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Reduce Heat Exchanger Maintenance Intervals because of coking and fouling and decrease carbon emissions with Watlow’s New HELIMAX™ Ultra-Efficient Electric Heat Exchanger
Contact details for European Headoffice:
Watlow Plasmatech GmbH
Brennhoflehen – Kellau 156
5431 Kuchl
Austria
Phone: +43 (0) 6244 20 12 90
Web: www.watlow.com
E-mail: watlowleads@watlowleads.com
One of the first questions that must be answered at the start of an electrification project is whether the local utility grid can handle the increased load. This is not simply a question of power availability, but of balancing power demands and supply availability.
Industrial organizations can push decarbonization forward by shifting process heater systems from fossil fuel-burning to electric. This kind of electrification needs to be done with a systems approach in mind—that is, considering the entire thermal loop.
Electrical boosting is a method of inputting extra energy into a glass furnace to enable better control of the melt flow for faster pull rates. The design of the boosting system can have an impact on the amount of energy used and consistency of the melt. This paper describes some of the advantages and possible side effects of different system designs along with some recommendations for better energy efficiency and end product quality.
Maximize sustainability and performance in the subfab with Data Insights sub fab monitoring. Our Sub Fab Monitoring Program is designed to provide visibility and enable proactive intervention in the sub-fab by collecting and analyzing data from thermal systems, enabling you to detect issues that could lead to unplanned downtime, and improve overall efficiency of systems in the subfab.
Raven SR, Inc. (Raven SR) is a clean fuels company that transforms waste into usable fuels. To do this, the company uses a process that requires high temperatures and precise control to maintain efficiency and, hence, cost-effectiveness. Watlow® provided extensive expertise in thermal system design, as well as Industry 4.0 control, in the development of this process. With Watlow’s help, Raven SR is well on its way to becoming a game-changing company offering
The demand for environmentally friendly and low-CO2 forms of energy generation has been increasing in Europe since the “Green Deal” was presented by the EU Commission in 2019, defining the climate neutrality of 26 member states up to the year 2050. Among other methods, the focus is on solar energy as an important representative in this area.
Process heaters, such as immersion heaters, use a range of sensor options to accurately measure and adjust the heat of a manufacturing process. If you’re a design engineer using the latest heating products, your process heater typically uses one of these three types of sensor:
Typical customer specifications for a direct electric heat exchanger (DEHE) in forced convection gas applications aim for efficiency and safety given the technology principles that have been in place for the last two decades. For example, this has led to specifications calling for lower heat fluxes (watt densities) to maintain safe sheath temperatures reliably. More recently, newer technologies allow for higher watt densities while maintaining both safety and reliability. While the older specifications are conservative and safe, the design may be sub-optimal. Letting go of the assumption that watt density is roughly equivalent to a safe sheath temperature helps open up the possibilities of new design solutions, many of which can reduce overall footprint and make processes more efficient and less costly.
One of the most common failures in electric process heaters used in various industrial applications involves electrical terminations and not the heating elements. Engineers at Watlow® believe designers across the industry are underestimating the temperature profile from the heater flange to terminal enclosure in these thermal systems.
Companies in liquified natural gas (LNG) and other industries have been taking bold steps to reduce their carbon footprint. The overall strategy of these companies is to tackle carbon emissions not only through alternative energy investment and increased efficiency, but also through converting key industrial processes (like process heating) to electric (rather than fuel-fired). This paper explores pressures to electrify process heating, as well as the role that electric heat exchangers are playing, particularly in light of innovations in the design of these heaters.
How ULTRAMIC® advanced ceramic heaters offer more design flexibility for mass spectrometers and other pieces of analytical equipment Advanced ceramic heaters offer a number of benefits when it comes to the design and marketing of analytical equipment. Many of the heaters used in today’s analytical equipment are metal-sheathed heaters based on legacy technology designed some 20 or 30 years ago, potentially limiting design innovation. By contrast, today’s advanced ceramic heaters are smaller, respond faster, can be more accurately controlled and can be more resistant to environmental contamination. They also offer more design flexibility and are easier to integrate into equipment, simplifying the manufacturing and assembly process. Watlow’s ULTRAMIC advanced ceramic heaters in particular can help analytical equipment manufacturers improve product performance and design, as well as accelerate their time to market.
Electric process heaters that interface with flammable materials in explosive environments need to be properly evaluated to protect the equipment against catastrophic failures. There are several possible protection methods that may be employed to protect from a potential explosion. A temperature class requirement will be provided by the user based on the explosive gases that may be present in the installation area. The maximum surface temperature of the process heater must then be evaluated to assure compliance. Temperature classes that are based on the maximum operating temperature for heaters prescribe the level of safeguards. Determining the temperature class for a specific electric process heater is unique compared to other electrical components installed in classified locations. The temperature code, or T-code, is highly dependent on the process conditions of the heating application. Global Temperature Classes/Codes are broken down into the following various levels.
Scott Boehmer and Mike Bange, Watlow, USA, outline how heater reliability can be improved by better predicting terminal enclosure temperature.
It has generally been assumed in energy process heaters that pins attaching heating elements to the power terminal do not generate heat on their own. That is why they are called cold pins. Engineers at Watlow believe cold pins actually generate heat creating an environment that is leading to heater failures.
Watlow partners with Raven SR to deliver precise temperature control
St. Louis, MO – Watlow®, a designer and manufacturer of complete industrial thermal systems, is pleased to announce that it has signed an agreement to acquire Eurotherm® from Schneider Electric, the global leader in the digital transformation of energy management and automation. The terms of the transaction were not disclosed.
While investment in clean energy plays a huge part in achieving global climate goals, it must coincide with the further electrification of industrial processes. Even in the oil and gas industry, there is significant room for the decarbonization of processes, particularly in thermal applications. Innovative technologies have solved many of the challenges that previously hindered the implementation of electric process heating, making it an obvious area where companies should focus their efforts. Here, Dennis Long applied thermal expert at industrial technology company Watlow, explains more.
St. Louis, MO – Watlow®, an industry leader in the design and manufacture of complete thermal systems, introduces its new PM PLUS™, an enhanced version of the popular EZ-ZONE® PM temperature controller. The PM PLUS is more intuitive than its predecessor and features an improved user interface for easier set up, programming and readability.
St. Louis, MO – Watlow®, an industry leader in the design and manufacture of complete thermal systems, recently introduced its new 1/32 DIN PM LEGACY™ controllers, which are the first 1/32 DIN controllers on the market to incorporate Bluetooth® wireless technology. Bluetooth® is used to enable EZ-LINK™, Watlow’s mobile app for setting up, monitoring and adjusting PM PLUS™ and PM LEGACY controllers.
St. Louis, MO – Watlow®, an industry leader in the design and manufacture of complete thermal systems, is pleased to announce that it has attained INMETRO certification on its HYDROSAFE® indirect heat exchanger. A certificate of compliance to the INMETRO regulations ensures electrical and electronic products can be sold and distributed in Brazil.
St. Louis, MO – Watlow®, an industry leader in the design and manufacture of complete thermal systems, recently introduced a batch processing feature for its powerful F4T temperature and process controller and D4T data logger.
St. Louis, MO – Watlow®, an industry leader in the design and manufacture of complete thermal systems recently launched ASPYRE®, a new power controller family. Available in sizes ranging from 35 to 700 amps, the ASPYRE family is flexible, scalable and offered with a variety of options allowing one platform to be reused across a wide range of applications.
Watlow®, an industry leader in the design and manufacture of complete thermal systems recently launched its EZ-LINK™ mobile app and added an option for Bluetooth® wireless technology to 1/16 DIN EZ-ZONE® PM products. Used together this makes setting up, monitoring and adjusting 1/16 DIN EZ-ZONE PM controllers and limits easy and painless.
Watlow®, an industry leader in the design and manufacture of complete thermal systems recently launched ASPYRE®, a new power controller family. Available in sizes ranging from 35 to 700 amps, the ASPYRE family is flexible, scalable and offered with a variety of options allowing one platform to be reused across a wide range of applications.
Watlow®, an industry leader in the design and manufacture of complete thermal systems recently launched its EZ-LINK™ mobile app and added an option for Bluetooth® wireless technology to 1/16 DIN EZ-ZONE® PM products. Used together this makes setting up, monitoring and adjusting 1/16 DIN EZ-ZONE PM controllers and limits easy and painless.
Watlow®, an industry leader in the design and manufacture of complete thermal systems, recently introduced the SERIES C1 extra-small, non-hazardous location control panel. This new addition to Watlow’s WATCONNECT® control panel family is simple to order, simple to setup and incorporates Watlow’s thermal components in a UL® recognized package that can be delivered in less than two weeks.
Watlow’s new ASPYRE® power controller family is flexible and scalable, and available with a variety of options allowing one platform to be re-used across a wide range of applications, which can help save time and money. ASPYRE models available include sizes from 35 to 700 amps.
The F4T with INTUITION® temperature process controller from Watlow® offers a wide range of field removable I/O modules for maximum design flexibility. Configurations can be custom tailored to meet the scaling needs of a tremendous range of equipment and applications while providing exactly the hardware types required for compatibility.
Watlow’s new FLUENT in-line heater is a small, lightweight, high-performance heater that can replace both a traditional immersion type heater or a heater wrapped around a tube as part of a thermal system. Watlow’s FLUENT heater is designed as an integrated solution that replaces multiple components in a system. This heater design reduces overall system cost and complexity. Because of its high watt density, it offers ultra-fast response leading to higher system performance.
Watlow has over 40 years of experience designing and manufacturing heat exchangers, and we have the knowledge, experience and expertise required to create optimal heating solutions. Watlow has taken the tried and true, critical design criteria and improved it to create a new generation heating technology – the OPTIMAX® Heat Exchanger.
Watlow® is now offering WATCONNECT® standard control panels that are quickly configured to your specific application requirements and delivered within two weeks. WATCONNECT panels integrate Watlow’s high-quality heater, sensor, temperature controller and power controller products for a complete thermal solution. Normally, competitive custom panels require significantly longer lead times. The broad range of standard features allows customers to quickly configure panels that usually would be considered custom for delivery within two weeks.
Watlow® has over 40 years of experience designing and manufacturing heat exchangers, and we have the knowledge, experience and expertise required to create optimal heating solutions. Watlow has taken tried and true, critical design criteria and improved it to create a new generation heating technology – the OPTIMAX® heat exchanger.
HYDROSAFE®, Watlow’s new indirect electric heat exchanger for dry gas seal applications, has been designed as a standardized thermal solution that minimizes custom engineering requirements because it can be adapted to a variety of conditions. The HYDROSAFE provides very flexible heating capabilities (12 to 31.2 kW) to compensate for changes in gas flow rates, or changes in gas composition, when interconnected to our purpose engineered WATCONNECT® control panel. Multiple units may be connected in series for higher kW needs.
