process heating control and efficiency - lanemark
TRANSCRIPT
Performance that goes on and on and on …
• Inanindustrywhereunplanneddowntimeistobeavoided,thesupportandstructureoftheLanemarkBurnerCarepackageiswidelyregardedasakeyelementoftheLanemarkservice.
• LanemarkBurnerCareisdesignedtoensureongoingoptimumperformanceandpeaceofmindforeverycustomerinthebrewingindustry.
• Theserviceincludesplannedmaintenancescheduleoptionsandcomprehensiveon-linesupportaswellassystemcommissioningandthesupplyofspareparts.
AllLanemarkTXinstallationsfeatureanexternallymountedburnerconnectedthroughthetankwalltoasubmergedtubularheatexchangerandthentoanexhaustheader/fan/flue.Thecompany’sacclaimedTxCalccomputermodellingprogrammeisusedtocalculatetankheatlossesandtomodeltheexpectedimmersiontubeheatexchangerheatoutputefficiencyperformancewhichisnormallyinexcessof80%.
aluminium anodising
Production efficiency and energy cost control – two factors that are central to aluminium anodising and both at the heart of the Lanemark process gas burner design.
LanemarkTXtankheatingburnersystemsareusedextensivelytoheatthewiderangeofliquidsfoundintheindustry,irrespectiveoftankconfigurationorsize.The‘pointofuse’designnotonlymaximisestemperaturecontrolaccuracybutalsooffersmarkedlygreaterefficiencycomparedtosystemsbasedoncentralisedsteamorhotwaterboilers,andalsosignificant
energysavingsincomparisontosteam,hotwater,thermaloilorelectricalalternatives.
Eachburnersystemoperatesintoasubmergedtubularheatexchangerwhichdeliversmaximumheattotheprocessliquidwhilekeepingintrusionintothetankspacetoanabsoluteminimum.Theimmersiontubeheatexchangerscanbefabricatedfromavarietyofmaterialsincludingmildandstainlesssteelsasrequiredbytheindividualprocesschemical.Combustiongasesareextractedbyanexhaustfan–oftenjustoneisrequiredpergroup
oftanks–minimisingthenumberofexhaustfluesneededforeachinstallation.
Withmorethan25years’experienceintheindustry,allLanemarksystemsbenefitfrom‘BurnerCare’whichprovidesinstallationexpertise,comprehensivesystemcommissioningandservicesupportaswellasaccesstosparesforalmostanyprocessgasburnersystem.
ThecasestudiessummarisedoverleafarejusttwoexamplesofLanemark’ssuccessinthiskeyareaofmanufacturingandprocessing.
Process Heating Control
and Efficiency
Specialistsub-contractorsHeywoodMetalFinishers–nowbenefitingfromLanemarkburnersystems.
Lanemark House, Whitacre Road, Nuneaton, Warwickshire CV11 6BW United Kingdom
Tel: +44 (0) 24 7635 2000 Fax: +44 (0) 24 7634 1166 E-mail: [email protected] www.lanemark.com
Indalex Ltd.
A significant reduction in energy costs has been realised by specialist sub-contract anodisers, Heywood Metal Finishers as the result of installing high efficiency process tank heating systems from Lanemark who also acted as turn-key project managers at the site.
Handlingsome50tonnesofaluminiumaweek,theoperationbenefitsfromaLanemarkTXsysteminstalledat‘pointofuse’oneachofsixprocesstankswhichreceiveextrudedandpressedcomponentsviajigssuspendedfromanoverheadcrane.Reducedwarmuptimesandimprovedtemperaturecontrolaccuracyhaveresultedinanoverallsavinginenergyforprocessandspaceheatingof38%–equivalentto1.5millionkWhoursovera12monthperiod.
“Becauseeachtankbenefitsfromanindividualtimeswitchcontrol,warmupproceduresonselectedtanksthedaybeforetheworkingweekhavebeenaddressed,”commentsBobChambers,MaintenanceManager,“whileareductioninmaintenancerequirementsandasavingonelectricalheatingandpumpsforheavyfueloil,whichsuppliedthemainsteamboiler,havealsobeennoted.”
TheLanemarksystemsareconnectedtojusttwoexhaustfansandfulfilarolepreviouslymetbyacentralisedsteamfacility,allowingtheprocesstogainfromsignificantlygreaterenergyefficiency–upto80%istypical.Thishashelpedtoreduceenergyconsumptionatthesiteandthecompany’sliabilitytotheClimateChangeLevy,andtoenhancegovernmentrebatesavailableviaHeywood’smembershipoftheAluminiumFederation.
“Webelieveitisanexcellentexampleofprocesstemperature,accuracyandcontrolcomingtogethertoproducebenefitsintermsofenergyuseandconsistencyofproductionqualityforacustomerinahighlydemandingmarket,”commentsLanemark’sGeneralManager,AdrianLangford.
HeywoodMetal Finishers
Monthly energy consumption savings of some 56% have been reported by Indalex Ltd. as the result of a conversion from centralised steam to ‘point of use’ gas process tank heating systems from Lanemark.
AseriesofTXburnersystemshasbeeninstalledtofireintosmalldiametersubmergedtubularheatexchangerslocatedinsidealineoftanks,eachofwhichmeasuresapproximately8mx1mx1.5m.Containingavarietyofprocesssolutions,aluminiumproductsaresecuredonjigsfixedtoanoverheadcrane–upto400extrudeditemsperboom–andproceedthroughasequentialimmersionprocess.
“TheTXburnersaremanagedbycontrolpanelsonanadjacentwalkwaywhichincludedigitaltemperaturecontrollers,”explainsLanemark’sGeneralManager,AdrianLangford.“Theheatexchangersthemselvesareconnectedtoatotalofthreeexhaustfanswhichpulltheproductsofcombustionthrougheachsystemtoachieveefficiencylevelsinexcessof80%.”
“Thetankscontainavarietyofprocessliquidsincludingetchesanddyeswhichareutilisedtomeettherequirementofeachjobandthelevelofcontrolwenowhavemakesanimportantcontributiontoproductquality,”explainsChrisTallboys,ProjectEngineeratIndalex.Eachtankcontains11,500litresandisraisedtowithin+/–2°Cofthedesiredprocesstemperatureensuringthatthechemicalsperformtotheirmaximumeffect.