Information & Resources

Please browse through our archive of selected articles, industry news and expert opinions

Resources & Information (31)

Thermal Products Inc, will be participating at the Craft Brewers Conference (CBC) & Brew Expo America in our nation’s Capital, Washington D.C., together with our partners Advantage Engineering http://thermalproducts.com/products/chillers/advantage-engineering and Enerquip Heat Exchangers http://thermalproducts.com/products/shell-tube-heat-exchangers/enerquip

This annual event allows exhibitors and buyers to develop profitable business relationships and helps brewing and brewery restaurant professionals encounter the latest and best products and services that industry vendors have to offer.

We’ll be there to show ours!

Please visit Scott Robinson of Thermal Products and our partners at the booth locations below.

Advantage Engineering Booth #645

Enerquip Heat Exchangers Booth #2002

Learn how Thermal Products can assist you with your quick tank heating needs to your fully customized tank heating needs for all types of fluids.

Application:
In 1998 the Environmental Protection Agency (EPA) ruled that owners of Underground Storage Tanks must conform to standards that were established for secondary containment. Secondary containment tank is a tank assembly consisting of a primary tank and an integral outer secondary containment means capable of being monitored for leakage. EPA required all Underground Storage Tanks to be retrofitted to meet secondary containment requirements, removed or replaced by Above Ground Storage Tanks. Many State Agencies have indicated the use of Above Ground Storage Tanks is the best option. Above-ground Storage Tanks are usually installed outdoors which can lead to problems when the product viscosity is affected by colder temperatures. The solution is to add a heater to warm the product and maintain a free flowing viscosity.

Design Requirements:
An 8,000 gallon rectangular Above-ground Storage Tank filled with diesel fuel was installed at a major airport in the U.S. With a design outside winter temperature of ‐20ºF and 10 MPH winds a heater is required to maintain the fuel at 40ºF. Since no openings were allowed in the side of the tank the only access for the heater was through the top of the tank. Using the new INDEECO I‐HEAT heater selection program it was quickly determined that a 2 KW immersion heater would be required.

Solution:
INDEECO selected an over‐the‐side flanged deep tank immersion heater with a remote industrial control panel. The heater used was a 3‐inch 150# carbon steel flange and 0.475 diameter steel elements rated at 6 watts per square inch. The 46‐inch long heating elements were mounted to a 76‐inch riser which positioned the elements in the lower half of the tank. The heater was furnished with both high limit and temperature control thermocouples.

One of INDEECO’s standard NEMA 4X industrial control panels equipped with a main power disconnect switch, controlling contactor, transformer, digital thermostat, Type J thermocouple controller, status pilot light and 150 watt enclosure heater was selected to control the heater.

INDEECO Advantages:
The customer was looking for a quick solution. INDEECO was able to offer a quick-ship standard industrial panel. The custom heater’s lead‐time was 5‐weeks and the panel was available in 2‐weeks.

Contact Thermal Products to see how we, with INDEECO can assist you with all your tank heating needs

Written by Indeeco

An Advantage Engineering, Evaporative Cooling Tower Stand is used to elevate the outdoor mounted cooling tower to facilitate gravity return of water from the cooling tower to an indoor tank. Saving energy, by eliminating the need for a cooling tower pump and conduit runs and opening up critical ground space for other equipment needs.

Advantage Power Tower cooling tower cells from 45-135 ton capacity use a galvanized steel bolt together stand.

The galvanized steel, bolt together stand provides a rigid mounting and is easy to install. It requires no welding or post assembly painting and is designed to last for many years.

The stand is available in three (3) heights; 5 foot, 10 foot and 15 foot.

Power Tower cooling towers from 170-540 ton capacity use a welded and painted steel stand.

Contact Thermal Products to discuss your application today!

Overview
 

The Metal Particle Detector switch from AMOT can detect and alert equipment operations of the presence of metal particles in nonconductive fluid lubrication systems (lube oil, transmission fluid etc).

Typical applications

Developed for use in manual and automatic control systems:

  • Reciprocating equipment
    - gas engines
    - diesel engines
    - compressors

  • Rotating equipment
    - gas turbines
    - steam turbines
    - transmissions and gear boxes
    - pumps
    - compressors

At utility gas let down stations, the natural gas transmitted through the pipelines is reduced in pressure from the transmission pressure (up to 700 psi) down to a pressure range of 30-50 psi.  As the pressure is let down, the gas expands.  During the expansion of the gas it will cool, generally in the range of 10 F for each atmosphere of expansion.  As the gas cools, the water vapor in the gas stream will freeze if the temperature of the gas drops low enough.  The ice from the gas stream will cause severe problems in the valves and piping.  To avoid the potential problem of ice formation, the gas is heated prior to the pressure let down.  Typically the natural gas is heated from approximately 320 F to 850 F using a hot glycol solution or thermal oil at 1500 F.

Thermal Products recommends a high pressure API Heat Transfer Basco TEMA Type BEP or BEU shell & tube heat exchanger for natural gas heaters.  A type BEP is a straight through design allowing the heat exchanger to easily be installed in the pipeline.  With the high pressure gas flowing through the tubes, the BEP's floating tubesheet design protects the unit from the stresses of differential thermal expansion. 

The U-Tube configuration of the type BEU allows it to handle differential thermal expansion since the bent tubing is inherently free to expand.  Both the BEP and BEU designs avoid the use of packing on the tubeside thus minimizing the chance for a dangerous natural gas leak to the atmosphere.  A glycol solution or thermal oil from a Thermal Fluid Heater is circulated through the shellside of the heat exchanger, and returned to the boiler.  Natural gas heaters are sized using the lowest gas pressure case, since the maximum tube velocity is obtained from the lowest operating pressure.

A variety of materials can be used but generally the heat exchanger is constructed entirely of carbon steel.  This provides the required strength for the critical operating conditions while minimizing the cost of the heat exchanger.  A rupture disc is normally provided on the shellside to protect the heat exchanger in the unlikely event of a tube failure.  The rupture disc allows a safe escape of the high-pressure gas should a tube rupture allowing the gas to enter the shellside of the heat exchanger. 

Contact Thermal Products for help with your application!

Two Basco Type 500 shell and tube heat exchangers with flanged connections ready for shipment.  Contact us today to see how Thermal Products can assist you!

Some of the Basco 500 Features include:

Performance notes.
 Cost-effective, standard design for maximum performance
at minimum cost
 Readily available with short lead times
 Uses precision-punched baffles to minimize fluid bypass
and maximize heat transfer
 Manufactured for a wide range of duties in state-of-the-art
ISO-certified facilities
Features and specifications.
 Removable and non-removable straight tube or
U-tube bundles
 One-, two-, and four-pass designs
 High-strength shells in carbon steel or stainless steel
 Tubesheets are welded to the shell; holes are precision
drilled for proper fit and sealing
 Baffles are hot-rolled punched steel for enhanced strength
and reliability – engineered for correct fit to reduce tube
wall damage from high-velocity liquids or gases
 Tubes are available in a range of materials, depending on
the application, and are roller expanded using controlled
pressure to ensure proper bond
 Heavy-duty mounting brackets can be reversed or rotated;
slotted holes allow for quick install
 Fabricated end bonnet heads are standard on TEMA-C
and some ASME units; zinc anodes available for
added protection
 Connections available, threaded or flanged, in 3 in., 4 in.,
5 in., 6 in., and 8 in. diameters – additional connections can
be added

Off-The-Shelf Sanitary and Utility Heat Exchangers

U-Tube Shell & Tube Heat Exchangers

Top producers of food, beverage, dairy and process products put their faith in Thermal Products and Enerquip, the leading provider of sanitary and industrial stainless steel shell and tube heat exchangers, for your critical heating and cooling needs.

Thermal Products and Enerquip’s resourceful team can provide you with sizing and design selection assistance. Our skilled sales engineers use state-of-the-art modeling software to recommend the right heat exchanger for each heating or cooling application. Your end result will be a high quality, sanitary or industrial heat exchanger with lead-times that are half of the industry average.

Thermal Products and Enerquip's 40 standard sized heat exchangers are either in stock or available to be shipped in days instead of months.

Contact us for quick shipping requirements today!

What sets Thermal Products and Enerquip’s sanitary shell and tube exchangers apart?

100% 304 stainless steel construction for corrosion resistance and cleanliness.

Built to high quality TEMA C guidelines, ASME hydro-tested and code stamped.

The perfect choice for heating or cooling low-fouling fluids.

Sanitary tri-clamp connections on the process side allow for easy installation.

U-tube design allows tubes to expand and contract freely to prevent damage.

Removable/replaceable tube bundle and o-rings make replacement quick and easy.

Wide selection of sizes from 4” diameter to 10” diameter in lengths up to 9’ long.

Heat exchangers built to 3-A standard 12-07 are available as an upgrade.

Options Available (Not all of these are Off-the-Shelf options.) :

Insulation and cladding with stainless steel jacket for heat conservation and personnel protection

Mounting foot supports – horizontal clamp-on saddles or vertical welded lugs

Baffle & connection changes for liquid to liquid applications

Upgrades to 3-A or double tubesheet design for high purity applications

Passivation and/or electro-polished product contact surfaces

Available in material upgrades to 316Lss, Duplex, Hastelloy, AL6XN and other alloys

Multiple-pass tubesheets and bonnets for a higher tubeside velocity in a small space

What about special requirements?

Thermal Products has a solution for the most unusual requirements and can custom design a shell and tube heat exchanger that will meet your specific application, size, special alloy or configuration in Sanitary or Utility applications. Contact us today!

Have you noticed decreased efficiency from your heat exchanger or circulation heater? So much so that your process is now operating out of acceptable temperature, pressure drop or flow range? You are most likely having significant fouling issues.

The most common reasons heat exchangers don’t provide the heat transfer rate they were designed for or have increased pressure drop from occlusion, is what we call fouling. Fouling is the buildup of sediments, mineral calcification and/or debris from the process that settles onto the surface area of a heat exchanger or circulation heater.

During the design stage, Thermal Products will inquire about specific process media makeup and the cooling or heating media. Thermal Products will ask you about the suspended solids, mineral content, and chemical content along with the typical needs of flow rate, heat load and temperatures in and out of the heat exchanger. With the provided information the Thermal Products design engineers will take into account the appropriate fouling factor to maximize the lifespan of the heat exchanger or preventative maintenance interval, reducing unexpected costs for the plant. The fouling factor essentially increases the surface area, over and above what is needed in order to perform the required heat load duty.

What are the different types of fouling?

Scaling is one of the most common types of fouling. Minerals and Salts commonly found in natural waters have a lower solubility in warm water than cold. Therefore, when cooling water is heated during the cooling process, particularly at the tube wall or plate wall, these dissolved salts will crystallize on the surface in the form of scale.

 

Thermal Products will design a heat exchanger or circulation heater with a lower tube temperature or watt density respectively, reducing the tube wall or element temperature. The Thermal Products design engineers will also look at process velocities through the heat exchanger or circulation heater, as slower velocities can exacerbate the problem.

This is noticed typically in the use of cold well water or open cooling tower applications.

Sedimentation, is the depositing of dirt, sand, rust, and other small debris and is most common when fresh water is used. This type of fouling typically leads to the heat exchanger or circulation heater becoming impacted and will completed occlude the flow, if left untreated. This can be controlled to a degree by the heat exchanger design through velocity control, but need to be careful as increasing the velocity too much will lead to erosion of your tubes or elements. Thermal Products will also design and offer upstream filtration or straining equipment to assist in removal of this type of debris before it gets to the heat exchanger or circulation heater.

If your process is sensitive, Thermal Products can design a closed-loop heating or closed-loop cooling process to eliminate the issues of sedimentation fouling completely.

Biological/Organic growth material typically occurs in marine, chemical, or bioorganic applications and can cause considerable damage if allowed to build up. Thermal Products can design a heat exchanger or circulation heater that can be resistant to biological fouling or organic fouling using different materials and design considerations.

Chemical Reaction Coking appears in oil heating applications, where the heat exchanger tubes or circulation heater elements are too hot. When the oil comes in contact, it burns the oil and deposits the resulting hydrocarbon on the heating surface. If left and the situation is not corrected, it will lead to premature failure of the heat exchanger or circulation heater. All oils are susceptible to Coking, but at a wide range of temperatures, dependent on the oil type.

As in mineral Scaling, Thermal Products will require the type of oil used so we can determine its flash point, thermal conductivity, specific heat and specific gravity so we design the proper heat exchanger or circulation heater.

Heat Exchanger and Circulation heater design are far more involved than looking at fouling, but it is an important factor to include when performing the design.

Any fouling, left untreated will result in the failure of that heat exchanger or circulation heater. The failure can be catastrophic in some cases.

As touched on earlier, Thermal Products can reduce the fouling possibilities greatly, by “closing the loop” if fouling is a chronic problem for your process. Thermal Products can design a Chiller, Closed loop cooling, closed loop heating or offer fired process heaters to perform the heating or cooling as your process dictates.

             

Contact any member of the Thermal Products team to discuss your process needs.

Application:

A Gas Compression company needed to reduce the noise level of their package by 20 dba measured at 3 meters from the core of the machine. The air temperature within the sound enclosure must remain at ambient temperature while accounting for 1,900,000 btu/hr heat rejection from the electric motors and compressor cores. The customer also needed the interior of the enclosure to be lighted with electrical outlets. Customer also required alarms notifying them of a gas leak.

Design Requirements:

This project required a complete sound enclosure measuring 30 ft long by 21ft wide and 12 ft high which encompassed the entirety of the gas compressor skid package. The design of the enclosure walls was required to be 4” thick with an inner perforated metal wall and an outer solid steel skin. We designed the inner mineral wool density to handle the noise reduction.

Equipment Included:

• Sound enclosure
• (2) doors
• (1) intake plenum and silencer
• (1) exhaust fan
• (4) light fixtures
• (4) light switches
• (1) gas detection system

Solution Offered:

The enclosure was designed with (1) 12,000 cfm exhaust fan with intake silencer and a 3HP explosion proof motor. To maintain ambient temperature inside the enclosure there needed to be an air flow switch and thermostats to control the fan operating and at what speed. Included was a gas detection system encompassing 4 individualized sensors wired back to a centralized enclosure alarm system tied to the customer’s main system. (2) light fixtures were mounted to the interior of the roof and (2) mounted above each of the (2) entry doors. Each door also had a light switch mounted to the entry point.

Thermal Products Advantages:

Thermal Products can offer an initial sound study completed to ensure you receive a properly designed sound enclosure. Every enclosure is factory assembled to ensure form, fit and function. Your enclosure can either ship assembled or in a kit disassembled. Our enclosures can either be finished with our in-house powder coat, galvanized steel or stainless steel. Although our enclosures are quite easy to assemble with the proper equipment, we do offer and perform onsite assembly from our trained factory assembly team.

When a local Biodiesel company decided to grow their process, there were several capacity challenges that they faced.  Thermal Products Inc. was consulted to help address the process cooling system utilized during the reclamation of methanol from the vegatable oil recycling process.  We designed a cooling tower and pump skid from Advantage Engineering and condensers from API Heat Transfer's Plate Heat Exchanger and Shell and Tube Exchanger groups.

 

                                                                           

 The collected vegetable oil waste from area commercial kitchens and food process plants is heated, broken down, and cleaned with an alcohol based fluid.  One of the results of this process is the by-product, Methanol. Reclaiming methanol is both environmentally sound and cost effective. The cooling challenge was that both vegetable oil and methanol reach high temperatures of 260F during the process. Once separated, the methanol vapor must be condensed back to a liquid, stored, and readied for reuse.

Thermal Products designed and offered an Advantage Engineering 45 ton evaporative cooling tower to provide a top end of 85F cooling water to an API Heat Transfer Shell and Tube exchanger that was designed to condense the Methanol to an inital 100F. This was achieved by the steady year round 85F water temperature that the tower could provide to a pump tank station combination.

The Methanol at 100F still needed to be at a final temperature of 60F.  Due to limitation of a cooling tower to provide 85F water during the summer months, a "trim" 15 ton water cooled chiller from Advantage Engineering, was provided to supply 50F chilled water to the API Heat Transfer plate and frame exchanger to reach the desired Methanol temperature of 60F.

                                                                                          

With high energy costs being a real challenge to process plants and their ability to be competitve, Thermal Products designed a hydrid process cooling system to have the majority of the heat load handled by an inexpensive open cooling tower and pump skid system.  Thermal Products then designed the "trim" cooling system for summer operation with the use of a small water cooled chiller.

Employing the provided hydrid process cooling system not only cut capital costs for the equipment, but the operation costs were much lower than they would have been if just employing a refrigerant chiller for the entire heat load.

Page 2 of 3

Contact Us

Fields marked with * are required

Latest Articles