Editorial

SICK has launched an Industry 4.0 on-premise data intelligence platform that empowers manufacturing and logistics organisations to optimise their operating performance. SICK Field Analytics can be quickly and easily set up to provide meaningful, application-specific condition monitoring and process insights, independently of an organisation’s existing machinery and systems.

SICK Field Analytics is a vendor-agnostic digitalisation platform that collects and aggregates data from any source, including sensors, machine controllers and other IIoT devices. The software can be configured to display real-time data, to provide timely alerts and alarms, and to visualise historical trends through powerful dashboard graphics.

Data Insights for Improved Performance

Using the SICK Field Analytics software solution and a dedicated computer, users can aggregate data from disparate machines and automation systems or augment legacy automation systems to provide additional data insights. The solution is highly scalable, enabling users to adopt it on a project-by-project basis or at a wider organisational level.

Charlie Walker, SICK UK’s Digital Solutions Consultant, says the SICK Field Analytics platform can support users to progress towards greater Industry 4.0 digital maturity:

“Operators who want to gain more insights across a production floor, factory or warehouse may feel quite daunted by the prospect of collecting and comparing data from many different machines or applications.

“Faced with a sea of information, it can be difficult to isolate the specific factors that are affecting operating efficiency. The data could come from all sorts of sources that use different communications protocols. Information could even still be recorded manually, be stuck in silos, or bogged down in bottlenecks.

“Even if operators already extract some data from their existing automation, they can find themselves locked out of PLCs or other systems, such as “legal for trade”. So, they cannot increase the amount of diagnostic data from their legacy systems, even when they replace switched devices with IO-Link sensors, or configure edge integrations using IO-Link Masters.”

Interrogate Operating Efficiency

“Field Analytics can solve these problems easily by collecting data from all these disparate sources without costly and time-consuming adaptation of existing systems. Operators can extract more information about the health of their machines, while interrogating their operating efficiency in new, and sometimes surprising, ways.”

The SICK Field Analytics software platform can be used in combination with data extracted from a wide variety of existing sources, including sensors from any vendor, PLCS, and smart IIoT edge devices such as Sensor Integration Machines. Where necessary, SICK can work with a customer to add smart sensors and edge devices to machinery or automated systems as part of a dedicated Field Analytics project.

Powerful Dashboards and Alerts

SICK Field Analytics incorporates a user management module to manage access rights. The data collected will depend on each organisation, but could range from the service status of sensors through to key data about the health of machinery, such as vibration, temperature, or shock. Organisations can configure their Field Analytics package to better understand the condition of their machinery using powerful dashboard graphics and visual alerts.  

Operators can set up and trend Key Performance Indicators both historically and in real time. Through real-time alerts, they can react more quickly to production or process anomalies that might otherwise lead to machine downtime.

Field Analytics can track overall operating effectiveness. The dashboard features can be also trend other measurements important to an organisation’s profitability and efficiency. For example, it could monitor compressed air usage or calculate and track production costs, for example of energy consumption.

SICK Field Analytics can also enhance the data already available from legacy automated systems, including those that operate at a higher organisational level. SICK Field Analytics is compatible with most common communications protocols, including Rest API, OPC UA and MQTT. 

www.sick.co.uk

Reducing CO2 emissions together with considerably lower running costs are two good reasons to embrace boiler technology and improve its efficiency.  The capital costs of installing new industrial boilers or retrofitting existing ones are, however, significant and can be technically challenging.  At the same time navigating the complex regulatory processes and ensuring ongoing compliance is both time-consuming and resource-intensive.

Compliance with boiler inspections and maintenance procedures is critical and potentially demanding for those industries that are already operating under intense pressure or with limited resources.

Burning less fuel in the boiler to both save money and reduce emissions without making the process more efficient is ineffective as the fuel usage and its equivalent CO2 output is balanced to production. Without on-site expertise it's advisable to call in the professionals who will carry out a full audit, surveying the system in place to identify the best route to facilitate efficient production capacity with lower fuel usage delivering lower emissions.  Boiler hire is the credible solution to the challenge of the enormous capital investment of replacing an inefficient boiler.

Increasingly businesses and institutions such as food manufacturing and healthcare are turning to hire. Long term hire is increasingly the preferred choice when ageing plant needs to be replaced or when expansion requires additional capacity.  It comes with the obvious cash flow advantages whilst offering the latest fuel efficient boilers. At Byworth Hire this includes the multi award-winning and most energy efficient steam boiler available in the UK:  Yorkshireman2 Boiler.  Developed with rising fuel costs in mind it is the best option for the truly energy conscious incorporating a number of energy saving features including Byworth's use of patented X-ID tubes making it a most cost effective route to choose.  Five years is a long time in the manufacturing cycle so to commit today to purchasing a boiler that is expected to deliver the goods for a potential increase in demand in five years' time makes hiring a more attractive option as in five years it can be sized up or down to suit the business needs. 

Short term hire is the solution for when there are emergency repairs to cover existing boiler breakdowns, annual inspections and maintenance as well as peak seasonal loading which ensures stability and security. This is particularly pertinent for such as food and drink manufacturing.

Hiring provides the latest technology and automation together with full servicing and maintenance plus the knowledge that the boiler being used is doing its bit to keep carbon emissions to a minimum.

Whichever solution Byworth's expert project management team will visit the site and work with the client to specify and conceive purpose-built boiler plant rooms incorporating all the ancillary feed, fuel and blow down tanks including water softening equipment. These plant rooms can be containerised or in purpose built pre-fabricated boiler houses providing a dedicated turnkey project with minimal site work.  By hiring the heavy capital outlay of purchasing new is avoided.

As Byworth Hire Sales Director, Michael Rutter emphasised: 'In a rapidly changing and challenging environment, we need to keep up to speed to deliver the latest advances in technology with reliability to our customers. Our fleet of award-winning modern boilers together with a comprehensive back up service enables us to do just that.'

All of us are likely to be accused sometimes of having our “head in the clouds”. But with the tremendous advances in Cloud computing and mobile communications, perhaps the advice should be “get ahead in the Cloud!”

Imagine a scenario where a condition based maintenance (CBM) team is responsible for a number of remote sites. This could be where a central ‘control’ site has a number of remote ‘satellite’ locations that have equipment that needs to be monitored. The measurements could be done by personnel based at the remote site, or the sites could be visited from time to time by CBM engineers. Another similar scenario is where a service company has multiple customers that are visited by a ‘fleet’ of CBM engineers.

In each of these scenarios, the central facility will most likely be running computerised maintenance management system (CMMS) software that is being used to monitor, trend and report on the equipment as part of the CBM strategy. The whole process can be greatly facilitated by the ability to remotely download lists of the measurements (Routes) that are required at the remote locations, and automatically upload the subsequent readings into the CMMS software.

For example, supervisors can send out Routes that can be remotely downloaded via the Cloud onto mobile devices (e.g. smart phones or tablets). Using a mobile App, users can then locally transfer the Routes to measurement devices, such as vibration meters, via Bluetooth. The readings then go in the opposite direction, via Bluetooth from vibration meter to mobile device, and via the Cloud from mobile device to the CMMS software.

Test Products International (TPI) has now made this process very easy with the release of the TPI Cloud-Bridge App. This FREE, subscription FREE, mobile App works in conjunction with the subscription FREE, C-Trend II PC Software, to easily allow multiple routes to be sent to multiple, remote users, anywhere in the world and receive the readings back for detailed analysis.

The versatility of the TPI Cloud-Bridge App also allows it to be used with virtually ANY version of CMMS software.

TPI manufactures a complete range of low-cost, high-performance vibration analysers from the £575, one-button-to-press TPI 9070 Smart Vibration Meter, to devices that include advanced diagnostics and machine balancing.

The TPI 9080 Smart Trend Meter from £1,100 comes complete with PC based trending and reporting software that includes automatic report generation and email notification of alarms, to implement a full CBM solution. The TPI 9080 features colour coded alarm levels and zoomable on-screen vibration frequency plots together with on-meter analysis for the detection of machine faults such as unbalance, misalignment, looseness and bearing wear.

The TPI 9080 can store Routes of up to 1000 machines, each with up to 10 measurement points, all with full vibration waveform and frequency spectrum (FFT) capture. Routes and readings can easily be transferred to/from the TPI 9080 in a variety of different ways.  Locally, via the included USB docking cradle or wirelessly via Bluetooth, or remotely, via a Bluetooth link with a smart phone or tablet running the TPI Cloud-Bridge App. This allows service personnel to receive and return routes and readings, wherever they may be.  

The Ex certified TPI 9080Ex is IECEx/ATEX certified for Zone 1 and has North American approval for Class 1, Zone 1 and hence is certified for use in hazardous locations anywhere in the world. In-line with TPI’s philosophy of being the value leader, the TPI 9080Ex is available at a list price of £3,500.

For more information please contact TPI Europe’s head office on +44 1293 530196 or take a look on the website at www.tpieurope.com or email This email address is being protected from spambots. You need JavaScript enabled to view it.

For pre-treatment tanks at a wastewater facility in Indonesia, Landia is supplying 12 of its digester mixing systems.

Part of a major Bio Production Plant in Java, the facility converts grass materials into biodegradable bags, with the excess matter utilised to produce biogas in six 4,000m³ rectangular concrete tanks.

To accelerate the installation, Landia is sending the pipework of its externally-mounted systems in self-assembly sets, with an appointed engineer to supervise the set-up. At the heart of the system is the Chopper Pump (invented by Landia in 1950), plus venturi nozzles, which will provide comprehensive mixing of the tanks, so that no crust forms on the surface of the liquid.

Fergus Clark, who heads up the Asia-Pacific region for Landia, said:

"This is a very important new order, which underlines the effectiveness of our digester mixing system and the unrivalled reputation it has for maximising biogas yields.  Operators also like the fact that it is so reliable, and that everything is easily accessible on the outside of the tank - with no working at height. Unlike some systems, there is no downtime or very costly emptying of the tank for servicing or repair."

www.landia.com

Regardless of whether the business is an automotive workshop, a small-to-medium sized manufacturing company or indeed any type of operation that simply needs dry and clean compressed air, the new G-TEC Air Compressor from FPS provides a complete compressed air workstation with ‘game-changing’ capabilities. This 6-in-1 offer comprises a high-performance compressor, refrigerated dryer, dual filtration, 270/500 litre air receiver, oil-water separator and controller, making the G-TEC Air Compressor the optimal and most convenient choice, for a whole host of applications.

Avoiding the need for many individual components that typically form part of a complex compressed air system, the G-TEC workstation features an integrated and modular design that saves space, reduces installation and improves efficiency. It delivers outstanding performance, producing a consistent supply of compressed air to power a wide range of pneumatic tools and machinery. With its high-efficiency motor and innovative design, this complete workstation also meets the growing demand for more sustainable and cost-effective compressed air solutions.

G-TEC workstations from FPS are available with a range of 7.5 to 22kW with pressure from 8 to13 bar. The high-efficiency screw compressors ensure optimal productivity and reliability. Importantly, the workstation comes with a 270 or 500 litre receiver and an integrated dryer and filters. The result? Clean, dry air for quality-assured pneumatic operations that lead to reduced downtime and maintenance costs and Indeed, reduced corrosion within pipes that also means fewer product rejects, and fewer costly air leaks, delivering yet more savings.

Another integral component of the G-TEC Air Compressor workstation is the condensate oil-water separator, supplied as standard by FPS to reduce environmental pollution. Furthermore, the intuitive built-in control panel makes using the G-TEC workstation easy to use for operators of all skill levels.

Among the business that can take advantage are automotive workshops. From tyre centres to body repair shops, the task of paint spraying and when using general garage equipment can benefit from the fixed and variable-speed models of G-TEC Air Compressor line-up. As a particular point of note, noise output is exceptionally low.

Further applications include pneumatic tools on production/assembly lines, woodworking tools such as sanders and staplers, and plasma/laser cutting. In all cases the outcome is the same: high-quality, professional compressed air delivery with economy and sustainability in mind. When operating variable-speed models, the remarkable energy-saving capabilities of the G-TEC Air Compressor workstation render it an environmentally responsible choice that also reduces operational costs by as much as 30%.

With its fully integrated components, the compact design of the G-TEC Air Compressor makes it ideal for any customer where space is at a premium. This, when combined with straightforward installation and maintenance, allows the G-TEC workstation user the benefit of a hassle-free and highly cost-effective solution for businesses of all sizes.

“Users of the G-TEC Air Compressor can achieve the perfect balance between power and efficiency, ensuring that your compressed air needs are met without excessive energy wastage,” states Moiz Palaci, Director of FPS Air Compressors. “At FPS, we are committed to providing innovative solutions that meet the evolving needs of customers. Our G-TEC Air Compressor is no exception, boasting a range of features that make it the ideal choice whenever low noise, energy efficiency, convenience and reliability are primary demands.”

Purchase, lease and rental options are available.

For detailed information on the G-TEC range of air compressors please visit:

www.fps-compressors.co.uk/gtec.html

Carbon capture and storage (CCS) plays a vital role in mitigating greenhouse gas emissions and combating climate change. Since 2019, the global capacity of CCS has grown by 183%, as of September 2022, demonstrating the popularity of this technology as a method to meet environmental targets. With new technology and processes come new challenges, and CCS is no exception. This article aims to explore the issue of corrosion in amine systems and how the risk can be mitigated by high nobility cladding solutions.

Amine-based systems capture carbon dioxide (CO₂) from industrial flue gases. However, these systems present a significant challenge when it comes to corrosion in process vessels due to the aggressive nature of the amine solutions. To address this issue, upgrading the metallurgy of process vessels through high nobility cladding offers an effective solution to prevent corrosion and extend the service life of the equipment.

Understanding Corrosion in Amine Systems

Amine systems involve the use of amines, such as monoethanolamine (MEA), as the solvent to absorb CO₂ from flue gases. The amine solutions are highly corrosive, particularly in the presence of oxygen and heat, leading to the degradation of process vessel materials. Corrosion in these systems can result in reduced operational efficiency, increased maintenance costs, and even potential safety risks.

There are several corrosion mechanisms that can occur in CCS amine systems:

• General Corrosion

It occurs uniformly across the metal surface and leads to a gradual thinning of the metal over time.

• Pitting Corrosion

Pitting is localized corrosion that leads to the formation of small holes or pits on the metal surface. This type of corrosion can be particularly dangerous as it can cause sudden failures in the equipment.

• Stress Corrosion Cracking (SCC)

SCC is the cracking of metals under the combined influence of tensile stress and a corrosive environment. Amine systems can create conditions that promote SCC, leading to catastrophic failures in stressed components.

• Corrosion by CO₂ Decomposition Products

CO₂ degradation products like carbamate and bicarbonate can also contribute to corrosion in the amine system.

Upgrading Metallurgy with High Nobility Cladding

To combat corrosion in amine system process vessels, upgrading the vessel's metallurgy through high nobility cladding has proven to be an effective solution. High nobility cladding involves the application of a protective layer of noble metals, for example, an alloy of Chromium, Nickel, and Molybdenum, onto the surface of the vessel. This cladding provides enhanced resistance to corrosion and extends the vessel's service life.

Benefits of High Nobility Cladding

• Corrosion Resistance

High nobility cladding materials offer superior resistance to corrosion, even in aggressive amine environments. The protective layer acts as a barrier, preventing direct contact between the amine solution and the base metal.

• Improved Reliability

By upgrading the process vessel's metallurgy, high nobility cladding significantly reduces the occurrence of corrosion-related failures. This leads to improved operational reliability and a decrease in unplanned downtime.

• Extended Service Life

The implementation of high nobility cladding enhances the durability of process vessels, resulting in extended service life. This allows for a more cost-effective and sustainable operation of the CCS amine system.

• Installation and Maintenance Considerations

The successful application of high nobility cladding in amine system process vessels requires careful planning and execution. Key considerations include:

• Surface Preparation: Proper surface preparation, including cleaning and pre-treatment, is crucial to ensure optimal adhesion of the cladding material.

• Cladding Selection: The selection of the appropriate cladding material should consider the specific corrosion resistance requirements of the amine system. Stainless steel, nickel alloys, or other high-nobility materials are commonly used for this purpose.

• Quality Control: Rigorous quality control measures should be in place during the cladding process to ensure the integrity and effectiveness of the protective layer. Non-destructive testing methods can be employed to detect any defects or discontinuities.

• Regular Inspections: Periodic inspections should be conducted to monitor the condition of the cladding and identify any signs of degradation or damage. This allows for timely maintenance and repairs to maintain the corrosion protection.

Introduction to HVTS

High Velocity Thermal Spray (HVTS) is a proprietary high nobility cladding solution developed by Integrated Global Services (IGS). Due to its superior corrosion protection properties, it is referred to as a cladding, rather than a coating. HVTS involves the on-site application of a high-alloy corrosion-resistant cladding that consists of flat and tightly packed micro-sized metallic particles.

HVTS provides excellent value and results for protecting amine systems from corrosion and improving longevity at a fraction of the cost and time of weld overlay.

The Benefits of HVTS

A cladding solution, specifically HVTS, has many benefits for carbon capture and storage plants. The benefits include:

• Corrosion Resistance

HVTS cladding provides excellent protection against corrosion. The dense and tightly bonded cladding acts as a protective barrier. This helps extend the lifespan of the amine system, reduces maintenance requirements, and enhances overall reliability.

• No Dilution or Heat Affected Zone (HAZ)

Unlike Weld Metal Overlay (WMO), HVTS does not generate a Heat Affected Zone (HAZ) and does not place residual stresses on the base metal as the temperature of the base metal remains low.

• Refurbished or Replaced In-situ

HVTS can be reliably refurbished or even replaced in situ without replacing the underlying component. This contrasts with 625 weld-overlaid components which must be replaced at the end of life.

• Fast Application

HVTS cladding can be applied relatively quickly, making the process efficient for large-scale industrial applications. The high-velocity spraying technique enables fast coverage of large surface areas, reducing downtime and production interruptions.

• Cost-Effective Solution

HVTS and other high nobility claddings offer a cost-effective solution for extending the service life of components and equipment. By providing corrosion and wear protection, the cladding can reduce the frequency of component replacements and maintenance requirements, resulting in cost savings over time.

• Environmental Benefits

HVTS cladding can contribute to achieving environmental targets. By improving the durability and longevity of components, they help reduce the consumption of resources and minimize waste generated from frequent replacements. Additionally, HVTS can enhance the energy efficiency of equipment, leading to reduced energy consumption and lower CO₂ and NO_x emissions.

HVTS Cladding Process and Application

The application of High Velocity Thermal Spray (HVTS) to amine systems is always undertaken by trained IGS cladding technicians as training and expertise in HVTS application techniques are crucial to achieving high-quality and reliable cladding.

The application of HVTS involves the following steps:

1. Surface Preparation

The surfaces of the metal need to be properly prepared before the application of HVTS cladding. This typically involves cleaning the surfaces to remove contaminants such as rust, scale, oil, or any other substances that could affect the adhesion of the cladding. Mechanical methods like grit blasting or wire brushing are sometimes used for surface preparation if required.

2. Cladding Selection

The appropriate HVTS cladding material is selected based on the specific requirements, such as corrosion resistance, wear resistance, or thermal insulation.

3. HVTS Equipment Setup

The HVTS equipment, including the spray gun, gas supply system, and control unit, is set up according to stringent IGS guidelines and specifications. The system is calibrated to ensure accurate and consistent application of the cladding.

4. Application of HVTS Cladding

The HVTS cladding is applied using a high-velocity thermal spray gun. The gun atomizes a proprietary wire feedstock in a supersonic gas stream, producing a cladding that consists of flat and tightly packed micro-sized particles.

5. Post-application and Quality Assurance

Quality control measures, such as visual inspection, thickness measurement, and adhesion testing, are conducted to ensure the integrity and effectiveness of the HVTS cladding. Any necessary touch-ups or rework can be performed if required.

High Nobility Cladding Application Experience

Integrated Global Services (IGS) has extensive experience and expertise in addressing corrosion challenges in amine systems. With a proven track record in the field of corrosion protection and metallurgical upgrades, IGS has successfully implemented high nobility cladding solutions in numerous amine system process vessels over the last 30 years.

A deep understanding of the corrosive nature of amine solutions and the detrimental effects they can have on process vessel metallurgy, is important. Leveraging industry knowledge and advanced technologies, IGS has developed tailored solutions to combat corrosion and enhance the performance and longevity of amine system equipment.

Through years of research and practical application, IGS has honed their cladding techniques to ensure optimal adhesion and corrosion resistance. Their team of highly skilled technicians follows stringent quality control measures during the cladding process, ensuring the integrity and effectiveness of the protective layer.

Moreover, IGS provides comprehensive corrosion assessment services, leveraging expertise to identify vulnerable areas in amine systems. By conducting thorough inspections and evaluations, recommendations can be made and implementation of the most suitable cladding materials and techniques to prevent corrosion and extend the service life of process vessels can be undertaken.

Preventing corrosion in amine system process vessels is crucial for the successful and sustainable operation of carbon capture and storage facilities. Upgrading vessel metallurgy through high nobility cladding offers an effective solution to combat corrosion, extend equipment service life, and ensure operational reliability. By implementing high nobility cladding, CCS operators can mitigate the adverse effects of amine corrosion, reduce maintenance costs, and contribute to the long-term viability of carbon capture technologies in the fight against climate change.

Find out more: www.integratedglobal.com

Convey parts, materials, waste - with no moving parts!

 A Line Vac Air Operated Conveyor is a fast, low cost way to convey plastic pellets, scrap trim, bulk solids, food products, and much more.

EXAIR’s compressed air operated Line Vac connects to standard hose or tube to create a powerful in-line conveyor. The compact design features large throat diameters for maximum throughput capability. Eleven sizes in aluminum and ten in stainless steel are suited to a wide variety of transfer applications.

Line Vac conveyors are ideal for moving large volumes of material over long distances. A small amount of compressed air is injected through directed nozzles to produce a vacuum on one end and high output flows on the other, with instantaneous response.

Threaded Line Vacs, Heavy Duty Line Vacs, Heavy Duty Threaded Line Vacs, Sanitary Flange Line Vacs and Light Duty Line Vacs are also available in stock at EXAIR. Learn More and watch our helpful videos.  https://exair.co/190_564

Burdened with cumbersome maintenance, expensive spare parts and very high energy costs, a wastewater treatment plant has replaced its multi-phase eccentric screw pumps with new Rotary Lobe pumps, made by Börger.

Installed for a chamber filter press, the space-saving Börger pumps have been supplied as a twin-pack unit; two identical Rotary Lobe Pumps, which are operated in series. Each Börger rotary lobe pump has its own frequency converter that allows speeds to be individually regulated.

When feeding the chamber filter press, operators at the wastewater treatment plant now have a choice between two phases - the pre-fill phase and the pressurized phase. During the pre-fill phase, large quantities of sludge are pumped at high speed into the chamber filter press to fill up its chamber.

As the solids in the sludge gather in front of the filter screens, the increasing filling level of the chamber increases the counter pressure in the chamber filter press. Using the frequency converter, the speed of the Börger pumps is then reduced accordingly.

In addition to improving the output and efficiency of the application, the new Rotary Lobe pumps have drastically reduced energy costs, and are also far easier to service with their easy access, Maintenance-In-Place design.

Borger UK

01902 798 977

www.boerger.com

This email address is being protected from spambots. You need JavaScript enabled to view it.

By releasing the new MGF X Line range of oil-free compressors into the UK market, FPS Air Compressors is providing dental labs running CAD/CAM-driven milling machines and 3D printers with a proven way to utilise a continuous and highly reliable source of clean, dry compressed air without risk of contamination.

Computer-Aided Design/Computer-Aided Manufacturing (CAD/CAM) systems are finding growing use in the creation of dental restorations such as crowns, bridges and veneers. The new X Line can supply clean and dry compressed air continuously and reliably to CAD/CAM-driven milling processes, ensuring the precise, reliable and high-integrity production of dental prosthetics.

A further benefit of using innovative MGF X Line compressor technology at dental labs is increased air capacity and, subsequently, lower energy bills. This advantage arrives courtesy of a patented MGF system that reduces the air requirements of the membrane dryer, which in turn increases the available flow of air from the compressor by 20-25% to help optimise dental lab processes such as milling.

The X Line is also ideal for serving 3D printers, which although an additive rather than a subtractive process like milling, still need a compressor that provides continuous, high air quality and low vibration to support the precision and stability demanded by the 3D Printers industry. Notably, as 3D printing technology becomes more widespread, the importance of air quality in the printing process is gaining more and more attention in the process.

                                                                                                                                                                        Continued ……

Producing consistent air quality is a primary capability of X Line compressors, which house a 0.01 µm filtration system and a high-quality, high-efficiency membrane dryer. The provision of clean, dry, continuous air allows dental labs everywhere to take advantage of uninterrupted workflows. X Line compressors run at a maximum pressure of 10 bar, producing constant air flow at the capacity stated from a broad range of models suitable for multi applications.

Offering yet another advantage, the low vibration of the cabinet-housed X Line air compressors contributes to quiet operation. In addition to the four ‘Base’ models, a trio of ‘Silent’ versions are available providing low noise levels that do not exceed 53-56 dB(A). Furthermore, with the robust build quality, X Line compressors offer highly durable operation and a long service life, helping to minimise total cost of ownership (TCO) for dental labs.

Ultimately, the MGF X Line combines efficiency, performance and reliability with extremely quiet operation, providing genuine added value to dental labs running CAD/CAM-driven milling and 3D printing processes.

In addition, FPS extensive range of oil-free and SCROLL compressors are suitable for a myriad of applications in other sectors that demand high air quality. These include: product handling and packaging at food and beverage plants; aseptic processes and cleanrooms in pharmaceutical facilities; circuit board manufacturing and chip production in the electronics market; jet looms and air splicing at textile factories; testing and analytical instruments at research laboratories; and sampling and analysis devices in environmental monitoring processes.

For further information on the X Line range oil-free compressors please visit:
https://www.fps-compressors.co.uk/oil_free_compressors-cadcam_applications.html

Introduction

Improving fired heater performance is crucial for optimizing energy consumption, reducing emissions, and enhancing overall process performance. In large-scale process facilities, energy typically accounts for at least 50% of operating costs. An energy use reduction of 10% will often improve margins by 5% and reduce CO₂ emissions by 10%.

This article will discuss symptoms and causes of fired heater performance issues, and the solutions available to fix them and improve efficiency.

What are the Symptoms of Underperforming Fired Heaters?

Inefficient fired heaters can lead to increased energy consumption, decreased production rates, and potentially unsafe operating conditions. There are several symptoms of fired heater underperformance:

• Elevated Bridgewall Temperature
• Tube Overheating
• High Stack Temperature
• Production Bottleneck
• Excessive CO2 and NOx Emissions
• Insufficient Process Pre-heat/Steam Production
• Excessive Ammonia Slip

What are the Causes and Solutions of Underperforming Fired Heaters?

Cause 1: Fouled Convection Section Tubes

Fouling, which is the accumulation of deposits on the inner surfaces of the heater tubes in the convection section, can reduce heat transfer efficiency. Common fouling agents include carbon deposits, coke, ash, and other particulates. Fouled tubes can reduce heat transfer rates, increase fuel consumption, and decrease overall efficiency.

Solution 1: Robotic Convection Section Cleaning

To restore heat transfer efficiency, convection section tubes should be cleaned regularly. Robotic methods to remove fouling are now favoured as they offer several benefits compared to traditional manual cleaning methods, including:

Increased efficiency and speed: Robotic systems are more precise and can navigate complex geometries and hard-to-access areas with greater speed. This results in faster cleaning cycles and reduced downtime during maintenance.

Remote Operation: Robotic cleaning systems are often operated remotely, allowing technicians to control and monitor the cleaning process from a safe distance. This is particularly advantageous in situations where the convection section poses safety challenges.

Cost Saving: The initial investment in robotic cleaning services can often be higher than manual labor costs, however, the long-term benefits often outweigh this. Improved efficiency, reduced downtime, enhanced performance, and decreased maintenance needs can lead to significant cost savings over the equipment's lifespan.

Environmental Benefits: Efficient convection section cleaning helps maintain optimal heat transfer efficiency, leading to reduced energy consumption and lower CO2 and NOx emissions. This aligns with sustainability goals and environmental regulations.

Conducting a technical evaluation before cleaning the convection section is advisable. This will indicate the expected performance gains in terms of increase in capacity, % reduction in emissions, and fuel consumption benefits.

Watch: Robotic Convection Cleaning

Cause 2: Radiant Tube Scaling

Radiant tubes are designed to transfer heat from the combustion of fuel to the process fluid or material being heated. However, they are susceptible to scaling, which is the deposition of solid materials on the external surfaces of the tubes. Scaling can have several negative effects on the performance and efficiency of radiant tubes including reduced heat transfer efficiency, tube overheating, emissions increase, and higher bridgewall temperatures.

Solution 2: High Emissivity Coatings

High emissivity coatings, such as Cetek coatings, are materials that besides improving radiant heat transfer, also prevent oxidation and scale formation on the radiant tubes. These coatings are applied to the external surfaces of the tubes and significantly enhance heat transfer to the process and protect tubes from scaling. They are designed to withstand high temperatures and harsh operating conditions.

Some of the benefits of high emissivity coatings include:

Extended Tube Lifespan: By preventing oxidation and associated tube wall thinning, the life of the radiant tubes can be extended, if oxidation is the limiting factor.

Reduced Fuel Consumption: High emissivity coatings can help achieve the desired process temperatures with less energy input by improving heat transfer efficiency. This can lead to reduced fuel consumption and lower operating costs.

Watch: Catalytic Reformer Heater Process Tube Coating

Cause 3: Refractory Deterioration

Refractory deterioration can lead to hot spots on refractory material. It is an area of localized high temperature within a furnace, kiln, or other high-temperature process equipment where the refractory material is exposed to more intense heat than the surrounding areas. Hot spots can occur for various reasons and can have negative implications for the performance, efficiency, and lifespan of the refractory lining.

In these cases, the operator must decide whether to interrupt production by bringing the heater off-line to make a conventional repair or continue at reduced capacity until the next scheduled shutdown.

Solution 3: Online Heater Repairs

To avoid costly shutdowns or operating at a reduced capacity, it is possible to conduct online refractory repairs until further maintenance can take place during a planned shutdown.

Online refractory repair can be a valuable strategy to extend the lifespan of refractory linings and minimize downtime. However, it should only be performed by qualified and experienced personnel following proper safety guidelines and in accordance with industry best practices. Consulting with Hot-tek refractory experts and conducting thorough assessments are essential to ensure a successful outcome.

See How It Works: Online Refractory Repair

Conclusion

There are many causes of fired heater underperformance. It is important to identify warning signs early as even a 1-2% decrease in efficiency in fired heaters can consume an additional $1m in fuel across a 12-month period.  

To address this issue, it's crucial to conduct regular inspections, implement proper maintenance practices, monitor operating parameters, and address any issues promptly. Engaging with experienced process engineers and fired heater experts can help diagnose and resolve underperformance issues effectively.

Contact Integrated Global Services (IGS) for a free technical evaluation.

IGS fired heater experts will perform a comprehensive technical evaluation that will determine your efficiency improvement (%) and the payback period as well as projected (%) improvement based on your objectives (fuel/emission reduction, capacity increase or a combination of both).

To Claim Your Free Technical Evaluation, Visit: www.integratedglobal.com

This article can also be found in the issue below.