 or
visit www.ihea.org.
24-26 — Seafood Expo Global/
Seafood Processing Global,
Brussels Expo, Brussels, Belgium.
Call 207-842-5538 or visit
25-27 — Process Flares Course,
Tulsa, Okla. Presented by John Zink
Institute. Call 918-234-5710 or visit
www.johnzinkinstitute.edu.
30-May 1 — Process Burners
Fundamentals Course, Tulsa, Okla.
Presented by John Zink Institute.
Call 918-234-5710 or visit
www.johnzinkinstitute.edu.
30-May 2 — Process Burners
Operators Training Course, Tulsa,
Okla. Presented by John Zink
Institute. Call 918-234-5710 or visit
www.johnzinkinstitute.edu.
May
1-3 — Ceramics Expo, International
Exposition Center (I-X Center),
Cleveland. Call 855-436-8683 or
visit www.ceramicsexpousa.com.

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www.process-heating.com MARCH 2018  11

 Air Heaters
Practical
AIR HEATER
Performance Evaluations
The ability to interpret air preheater performance and analyze results is enhanced
with an understanding of the process variability within both the air and gas systems.
By Lonnie Coffey,
Shawn Goedeke
and Alex Turner,
Corrosion Monitoring Services
H
istorically, air preheater repair
decisions were based on the
boiler approaching operation-
al limitations and inspection
results. When administratively imposed
performance tests were budgeted, these
tests were based on industry practices
recommended by the American Society
of Mechanical Engineers (ASME). The
financial environment for funding these
12  MARCH 2018 Process Heating
tests has changed considerably in the past
10 to 15 years.
This article addresses some of the draw-
backs of applying conventional testing as
well as a common-sense approach that can
be applied. The alternative air preheater
evaluation results can be compared to the
ASME testing for both rotary and tubu-
lar air preheaters. The primary focus of the
article is on tubular-type air preheaters
because they are more common, except for
larger coal-fired units.
The ability to interpret the air preheater
performance and analyze the results is
greatly enhanced by understanding the
process variability within both the air and
As a part of the air preheater
performance analysis, the volume of
additional fuel consumed is calculated,
and specific analysis is performed on
upstream and downstream equipment
and processes.
gas systems. Examples of the complexi-
ties in evaluating boiler and air preheater
performance are provided in the following
sections. These generic problems can be
any combination of air leakage, air bypass,
flow limitations and heat transfer. The key
to the success of implementing the alterna-
tive method is having sufficient time-based
operational process data to perform boiler
and air preheater performance calculations.
The Analysis and
Reporting Process
A performance analysis often can be ac-
complished using customer-provided pro-
cess data directly from the heater’s human
 Air Heaters

O2 Percent When 30 Min Interval Over 165

9.0

8.0

7.0

6.0
A O2%
5.0
B O2
4.0 C O2
3.0 D O2

2.0

1.0

0.0
1
19
37
55
73
91
109
127
145
163
181
199
217
235
253
271
289
307
325
343
361
379
397
415
433
451
FIGURE 1. Values measured by a four-sensor system on a 200 MW boiler are shown. Sensors B and C are indicating
approximately the same average, but the two are not synchronized. Sensor C is indicating a higher value than all the
others. This may be an indication of air in-leakage or an imbalance in firing.

machine interface (HMI) or distributed
control system (DCS) historian. The pro-
cess measurements I/O list is used to select
specific unit process variables for perform-
ing calculations similar to ASME Power
Test Code procedures. Boiler performance
with air heater thermal efficiency and leak-
age are calculated from the process data.
In addition, the emissions reductions
may be estimated using basic stoichiom-
etry as part of the process. Gross and net
power (or process steam values), repre-
sentative fuel analysis data and measured
combustion gas characteristics are applied
with other process measurements. Sup-
porting technical information — heat
balance diagrams and cycle flow for air,
gas and water, if available — is utilized
along with other operating data to estab-
lish the model of the unit configuration.
This process relies on the ability to prop-
erly evaluate the air preheater leakage. In
order to accomplish this, a good under-
standing is required of the O2 readings
around the air preheater.
Boiler O2 Measurements
One would expect the combustion gas
leaving a boiler to be well mixed after
passing from the combustion zone and
through a maze of vertical and horizontal
tube-bundles. The gases change flow-path
directions several times just to enter the
air preheater. The combustion gas includes
moisture from the fuel and excess combus-
tion air (O2). From the combustion chem-
istry, the gas composition is often highly
stratified, with zones of variations in con-
centrations and properties. Boiler sensor
probes vary greatly based on the boiler size
and operation. While these sensors may be
located vertically or horizontally, the num-
ber of sensors varies. In addition, interpre-
tation of the data in the control system is
not consistent from one boiler to the next.
The point of this discussion is that boil-
er O2 measurements do not represent an
isokinetic sample arrangement. The result
is that boiler control elements are not ca-
pable of providing the correct fuel-air ratio
for all zones. Essentially, a few square inch-
es sampled represent thousands of square
feet of area in the gas-flow path. Figure 1
is typical and indicates values measured by
a four-sensor system on a 200 MW boiler.
Sensors B and C are indicating approxi-
mately the same average, but the two are
not synchronized. Sensor C is indicating a
higher value than all the others. This may
be an indication of air in-leakage or an
imbalance in firing. These are dynamic sys-
tems providing constant cycling of compu-
tation product concentrations. The ability

www.process-heating.com MARCH 2018  13

 Air Heaters

Control of Outlet Oxygen at Economizer

8

Test Period
3

2
1
7
13
19
25
31
37
43
49
55
61
67
73
79
85
91
97
103
109
115
121
127
133
139
145
151
157
163
169
175
181
187
193
199
205
211
217
223
229
235
241
247
253
259
265
271
277
283
289
295
301
307
313
319
325
331
337
343
FIGURE 2. The composed O2 value at the economizer outlet is shown. It is one of the control drivers for the unit. The
test period near the center of the chart (points 151 to 231) identifies a test period where the unit was set to base load
for testing purposes.

to determine the absolute excess air enter-
ing the air heater is challenging.
In other cases, data may be represented
as a single trace like the chart in figure 2.
That data was collected at the economizer
from a medium select O2 measurement ar-
rangement over a period of just a few hours
of a typical unit operating under control
near base load. This is a single point driv-
ing multiple processes that are not in tune.
Figure 2 represents the composed O2
value at the economizer outlet and is one
of the control drivers for the unit. The test
period near the center of the chart identi-
fies a test period where the unit was set to
base load for testing purposes. The variabil-
ity within this stable period is presented
as approximately 1 percent; however, it is
composed from several points of different
values and cycling rates that tend to mini-
mize the variability of any single point.
Based on the two examples shown in
the figures, it is easy to see that there is a
potential for confusion when analyzing
plant data. In cases such as in figure 1, the
variation between sensors may be caused
by variations in the combustion process, or
there may be a leak near the sensor. In those
cases, it may be necessary to perform some
type of evaluation with temporary instru-
mentation. Based on what is seen in figure
2, coordinating either a traverse of the duct
or installation of a temporary sensor array
(as required for ASME PTC testing) is
critical to understanding the situation.
Although the unit processes are con-
tinually cycling, there is value added from
progressing through the process of the
slow method traverse testing. Sometimes,
anomalies can be detected that may not
be indicated anywhere else in the process
data. Zones of high CO or abnormal O2
concentrations sometimes can be identi-
fied and evaluated from the traverse data.
The combustion gas stream can be imag-
ined as a river with fruit trees lining both
banks. Flowing within the river are varieties
of fruit that have fallen out of trees. Imagine
the the sampler is a hungry traveler wading
across the river. He catches a few pieces as
they pass him and use those he is able catch
to determine which tree they came from
and which fruit is of high quality.
Some plant operators attempt to utilize
traverse data to locate areas to target for
inspections or repairs. When doing so, they
may make the mistake of assuming that
the leaking area must be located near the
high O2 indications. Many inspections and
repairs have proven that an air preheater
tube can develop a leak and then plug be-
cause the single tube was cooled below the
dewpoint downstream of the leak. When
that occurs, high pressure air sometimes
flows back toward the boiler and follows
the path of least resistance. This creates a
high O2 concentration at the end of that
path not related to the location of the leak.
In this case shown in figure 3, the air
preheater had dewpoint corrosion near the
hot gas inlet. To add to the difficulty of the
analysis, in this design, the cold air is ad-
mitted to the air preheater on the hot gas
side. There is a possibility of high pressure
backflow artificially raising the inlet O2

14  MARCH 2018 Process Heating

 Air Heaters

High Dewpoint Unique Cold Air Inlet to Hot End

Any leakage flows in both directions with a short Dewpoint corrosion reported at the
easy path to the boiler to mix with other tubes top of tube bundle.
toward the outlet.

Possible Areas of Airflow Leakage

Within the Bundle

The shear effect of airflow and gas acts as a restriction,

cutting off flow to outlet. This area previously had turning
vanes but they have been cut out.

FIGURE 3. An air preheater tube can develop a leak and then plug because the single tube was cooled below the
dewpoint downstream of the leak.

level, thus reducing the calculated air pre-
heater leakage. Once again, this is a situa-
tion where understanding the operation of
the unit and air preheater, having access to
inspection reports and having multiple O2
measurement locations helps to better un-
derstand and define the performance.
The two charts in figure 4 indicate the
real drawbacks of attempting to utilize tra-
verse test data alone. By now, it should be
clear that the O2 concentrations are con-
stantly cycling. By the time the equipment
is moved from one point to another and
from one sample port to another, the in-
dicated differences make it impractical to
accurately identify localized defects.
equipment. Simple O2 concentration lev-
els of all the air preheater downstream
equipment may locate other sources of air
in-leakage. While this method shows an
increase in total system leakage, often spot
checks of the O2 levels are required to sep-
arate the effects, and this gets back into the
O2 measurement issues already discussed.
Other parameters such as the air pre-
heater exit gas temperature and power out-
put are used to track overall performance.
Figure 5 shows a typical plot of increasing
O2 difference between the inlet of the air
preheater and the stack.
A Performance
Analysis Method
Once the operational analysis is complete
and a reasonable understanding of the
plant operation is gained from reviewing
the data with plant operators, the deter-
mination of the boiler and air preheater
performance can begin. To accomplish
this, an Excel spreadsheet has been devel-

Operational Analysis
A multiyear dataset often is reviewed and
analyzed in order to determine the opera-
tion and any performance degradation of
the air preheater and other downstream
equipment. If there are measurements at
the stack, it is possible that leakage may A B
be occurring in multiple locations such as
ash collection devices, ductwork and inner-
diameter fan seals. FIGURE 4. The two charts indicate the drawbacks of attempting to utilize
traverse test data alone. The O2 concentrations are constantly cycling. By
This additional leakage often is defined
the time the equipment is moved from one point to another and from one
by evaluating key parameters such as dif- sample port to another, the indicated differences make it impractical to
ferential pressures and temperatures across accurately identify localized defects.
the air preheater and all downstream

www.process-heating.com MARCH 2018  15

 Air Heaters

— PB1 Raw Steam Flow —Diff Wet O2 Inlet & Dry O2 Stack
600 11.0
500 10.0
400 9.0
300 8.0
SH Steam Flow (KPPH)

200 7.0

Difference in O2
100 6.0
0 5.0
-100 4.0
-200 3.0
-300 2.0
-400 1.0
-500 0.0
9/5/2015

10/6/2015

11/6/2015

12/7/2015

1/7/2016

2/7/2016

3/9/2016

4/9/2016

5/10/2016

6/10/2016

7/11/2016

8/11/2016

9/11/2016

10/12/2016

11/12/2016

12/13/2016

1/13/2017

2/13/2017

3/16/2017

4/16/2017

5/17/2017

6/17/2017

7/18/2017

8/18/2017
FIGURE 5. This typical plot shows increasing O2 difference between the inlet of the air preheater and the stack.

Discounted Savings Savings

9,000,000
8,000,000
7,000,000
Cumulative Savings

6,000,000
5,000,000
4,000,000
3,000,000
2,000,000
1,000,000
0
0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5
Year

FIGURE 6. This figure examines the information and shows an amortized costs for repairs.

16  MARCH 2018 Process Heating

 Air Heaters

oped that utilizes a suite of preconfigured
thermal properties. The calculations are
based on the ASME PTC 4.1 and PTC
4.3 methodologies. This calculator is con-
figured to identify and isolate the impact
related exclusively to air heater leakage and
to correlate the direct impact to specific
equipment. For example, the volume of
additional fuel consumed is calculated, and
specific analysis is provided on upstream
and downstream equipment as well as pro-
cesses. This includes the volume of addi-
tional pollution-control additives injected
to compensate for the deterioration of the
air heater. If sufficient process measure-
ments are not available within the histo-
rian, site measurements will be required. In
most cases, the missing data will be related
to air heater outlet O2 concentrations.
The information for this type of analy-
sis often comes from the data collected for
the operational analysis. Ideally, data from
when the air preheater was not leaking is
available and can be used as a reference
case. If not, estimations of the performance
gains are made based on operational experi-
ence and documented assumptions. Using
the difference between the operational case
and the reference case, a determination of
the change in operational costs then can be
calculated. These costs are amortized over
a set time period — say, five, seven or 10
years for the payback. Ultimately, the level
of savings must be greater than the repair
cost to entice management to authorize
the air preheater repairs.
At best, these measurements and meth-
ods may not provide the most precise tests
for the air heater; however, they are ex-
tremely valuable and can be used to assess
additional leakage points between the boil-
er outlet, including the air heater, to other
measurement locations. In order to under-
stand the actual process, it is desirable to
accomplish the near impossible with the
current environment, which is to be able
to view all of these variables in a single
snapshot quickly. While not optimum,
there is substantial value in collecting the
historical data from the plant historian and
continuous emissions monitoring systems
(CEMS) data to support the performance
evaluation and financial impact. These
alternative methods are economical and
powerful enough to be used for pre-/post-
repair studies and performance monitoring
to determine the optimum time to initiate
a major repair. With this information and
discussions with plant operators, experts
can assist processors by understanding the
unit constraints and applying these to the
financial impact determination. With this
information as well as physical inspection
of the air preheater, and expert can propose
a viable solution.
Alex Turner is president of Corrosion
Monitoring Services, and Dr. Shawn M.
Goedeke and Lonnie Coffey are also with
Corrosion Monitoring Services. The St.
Charles, Ill.-based company can be reached at
630-762- 9300 or visit www.cmsinc.us.

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www.process-heating.com MARCH 2018  17

 Industrial Automation
for Process Heating Applications
It is time to move beyond the language and promises of IIoT to solutions that
improve asset availability and production outcomes.
By Michael Risse,
Seeq Corp.
T
erms such as the Internet of
Things (IoT), the Industrial
Internet of Things (IIoT), Big
Data and Industry 4.0 are ban-
died about in industrial contexts. Imple-
menting these initiatives promises benefits
that improve business outcomes through
new insights on production results.
Opportunities for an integrated plant
are driven by a new generation of wired
and wireless sensors. Such sensors enable
generating, gathering and storing data
economically, and in quantities never
previously available. The data then can
be sent to process control and monitor-
ing systems via plant networks or through
the internet.
18  MARCH 2018 Process Heating
Applying
IIOT
Organizations implementing IIoT so-
lutions will improve real-time control and
help plant engineers and operators make
better decisions regarding operations and
maintenance. Data gathered also can be
directed to data-analytics software, which
plant personnel can exploit to find addi-
tional information to increase efficiency,
diagnose equipment problems and im-
prove safety (figure 1).
The three most common ways to de-
ploy such a system in an industrial plant
or facility are brownfield, greenfield
and “servicization.” All three scenarios
can be implemented independently, or
they can coexist within the same plant
or facility.
• Brownfield is when new sensors are
added to existing control or plant net-
works. Common brownfield scenarios
include adding a wireless network and
sensors to expand operator visibility and
asset-monitoring capabilities.
• Greenfield scenarios are deployments
in plants or facilities just coming online
with IIoT projects. Typically, they are
associated with cloud-based monitor-
ing systems because the project is not
designed around an on-premises con-
trol and monitoring system.
• Servicization involves a supplied asset
and remote monitoring and services
provided by a vendor. Vendors of heat
exchangers, compressors, pumps, valves
and other asset types are introducing
subscription services whereby their
equipment is installed on customer
premises and the supplier provides on-
going monitoring of the equipment.
 Industrial Automation

Identify initial patterns (using moving Identify core determinants of process

averages, distribution histograms, standard performance and form an initial hypothesis
deviations and clustering) to prioritize data about root causes of yield drop and variability
collection and analysis

Using data visualizations Using correlation analyses

y y y

x x x
Zero Correlation High Correlation

rlinkage
Inte s

Advanced
analytics helps
decode complex
Depe

manufacturing xity
processes
ple
nd
en

cy
m

Co

0.4

0.3
Input Predicted
0.2
Variables Output
0.1 Variables
0
-30 -20 -10 0 10 20 30

Using significance testing Using artificial neural networks

Test initial hypothesis of root causes of Model complex processes to quantify
yield drop and variability and focus on the the impact of and optimal ranges for the
most statistically significant factors for further identified parameters
investigation

FIGURE 1. Data-analytics software can be used to improve production outcomes in process heating applications
across a variety of process industries.

www.process-heating.com MARCH 2018  19

 Industrial Automation

lels with your company’s plants and facili-

ties. Much of the language about deploy-
Organizations implementing IIoT solutions will ment from software vendors is vague and
improve real-time control and help plant engineers relates to ambiguous platforms and analyt-
ics without specific context about either.
and operators make better decisions regarding This is sometimes promulgated in an effort
operations and maintenance. to present a product as having a solution to
any type of data-analysis problem.
The unspecific language also can sug-
gest multiple IIoT implementations. The
Regardless of the deployment method, bandied about, including those used earlier use of “platforms,” for example, can imply
these IIoT solutions collect, integrate and in this article as well as others like digital the development of custom code and con-
organize data for engineers and scientists transformation, smart manufacturing and sultants versus an off-the-shelf solution.
to analyze and improve production output. the Fourth Industrial Revolution. Yet, re- Likewise, the term “analytics” has taken on
Possible outcomes include improved main- gardless of what a connected and sensor- a thoroughly ambiguous meaning: Many
tenance programs for higher reliability at equipped, integrated factory is called, the products and offerings claim to enable
lower cost, optimized resource usage and competitive advantages enabled by having or provide analytics, but there is no spe-
predictive analytics on future outcomes in access to accurate data-driven insights on cific definition or consensus of what those
time to address issues. production are too important for many terms mean for specific applications.
These and other benefits are why the firms to ignore. Instead of relying on vague terminology,
enthusiasm and growth in IIoT has been With an understanding of the imple- users should ask to see concrete examples
so strong over the past few years. Unfor- mentation methods and the theoretical where a supplier’s solutions have been ap-
tunately, the rapid growth does not mean benefits of an IIoT strategy, the final step plied to solve real-world problems. Practi-
the industry has agreed on its naming before deployment is reviewing use cases cal examples demonstrate IIoT technolo-
conventions. Instead, various terms are to ascertain actual benefits and draw paral- gies in action.

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20  MARCH 2018 Process Heating


Four use cases show how off-the-shelf
solutions can be used to rapidly achieve in-
sights in production environments. These
use cases focus on demonstrating positive
impacts to the bottom line via the applica-
tion of data analytics.
Large Molecule Pharma
Laboratories Analysis
Merrimack Pharmaceuticals was experienc-
ing scale-up issues with a new upstream
bioreactor process. Like many bioreactors —
and reactors used in chemical, refining and
other industrial applications — measure-
ment and control of temperature, and con-
trol of heat sources are critical to operation.
Protein degradation due to a low mo-
lecular weight species was appearing over
time in the production bioreactor. This re-
sulted in a low concentration of the desired
protein. The viable cell density and the titer
data suggested the culture was successful
at the 1000-liter (~264 gal) scale. In real-
ity, the process needed modifications to
achieve the desired final product concen-
tration before scale-up could continue.
In response to the issue, significant re-
sources were quickly deployed to develop
and test science-based hypotheses using
the workhorses of the laboratory. (The fa-
cility included multiple master cell bank
vials and 3-liter and 100-liter bioreactors).
The sum of the additional upstream data,
downstream data and corresponding
offline analytics data resulted in a typical
challenge often found in scale-ups: the
manual and laborious spreadsheet-based
approach confounded the efforts of scien-
tists and engineers to derive insight from
their data.
To address these issues, the IIoT tech-
nology provided the following approach:
• Define the physical situation to deter-
mine the key physics involved.
• Identify the key variables and determine
all the data streams — both online time-
series data like O2 flow rates, glucose ad-
dition rates, acid or base addition rates,
temperatures and pH — and offline
contextual data like integrated viable
cell density, titer and media component
concentrations.
• Recognize how and where this key data
Industrial Automation
Sensors:
Pumps delivering T, pH, O2, CO2
glucose, nutrients, O2
SAMPLE
PORT
Sample
Bioreactor Delivery
System
Operation
Multiple Analytical Data
Devices
Data Historian
Pump Operation Data
Analytical Data Outputs
[Protein], [Cell], [Nutrient],...
FIGURE 2. A historian (bottom right) is often used to store collected data,
with data-analytics software (not shown) interfacing to the historian to
provide insight.
is collected and stored. cals was able to avoid the manual, time-
• Leverage an effective data analysis, consuming data investigation and analysis
visualization and reporting applica- typically required. Merrimack’s scientists
tion alongside laboratory-scale and and engineers were able to quickly assess
pilot-scale experimentation using what was happening at the cell level and
data-analytics software. the process level for multiple scales and
operating conditions.
The data-analytics software provided The data-analytics software yielded in-
plant personnel with quick access to time- sights into these relationships by providing
series features and contextual data by au- visualization of individual process vari-
tomatically connecting to historians and ables. It also provided insights by utilizing
manufacturing systems. This made aggre- an internal calculation engine to determine
gation, management and modeling of the relationships such as cell-specific oxygen
required data from disparate data sources uptake rates — an important metric when
and types a simple and expeditious process. comparing the micro-environment across
The data-analytics software also sup- equipment scales.
ported the required standard internal work- In the example outputs (figure 3), each
flows for both analysis and communication of the required variables was visualized, and
of results. It included the tools for sharing the resulting calculations were developed.
insights among colleagues and for export to All were performed within a single process-
other applications for reporting and dash- ing environment while leaving the original
board creation. The time-series data from data untouched in its original location.
the Emerson DeltaV historian was ac- Using this newly implemented data strat-
cessed by the data-analytics software along egy, additional work was done within the
with multiple analytical devices (figure 2). data-analytics software to review biological
Through implementation of the data- growth and productivity data while testing
analytics software, alongside appropriate the remaining science-based hypotheses.
investments in the appropriate historians Additional process parameters were investi-
and databases, Merrimack Pharmaceuti- gated along with additional offline analytics
www.process-heating.com MARCH 2018  21
 Industrial Automation
FIGURE 3. In this example, the results from using software to perform the rapid data analysis and investigation are
shown. The software outlines the course of action for a particular bioreactor process.
data, giving plant personnel the power to
assess the impact of several important pa-
rameters on the bioreactor process.
For Merrimack Pharmaceuticals, this
approach to data management, analysis,
visualization and reporting resulted in the
following specific improvements:
• It uncovered important issues related
to bioreactor scale-up, including quick
comparisons of key process steps across
multiple batches.
• It quickly calculated and compared du-
rations of sensitive growth periods dur-
ing an intensive cell-growth phase.
• It enabled analysis of related down-
stream process operations. For example,
rapid evaluation of chromatography
curves using pattern-recognition fea-
tures allowed downstream processing
data to be visualized easily alongside
other process data.
• It provided an environment aligned with
the need to evaluate multiple unit op-
erations together in a single place such
as bioreactors with downstream chro-
matography.
22  MARCH 2018 Process Heating
Power Plant Asset Optimization
For one power plant, the plant operators
knew the feedwater heaters tended to foul
and lose efficiency in a predictable manner.
Despite that, the operators were never suc-
cessful in efforts to quantify the process so
maintenance could be optimized.
An analysis of the boiler’s heat rate pro-
vided the information necessary to deter-
mine the effect a cleaning effort has on
efficiency, yielding a specific value. Opera-
tors can now optimize cleaning frequency
based on the cost/benefit relationship.
Cement Production
Energy Efficiency
Given the high energy intensity of cement
manufacturing, the company struggled to
optimize all the variables related to feed rates,
fuel consumption, heat recovery and environ-
mental regulations using conventional tools.
The ability to handle data from numerous
sources and make it comparable and predic-
tive helped resolve tradeoffs when working
with alternative fuels and feedstocks while
still maintaining product quality and effi-
ciency across varying production levels.
Ore-Smelting Operations
Heavily regulated and energy-intensive
production steps such as smelting were
difficult to characterize using conven-
tional spreadsheets. Consequently, bal-
ancing multiple factors and making opti-
mal tradeoffs among costs, environmental
factors and energy efficiency was almost
impossible.
The ability to analyze tradeoffs among
multiple variables made it much easier to
control the process based on which vari-
able was the most critical at any given
time. Adjusting the mix for evolving costs
or new regulations was simplified by trying
out various what-if scenarios.
These use cases show how data analytics
is no longer just another overused buzz-
word. Instead, it is being applied by process
industries worldwide to improve produc-
tion outcomes.
Michael Risse is a vice president at Seeq
Corp., Seattle. For more information about
data-analysis software from Seeq, call
206-801-9339 or visit www.seeq.com.
PROCESS HEATING

DIRECTORIES
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Equipment Guide
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MANUFACTURERS YOU NEED,
ALL IN ONE PLACE!

process-heating.com/directories
 Temperature Sensing

Selecting
PROCESS
TEMPERATURE
SENSORS
Would you like to improve industrial temperature measurement performance?
Gain and apply a theoretical understanding of temperature sensor characteristics
to make the best choice for your heat processing applications.

By Neil Larson tions: thermocouples (TCs) and resistance
temperature detectors (RTDs).
and Todd Olin,
It is not difficult to find resources dis-
Emerson Automation Solutions
cussing the differences between the two
technologies. But, for purposes of this ar-
differences between the two sensor tech-
nologies. Figure 1 shows the applicable
temperature ranges for several types of
thermocouples and a typical RTD.
A thermocouple is a closed thermoelec-

A
pplications involving heating
invariably require temperature
measurement instrumenta-
tion. Temperature instruments
typically consist of a thermowell, a sensor
and a transmitter to convert the sensor
data to an industry-standard signal such as
4 to 20 mA or fieldbus digital communica-
tions. Temperature sensors come in many
shapes and sizes, but for industrial use, two
technologies cover the majority of applica-
ticle, which is part one of a two-part series,
we will focus on some of the more nuts-
and-bolts aspects of the selection process.
In addition, this article will describe ways
to improve temperature-measurement
performance regardless of the selected sen-
sor technology.
Thermocouples vs. RTD:
Basic Considerations
To begin, let’s briefly review the basic
tric circuit consisting of two wires of dis-
similar metals joined at both ends. A volt-
age is created when the temperature at one
end or junction differs from the tempera-
ture at the other end. This phenomenon is
known as the Seebeck effect, and it is the
basis for thermocouple temperature mea-
surements. The voltage created is propor-
tional to the temperature difference at the
two junctions. This means a thermocouple
cannot provide a temperature reading

24  MARCH 2018 Process Heating


without an external temperature reference.
An RTD uses a characteristic found in
many metals whereby the electrical resis-
tance increases as temperature increases.
This is a phenomenon known as thermal
resistivity. A given metal will have a given
resistance at a given temperature. If this is
properly quantified, an RTD can provide
an accurate temperature reading.
Thermocouples
Remain Popular
Thermocouple technology is the oldest
electronic temperature-measuring method,
with the Seebeck effect recognized for al-
most 200 years. It remains the most com-
mon technology, but it is losing market
share to RTDs. A thermocouple is much
like a differential pressure reading: it can
tell you the difference between two points
but not the absolute value of either. One of
the temperatures must be known to calcu-
late the other, which is why the two junc-
tions are called sensing and reference.
In a high-school physics class, the ref-
erence junction is usually ice water, which
provides a specific temperature reference.
In industrial applications, the transmitter
will have its own temperature sensor, typi-
cally a thermistor, to provide a reference
reading. The reference-junction sensor can
be anywhere and at any temperature as
long as it is measured accurately. Conse-
quently, the reading accuracy from a ther-
mocouple is no better than the reference-
junction accuracy.
Thermocouples are made in types des-
ignated by a letter indicating the combi-
nation of wires. For example, a Type K
thermocouple uses one wire made from
chromel and the other from alumel, with
each metal having different thermoelectric
characteristics. Each thermocouple type
has its own temperature range limitation
(figure 1).
One of the biggest advantages of a ther-
mocouple over an RTD is its ruggedness.
Because the sensor consists of two wires,
typically welded together, it is not delicate.
So long as the junction is sound, the in-
sulation is intact and the wire itself is not
corroded, a thermocouple will work. The
wire used is usually of a relatively heavy
gauge, so a thermocouple can withstand a
Temperature Sensing
lot of punishment and vibration. Even so, In either case, both are normally encased
naked-wire thermocouples are relatively in insulation and inserted in a stainless
rare. The sensing junction is normally in- steel sheath.
serted into a stainless steel sheath. This
produces a variety of effects. Accuracy, Response Time and
Durability
RTDs for Greater Accuracy The conventional wisdom says that for ap-
RTDs have a resistive element with leads plications where a high degree of accuracy
attached. The elements and leads are is needed, an RTD is the better choice for
packed in insulation and inserted into a several reasons:
protective sheath. The resistive material is
usually platinum because of its high accu- • If the thermocouple reference-junction
racy, excellent repeatability and exceptional sensor changes, it will cause the reading
linearity over a wide range. Platinum ex- to change.
hibits a large resistance change per degree • Corrosion of the thermocouple wires
of temperature change, making it a good can cause reading drift.
choice for RTDs. • RTDs generally have a higher degree of
Whereas the signal from a thermocou- reading stability.
ple is a voltage, the signal from an RTD • RTDs have accuracy classes that include
is resistance, measured in ohms. To over- very specific tolerances.
come the effect of the lead-wire resistance • Accuracy for a thermocouple depends
unduly influencing the temperature read- upon the metallurgy of the wires. If the
ing, RTDs use wiring methods designed alloy is at one extreme of the specifica-
to compensate for the resistance of the tion, or if it changes due to prolonged
lead wire. exposure to heat, it can allow readings to
Given the cost of platinum, RTDs are drift. Over time, some degree of drift is
designed to use as little of it as possible. inevitable.
The actual sensor element typically is fine • RTDs can be matched to a specific
wire wrapped around a ceramic mandrel transmitter. This allows for an excep-
or a thin-film deposition on a substrate. tionally high degree of accuracy.
3632ºF
(2000ºC)
2732ºF
(1500ºC)
1832ºF
(1000ºC)
932ºF
(500ºC)
32ºF
(0ºC)
-868ºF
(-500ºC)
E J K T N R/S RTD
Sensor Type
FIGURE 1. Different thermocouple types have different and wide effective
measurement ranges. RTDs (far right) have a much narrower range. Types
R and S thermocouples are shown as a single column because they
effectively cover the same range.
www.process-heating.com MARCH 2018  25
 Temperature Sensing

By contrast, thermocouples tend to win
when response time and durability are par-
amount. Thermocouples also are better for
high process temperatures. Other thermo-
couple advantages include:
• Thermocouples do not need as much
insulation within the sheath, so there is
less material to slow heat flow.
• Thermocouples can be welded directly
to the inside of the sheath (provided the
application allows for a grounded sen-
sor), speeding up heat transfer.
• For extreme applications, the thermo-
couple junction can be welded directly
to the surface to be measured to provide
the ultimate in fast heat transfer and re-
sponse.
• Thermocouples are more robust. RTDs are
more delicate physically, so they can break
more easily due to shock or vibration.
• Specific thermocouple types can be used
in applications from -328 to 2640°F
(-200 to 1450°C).
Manufacturing
Technologies Evolve
Given the simplicity of thermocouples,
their construction and manufacturing
techniques are mature, and there is not
much in the way of new developments.
RTDs, by contrast, are moving through
a transition.
As mentioned previously, the traditional
construction of RTDs has been the wire-
wound version where very fine platinum
wire is wound into a helix or around a ce-
ramic form. These are built by hand, and
their quality depends upon the skill of the
assembler to be extremely precise with re-
spect to assembly and lead mounting.
Also as mentioned earlier, there are
thin-film RTDs where the platinum sen-
sor element is deposited on a substrate like
a tiny printed-circuit board. This process
is automated using the same techniques
as computer chips and integrated devices.
While the quality of a hand-made RTD
depends on the skill of the assembly per-
son, thin-film sensors made by an auto-
mated process can be extremely precise
and consistent. These types of RTDs also
tend to be more shock and vibration resis-
tant due to their smaller mass and support
of the platinum element by the substrate.
Many users still regard wire-wound sen-
sors as the gold standard and specify them.
Given the advances in thin-film produc-
tion technology, however, the only legiti-
mate technical reason to call for a wire-
wound sensor is for cryogenic applications.
Highest Accuracy from an RTD
RTDs offer two methods for approaching
applications where the highest accuracy is
necessary. First, there are accuracy classes
A and B (figure 2), which are verified using
techniques outlined in IEC 60751. Natu-
rally, these command premium prices justi-
fied by the tight manufacturing tolerances
and precise calibration required.
Another approach is to fine-tune an
RTD sensor to a specific transmitter (fig-

Attribute RTD Thermocouple

Accuracy Class A: ± [0.15 + 0.002 (t)] Typical is ±1.98°F (±1.1°C), or ±0.4 percent of measured
Class B: ± [0.30 + 0.005 (t)] temperature (whichever is greater). Depends on type
Interchangeability Per IEC 60751 and range. Degraded by extension wire.

±0.09°F (±0.05°C) per 1000 hr at ≤572°F (≤300°C). Highly dependent on thermocouple type, quality of the
Stability Greater at higher temperatures. wire and operating temperature.
Wire wound better than thin film. Typical is ±3.6 to 18°F (±2 to 10°C) per 1000 hr.

Speed of Response in For 6 mm sensor, about the same as For 6 mm sensor, about the same as RTD.
Thermowell Installation in Liquid thermocouple. Slightly faster for 3 mm sensor.

Easily recalibrated for long service life. Limited to in situ comparison to standard
Calibration Best accuracy with sensor-transmitter matching. thermocouple.

Potential Temperature Range -328 to 1562°F (-200 to 850°C) -454 to 4172°F (-270 to 2300°C)

Degradation indicates frequent replacement.

Many years.
Life Span Shorter at higher temperatures.
Much shorter at high temperatures.
Higher lifecycle costs.

Use standard coper wire. Requires expensive matching extension wire.

Installation Considerations Good EMI and RFI immunity. Low level signal is susceptible to EMI and RFI.

Vibration Tolerance Thin film design is very good. Larger wire diameters are very good.

Lifecycle Cost Lower. Higher.

Thin film design about the same.

Purchase Cost Wire wound higher.
Types R and S most expensive.

System Performance with

Always better below 1202°F (650°C). Order of magnitude lower.
Transmitter

FIGURE 2. Thermocouple and RTD technologies are different in concept, so they bring different considerations when
analyzing performance tradeoffs.

26  MARCH 2018 Process Heating


FIGURE 3. By using a dry-block calibrator and Hart communicator, a transmitter and RTD sensor can be individually
matched to create a highly precise measurement setup.
ure 3). In a laboratory environment, it is
possible to put the sensor into a dry-block
calibrator set at temperatures close to the
expected operating range of the final in-
stallation. The transmitter can be adjusted
to match the exact output of the sensor.
So, if a reading at 329°F (165°C) is 33.79
Ω, the transmitter can be set manually to
match those two values.
Obviously, this takes some time. It is
normally necessary to set a series of tem-
perature values above and below the most
critical value. The result is a specific tem-
perature curve for that sensor/transmitter
combination, making it possible to provide
the highest degree of accuracy within the
critical operating range.
Some users wanting to make this type
of adjustment make the process more ex-
pensive than necessary by combining this
technique with a Class A sensor. If this
hand-calibration process is being done, it
can be applied to a conventional sensor be-
cause RTDs are generally stable. Once the
curve is corrected, it will stay that way, so it
is not necessary to purchase a high accura-
cy sensor if hand calibration and matching
to a specific transmitter is planned.
Improving Accuracy Overall
Accuracy of a given application depends on
more than just the sensor. There is a chain
of components between the sensor and the
final input point, which can be on anything
from a local transmitter display to a plant-
wide control or monitoring system. Every
termination, and even the cable itself, can
cause reading drift by interfering with the
voltage or resistance measurement. The
transmitter or input card also will have its
own error factor, so it is important to un-
derstand how these all add up. Suffice it to
say, an expensive Class A RTD supported
by lower-grade components will be no bet-
ter than the worst link in the chain.
In the real world, applications requiring
the highest degree of accuracy are relative-
ly rare. More often than not, repeatability
is as important — if not more so. For many
processes, maintaining the same tempera-
www.process-heating.com MARCH 2018
Temperature Sensing
ture value is more critical than knowing
exactly what it is. In other words, stability
may trump accuracy. So long as operators
see the reading at the outlet of a reactor
remaining stable, the process can operate
safely even if the reading is consistently
some number of degrees off. If other criti-
cal variables are what they should be, there
is probably nothing to worry about.
Neil Larson is a design engineer for
temperature product development, and
Todd Olin is the Rosemount product manager
with Emerson Automation Solutions.
The Shakopee, Minn.-based company can
be reached at 800-999-9307 or
www.emerson.com.
Part 2 of this article will appear
in the April 2018 issue of
Process Heating. It will cover
options for sensor mounting
along with more detailed
information about transmitters
and device diagnostics.
 27
 Heat Recovery
A heat recovery system on a
regenerative thermal oxidizer is
used in animal feed production.
Optimizing Your
THERMAL OXIDIZER
Optimization saves energy and operating costs through heat recovery.
By Jim Griffin,
Durr Systems Inc.
C
ompanies in all industries are
constantly seeking ways to re-
duce a plant’s operating costs
and carbon footprint. At the
same time, they are looking to avoid costly
utility-distribution improvements by opti-
mizing the facility’s energy consumption.
Thermal oxidizers require significant
amounts of energy to achieve their intend-
ed benefit. One of the reasons for this is
that treatment of the process exhaust air re-
quires heating it to the highest autoignition
temperature of compounds to be oxidized.
The combustion chamber temperature can
28  MARCH 2018 Process Heating
range from 1400 to 1700°F (760 to 927°C)
— or higher as needed. Though various
configurations exist to improve on energy
efficiencies, thermal oxidizers remain a sub-
stantial user of natural gas and electricity.
One way to mitigate an oxidizer’s oper-
ating costs and carbon footprint is to con-
sider adding a secondary heat exchanger as
a means to recoup heat from the oxidizer’s
exhaust. Energy recovered can be used to
heat fresh air, recirculated air, water, ther-
mal oil or steam. The amount of heat re-
couped varies with the types of thermal
oxidizer. Obviously, the more thermally
efficient the oxidizer, the less available heat
there is to recover from its exhaust, though
there are some important exceptions.
Types of Thermal Oxidizers
and Heat Recovery
Non-recuperative direct-fired thermal
oxidizers typically are used in situations
with high concentrations of volatile or-
ganic compounds (VOCs) or where mini-
mal initial capital investment is required.
Though this type of thermal oxidizer is low
in upfront capital cost, the operating costs
can be high. This is especially true in appli-
cations where the amount or composition
of VOCs provides little supplemental heat
to the combustion chamber (low heat of
combustion energy relative to the mass of
exhaust). Because heat recovery is not in-
cluded with this type of oxidizer, the high
outlet temperature of non-recuperative

oxidizers makes them good candidates for
secondary energy recovery.
Recuperative thermal oxidizers differ
from non-recuperative systems by incorpo-
rating a heat exchanger to preheat the pro-
cess exhaust air prior to entering the com-
bustion chamber. Mass-corrected thermal
efficiencies (MCTE) typically range from
60 to 65 percent, and some recuperative
thermal oxidizers can provide as high as
70 percent MCTE. While this may seem
high, it is short of what can be achieved by
regenerative thermal oxidizers. Therefore,
recuperative thermal oxidizers may offer
good energy recovery opportunities.
Regenerative thermal oxidizers (RTOs)
were developed to optimize energy us-
age. By alternating the process flow past
heat-capturing ceramic media, heat is
transferred from the regenerative thermal
oxidizer’s exhaust air back to the incoming
process exhaust air. RTOs readily achieve
greater than 95 percent MCTE. At first
glance, this might seem to provide only
longer-term heat recovery returns on in-
vestment. Certain conditions, however,
significantly decrease the time needed to
justify the cost of heat recovery equipment.
If the VOC concentration entering the
combustion chamber is high enough, the
operation becomes auto-thermal; that is to
say, the combustion of VOCs is self-sus-
taining. No additional heat is needed from
the burner. VOC concentrations above
auto-thermal result in excess heat not re-
quired to maintain the oxidation process.
In auto-thermal cases, once the chamber
temperature increases above the combustion
chamber setpoint, a hot-gas-bypass system
is activated. Temperature in the chamber
is controlled by a variable energy recovery
(VER) system, which opens a bypass damper
to allow a certain portion of the hot gas from
the burner chamber to bypass the ceramic
heat-exchange media. This hot gas stream
provides a good source of recoverable heat.
Frequently, secondary heat recovery is
achieved using either air-to-air (200°F
[93°C] and higher exhaust gas tempera-
ture) or air-to-liquid (300°F [149°C] and
higher exhaust gas temperature) heat-ex-
change methods.
There are different opportunities to re-
cover heat from hot exhaust air:
This large-scale heat recovery system captures heat from 12 regenerative thermal
oxidizers at a mine in China.
• Air can be extracted directly from the
stack at high volumes. This method
would be used in the absence of a regen-
erative thermal oxidizer hot-gas-bypass
system.
• Exhaust air can be blended with hot by-
pass air from the VER system.
• Hot bypass air from the VER system
can be used on its own.
Air-to-air systems recover heat either
directly through recirculation or indirectly
using heat exchangers. These systems are
a good fit when the distance from the
thermal oxidizer to the intended source
for the heat is relatively short. Air-to-air
heat recovery may be used effectively to
preheat combustion air for the oxidizer or
the building HVAC, or to heat an oven in
other applications.
Liquid heat recovery systems transfer
the excess energy from air to fluid and then
to the heat-exchange device for hot water
or oil. When the temperatures needed are
below 300°F, high temperature, high pres-
sure (HTHP) hot water is ideal. At these
temperatures, it is easy to make 300°F hot
water and economically pump it a long
distance through small diameter insulated
pipes. When the need is for multiple zones,
the main heater can be tapped at several
www.process-heating.com MARCH 2018
Heat Recovery
places. Each zone can be independently
and precisely controlled by a throttling
valve with a separate temperature control
loop. These systems generally are limited to
producing 330°F (166°C) hot water at 100
psig. Typical systems can be constructed
using schedule 40 ASTM A106, A53 pipe,
150 lb flanges, valves and fittings. Local
codes and plant requirements may change
this, so they must be consulted. A signifi-
cant advantage of HTHP water is that
these systems can be FDA compliant.
When the temperatures are higher than
300°F, liquid heat recovery systems use
synthetic oils instead of water as the heat
transfer medium. System complexity in-
creases, along with construction and mate-
rial costs. Most systems use 600 lb flanges
and components. Despite their complexity,
these systems share the same flexibilities
as the HTHP water systems. Recovered
heat at high temperature also can be used
to generate steam via a waste-heat boiler.
These systems are quite popular in chemi-
cal and petrochemical plants.
Installation Considerations
for Heat Recovery Systems
Whatever heat recovery method you con-
sider, there is the possibility an air-to-air
or air-to-liquid heat recovery system can
 29
 Heat Recovery
be used with success. When designing and
implementing a proper heat recovery sys-
tem, it is important to consider:
• Location.
• The differential pressure across the sys-
tem (for regenerative thermal oxidizers).
• Materials of construction.
• Bypass capability and maintenance access.
Location. The distance between the ther-
mal oxidizer and where the recovered heat
will go is critical. Transferring heat a large
distance via insulated duct may be costly.
Differential Pressure across the System.
The addition of heat recovery can increase
pressure requirements for the system’s fan. It
should be evaluated to determine if the exist-
ing fan is suitable or if a new one is needed.
Materials of Construction. Depending
on the process stream, chemical changes to
abated exhaust air may be destructive to
milder steels. Heat recovery components
should be evaluated and selected to avoid
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30  MARCH 2018 Process Heating
Obviously, the more
thermally efficient the
oxidizer, the less
available heat there
is to recover from
its exhaust.
corrosion or a chemical attack.
Bypass Capability and Maintenance
Access. Access to the heat recovery system
should be taken into consideration when
choosing a system and its location at the
facility. Maintenance access to the heat re-
covery system should be available without
shutting down the thermal oxidizer.
Heat Recovery Alternatives
A slowly emerging technology that can
be used for secondary heat recovery is the
organic-rankine cycle (ORC) process. The
ORC process — known and applied for a
long time in geothermal applications — is
gaining more importance in the industrial
sector as a waste-heat-to-power-conver-
sion process.
The ORC process is a steam cycle that
uses heat from the exhaust gas of the
oxidizer or other heat sources to gener-
ate electricity. It can recover heat from
exhaust gases at the stack or from a VER
hot bypass system. During the ORC pro-
cess, hot exhaust gas flows from the heat
source into the ORC module. There, the
working medium is evaporated through
the thermal energy. The pressurized steam
is led into a turbo-generator, where part
of its thermal energy — 11 to 20 percent
— is converted into electricity. After that,
the vapor is condensed through cooling. A
pump injects the liquid working-medium
back into the evaporator.
The recent development of smaller ORC
compact units makes the technology suit-
able for applications with smaller waste-
heat sources (less than 200 kWth). In in
installations employing combined heat
and power (CHP) technologies as well,
the ORC technology can transform waste
heat into valuable energy with an overall
efficiency of greater than 95 percent. Be-
cause the ORC technology is still capital
intensive, the number of applications in
combination with thermal oxidizers is low.
Nonetheless, it presents an interesting fu-
ture alternative.
In conclusion, companies with thermal
oxidizers may be able to optimize the fa-
cility’s energy cost by recovering heat from
the existing process. The recovery of waste
heat from an oxidizer may reduce a plant’s
carbon footprint and improve the bottom
line. A properly selected and designed heat
recovery system will help any processor
optimize energy and utility consumption.
Consult with an oxidizer supplier to see
how much can be saved through secondary
heat recovery.
Jim Griffin is a key account manager with
Durr Systems Inc. The Southfield, Mich.-based
company can be reached at 248-450-2000 or
visit www.durr-cleantechnology.com.
Always There
When You Want It!
process-heating.com/digitaleditions
Digital Edition
Equipment Overview Ovens

I ndustrial ovens cover the gamut of configurations, heating

methods and manufacturing processes. With so many suppli-
ers offering a range of designs, how do you know where to start?
Whether you want a booster oven or a completely new ther-
mal processing system, use Process Heating’s annual Equipment
Overview on Ovens to find suppliers and save time specifying
your oven.
Complete listings are shown below. To view the matrix of
industrial oven manufacturers online and automatically widen or
narrow your search results based on the criteria you select, visit
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Photo courtesy of Grieve

Oven Configuration

Continuous, Cross-Bar Conveyor

Continuous, Fixture Conveyor

Continuous, Pusher Conveyor

Continuous, Screw Conveyor

Continuous, Walking Beam

Continuous, Belt Conveyor
Continuous, Conveyorless

Continuous, Power Roller

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Batch, Truck/Walk-In

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Idler Rolls

Top Load
Other
Companies
Ajax Tocco Magnethermic Corp.
330-372-8511, www.ajaxtocco.com • • • • • • • • • • • •
Blasdel Enterprises Inc.
812-663-3213, www.blasdel.net •• • • • • • • • • • • • • • • • • ••
Fostoria Process Equipment, Div. of TPI Corp.
423-477-4131, www.fostoriaprocessequipment.comH • • • • • • • • • • • • • • • • • ••
Grieve Corp.
847-546-8225, www.grievecorp.com • • • • •
JPW Industrial Ovens & Furnaces Inc.
570-995-5025, www.jpwdesign.com • • • • • • • • • • • ••
Steelman Industries Inc.
903-984-3061, www.steelman.com • • • • • • •
Thermcraft Inc.
336-784-4800, www.thermcraftinc.com •• • • • • • • •
Wisconsin Oven Corp.
262-642-3938, www.wisoven.com • • • • • • • • • • • • • • •
Advance Systems Inc. • 920-468-5477, www.advancesystems.com • • • • • • •
Affiliated Steam Equipment Co. • 800-424-5392, www.affiliatedsteam.com
Ambrell Induction Heating Solutions • 585-889-9000, www.ambrell.com
Amiberica Inc. • 773-247-3600, www.amiberica.net • • • • • •
Applied Test Systems • 724-283-1212, www.atspa.com • •
Babcock & Wilcox Megtec • 920-336-5715, www.megtec.com • • •
Baker Furnace Inc. • 714-223-7262, www.bakerfurnace.com • • •
Banner-Day • 877-837-0584, www.banner-day.com
Bayco by Guspro Inc. • 519-352-4550, www.guspro.com •
BBC/Black Body • 636-343-5600 x221, www.bbcind.com • • • •
Benko Products Inc. • 440-934-2180, www.benkoproducts.com • • • •
Buhler Aeroglide • 919-851-2000, www.buhlergroup.com/drying • • • • • •
C.A. Litzler Co. Inc. • 216-267-8020 x610, www.calitzler.com • • • • • • • • • •
Cascade Tek • 971-371-4096, www.cascadetek.com •
Casso-Solar Technologies LLC • 845-354-2010, www.cassosolartechnologies.com • • • • • • • • • • • • • • • •
Catalytic Industrial Systems • 620-331-0750, www.catalyticirovens.com • • • •
Cire Technologies Inc. • 973-402-8301, www.ciretechnologies.com • • • • •
CMM Group LLC • 920-336-9800, www.thecmmgroup.com • • • • • • • • • • • •
Col-Met Spray Booths Inc. • 888-452-6684, www.colmetsb.com • • • • • • • • • •
Consolidated Engineering Co. • 770-422-5100, www.cec-intl.com • • • • • • • • • • • • •
Corbett Industries Inc. • 800-442-4028, www.corbettind.com • • • • • • •
CPM Wolverine Proctor • 215-443-5200, www.cpmwolverineproctor.com • • • • •
D.F. Industries Inc. • 909-613-9424, www.dfindustries.com • • • •
David Weisman LLC • 203-322-9978, www.weismanovens.com • • • • • • • • • • • •
Davron Technologies Inc. • 888-781-0836 x220, www.davrontech.com • • • • • • • • • • •
DBK USA Inc. , DBK Group • 864-599-1600, dbkusa.com • • • • • • • • • • • • • • • • • • • •
Companies with an in front of their names have an advertisement in this issue.

32  MARCH 2018 Process Heating

 Equipment Overview Ovens

have upgraded listings that include a link to the company website
as well as datasheets and other product information.
If you need more information, visit the Equipment Overview
on Ovens online and click on a company name. Complete contact
information is included for each manufacturer. Or, use our RFP
Builder to collect information from multiple suppliers. To do so, go
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Product
Heating Method Energy Source Manufacturing Process Industries Served

We manufacture aftermarket parts/supplies

Heated

Sheets/Webs Continuous Material)

Convection/Infrared Combination

Oil & Gas/Ethanol/Biodiesel Fuels

Microwave/Radio Frequency

Sterilizing/Depyrogenation

Chemicals/Petrochemicals
Convection, Impingement
Convection, Counter-Flow

Convection, Through-Air

Infrared, Medium Wave

Parts/Discrete Products

Paper/Pulp/Converting
Convection, Flotation

Infrared, Short Wave

Infrared, Long Wave

Packaging/Printing
Infrared, Catalytic

Particles/Powders

Pharmaceuticals
Baking/Cooking

Thermoforming

Plastics/Rubber
Heat Shrinking

for our ovens.

Pre-Heating
Heat Setting
Dehydrating

Pre-Drying
Natural Gas

Laminating
Conduction

Electronics
Annealing
Hot Water
Electricity

Soldering
Dual Fuel

Finishing
Burn-Off
Bonding
Propane

Burn-In
Slurries

Testing
Hot Oil

Drying
Fusing
Curing
Steam
Other

Other

Other

Other

Food
Oil

•• •• •• •••• • • • • •••• • ••••••• •• • • •• •• • *

•• •••••• •• • • • • • •• ••••• • • •••••• •• • • • • • • *

••• •••••• • • • • • • • •• •••••• • • ••••••••••• • • ••••• • • Yes

• • • • • • • • • • • • •• •• • • •• • • Yes

• •• • • •• • • • • •••••• • • ••••••••••• • • ••••• • • Yes

• • • • • • •••••• • •••• • • • • *

• •••• •• ••• • • •• • •• • • • •• •• • • • • Yes

•• • •• •••• • • • • • • • • •••• • ••• • • • •• •• Yes

• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • *
• • • • • • • • • • • • • • • • • *
• • • • • *
• • • • • • • • • • • Yes
• • • • • • • • • • • • • *
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • Yes
• • • • • • • • • • • • • • • • • • • • • • • • • • Yes
• • *
• • • • • • • • • • Yes
• • • • • • • • • • • • • • *
• • • • • • • • • • • • • • • • • • • • • • • • • • • Yes
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • Yes
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • *
• • • • • • • • • • • • • • • • Yes
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • Yes
• • • • • • • • • • • • • • • • • • • • Yes
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • Yes
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • Yes
• • • • • • • • • • • • • Yes
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • Yes
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • *
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • Yes
• • • • • • • • • • • • • • • • • • • • *
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • Yes
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • Yes
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • Yes
Manufacturers listed in this Equipment Overview responded to a special mailing by Process Heating and do not necessarily represent
the entire oven market. To be included in future listings, contact Linda Becker at BeckerL@bnpmedia.com.

www.process-heating.com MARCH 2018  33

 Equipment Overview Ovens
Photo courtesy of Wisconsin Oven
Oven Configuration

Continuous, Cross-Bar Conveyor

Continuous, Fixture Conveyor

Continuous, Pusher Conveyor

Continuous, Screw Conveyor

Continuous, Walking Beam

Continuous, Belt Conveyor
Continuous, Conveyorless

Continuous, Power Roller

Continuous, Drag Chain

Continuous, Turn Table

Continuous, Monorail
Batch, Truck/Walk-In

Continuous, Slat
Batch, Cabinet

Tenter Frames
Batch, Bench
Batch, Bell

Idler Rolls

Top Load
Other
Companies
Despatch Industries • 952-469-8240, www.despatch.com • • • • • • • • • • • • • • • • •
Dürr Systems Inc. • 248-450-2000, www.durr-northamerica.com • • • •
Elnik Systems LLC • 973-239-6066 x212, www.elnik.com • •
Engineered Product Sales Corp. • 714-532-2742, www.epsovens.com • • • • • • • • •
Epcon Industrial Systems LP • 936-273-3300, www.epconlp.com • • • • • • • • • • • • • • • •
Espec North America • 616-896-6100, www.espec.com • •
Etter Engineering • 860-584-8842, www.etterengineering.com • • • • • • • • • • • • • • • • • • • •
Fannon Products Co. • 810-794-2000, www.fannoninfrared.com • • • • • • • • • •
Ferrite Microwave Technologies LLC • 603-881-5234 x151, www.ferriteinc.com •
Fives North American Combustion Inc. • 800-626-3477, combustion.fivesgroup.com
Furnace Brokers International • 860-875-3712, www.fcebr.com • • • • • • • •
Furnace Fixers Inc. • 630-736-0670 x104, www.furnacefixers.com • • • • • • • • • • •
General Fabrications Corp. • 419-625-6055, www.gfcfinishing.com • • • • • • • • • • • • •
George Koch Sons LLC • 812-465-9672, www.kochllc.com • • • • • • • • • • •
Georgia Thermal Products • 844-487-6836, www.gathermal.com •
Gerref Industries Inc. • 616-794-3110, www.gerref.com • • • • • • • • • • •
Glenro Inc. • 888-453-6761, www.glenro.com • • • • • • • •
Global Technologies LLC • 920-779-5252, www.globaltechllc.com • • • •
Guspro Inc. • 519-352-4550, guspro.com • •
Harper International • 716-276-9900, www.harperintl.com • •
Harrop Industries Inc. • 614-231-3621, www.harropusa.com • • • • • • • •
Heat and Control Inc. • 800-227-5980, www.heatandcontrol.com •
Heller Industries • 973-377-6800, www.hellerindustries.com • • •
Heraeus Noblelight America LLC • 678-835-5764, www.heraeus-thermal-solutions.com • • • • • • • • • • • • • •
Herr Industrial Inc. • 717-569-6619 x135, www.herrindustrial.com • • • • • • • • • • • •
Hi-Heat Co. Inc. • 860-528-9315, www.hi-heat.com • • • • • •
Higuchi Inc. USA • 888-913-1313, www.hikarilamps.com
Hix Ovens • 620-231-8568 x210, www.ovens-dryers.com • • • • • • • • • • •
Indesco Oven Products Inc. • 217-622-6345, www.indescoop.com
Industrial Heater Corp. • 800-822-4426, www.industrialheater.com • •
Industrial Microwave Systems • 919-371-1407, www.industrialmicrowave.com • •
Infratrol LLC, ARC Group • 79-475-3098, www.infratrol.com • • • • • • • • •
• • • • • • • • •
Innovative Industries LLC • 330-468-2601, www.innovativeindustries.com • • • • • • •
Intek Corp. • 636-584-8500, www.intekcorp.com • • • • • • • • • •
• • • •
International Thermal Systems LLC • 414-672-7700, www.internationalthermalsystems.com • • • • • • • •
• • • • • • •
Jensen Industries Inc. • 810-224-5005, www.jensenind.com • • • • • •
• •
Kono Kogs Inc. • 920-434-4872, www.konokogs.com •
L&L Special Furnace Co. Inc. • 610-459-9216, www.llfurnace.com • • • • •
Lanly Co. • 216-731-1115, www.lanly.com • • • • • • • • • • • • • • • • • •
Lewco Inc. • 419-502-2780, www.lewcoinc.com • • • • • • • • • • • • • • • • • •
Marsden Inc. • 856-663-2227, www.marsdeninc.com • •
Micropyretics Heaters International MHI) • 513-772-0404, www.mhi-inc.com • • • •
Perceptive Industries Inc. • 269-204-6768, www.perceptiveindustries.com • • • • • • • • • • • •
Pollution Control Products Co. • 214-358-1539, www.pcpconline.com •
Precision Control Systems • 952-829-8358, www.pcscontrols.com • • • •
Premier Furnace Specialists/BeaverMatic Inc. • 248-596-9000, www.beavermatic.com • • •
Process Thermal Dynamics Inc. • 320-834-3370, www.pro-therm.com • • • • • • • • • •
Pyradia • 450-463-3344, www.pyradia.com • • • • • •

34  MARCH 2018 Process Heating

 Equipment Overview Ovens

Product
Heating Method Energy Source Manufacturing Process Industries Served

We manufacture aftermarket parts/supplies

Heated

Sheets/Webs Continuous Material)

Convection/Infrared Combination

Oil & Gas/Ethanol/Biodiesel Fuels

Microwave/Radio Frequency

Sterilizing/Depyrogenation

Chemicals/Petrochemicals
Convection, Impingement
Convection, Counter-Flow

Convection, Through-Air

Infrared, Medium Wave

Parts/Discrete Products

Paper/Pulp/Converting
Convection, Flotation

Infrared, Short Wave

Infrared, Long Wave

Packaging/Printing
Infrared, Catalytic

Particles/Powders

Pharmaceuticals
Baking/Cooking

Thermoforming

Plastics/Rubber
Heat Shrinking

for our ovens.

Pre-Heating
Heat Setting
Dehydrating

Pre-Drying
Natural Gas

Laminating
Conduction

Electronics
Annealing
Hot Water
Electricity

Soldering
Dual Fuel

Finishing
Burn-Off
Bonding
Propane

Burn-In
Slurries

Testing
Hot Oil

Drying
Fusing
Curing
Steam
Other

Other

Other

Other

Food
Oil
• • • • • • • • • • • • • • • • • • • • • • • • • • • • •
• • • • • • • • Yes
• • • • • • • • • • Yes
• • • • • • • • • • • Yes
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • *
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • *
• • • • • • • • • • • • • • Yes
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • Yes
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • *
• • • • • • • • • • • Yes
• *
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • *
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • Yes
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • Yes
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • Yes
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • Yes
• • • • • • • • • • • • • • • • Yes
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • Yes
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • Yes
• • • • • • • • • • • • Yes
• • • • • • • Yes
• • • • • • • • • • • • • • • • • • • • • • • • • • • • Yes
• • • • • • • • • • • • • • • • • • • • Yes
• • • • • • • • • • • • • • • • • Yes
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • Yes
• • • • • • • • • • • • • • • • • • • Yes
• • • • • • • • • • • • • • • • • • • • • *
• • • • *
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • *
• • • • • • • • • • • • • • • • • • Yes
• • • • • • • • • • • Yes
• • • • • • • • • • • • • • • • • • Yes
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • Yes
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • *
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • Yes
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • *
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • Yes
• • • • • • • • • • • • *
• • • • • • • • • • • • Yes
• • • • • • • • • • • • • • • • • • • • • • • • • •
• • • • • • • • • • • • • • • • • • • • • Yes
• • • • • • • • • • • • • • • • • • • • • • • •
• • • • • • • • • • • • • • • • • • • • • • • • Yes
• • • • • • • • • • • • •
• • • • • • • • • • • • • • • • • • Yes
• • • • • • • • • • •
• • • • • • • • • • • • • • • • Yes
• • • • • • • • • • • • • •
• • • • • • • • • • • • • • • Yes
• • • • • • • • • • • • Yes
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • Yes
• • • • • • • • • • • • • • • Yes
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • Yes
• • • • • • • • • • • • • • • • • • • • • • • • • • • Yes

www.process-heating.com MARCH 2018  35

Equipment Overview Ovens
Photo courtesy of Lewco Inc.
Oven Configuration

Continuous, Cross-Bar Conveyor

Continuous, Fixture Conveyor

Continuous, Pusher Conveyor

Continuous, Screw Conveyor

Continuous, Walking Beam

Continuous, Belt Conveyor
Continuous, Conveyorless

Continuous, Power Roller

Continuous, Drag Chain

Continuous, Turn Table

Continuous, Monorail
Batch, Truck/Walk-In

Continuous, Slat
Batch, Cabinet

Tenter Frames
Batch, Bench
Batch, Bell

Idler Rolls

Top Load
Other
Companies
Pyromaitre Inc. • 418-831-2576, pyromaitreovens.com • • • •
Quincy Lab Inc. • 800-482-4328, www.quincylab.com •
Radiant Energy Systems Inc. • 973-423-5220, www.radiantenergy.com • • • • • • • • • •
Radyne Corp., An Inductotherm Group Co. • 414-481-8360, www.radyne.com •
Rapid Engineering LLC • 616-784-0500, www.rapidengineering.com • • •
Scott Can Industries Ltd. • 780-463-5505, www.scottcan.com • • • • • • • • • • • •
Solar Products Inc. • 973-248-9370, www.solarproducts.com
Solo Swiss SA • 41 032 465 96 00, www.solo.swiss • •
Spooner Industries Ltd., Moorland Engineering Works • 44 0)1943 609505, www.spooner.co.uk • • • • • • • •
SSM Industries LLC • 313-931-6880, www.ssmindco.com • • • • • • • • •
Stelter & Brinck Inc. • 513-367-9300, www.stelterbrinck.com •
Therma-Tron-X Inc. • 920-743-6568, www.ttxinc.com • • •
Thermal Engineering Corp. • 803-783-0750, www.tecprocess.com • • • • • • • • • • • • • •
Thermal Innovations Corp. • 732-223-1812, www.thermalinnovations.com • • • • • • • • •
Thermal Product Solutions TPS • 570-538-7200, www.thermalproductsolutions.com • • • • • • •
Trent Inc. • 800-544-8736, trentheat.com • • • • •
Trimac Industrial Systems • 913-488-1694, www.trimacsystems.com • • • • • • • • •
Wenger Manufacturing Inc. • 785-284-2133, www.wengerdryers.com •
Wyssmont Co. • 201-947-4600, www.wyssmont.com •

WE KNOW ELECTRICITY
Questions about SCR
power control systems?
We can help.
OVENS & FURNACES
• Fusing
• Cooling
• Heatsink Design
• Voltage protection
• Application assistance

For more than 40 years we have been

designing and building SCR controls for
hundreds of thousands of users like you.

For answers to your solid state control questions

Call 1-800-331-1345 Multi-Purpose Bench Ovens

Box 70 Scott Depot,
WV 25560-0070 Rugged construction 5-36 cu. ft. capacity
Fax: 304-757-7305 Class A flammable solvent models 300ºF-1000ºF
sales@payneng.com
www.payneng.com www.grievecorp.com 847-546-8225
36  MARCH 2018 Process Heating
 Equipment Overview Ovens
Product
Heating Method Energy Source Manufacturing Process Industries Served

We manufacture aftermarket parts/supplies

Heated

Sheets/Webs Continuous Material)

Convection/Infrared Combination

Oil & Gas/Ethanol/Biodiesel Fuels

Microwave/Radio Frequency

Sterilizing/Depyrogenation

Chemicals/Petrochemicals
Convection, Impingement
Convection, Counter-Flow

Convection, Through-Air

Infrared, Medium Wave

Parts/Discrete Products

Paper/Pulp/Converting
Convection, Flotation

Infrared, Short Wave

Infrared, Long Wave

Packaging/Printing
Infrared, Catalytic

Particles/Powders

Pharmaceuticals
Baking/Cooking

Thermoforming

Plastics/Rubber
Heat Shrinking

for our ovens.

Pre-Heating
Heat Setting
Dehydrating

Pre-Drying
Natural Gas

Laminating
Conduction

Electronics
Annealing
Hot Water
Electricity

Soldering
Dual Fuel

Finishing
Burn-Off
Bonding
Propane

Burn-In
Slurries

Testing
Hot Oil

Drying
Fusing
Curing
Steam
Other

Other

Other

Other

Food
Oil
• • • • • • • • • • • • • Yes
• • • • • • • • • • • • • • • • • • • • • • • Yes
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • Yes
• • • • • • • • • • • • • *
• • • • • • • • • • • • • • Yes
• • • • • • • • • • • • • • • • • • • • • Yes
• • • • • • • • • • • • • • • • • • • • • • • • • • • • Yes
• • *
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • Yes
• • • • • • • • • • • • • • • • • • • • Yes
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • *
• • • • • • • • • • • • • • • • • • • • • • Yes
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • Yes
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • Yes
• • • • • • • • • • • • • • • • • • Yes
• • • • • • • • • • • • • • • • • • • • • • • Yes
• • • • • • • • • • • • • • • • • • • • • • • • • • • Yes
• • • • • • • • • • • • Yes
• • • • • • • • • • • • • • • • • • • • • • Yes

www.process-heating.com MARCH 2018  37

Product Highlights

Wondering where to find products beneficial to your process? This department provides a number of new products each month and allows you to easily request more
information. Simply call those companies in which you are interested, or visit those companies’ websites.

Fives North American Combustion Inc. Grieve Corp.

Direct-Fire, Nozzle-Mix Burner Offers 500°F Walk-In Oven
Compact Design Grieve walk-in
oven has 4" thick
insulated walls with
an aluminized steel
interior and exterior.
A four-port vacuum
manifold with
pressure gauge and
hand valve on each
port is included, and
the solenoid valve
can be used to bleed air into the manifold and a resin trap
North American Tempest SE offers multi-fuel capability, leading to the vacuum pump. A two-stage rotary vacuum
with various nozzle options, and enables any control pump rated at 10 cfm is provided. Model 1016 is a 500°F
methodology, including pulse firing, excess air or (260°C) walk-in oven used for composite curing. Workspace
stoichiometric. The direct-fire, nozzle-mix industrial burner dimensions measure 72 x 120 x 78", and 100 KW are
has a compact design that can improve temperature installed in Incoloy-sheathed tubular elements to heat the
uniformity, product quality and system efficiency, says oven chamber. A 10,000-cfm, 10-hp recirculating blower
the manufacturer. Performance benefits include low NOX provides horizontal airflow to the workload.
emissions; DMC mode capable of achieving ultra-low NOX 847-546-8225
emissions; direct-spark ignition; sturdy cast construction; www.grievecorp.com
wide operating limits; and low air pressure requirements.
It is offered in four tile types with two velocity options. Cleaver-Brooks
800-626-3477 ASME U-Stamp Certified,
www.tempestburners.com Condensing Economizer
A two-stage condensing
Spirax Sarco economizer designed
Float and Thermostatic Steam Traps for 100 to 800 hp
Suitable for heavily boilers offers 94 percent
contaminated steam efficiency, says the
applications, the FT23 manufacturer. Exclusive
range is available in sizes technology allows the
1.5 to 2" and C2X-HE to provide
two body maximum heat recovery.
materials: Efficiencies can be
carbon achieved depending
steel body on boiler firing rate,
with stainless makeup or process flow
steel cover and and temperature. The
stainless steel body first-stage economizer,
with stainless steel cover. made of 304 stainless steel tubes with aluminized steel-
Features include an external manual blockage fin material, returns wasted heat to the boiler feedwater.
lever that allows for manual operation of the steam trap to Its second-stage condensing section, constructed of 304
purge contaminants. The plug-and-seat design with self- stainless steel tubes with aluminum-fin material, preheats
cleaning capability makes the steam trap less susceptible makeup or process water. It is suited for applications with a
to the risk of failure due to fouling. The stainless steel cover 50 to 100 percent makeup water requirement and process
provides corrosion resistance. hot water applications such as food processing.
800-883-4411 800-250-5883
www.spiraxsarco.com/global/us cleaverbrooks.com

38  MARCH 2018 Process Heating

 Product Highlights

United Electric Controls Oven Industries Inc.

Safety Shutdown and Alarm Control Temperature Controller for
With its ability to directly switch 24 Heating or Cooling
and 125 VDC loads as well as 250 The bidirectional
VAC loads, the One Series ST or unidirectional
can provide SIL 2-certified H-bridge
control for final control configuration of
elements such as pilot the temperature
valves, actuators and controller
motor controllers, allows seamless
without involving transitions
a DCS or safety between heating
PLC. The ability and cooling as it
to directly control commands the
legacy equipment thermoelectric
that utilizes 125 VDC control modules. The
schemes is especially valuable included user-
to power plants. A process friendly PC software allows users to change control
sensor, logic solver and safety configurations through the RS232 or RS485 interface,
relay are embedded in a single, which has 1500 VAC isolation from the electronic circuitry
SIL 2-certified field device. to eliminate interference from noise or errant signals. Once
Although the device looks like a the temperature controller is setup, the computer may be
traditional temperature or pressure disconnected, and the temperature controller becomes a
transmitter, it can switch final elements such as valves, standalone unit. The computer can remain connected for
motors, and blowers directly from the transmitter. data acquisition. The load circuit is pulse-width modulated
617-926-1000 at 2.7 KHz and delivers a load current of 0.1 to 25 A.
www.ueonline.com 717-766-0721
www.ovenind.com
Radio Frequency Co.
Two-Zone Post-Baking Dryers Moore Industries
Functional Safety, Dual-Input
Temperature Transmitter
Model TZ is certified by exida to
IEC61508 for systematic integrity up
to SIL 3, and for single use in safety
instrumented systems (SIS) up to SIL 2.
The functional safety, dual-input smart
Hart DIN-style temperature transmitter
with associated IS sensor connections
configures quickly and easily to accept
a single or dual input. The intrinsically
safe AIS option for the STZ-DIN allows
direct connection of sensors located
in hazardous locations by including an
embedded intrinsically safe barrier in the
The Double-Bantam Series Macrowave does not require front end of the STZ-DIN. The associated apparatus is suitable
plant cooling water or heavy electrical drops. The for mounting in nonhazardous or Class I, Division 2/Zone 2
air-cooled systems reduce the amount of preventive hazardous locations with sensor input terminals connected
maintenance required. Capable of boosting oven line to sensors or equipment in Class I, II, III, Division 1/Zone 0/1
productivity, radio frequency post-baking dryers eliminate hazardous locations. Inputs accepted include sensors and
checking and over-coloration problems in industrial analog devices such as RTDs, thermocouples, resistance and
baking operations. potentiometer devices, and direct millivolt inputs.
508-376-9555 818-894-7111
www.radiofrequency.com www.miinet.com

www.process-heating.com MARCH 2018  39

Product Highlights
Marsh Bellofram Group,
BelGas Flame Management Div.
Flame Arrestors for Industrial Pipelines
Flame arrestors mitigate the risk of combustion in pipeline
systems. A flame arrestor device inhibits or prevents flame
transmission while allowing gases and liquids to pass
through. The company offer custom fabrication services
to industries such as oil and gas, refining, pharmaceuticals,
power generation and mining.
800-727-5646
www.marshbellofram.com
GEA
Freezer and Chiller for Food Processing
Model S-Tec has a fully welded food-zone assembly, open
profiles, fully welded modular floor configuration option
and efficient cleaning-in-place options. Capable of handling
capacities up to 7 tons/hr, the spiral freezer and chiller is
designed to exact specifications based on the product
characteristics, capacities, facility space and line layout.
Full-height horizontal airflow and exact air temperature
control ensure the freezing and chilling performance and
product quality. The machine can handle single-shift to
14-day operations without interruption to defrost, based on
the evaporator configuration selected for customers’ needs.
The company’s freezing process control continuously
measures the product level of frozenness at freezer outfeed
and adjusts freezing time, air temperature and fan speed
to achieve the exact freezing quality with minimum energy
consumption.
844-432-2329
www.gea.com
Emerson, Ridgid brand
Thermal Imagers Help Detect
Overheating Motors, Insulation Voids and
Thermal Bridges
Ridgid line includes four thermal imagers — RT-3, RT-5x,
RT-7x and RT-9x — that provide up to 320 x 240 pixel
thermal images. Some models also show a digital camera
image alongside the thermal image. Features common to
the line include SuperResolution, a pixel-shift technology
40  MARCH 2018 Process Heating
that effectively doubles the resolution of the camera
for saved images, says the manufacturer. This allows
greater detail to detect anomalies. Some models include
ε-Assist via the integrated digital camera. The thermal
imager recognizes a placed reference sticker, determines
emissivity and reflected temperature, and sets both values
automatically. In addition, a mobile app allows users to
create and share reports as well as view, edit and analyze
captured images from the thermal imager directly on a
mobile device.
800-769-7743
www.ridgid.com
TestEquity LLC
Compact Temperature/Humidity Chamber
Model 101H fits on a test bench and is
designed for device characterization
and tests, including mobile phones
and tablets, passive and active
components, and small PC boards.
The temperature/humidity chamber
has a 1.1 ft3 interior workspace and
is powered by a standard 120 V, 15 A
outlet. It can simulate humidity from
10 to 95 percent within the range
of 50 to 185°F (10 to 85°C), limited
by a 10.8°F (6°C) dewpoint. Lower
dewpoint conditions can be achieved
with purge or dry-air purge options.
It has a temperature range of -0.4 to
116°F (-18 to 130°C) in temperature-only mode. A built-in
water reservoir and recirculation/filter eliminate the need
for plumbing or drain lines.
805-498-9933
www.testequity.com
Yokogawa
Scalable Network-based Control System
The network-based
control system consists
of the company’s
FCN autonomous
controller, VDS web-
based human/machine
interface (HMI), and
the Fast/Tools SCADA package. An E2 bus interface module
developed for use in FCN-500 autonomous controller
extension units allows construction of systems that
have more I/O points and cover a wider area. The open-
network control system combines components for control,
operation and monitoring functionality in oil-and-gas and
small-to-medium plant applications.
800-888-6400
www.yokogawa.com/us
 Product Highlights

GF Piping Systems real-time data that is transmitted
Corrosive Waste via the internet in the cloud-based
Piping System CMMS. Users can run the internet-
based CMMS independently to
manage failure or preventive work
order/maintenance activities. Adding
smart IoT sensors allows users to
capture real-time data for condition
monitoring through which alerts
can be viewed directly via CMMS
dashboard. If the temperature or
vibration signal is above set alert
limits, the user can generate a work
order with one click.
440-545-2296
www.ezmaintain.com

POWER. PRECISION. PERFORMANCE.

Fuseal is offered in sizes from 1.5
to 18" for both pipe and fittings. Its
chemical and physical properties
make the polypropylene piping
system suited for handling corrosive
waste streams in applications such
as dairy, food processing, beverage,
chemical and industrial plants. The
piping resists the corrosive action
of alkalis, alcohols, acids, solvents
and salt solutions. The piping does
not rust, pit, scale or corrode, and it
will not be affected by electrolysis.
It was specifically developed to
handle corrosive waste and high
temperatures in applications. The
piping is offered in a flame-retardant
version in all sizes except 14, 16
and 18".
800-854-4090
www.gfps.com

EZmaintain
IoT Sensors Integrate with
Cloud-Based Conditioning-
Monitoring System

Computerized maintenance 500F CURING OVEN FOR THE AUTOMOTIVE INDUSTRY.

management software (CMMS) can
integrate IoT sensors to measure CALL TODAY FOR A QUOTE
6080 State Route 14 | Trout Run, PA 17771
temperature and vibration levels of 570.995.5025 | www.jpwdesign.com
equipment such as motors, gearboxes
and generators. The sensors generate

www.process-heating.com MARCH 2018  41

SUCCESS STORIES
JPW INDUSTRIAL OVENS AND FURNACES
500°F INERT ATMOSPHERE WALK-IN OVEN FROM GRIEVE
No. 1038 is a 500°F (260°C),
inert atmosphere walk-in oven
from Grieve, currently used for
annealing polyurethane tub-
ing at the customer’s facility.
Workspace dimensions of this
oven measure 60” W x 72” D x
84” H. 40 KW are installed in
Incoloy-sheathed tubular heating
42  MARCH 2018 Process Heating
elements, while a 4200 CFM,
3-HP recirculating blower pro-
vides vertical downward airflow
to the workload.
This Grieve walk-in oven has
6” insulated walls and an alu-
minized steel exterior with white
epoxy paint. Type 304, 2B fin-
ish stainless steel interior with
Who is JPW Industrial Ovens
and Furnaces? JPW is a manu-
facturer of industrial ovens and
furnaces for various markets
such as Aerospace, Medical,
Finishing, Heat Treating, Curing
and the list goes on. The prin-
cipal owners of JPW started out
working in the oven industry for
some top brand names; they
have over a hundred years of
combined experience in the
business. Seeing a need for a
company that could respond
to customers with personalized
service in a fast, cost-effective
manner, they formed JPW. JPW’s
mission is to offer the right solu-
tion at the right price, whether
it is standard offering or solu-
tion based. We hit the ground
running over a decade ago by
offering a selection of standard
batch ovens with temperature
continuously backwelded seams
and inert atmosphere construc-
tion are also onboard, including
a pressure regulator, flow meter,
pressure gauge, inner oven walls
sealing directly against ½” thick
silicone rubber door seal, blow-
er shaft seal, positive latching
door hardware, adjustable offset
advertorial
ranges up to 1400F. Our spring-
board into the market was through
well established distribution chan-
nels. Now, after several expansions,
we continue to evolve through our
diverse offerings for batch, con-
tinuous and solution based heat
process systems. We have built our
brand from an unknown to a top
contender in the oven and furnace
market. The best example of our
success has been through repeat
customer sales. Our customers look
at JPW as not just a supplier, but as
a partner for their oven and furnace
needs. As a result, they experience
power, precision and performance
that meet or exceed their expecta-
tions. We look forward to solving
customer challenges and welcome
you to put us to the test.
JPW
www.jpwdesign.com
door hinges, outlet with pressure
relief, interior seams welded gas-
tight and all wall penetrations
fitted with compression fittings.
The oven has a 4” insulated floor
with truck wheel guide tracks
mounted on top of the floor.
Controls on the No. 1038
include a digital programming
temperature controller plus a
paperless event recorder.
For more information,
please contact: THE GRIEVE
CORPORATION, 500 Hart Road,
Round Lake, Illinois 60073-
2835 USA. Phone: (847) 546-
8225. Fax: (847) 546-9210.
Web: www.grievecorp.com. Email:
sales@grievecorp.com. Attention:
Frank Calabrese.
THE GRIEVE
CORPORATION
www.grievecorp.com
SUCCESS STORIES
HEAT TRANSFER FLUID SAVES PLANT 35% IN ENERGY SAVINGS
A food processing facility recently
transitioned their heat transfer
fluid to Caldera 3 Food-Grade Heat
Transfer Fluid. After performing the
fluid change, the facility noted that
it could lower its boiler temperature
from 585°F to 550°F and still
maintain their required operational
temperatures.
Plant Details:
• The fluid returning to the boiler,
after passing through the various
heated processes, is a consistent
450°F – regardless of the fluid
being used.
• When utilizing competitive fluid,
the boiler heats the fluid from
450°F to 585°F.
• When utilizing Caldera 3, the boil-
er heats the fluid from 450°F to
550°F.
• Both fluids are pumped through
the boiler at 40 gallons per min-
INDUSTRIAL OVENS
Wisconsin Oven Corporation has
been designing, engineering, and
manufacturing industrial ovens
and other heating equipment since
1973. Their custom and standard
industrial ovens are used for a
multitude of applications, includ-
ing metal finishing, preheating,
composite curing, drying, aging,
heat-treating, decontamination,
sterilizing and shrink-fitting. Many
of the industries they serve require
specific temperature uniformity and
equipment performance documen-
tation. Their experienced design
team is able to meet even the
most stringent standards for each
customer's equipment. Custom
equipment is designed around
the customer’s specific process
requirements, but Wisconsin Oven
also offers hundreds of standard
batch models.
Batch oven units include
advertorial
ute. The heater is run for 96 hours
per week
Switching from a competitive
fluid to Caldera 3 resulted in the
food processing facility saving
approximately $6,236.15 (~35%)
in energy costs per year. This is
mostly related to the improved ther-
mal properties of Caldera 3 and its
unique combination of high quality
base fluids and advanced additive
technologies.
Caldera 3 offers the safety of
a food grade formulation without
compromising performance or fluid
life. The end result is a heat transfer
fluid that offers improved thermal
properties, a long fluid life, and
clean operation.
CALDERA FLUIDS
calderafluids.com
laboratory, cabinet, pit, walk-
in, car-bottom, top-load, eleva-
tor, and drop-bottom configura-
tions. Continuous ovens can
be arranged as a belt conveyor,
monorail (overhead-trolley), index-
ing, pusher, Ferris wheel, carousel
or spindle (chain-on-edge). The
industrial ovens are designed with
standard temperature ratings of
500, 650, 800, 1000, 1250, and
1400°F. They can be heated by
gas (direct or indirect fired), elec-
tric and steam.
Wisconsin Oven stands behind maximum operating temperatures tory assembled and tested prior
the quality of their equipment and higher than 650°F are backed by to shipment to help reduce instal-
backs it by the industry’s best, Wisconsin Oven’s 3-Year WOW™ lation and start-up times. Turnkey
longest, and easiest to under- warranty. Wisconsin Oven’s exclu- installations, start-up service,
stand warranty. Standard Ovens sive 3-Year Warranty on the heat spare parts and PM programs are
with maximum operating tempera- and recirculation components is also available through our Service
tures of 650°F and lower fea- included on standard batch ovens department, service@wisoven.com.
ture Wisconsin Oven’s Exclusive with temperature ratings of 800°F
and Unprecedented 5-Year WOW™ or less. WISCONSIN OVEN
warranty. Standard Ovens with Equipment is completely fac- www.wisoven.com
www.process-heating.com MARCH 2018  43
SUCCESS STORIES
FECO OVENS BY AJAX TOCCO
Ajax TOCCO Magnethermic® FECO
division is a global leader in the
supply of industrial ovens for ther-
mal processing applications. Ajax
TOCCO has the products and the
expertise to integrate an optimal
oven system. From design to deliv-
ery and installation, we fabricate
and assemble every furnace in-
HEATEC HELPS CONVERT POWER PLANT FROM COAL TO GAS
When a power plant in
Pennsylvania decided to convert
from coal to natural gas as fuel for
their turbines, they ran into some
challenges making the switch. One
of the challenges they faced was
the source of the natural gas
was on the other side of a moun-
44  MARCH 2018 Process Heating
house and perform an operational
quality-test prior to shipment.
With over 90 years of experi-
ence designing custom ovens, Ajax
TOCCO builds to the highest stan-
dards of the automotive and aero-
space markets, achieving heating
profiles/curves that exceed the
expectations of these demanding
tain several miles away. They had
to drill a tunnel and run piping
through the mountain to the power
plant. Over twenty miles of piping
were required from the source to
the plant.
Heatec helped them overcome
another challenge faced by any
markets (automotive CQI-9 and
aerospace AMS 2750E).
Our specialty is unique appli-
cations, with the exclusive capa-
bility of combining Ajax TOCCO
Induction with Convection Oven
technology to deliver the most
efficient and precise heat process
systems. As a result, we offer a full
plant that has to drastically reduce
gas pressure, ice and hydrates.
Heatec built three water bath heat-
ers to heat the natural gas. Heating
natural gas prevents ice and hydrate
formation when its pressure is
reduced for the burners of the tur-
bines. Eliminating ice and hydrates
advertorial
range of industry-prov-
en oven designs and
handling equipment to
ensure an optimum pro-
cess is achieved with
maximum uptime.
In addition to supply-
ing world-class equip-
ment, Ajax TOCCO offers
global customer sup-
port services, including
field service, replace-
ment parts, installa-
tion and training. As
an authorized OEM
for FECO and MOCO ovens, Ajax
TOCCO can design, build, install
and service an oven for any heat
process requirement. Visit us at
www.AjaxTocco.com.
AJAX TOCCO
www.AjaxTocco.com
is extremely important because
they can cause numerous problems
such as clogging fuel lines, freezing
control valves, or damaging regula-
tor diaphragms. Even small ice par-
ticles in the fuel can cause extensive
damage to turbine engines. Heating
the natural gas before its pressure is
reduced eliminates these potential
problems.
It was also important to main-
tain a steady temperature of the
gas since the gas was being used
with turbines. Ambient tempera-
tures will cause the gas tem-
perature to fluctuate, causing
performance issues with turbines.
Heatec water bath heaters are per-
fect for that application because
of their ability to precisely main-
tain temperatures.
HEATEC
www.heatec.com/heaters
PH Classifieds Display Classified Rates:
1X $130 • 3X $125 • 6X $120 • 12X $110
Send advertising copy to:
Process Heating/Attn. Becky McClelland
Phone: 412-306-4355 • Fax: 248-502-1076
E-mail: becky@bnpmedia.com

Equipment for Sale

HEAT EXCHANGERS
For $30 Liquid Cooled

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we will
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post & link Air Cooled

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your print ad on FOR GASES & LIQUIDS!
Talk Directly with Design Engineers!
www.process-heating.com Blower Cooling Vent Condensing

(952) 933-2559 info@xchanger.com

ADVERTISING INDEX
7 Ajax Tocco Magnethermic 800-547-1527 www.ajaxtocco.com

17 Blasdel Enterprises Inc. 812-663-3213 www.blasdel.net

30 Clayton Industries 800-423-4585 info@claytonindustries.com

37 Fostoria 800-495-4525 www.fostoriaprocessequipment.com

2 & 36 Grieve Corporation 847-546-8225 www.grievecorp.com

48 Heatec, Inc. 423-821-5200 www.heatec.com

11 Isel 800-503-9533 www.calderafluids.com

41 JPW Industrial Ovens & Furnaces 570-995-5025 www.jpwdesign.com

10 Micron Fiber-Tech 386-668-7895 www.mft-com.com

47 NPE (The Plastic Show) attend@npe.org www.NPE.org

36 Payne Controls 800-331-1345 www.payneng.com

17 Protection Controls 847-674-7676 www.protectioncontrolsinc.com

10 Steelman Industries Inc. 888-735-8831 www.steelman.com

20 Thermcraft Inc. 336-784-4800 www.thermcraftinc.com

9 Wisconsin Oven 262-642-3938 www.wisoven.com

www.process-heating.com MARCH 2018  45

Places Faces
Huber USA, a
subsidiary of
temperature control
systems maker
Peter Huber
Kältemaschinenbau
Nock
AG, named Michael
Nock its director of technical service.
Nock previously worked as part of
the customer support team at Huber
headquarters in Offenburg, Germany.
Lewco Inc., Sandusky, Ohio, added
eight representatives serving 21 states.
They will support Lewco’s industrial
oven sales and provide application
assistance. They include CVA Energy,
covering Virginia; Beacon Industrial
Group, handling North and South
Carolina, Georgia and Florida; Matrix
Controls Corp., serving Arkansas,
Louisiana, Oklahoma and Texas;
Baillie Sales & Engineering, handling
North and South Dakota, Iowa,
Minnesota and northern Wisconsin;
DeMar & Associates, covering
Kansas and western Missouri; Dahl-
Vaughn Inc., serving California
and the city of Reno, Nev.; Solids
Technology, covering Arizona, New
Mexico, and the cities of Las Vegas
and El Paso, Texas; and M Squared
Solutions, covering Illinois, northwest
Indiana, southern Wisconsin, the upper
peninsula of Michigan and the city of
St. Louis and surrounding counties.
The Chicago-based business office of
Raymond Bartlett Snow, previously
located in Warrenville, Ill., relocated
to the company’s global headquarters
at its applications development and
research and development laboratory
in Naperville, Ill. The testing laboratory
contains pilot-scale equipment for
46  MARCH 2018 Process Heating
thermal processing, size reduction and
classification of minerals, chemicals,
food products and other materials. The
use of pilot-scale rather than bench-
scale equipment generates results
that are more accurately scalable to
production-size machines. A member
of the Arvos Group, Raymond Bartlett
Snow can be reached at 2151 Fisher
Drive, Naperville, IL 60563. The
website remains www.arvos-group.com.
Snehal Desai, former
global business
director of the Dow
Water & Process
Solutions business,
joined Pittsburgh-
Desai
based Evoqua
Water Technologies as chief growth
officer, a newly created position.
Also, Evoqua named Jim Kohosek
as executive vice president and chief
administrative officer.
Temperature and flow control
equipment provider Endress+Hauser,
Greenwood, Ind., inked partnerships
with three automation companies.
The companies will collaborate to
help drive the “digital oilfield” in the oil
and gas industry. Each company will
contribute focused areas of expertise:
Endress+Hauser’s intelligent field
instruments and digital communication
expertise; Angus Measurement
Services’ systems fabrication and
technology consultants help optimize
the performance of gas, oil and
water assets; TechnipFMC’s oil-and-
gas measurement technology; and
Vector Controls and Automation
Group’s expertise in gas analytics,
measurement and control.
The International Society of
Automation published Mission-
Critical Operations Primer, authored
by Steve Mustard. It focuses on 16
critical infrastructure sectors whose
failure could result in significant
financial loss through production
impact or plant damage. To purchase a
copy, visit www.isa.org/store.
SUBSCRIPTIONS
For subscription information or service, please contact
Customer Service at:
Phone: 800-952-6643 or Fax: 847-763-9538
Email: processheating@omeda.com
PUBLISHING STAFF
Senior Group Publisher • DARRELL DAL POZZO
847-405-4044 • dalpozzod@bnpmedia.com
Associate Publisher and Editor • LINDA BECKER
262-564-0074 • BeckerL@bnpmedia.com
Technical Editor • REED MILLER
412-306-4360 • reed@process-heating.com
Associate Editor • BILL MAYER
412-306-4350 • bill@process-heating.com
Contributing Editor • JOY LEPREE ANDERSON
856-582-9554 • joylepree@gmail.com
Art Director • MANDA CHAN
323-486-8080 • Chanm@bnpmedia.com
Production Manager • SOUZAN AZAR
248-786-1700 • AzarS@bnpmedia.com
Advertising Director • SUSAN HEINAUER
412-306-4352 • HeinauerS@bnpmedia.com
Classifieds & Reprint Sales • BECKY MCCLELLAND
412-306-4355 • McClellandB@bnpmedia.com
ADVERTISING SALES
NORTH AMERICA • Susan Heinauer • Advertising Director
412-306-4352 • FAX 248-502-1046 • HeinauerS@bnpmedia.com
NORTH AMERICA • Frank Prokos • National Sales Manager
847-405-4033 • MOBILE 312-343-3253 • ProkosF@bnpmedia.com
EUROPE • Steve Roth • steve@process-heating.com
520-742-0175 • MOBILE 847-922-0910 • FAX 847-620-2525
CORPORATE DIRECTORS
Publishing: JOHN R. SCHREI
Corporate Strategy: RITA M. FOUMIA
Creative: MICHAEL T. POWELL
Events: SCOTT WOLTERS
Finance: LISA L. PAULUS
Information Technology: SCOTT KRYWKO
Human Resources: MARLENE J. WITTHOFT
Production: VINCENT M. MICONI
Clear Seas Research: BETH A. SUROWIEC
CORPORATE STAFF
BNP Media Corporate Office • 248-244-6400
Directory Development Manager • ERIN MYGAL
248-786-1684 • mygale@bnpmedia.com
AUDIENCE MARKETING
Audience Marketing Coordinator • ASHLEY BURTON
Integrated Media Specialist • GRISELDA UVARIO
Audience Audit Coordinator • CAROLAN BIENIEK
LIST RENTAL
POSTAL & EMAIL CONTACTS
KEVIN COLLOPY • Sr. Account Manager
Phone: 402-836-6265
Toll Free: 800-223-2194, ext. 684
Email: kevin.collopy@infogroup.com
MICHAEL COSTANTINO • Senior Account Manager
Phone: 402-836-6266
Email: michael.costantino@infogroup.com
SINGLE COPY SALES
ANN KALB
kalba@bnpmedia.com
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 machined.
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Innovation. Technology. Sustainability. sealed.
From equipment and trends to the people advancing
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has it covered. Be there to discover new ways to packaged.
maximize efficiency, advance your operations and
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MAY 7–11, 2018 | ORL ANDO, FL , USA
• Bath Heaters
• Glycol Heaters
• Electric Heaters
• Regen Gas Heaters
• Waste Heat Recovery
• Fuel Gas Conditioning
• Thermal Fluid Heaters

SPECIALISTS
IN PROCESS HEATING
Heatec has been designing and manufacturing
process heating systems for over 40 years. Our
experience and knowledge is a valuable tool for
you. We will help you choose the right system
for your process, custom design it and build it
to meet your specifications. When you need a
process heating system for your plant, talk to a
specialist. Talk to Heatec.

423.821.5200 www.heatec.com

H E AT E C , I N C . an Astec Industries Company

5200 WILSON RD • CHATTANOOGA, TN 37410 USA 800.235.5200 • FAX 423.821.7673 • heatec.com