FEATURE HEAT TRANSFER THREE TIPS FOR FUTURE SUCCESS


Clive Jones, managing director, Global Heat Transfer, gives three considerations for manufacturers operating thermal fluid heat transfer systems to safeguard the system’s future over the long term


safety, flexibility and efficiency with the added bonus of a less intense maintenance programme. Because of their benefits, thermal fluids


T


he Oxford Electric Bell has been ringing constantly for over 175 years –


so much so, that the apparatus has been dubbed the world’s most durable battery. But after all this time, it is still a scientific mystery how the bell has functioned for so long. For operators of thermal fluid systems, keeping operations running doesn’t have to be a mystery. In chemical processes that require


indirect heat, there are two methods that dominate the industry — steam and thermal fluids. To achieve high operating temperatures, steam requires very high pressure and an intensive continuous maintenance programme. In contrast, thermal fluid systems offer increased


The best way to manage thermal fluid condition is to incorporate a proactive maintenance programme that encompasses regular thermal fluid sampling and analysis, training and engineering support


are used in many industries including pharmaceutical or food and beverage processing, chemical and industrial manufacturing. Although thermal fluids don’t require the level of assessment of steam systems, there are still factors the operator needs to be aware of to keep the system safe and efficient. Here, we explore three ways to increase system life span, maximise productivity and reduce the risk of costly downtime.


KNOW THE LEGISLATION There is a body of health and safety legislation that companies must follow to ensure a safe working environment, particularly when working with flammable materials. The system operator should have a detailed understanding of the legislation that applies to thermal fluids — the Dangerous Substances and Explosive Atmospheres (DSEAR)


ODOUR ABATEMENT AND HEAT RECOVERY


Babcock Wanson has provided Bakkavor Meals London with an efficient solution to both heat supply and odour abatement for its frying facilities at the Park Royal, North West London premises. Babcock Wanson worked closely with the ready-meals and ethnic foods manufacturer to understand its needs. The result is the installation of two COMBI 4000 Recuperative Thermal Oxidisers and a Thermal Fluid Heater, with the complete system designed and commissioned by Babcock Wanson. Exhaust Gas from the frying process can be unpleasant to smell and needs to be treated, this is


particularly important as Bakkavor Meals London’s processing facilities are located in a densely populated urban area. The most effective method to achieve this is thermal oxidation. Pollutant gases are heated to high temperatures - 850°C in this instance - in a combustion chamber and are fully oxidised before being discharged to atmosphere as a harmless gas. Each Oxidiser burns up to 4000 kg/h of fryer exhaust and in doing so recovers valuable heat to thermal fluid to heat the production line. The recovered heat is also used to produce steam for processing needs and to heat washdown water. The


Thermal Fluid Heater supply to the heat the fryers is automatically adjusted to suit the process through the use of software specifically developed for this process, thereby ensuring the product quality demanded by Bakkavor is met without any problems. Loucas Antoniou, engineering manager at


Bakkavor Meals London, said: “The Thermal Oxidiser is the most efficient way of removing any smells and it’s also very straightforward to use. We have been a customer of Babcock Wanson for many years and have always enjoyed a good service.” In addition to COMBI 4000 recuperative Thermal


Oxidisers Babcock Wanson also fitted a TBC600B Thermal Fluid Heater as top up to meet the peak process demand and a backup system. Babcock Wanson www.babcock-wanson.co.uk


regulations and the Explosive Atmosphere Directive (ATEX 137). Staff training can help make sure that employees are aware of what is necessary for compliance.


BE AHEAD OF THE CURVE Not all manufacturers are aware that thermal fluids can degrade if they are left neglected for long periods of time. The degradation processes of oxidation and cracking can produce by-products that increase the risks associated with the system, so it is important the operators prioritise their maintenance regime. Oxidation and cracking can lead to safety


risks if light ends are produced and reduce the flash point of the fluid. Further degradation can lead to carbon build up in the pipes which reduces system efficiency. If these problems are addressed early, they can be tackled with a simple diluting process or other interventions, rather than a more time consuming and expensive full clean and flush. It is therefore in the best interests of the manufacturer to stay on top of thermal fluid condition from day one, with proactive maintenance that happens before anything has had a chance to go wrong.


STAY ON THE BALL The plant manager should also ensure that the facility always has members of staff available on site that have been trained in thermal fluid management and thermal fluid systems. Employees should be trained on thermal fluid maintenance, general housekeeping, storage, safe handling and how to survey a system. It may also be helpful to make them aware of the insurance and legal obligations. The best way to manage thermal fluid


condition is to incorporate a proactive maintenance programme that encompasses regular thermal fluid sampling and analysis, training and engineering support, such as Global Heat Transfer’s Thermocare. Having a comprehensive programme in place can give the manufacturer peace of mind, and a better understanding of how to safeguard their system, removing the mystery of how to minimise downtime.


Global Heat Transfer www.globalheattransfer.co.uk


18 JULY/AUGUST 2017 | PROCESS & CONTROL / PROCESS&CONTROL


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