This article highlights the value of efficient design in developing high quality heaters for the process industry. WATTCO uses advanced techniques such as computer simulation to produce effective heaters that not only provide efficacy but also save significant construction time and material costs.
From its inception, WATTCO has emphasized quality. This often required over-designing and over-engineering heaters for the process industry. To ensure quality, designs of WATTCO’s heaters were based on chosen parameters to deliver performance, rather than on company concern for cost or design time. A complicated design often took years to create a prototype. Building prototypes also took considerable investment.
WATTCO has begun to design heaters using simulation in recent years. Simulation or computer aided design (CAD) techniques provide insight into manufacturing. These techniques or simulations can study the behavior of heaters that are subject to external effects such as fluid dynamics, thermal and structural stress in scenarios very similar to reality. Design by simulation has several benefits. For example, it reduces design time and design costs. This is possible because simulation helps to optimize the design. The cost benefit comes from recommending precise dimension of heater components, for example flanges. This saves expense on various materials.
Furthermore, WATTCO engineers avoid the significant cost of prototyping. It is often not necessary for intermediate steps. In particular, WATTCO could reduce the flange thickness (See Figure 1.) as much as 50% using simulation—without degrading the heater performance. In fact, this kind of optimization leads to enhanced performance in addition to significant material cost savings.
WATTCO engineers use simulation to improve heat transfer for process heaters that use baffles. Simulation provides an understanding of how baffles can be used in a heater where heater shape, viscosity, fluid temperature, fluid dynamics are taken into account. Baffles are often used in round-shaped heaters to improve mixing for low viscosity fluids. (See Figure 2.) Traditional designs recommend a baffle design that is subject to tank diameters, as shown in Figure 3. A simulation design can provide more precise information for the number of baffles as well as their angles. WATTCO also specifies the exact location of baffle mounting on heaters, for example, based on the baffle width.
WATTCO is enhancing heater design for the process industry including the petrochemical industry and the semi-conductor industry. Performance and safety can be assured while still keeping a lid on cost for design.
In the case of liquids that have solid suspension baffles should induce swirl, ensuring particles are in constant motion.
WATTCO engineers rely on simulation to provide design details that are accurate and reliable. The main reason for accuracy comes from the fact that simulation not only considers the theoretical modeling but also exhibits the heater behavior based on different external and real time scenarios as if they are being used in their actual industry environment. Design engineers also find simulation or computer modeling efficient as it provides flexibility in changing parameters to see the performance even before a prototype is fabricated.
Why is Mineral Oil Used in Thermal Heaters?
Thermal heaters, also known as thermal fluid heaters, employ the use of a thermal liquid such as wat...
What to Use When Heating Wax
SituationA popular chemical compound that often requires heating is wax, which is an organic compoun...
What is Passivation? Why do We Need to Passivate Flanged Heaters?
Most of the parts of flanged heaters are made of stainless steel—an alloy that is mainly compri...
What is a Digital Controller?
Control panels are essential elements of any electrical device. Control panels are especially i...
Vegetable Oil Heating
Food Industries and Vegetable Oil Viscosity In Cleveland Ohio, a large food manufacturer called WATT...
Electric Process Heaters within Industries
A process heater is any equipment with the express purpose of heating chemical process streams. Any...
There are many uses and applications for electric heating elements, such as immersion and circulatio...
COME VISIT US AS THE 2018 ADIPEC SHOW IN ABU DHABI – STAND #2470
The Importance of ASME Vessels in Boiler Heater Safety
The ASME Boiler & Pressure Vessel Code (BPVC) is the set of codes and standards to increase the ...
A Look at the Efficiency of Flanged Heaters
Most industries today require heating solutions for various industrial processes in their production...
Electric Heating Coils: Selection & Design
Electric heating coils transfer energy into heat in a variety of heating applications. They’re an ...
What is a Pressure Vessel?
Pressure vessels are carefully fabricated, enclosed containers designed for the purpose of holding e...
Duct Heating in HVAC and Building Construction
Heating, ventilation, and air-conditioning (HVAC) systems are used for heating and cooling residenti...
Temperature and Power Controls for Industrial Electric Heating
A control system is an essential part of every industrial heating system. Whereas some applications ...
.Crude oil, unprocessed fossil fuel, is one of the most important natural resources. In its unproces...