Fuel Saving

¿DID YOU KNOW…?

That in a heating process with thermal fluid fuel consumption is between 20 and 25% lower than with steam.

Of course you did. Despite and maybe because not everybody did, I’m not get bored to repeat. Nowadays energy and industry are focused in the climatic change, fuel fossil exhaustion and in its consequent price increase. Then, to choose the suitable technological option to heat up a process becomes the key not just for our planet but also for our pocket.

Still there are many companies and process burning more than 20% strictly needed. The global efficiency of one indirect heating installation is 65 - 70%. That is to say more than 30% of the energy is get lost. Third part of it is getting lost by the chimney. Exhaust recovery has to be develop notably in the coming years. But this is not the topic of today. The worst is the other 20% of the whole burnt fuel. Condensates and steam traps are in charge of it.

The good new is that this same process heated up by hot oil will have a global efficiency of 90%. The other 10% is getting lost again by the stack. But that’s all. Is not phase change, nor condensates recovery, nor steam traps. It’s just a closed circuit. Read More!

The most interesting published subjects

Three years ago, we published the first post in this blog. After this lapsed time, we have stated that some subjects have been more visited and interesting than others and for that reason, following you can find them:

• What is a electrical thermal oil boiler?
• What is a thermal oil heater?
• Pirobloc electrical steam boilers
• The thermal fluid transmitters of heat 

The day to day and just the short time at disposition, they do that our readers receive by RSS the new publications on the blog, but we receive very little commentaries.

Thanks to your commentaries, we could know what information is more interesting to you than other of each subject, and thus we can develop it or answer to you.

We invite to you to comment and in any case, we promise to always answer.

Good year to all! Read More!

Comparison between thermal fluid and steam

In previous posts we informed on the thermal fluid transmitters that can be used in an industrial installation. In this blog we want to make a comparison between the use of the thermal fluid versus the steam, both perhaps the most extended systems world-wide.

The requirements for the steam facilities are more restrictive than those of thermal fluid:

• Steam boilers of a certain size and water volume have to be installed in a separate boiler room. In many countries the boiler room cannot be located within the main building or production site, but has to be separated at a certain minimum distance. Moreover, protection walls of such boiler room have to be of a minimum thickness, depending on the category of the boiler.
• Water treatment is an absolute requirement for every type of steam boiler, whether of the coil type, water tube or fire tubes. Water treatment consists of a water softening plant (which should be a twin system in most of the cases) in combination with a chemical treatment of pH control and oxygen scavenger. A water softener “Twin” system consists of two cylinders to hold the resin in order to allow a regeneration of one column whilst the other resin column remains in service. A twin softener is an absolute must in production plants with a continuous operating cycle of 24/24 h.
• Oxygen removal and pH control can be done by means of a chemical dosing system (dosing pump with dosing tank). With some type of boilers, especially of the coil type, special care has to be given during “stand-still” periods. If no measures have been taken to keep the coil either completely dry or completely filled by means of a time controlled “post-run” system, the risk of oxygen corrosion during standstill period is very high. (Note: Post-run means that the water pump has to remain in operation to keep the coil filled with water whilst the system cools down, in order to prevent air pockets to be formed in the upper part of the heating coil which would introduce oxygen in the heating coil and cause a typical form of “pit corrosion”).
•  With too much concentration of TDS (Total Dissolved Solids), a carry over of chemicals will take place. Too high concentration of dissolved solids (example over 3.000 mg/l) can be caused either when blow down periods are not being strictly adhered to or during “peak-loads” which demand momentarily more steam than the average nominal capacity of the boiler size. This carry-over will result into wet steam and the chemicals which will remain in “wet steam” can block steam traps, steam regulating valves etc. Hence, high maintenance costs and waste of energy in case steam traps do not function properly and do not shut off properly.
• Some more details are referred to in the section “Corrosion” hereafter. Especially in fire tube boilers, because of the larger water content, explosion risk remains despite added automation on modern boilers.

Efficiency

The thermal fluid does not require any special treatment once the installation has been filled up. Its life oscillates between 10 and 12 years. This means that the cost of this element is really insignificant.

The thermal fluid, which comes out of equipment after having heated it, will enter into the generator with only 1 or 2 ºC less temperature. This shows that the loss of heat during its way in the line is situated at the minimum.

There has to be taken into account, that the outcoming steam of a purge has an average temperature of 120 ºC, whereas when it reaches the tank of condensed it usually does not exceed 90 ºC, and in many occasions it does not even reach this low temperature. On the other hand it should also be taken into account, that there always remain a flow of steam in the purges which gets lost through evaporation and these calories are never more recovered.

Thermal fluid systems suffer none of the above-described losses.

Legal requirements

These are generators working WITHOUT HIGH PRESSURE. This fact exonerates them of the walls, distances to neighborhood, and all the other norms which have to be taken inTO account and accomplished for the steam type boilers. Thermal fluid boilers may be installed in any place, even just besides the manufacturing machines.

Corrosion

Neither the generator nor the pipeline suffer from wearing away, as the function is done with lubrication liquid, NOT CORROSIVE like water.

Maintenance

Any kind of dragging, such as for water, of salts, of oxides, or of any other indissoluble solids is not necessary. This means that nothing can affect the goodness of heat transmission through thermal oil. This type of installations are practically free of maintenance.

Fuel saving

When heating is done through thermal fluid, we are able to obtain a level of temperature regulation till ± 2 ºC in the machines. When using steam heating this is completely unthinkable, as the differences in a normal installation are situated around ± 10 ºC.

This is of course also a very important factor in saving fuel, as it allows organizing a very regular temperature average, without any fear that the quality of the product may get spoiled due to the ups and downs which could occur when treated with steam.

The sum of the related factors results on a fuel saving around a minimum 12 to 18% according to concrete data taken in facilities which are working for a long time to total satisfaction of our clients.

Technology

Another advantage when using thermal fluid, is that all problems concerning passing preferences, as usually they appear in steam installations, are completely cancelled: When working with steam all the machines, which are located nearer to the boilers, they will receive the full amount of flow which they need. Those machines which are at a greater distance very often have a lack of flow.

With the thermal fluid and through our system of ballast check valves we assure to each individual machine the whole quantity of necessary hot oil, ensuring a temperature stability.

Safety

No risk of explosion, because there is no high pressure inside and neither hot oil storage.

Cavitations do not appear in the recirculating pump of thermal oil.

In steam installations they may arise when the feeding water which is recovered from the condensed surpasses a temperature of 90 ºC, at that stage either it is cooled down with water entering in the line or part of the condensed are thrown away, but this last supposition is really absurd in view of the cost of the fuel.

With the details we have mentioned above, we intend to offer you a global view on the subject of the thermal fluid installations. However in order to get a more precise knowledge it is necessary to enter deeper in this kind of equipment, for this purpose we remain at your entire disposition. Read More!

Heat transmission fluids (2)

SMOKE or GASES. This source of heat is used generally when a surplus of energy in the form of smoke or hot gases exists.

In those cases, it is profitable to invest in a recovery unit or economizer that helps to reuse the heat that those smokes contain. Its design will be adjusted to the final application to which the residual heat will be destined. To do this, the recovery unit has coils, chambers, etc. through which water, air or any other fluid that it is interesting to warm up for other subsidiary process in the plant, will be forced to circulate.

Applications: Fuel saving by an industrial burner as a result of the preheating of the air used by it, for example, or, as a central heating or air conditioning of a plant, etc.

Water heating, steam production, etc.

The recovery systems are usually provided with a by-pass or diverter, to interrupt or to turn aside the smoke flow of its passage by the economizer or heat recovery unit.



THERMAL OIL. There are two types, synthetic and mineral, being different marks and models in the market, to work to different temperature ranks. We wrote about in a old post about the thermal fluid transmitters of heat.

The main characteristic of the oil is that it does not change of state when working over 100ºC under absolute pressure, reason why the circuit pressure that it generates it is not as high as the generated by other fluids.

We advise about the use of the thermal oil in processes in which it is needed indirect heat and high working temperatures (from 150 to 300 ºC).

Please remember that at the end of the useful life of the thermal oil, the user must recycle it, but about that we will speak in the next blogs. Read More!

New regulation of machines under pressure

The Regulation of machines under pressure has been modified by the R.D. 2060/2008 that was published in the BOE nº 31 of 05th/02/09 and which will enter in force the 05th/08/2009. With this modification, the E.U. try that every national regulations of machines under pressure of each country, they converge progressively in an unique European common regulation.

The contributed modifications are made in order to approach the Regulation of Installation of Equipments working under Pressure (used by the installers of equipment of these characteristics in Spain) to the European Directive 97-23-EC (used by the manufacturers of equipments of these characteristics, at European level), using similar concepts at which appear in the E.D. 97-23-EC .

It’s also pursued the uniformity to the values of the pressure tests, in reference to the differences that existed until this moment between both norms. They change the following categories:

• About the boilers: from type A, B and C, they convert into 1^st and 2^nd class, although the criteria to determine the category are similar.

• About the installer companies.

• About the titles and attributions.

• The periodicity of the inspections with or without pressure test.

• They exist now 3 levels of tests, existing before 2 types.

• The periods of application change.

• It appears the figure of the Agent, who will be the organism in charge to make the tests.

• They change the organisms which apply the test, with more participation of the OCA’s (Authorized Control Organism).

• It changes the design of the plates.

There will be changes in reference to equipment and securities, but in a less way.

Do not hesitate to consult us the projects that you have in mind and how the new regulation can affect to them.

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A year of great changes and boldness

First of all, we wish that this year 2009 is more propitious for all us than the arrived prognoses from different sectors.

By our part, we have closed a year that began with uncertainty, reaching the same economic result of 2007, which fills of satisfaction to us. Logically the objective is exactly the same for year 2009, in spite of the global economic conjuncture.

Like all you, with the new year we have written our own list of personal and professional intentions, which will be announced, being some of them the following ones:

• PIROBLOC is releasing its new slogan.
• PIROBLOC develops its line of electrical steam boilers.
• PIROBLOC will release new website.
• PIROBLOC will change of headquarters in spring of this year.
• PIROBLOC will qualify even more its personnel.
• ...
  

We hope that the present objectives influence positively in all: We have in our hands the possibility to turn situations in improvement options.

Do you agree with me?

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One year ago...

One year ago, we published the first blog in google.

Lapsed that time, I hope our blogs have provided to you information and new points of view on us, our products and the world of the thermal fluid.

By our side, we thank you very much for the visits received in our page and also for the comments of the readers.

PIROBLOC born in the secondary sector with a local and national orientation that later would become into international, it bets to continue using the new technologies to continue evolving in that sense.

We are opened to everybody who they want to read on us and to know our perspective of the sector present time.

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The used oils and their elimination

For those already users of thermal oil facilities, as well as, for the companies taking the decision of installing this technology, we want to clarify the question: What can you do with the used thermal oil, once its useful life is finished?
Following what we have said in our previous blogs, the oil of industrial use, being mineral or synthetic, it has some properties that make it able for the transport and transmission of indirect heat in industrial processes thanks to its properties, having a useful life superior to the 25.000 working hours, whenever the installation has the following premises:

• A correct dimensioning of the installation.
• A correct design of the thermal oil heater.
• A correct evacuation of the vapors.
• The tightness of the installation to avoid the oil oxidation.
• Demanded hours of work.
• And the election of the most appropriate thermal oil for the necessary working temperature in the process, as well as, of the recirculation group.
  

Once the oil has lost its properties, it should be changed, using a new one. In the market there are companies that they collect it for its destruction, or in some cases, for its preparation for its use as fuel in big steel furnaces and big industrial companies of several sectors.

Other types of used oils (as dielectric ones, lubricant oils, etc.) they are regenerable if the owner doesn't mix them with vegetable oils, synthetic ones, water or solid particles, before they are picked up by the company specialized in recycling. The service of picking up will be free or paid, according with the analyses previously realised by them on oils. Read More!

An interesting article about chips

Following our last blogs, I would like to treat today the use of the thermal fluid in the food industry and concretely to ask your attention on an article published in the Spanish magazine ALIMENTACIÓN Equipos y Tecnología, nº 233. This article speaks about the correct manipulation of the potato like primary element and base of a great industry in Spain and also in other countries like Poland (origin country of part of this article) like the snack sector.

It comes off the article, that in the process of production of the fried potatoes (chips), it is necessary to have in consideration the quality and characteristic of them, that they can vary according to the rain of the origin area, composition of the floor, etc., but it is also necessary to have into account the temperature of the fry oil which should be about 180º C if we want to obtain a final good product to the palate. The most efficient way to achieve that temperature, preserving the possible maximum time the useful life of the vegetable oil used to fry, it is using indirect heat production systems, as thermal fluid heaters through white oils as heat transfer fluids.

We recommend the reading of this article for all people interested in the topic at background level.

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The white oils and their uses in the industry (II)

As I have already written in our previous blog, in this occasion we will enumerate processes in those white oils are used, being two the mainly ones:

• as heat transfer fluid in installations in those the final products are for direct human consumption ,
• as an oleic base of a final product that will be used directly by humans, and which we consider medicinal white oils.

In relation to the first topic, it is recommended the use of the white oils as heat transfer fluids in the installation of thermal fluid heaters, when the last ones are used with reactors, friers or equipments able to produce pharmaceutical products, food, etc., in order to avoid the alteration of the final product of human consumption during the production process, because of an accidental leak of a toxic thermal fluid.

According to the information that we have found, we think that there are two types of white fluids: the medicinal ones (base of products) and those used as heat transfers, both with low toxicity. If some reader agrees with the present statement, please confirm!!!!

In reference to the second subject, hereby we include a list of products in which medicinal white oils are present as base component:

Preparation of cosmetics:

- Cream, sun lotions and milks, ointments, paper impregnation, etc.
- Softening and moisturizers (oils and cleaner milks, lipsticks, powdered make-up);
- Products for children (shampoos and bathroom oils);
- Products for the hair care;
- As protective and neuter diluter for other ingredients of cosmetics, as essential oils; as anti-perspirants and deodorants in bar.

For their use in the food industry are added inhibitors of the corrosion:

- Unmolding in bakery products and pastries,
- Frying potatoes or chips, fruits as peanuts, etc… and ready or pre-cooked meals.
- Also used in treatment of rice,
- Emulsified oils for jams,
- Packaging of fruits,
- Conservation of eggs.

In the pharmaceutical industry, it has a high level of security due to:

- Their maximum purity (absence of toxic aromatic polyciclics and heavy metals),
- The complete destruction of germs in the process of production at high temperature,
- Used in specific procedures of packaging and manipulation: ingredients of the pharmaceutical ointments of topic use and petroleum jellies.
- It can be used as auxiliary element in the production of pills and in the production of capsules of jelly. The white medicinal oil is used in laxatives and liquid vaselines.

The white medicinal oils should satisfy the requirements of the regulation FDA defined in the clause 21 CFR 172.878 of the U.S.P. (USA), D.A.B. (Germany), B.P. (United Kingdom), CODEX (France) and Spanish Pharmacopea.

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The white oils and their uses in the industry (I)

The raw oils are mixtures that contain thousands of different molecules. Because these complex mixtures are difficult to identify chemically, the oils are classified, according to the type of predominant hydrocarbon and their refinery process: paraffinical and naphthenics or aromatic.

The naphthenic oils are obtained directly from the refinement of the raw petroleum and they are practically free of paraffin (they only contain a 45%). This implies a constant flow of very low temperatures, essential characteristic in several applications. To obtain "refrigeration grade" naphthenics oils, they should be put under complex physical and chemical treatments as unparaffin, bleach, elimination of sulphur, treatments with acids and solvents,...

The paraffinic oils possess a 75% of paraffin and only 25% naphthenic and aromatics.

Next, we will speak about the white oils, and their applications will be treated on the next number of this blog.

The white oil is obtained starting from paraffinic fractions of mixed base or naphthenic one, depending on the definitive use. The process is carried out for vacuum-distillation, followed by several refinement processes, included a final purification with catalytic regeneration. Their applications are specially important in products that have direct and forced contact with the human being, for what should be no toxic, not to stain and nor to contaminate.

The highest purity white oil is free of not saturated components: it is colourless due to the inert chemically nature of the hydrocarbons contained in. On the other hand, these oils are obtained with a process of hydrogenation by that the content of aromatics decreases to values smaller than 0.1%.

The white oils can be of two types: for technician or industrial use and for medicinal use.

The medicinal white oil is colourless, odourless and insipid and it has chemical and thermal great stability. It is liquid slight paraffin and an excellent lubricant that presents a good adherence and greasiness.

You can consult: www.quiminet.com.mx

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The thermal fluid transmitters of heat

PIROBLOC as specialist in the design and manufacture of thermal fluid heaters and other apparatuses that use that type of heat transmitting fluids, is today interesting to approach them to you and giving you more data on such.

Types:

The synthetic fluids fulfill the majority specific functions. Some of them have problems due to the toxicity, to the high point of freezing or the high viscosity at low temperature.
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The mineral oils fulfill with the next described requirements, a rank of application of temperatures from -10º C to 300º C and an index of viscosity in the rank 0-100 ST.

The basic requirements of any fluid are the following ones:

- They must be thermally stable to the temperature of service.
- It has to have high thermal exchange coefficients.
- The pressure of vapour at the operating temperature must be low in order that the system can work at atmospheric temperature.
- It must have a low viscosity to favour a turbulent work conditions, and at the same time, the viscosity at low temperature must be sufficiently low to favouring the cold starting.
- It does not have to be corrosive nor toxic.
- It must be safe and easy to use.

In reference to the viscosity, it is considered from two points of view: separately and its variation in reference to the temperature.
The oils have advantages in comparison with other fluid, thanks to their better relation viscosity/temperature, that it is expressed in terms of the Index of Viscosity. It is calculated by an empirical formula from viscosities at 40º and at 100º C. A high value means a small change of viscosity in relation to the temperature.

The point of freezing of a fluid measures the temperature to which the oil stops flowing by simple gravity, important factor in relation at the moment of the starting and its properties to low temperatures. In order to reduce this point, most of fluids incorporate additives.

The density is the mass by volume unit. The density is marked in kg/l or g/ml in relation to 15º C. Most of oils have values around 0.85 - 0,9.

The specific heat measures the amount of heat absorbed by unit of weight when its temperature increases one degree Celsius. The oils have values between 0.45 and 0.70 in the rank of temperature of habitual work.

The flash point is the temperature to which, with certain test conditions, a flame applied to the surface of the oil causes the ignition of the vapour but not a continued combustion. It is very important not to confuse this temperature with the temperature of combustion or self-ignition.

Once approximated a flame or spark, the combustion point is the temperature to which, in the presence of comburent air (oxygen), the flame maintains at least 5 seconds ignited. The normal values are located around 210º C.

The self-ignition point is the minimum temperature to which the thermal fluid ignites by itself, without presence of flame or spark that initiates the combustion. Logically, the presence of comburent air is necessary.

Consequently, the temperature to be considered in reference to a possible escape of thermal fluid, it is the temperature of self-ignition.
It’s necessary to have a escape, because without it, there is no oxygen in the circuit and therefore, although we reach temperatures of point of self-ignition in the close circuit, it would not be possible a combustion.

By all it, the probability of a fire in an installation of thermal fluid PIROBLOC, is practically null. The kindness of this affirmation, it comes authenticated by the effective legislation in Spain, which considers the thermal fluids like NO INFLAMMABLE LIQUIDS (B.O.E. nº 120, 20/5/82).

In reference to our thermal fluid circuits, being closed and not existing oxygen presence in them, a combustion or fire is impossible, unless there is a escape.

In the following picture we can observe the characteristic temperatures of the main thermal fluids of the market. We can observe that the maximum temperature of service (indicated by the manufacturer) and the temperatures of flash point and self-ignition do not keep a direct relation:

Please, click in the image to Zoom In.

PIROBLOC supplies the PIROBLOC-A, a thermal fluid with the following typical characteristic:
- Density at 15 ºC: 0,880 kg/l
- Viscosity at 40 ºC: 20 cSt
- Viscosity at 100 ºC: 4,5 cSt
- Viscosity index: 80/90
- Flash Point P.M.: 180 ºC
- Freezing Point: -45 ºC
- Specific Heat 50 ºC: 0,48

In our next blog, we will continue speaking about this subject with special attention to the white fluids (the unknowns by the users).

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THE WEB 2,0 AND PIROBLOC, S.A.

The appearance of Web 2,0 characterizes the change in the World Wide Web: At the beginning it was a compilation of static sites. Now it has turned a global space where the connections of broadband and the applications multimedia provide a more extensive content and one more a narrower interaction with the end user.

The present web technologies offer more complete and interactive methods to contact the end-users. Some of the services and the companies of Web 2,0 have become very known in a shortly period of time, due to change quickly the dynamics of marketing and the publicity in Internet.

One of these new platforms is the Blog (space of opinion opened to the direct communication with the reader) and in which PIROBLOC has been present for some months. Another service of Web 2,0 is the platform of videos in line, YouTube (space leader of the video online and the favourite destiny of the users of Internet to see and to share original videos anywhere in the world).

Next we invite you to see our first video on the technology of the thermal fluid done in Spain and perhaps in the world, on our boiler ATEX.



To teach and to show is today essential to share the knowledge and to open doors to possible alliances, sales, etc... And you, what do you think about?

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PIROBLOC AND ITS INTERNATIONAL EXPANSION POLITICS

The present year PIROBLOC continues its focused internationalization activity in three European markets objective: United Kingdom, Poland and Portugal.

They are very heterogeneous markets to each other, but very attractive for us, since each one in its idiosyncrasy, represents a great potential market for our product, little implanted in some of them or totally not known in some one.

In order to obtain a correct positioning in these countries, it is essential to catch the attention of end users, as well as, from possible commercial actors, and there are several ways to do it like the translation of the Website into the language, attending fairs in the country which we want to enter, maintaining the made contacts alive, publishing announcements in specialized magazines...

There are companies that extrapolate their model of commercial structure in origin and assume that it will also run in its objective countries. PIROBLOC by its type of product or by its restlessness of knowing the best possible the new markets, it studies which is the more suitable commercial figure for each market (distributors, commercial agent, opening of delegation, technical service,...) and then it acts. With this system, we do not keep awake anything new, but we are convinced that our main and matchless value, the human capital, is unique and efficient.

All we wish to conquer new markets, but also we wish that there is chemistry between our staff, our product and our clients, isn’t it?

Please, be so kind to put you in contact with us to give us your opinion or if you are interested in working with PIROBLOC, S.A.

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