When high volumes of hot water are needed, Thermal Engineering’s “SUPERHEATER” Direct Contact Water Heater should be your first choice. The near 100% energy efficiency can provide the most economical water heating costs. Traditionally, water heating has involved transferring all the heat thru one or two metal walls. Water quality, fouling, rust, etc, all combine to reduce the efficiency of the heat transfer process. The result is an exhaust stack gas temperature many hundreds of degrees above that of the incoming water to be heated. Direct contact water heaters have ended these problems! Since their commercial introduction during the energy crisis years of the seventies, thousands of these heaters have been installed and have resulted in unmatched levels of performance.
THIS IS HOW THE “SUPERHEATER” WORKS
When heated water is needed, the natural gas burner is started which generates large volumes of hot gases. These gases enter the lower heat transfer chamber and start moving upward thru the “packed mass” heat exchanger. At the same time, cold fresh water starts flowing thru the distributor, onto and downward thru the torturous path of the packed mass heat exchanger. The large surface area of the packings causes the water to spread out into a very thin film. The hot gases traveling upward through the packings readily releases its heat to the water film which rapidly raises its temperature. Just as quickly, the hot gases cool. The efficiency of the heat transfer is dramatic - the hot gases are normally cooled to within 10 or 15 degrees of the incoming cold-water temperature before discharge into the exhaust stack.
The heated water trickles downward through the packed mass keeping it cool and protecting it from the high temperatures of the combustion gases. The water falls thru the lower heat transfer chamber where it picks up additional heat before going into the reservoir. A temperature sensor in the reservoir controls the burner to insure the proper amount of hot gases is generated to maintain the desired hot water discharge temperature.
THE ENERGY BONUS
How can the “SUPERHEATER” claim near 100% thermal efficiency? It’s done by “over-cooling” the exhaust gases. The normal combustion process of natural gas combines hydrogen and oxygen chemically to form water, which is instantly vaporized by the heat of combustion. This process absorbs heat and it is normally lost to the atmosphere with the exhaust gases.
The “SUPERHEATER” ends this loss!
As the hot combustion gases pass thru the packed mass heat exchanger, the gases cool so much that the water vapor in the combustion gases re-condense releasing the heat it took to vaporize it initially. It is a fact that about 12% of the total heat contained in natural gas is absorbed in vaporizing the water generated - and the “SUPERHEATER” RECAPTURES THIS HEAT.
STRUCTURAL COOLING: “The key to long heater life”
With the burner being able to generate hot gases of over 3500 degrees F, uncooled metal walls exposed to this heat can rapidly fail. Only TEA offers high velocity cooling jackets in the combustion zone on its Direct Contact Water Heaters. By precisely controlling the velocity of water thru special cooling channels, the temperature of the inner structural walls can be maintained near cooling water temperatures. This controlled wall temperature is the key to long heater life. Thermal stresses are controlled eliminating the resulting cracking and distortion so common in other heaters.
Actually, the cooling water also picks up a significant quantity of transmitted heat. And this cooling water is added to the water passing thru the combustion zone, further reducing the quantity of heat necessary to produce the desired final water discharge temperature. This SUPERHEATING further increases the efficiency of the TEA heater. R
THERMAL HEAT PLATE EXCHANGER
- PERFORMANCE: 300% more efficient than continuous tube type heat exchangers.
- EXPANDABLE: Just add plates for additional capacity – a one-hour job.
- NON-FOULING: Highly turbulent corrugated and electro-polished heat transfer surfaces easily release soap scum build-ups
- SERVICEABILITY: Simply remove compression bolts and spread plates apart for a full internal inspection of both the waste and fresh water heat transfer surfaces.
- HEAT LOSS: Practically none – No insulation is needed.
- COMPACT: Entire system occupies 25 to 35% of floor space compared to 30-foot long continuous tube type heat reclaimers.
A HISTORY OF EFFICIENCY
The energy crisis of the 70”s resulted in demands for the best laundry waste water reclaimers possible. Existing shell and tube units developed in the 30’s and 40’s, while adequate for those times, just did not have the performance capabilities needed when energy costs rose to 10 times previous costs.
In 1978. Thermal Engineering of Arizona (TEA) introduced its patented Thermal Heat Recovery System to the laundry industry. The exclusive corrugated heat transfer surfaces produce water flow turbulences which resulted in 300% more heat transfer efficiency that even the best existing continuous tube reclaimers.
Combined with its integral Shaker Screen for automatic wastewater Clean up. TEA’s prepackaged, wired and piped Heat Recovery Systems quickly gained a position as the technological leader in the laundry industry.
In 1980. TEA introduced its patented hot and tempered water pre-heating wastewater heat recovery system – the greatest single improvement in laundry heat recovery ever. Today, fully 90% of all plants being built are using TEA’s concept of heat reclaimed tempered water preheating.
And the results are spectacular. TEA systems are today achieving the highest levels of laundry wastewater heat recovery ever achieved. Plants are normally designed to recover 75% and more of the total heat contained in the wastewater before discharge to the sewer.
CHEMICAL FREE WASTEWATER RECYCLING AND WASTEWATER TREATMENT
Plants with sewer discharge compliance issues can use the ultra-filtration capabilities of the Cera-Pure System for chemical free treatment of the wastewater. The resultant filtered water can be used as recycled water in the plant. Recovery rates for recycled water can be as high as 90% of the water processed through the Cera-Pure system, with the remaining being sludge for disposal.
To use the Cera-Pure System most effectively, wastewaters should be segregated into black water and dischargeable gray water. In laundries, split trenches work best. The black water is processed through a Shaker Screen to the finest micron level possible, generally about 150 microns. This filtered black water is discharged into a cone bottom equalization tank. Wastewater is pumped, from an intermediate level in the equalization tank, to the Cera-Pure System, where pre filters remove entrained solids down to the 5-10 micron level.
This filtered water is then pressure fed into the circulating loop of the ceramic filter module for final separation. Both high pressure and high velocities are used to separate the wastewater into filtrate water, and unfiltered concentrate water. Continuous reverse flow shock waves dislodge accumulated material from membrane pores maintaining filtrate flows. The filtrate can now be recycled for use in the plant. The filtrate water is usually within a few degrees of the incoming unfiltered water temperature. Concentrate water is returned to the equalization tank for mixing with incoming black waters and re-processing.
At the end of the processing day, the equalization tank is allowed to settle out. Most suspended solids will settle out over night. Any free oils will float to the top. Before start up in the morning, the settled sludge is pumped out to a sludge storage tank along with floating oils. At this time, the system is ready to begin processing plant wastewater again.
TEA TANKS are specifically manufactured to commercial standards to meet the storage and processing needs of most industrial applications. Unique forming and welding techniques result in finished tanks which have excellent functionality when compared to purchased cost.
Tanks are quickly available in either T-304 or T-316L Stainless Steel. They are either flat bottomed or coned bottom on legs. Tops can be open, flat, cone, or with removable covers.
Standard finish is #2b mill. Other mill finishes available on special order. Outside welds cleaned of scale and discoloration. For most applications, T-304 is TEA’s standard tank material. These tanks will have internal crevices and should not be used for sensitive processing where cleaning and/or cross contamination can be a problem.
T-316L stainless steel offers higher corrosion resistance to most products. Double thickness overlapping joints are fully welded both inside and out. This no-crevice construction allows for easy cleaning, preventing product cross contamination. This construction will exceed the most demanding application requirements.
TEA TANKS are designed to hold liquid or solid materials up to a specific gravity of 1.2 at atmospheric pressure.
TEA is well qualified to fabricate custom designed tanks of up to 1/2" thick stainless steel, up to 12 feet in diameter, and to 24 feet high.
DIRECT CONTACT STACK ECONOMIZER
The biggest heat loss in a steam boiler is what goes up the stack.
Recovering this heat loss is what Thermal Engineering’s Supermizer Direct Contact Stack Economizer does. When large volumes of hot boiler exhaust gases are discharged to the atmosphere, substantial quantities of valuable heat are needlessly lost. This heat can be easily re-captured and added to the incoming fresh water make-up as pre-heating. The hot exhaust boiler gases are directed by way of a damper on the boiler stack and enters into the lower heat transfer chamber and starts moving upward through the “packed mass” heat exchanger. When plant make-up water is needed, automatic controls start the regulated flow of water into the Supermizer. The incoming water enters the flow distributor where it is evenly spread out over the Packed Mass heat exchanger. It now starts to flow downward through the torturous path of the Packed Mass heat exchanger. The large surface area of the packing causes the water to spread out into a very thin film. The hot gases traveling upward through the packing readily releases its heat to the water film, rapidly raising the water temperature. Just as quickly, the hot gases cool. The efficiency of the heat transfer is dramatic – at full power and maximum water flow rates, the hot exhaust gases are normally cooled to within 10 to 20 degrees of the incoming water temperature before discharge to the exhaust stack. In a well tuned boiler, this can amount to about a 20% energy recovery of the on-line boiler load.
Thermal Engineering’s SHAKER SCREENS can meet the critical screening requirements of virtually every processing industry. Ideally suited for dry separation, wet or dry classification or liquid-solids separation. This “State of the Art” screening equipment will meet your high volume screening specifications efficiently, reliably, and economically.
The SHAKER SCREEN is a vibrating circular screen separator. Vibration is caused by a screen mounted electric motor with rotating upper and lower eccentrically weighted arms. The upper arm causes a screen horizontal motion which is necessary to move oversized material to the outside shell. The lower arm produces a vertical and tangential movement which accelerates the movement of filtered liquid or undersized product through the screen. The angular distance between the arms plus the number of heights used can be varied for maximum screening efficiency of any screenable product – wet or dry – heavy or light – coarse or fine – hot or cold.
The SHAKER SCREEN is used in many industries including food, chemicals, metallic and non-metallic minerals, pharmaceutical, abrasives, ceramics, plastics and others. It is also ideally suited for high volume dewatering operations like waste water treatment and product recovery from liquid streams.
TEA is the only SHAKER SCREEN manufacturer that can offer complete systems. We are able to manufacture stainless steel and mild steel tanks, hoppers, bins and stands to incorporate the SHAKER SCREEN as part of a system or production line. We can design and manufacture feed systems to meter the flow of either dry or wet materials onto the SHAKER SCREEN.
TEA also offers custom fabrication and design of tanks, tote tanks, platforms, piping systems and other various fabricated parts to complete the installation of your process plant or production line.