Process Heat

Getting the kW right is only half the equation — here's why watt density is the real key to heater reliability and longevity.

Learn the fundamentals of heat transfer and how conduction, convection & radiation impact heater performance. This Engineering 101 guide makes complex thermal concepts easy to understand and helps you choose the right heating solution for your process.

Taking a systematic approach to specifying a tank heater can help ensure the equipment specified delivers the heating performance desired. Factors to consider include the amount of energy needed, heat loss, direct or indirect heating, materials of construction, and controls.

There are many types of options to sift through, and keying in on the ones that benefit your process the most will guide you to the most appropriate controller.

The first step to solving a problem is recognizing that one is present. An operations team cannot adequately put a sufficient maintenance plan in place if there is no awareness that maintenance is required.

For any process where temperature needs to be monitored or controlled, a thermal loop is required. Typically, a process that contains a thermal loop includes some key elements: the process itself, the temperature sensor or transmitter, the temperature controller and the power controller. 

In this article, featured in Process Heating Magazine, Ryan Kraus discusses the various criteria to consider when selecting a circulation heater.

A fuel leak in any part of a generator set can potentially be a catastrophe for the operator. But the issue can be tackled.

Most facilities in the chemical process industries (CPI) require some form of heat. The amount of heat required, and the necessary level of consistency can vary from process to process. Regardless of the details, engineers must decide on a heating source that works best for a particular process.

In terms of what matters to most in the field today, it is safe to assume that reliability, flexibility, accuracy and cost are at the top of the list. With these factors in mind, implementing a silicon-controlled rectifier (SCR) control system for an electric heater is often an optimal approach.

Maintaining a consistent internal environment for your enclosures is critical for equipment to function properly. The National Electrical Manufacturers Association (NEMA) has defined standards for specific enclosures designed for the application and environment when correctly installed. Learn more.

Reducing the amount of hydrocarbon leakage from compressor stations is not only imperative for the environment, but for your bottom line. Compressor-related emissions can be reduced by using electric heaters to heat the pressurized natural gas.

Several different processes require a product to flow through a pipe from one piece of equipment to another. A certain level of heat is often required for this process piping, and this heat must be at very high levels for many applications.

Achieving effective catalyst regeneration requires a process that produces a very high level of heat in a very efficient manner. Over the years, there have been several different approaches to create this required heat. Traditional steam and heated transfer media have limitations. Learn more.

Laying out an effective heat tracing design requires careful attention to detail. Every aspect of the system must be meticulously considered, including both the temperature requirements of the fluids being protected as well as the physical characteristics of the equipment being heat traced.

An operator in a fluid handling process is only as effective as his ability to work with a given controller. If there are factors that keep this individual from doing what is necessary for a smooth operation, adjustments need to be made.

Premature heater failures can lead to unexpected process downtime. Tactics such as testing, planned replacement programs, and preventing moisture ingress can help prevent premature heater failures.

A plant operator's biggest fear is an unplanned shutdown. The process can place a heavy amount of stress on both operations and maintenance personnel. Alternatively, taking full advantage of a planned shutdown or turnaround is critical.

Developing a strong preventative maintenance plan for plant shutdowns and turnarounds is the best way for operators to minimize the risk of equipment failure, which can lead to unnecessary shutdowns and ultimately, higher costs.

With the cold months on the precipice, November is a great time to review the actions that plant managers and operators should take to better ensure a winter free from incident.

Thermocouples and controllers themselves do not prevent a failure from occurring. What they can do is create a temperature profile for a heater that can be used as a maintenance log.

In environments with persistent cold weather, ice buildup on flat commercial roofs is both a safety hazard and a costly liability for many businesses. There are three main roof drainage systems used by commercial facilities: drainage, scupper, and traditional pitch and gutter drainage. Learn more.

In today's coal-fired power generation plant, one element of critical preventative maintenance is keeping everything at a temperature that will prevent instrumentation from freezing. Learn more about the successful application of heat trace solutions in coal-fired power generation plants.

In applications requiring heated concrete to prevent snow or ice accumulation, the ideal solution is mineral-insulated heat trace cables embedded in concrete.