Radiant Heaters for industrial processes

into an air vein with atmospheric mixing and ... generator, need of insulated pipes, ... water is involved in...

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SUNRAD Infrared emitters

IGRAF

Process heaters

Radiant Heaters for industrial processes Reference book

Radiant System Innovation

Innovation, Technology and Quality Radiant heating systems for industrial processes Fraccaro S.r.l. is the European leader in manufacturing radiant heating systems. For many years it has been successfully moving its relevant know-how to the production of radiant heaters for industrial drying processes. Radiant heaters include the exchange circuits of the IGRAF commercial line and the incandescence emitters of the SUNRAD line.

IGRAF - Heat exchanger circuit

SUNRAD - Infrared Emitter

The heaters of the IGRAF line are composed by a burner with gas sucked into an air vein with atmospheric mixing and premixing, by an intake unit and a special steel heat exchanger resistant to high temperatures and to the aggression of external chemical agents. The products indicated below run with methane gas or LPG.

SUNRAD infrared emitters are composed by a radiant unit with a series of honeycomb ceramic plates that reach a temperature of 900°C, by a control unit that guarantees maximum safety and by a reflector that concentrates the radiant heat in the areas to be heated.

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Radiant System Innovation

1. APPLICATIONS____________________________________________________ FRACCARO radiant heaters are a very flexible and reliable solution designed to be installed in many different industrial processes that requires supply of heat, like the following applications:           

Marble processing Wood drying and wood processing Coating ovens, static and dynamic drying ovens Metal oxidation processes Degreasing processes Food machinery industry Industrial washing Textile industry Drying plants Foundry industry Many other heating applications

Many industrial processes require a consistent contribution of heat during intermediate working and this is often complicated due to the need for space or the compact production line. Furthermore, incorporating economic, clean and efficient heaters into the process lines can become a great problem if the necessary skills and experience are lacking. Fraccaro products, which use radiant technology, guarantee exceptional thermal exchange qualities and therefore high thermal efficiency in small spaces. Fraccaro radiant heaters can be incorporated in compact size inside any industrial process where heat is required. HEATING OF SURFACES: Heaters from the Fraccaro line are widely used for heating surfaces and the features of radiant heating are exalted in this type of application. In fact radiant heat exchangers produce direct heating of the surfaces without using intermediate thermal carrier fluids (for example, air), therefore reaching an extremely high thermal exchange yield. Moreover, maximum cleaning of the surfaces treated is guaranteed since there is no movement of air or dust. IGRAF gas heaters with radiant heat exchanger are the ideal solution for the heating and drying of marble slabs, resin-bonded surfaces, scrap iron; for all drying ovens and cockles for wood and minerals. HEATING OF LIQUIDS: Another field of application for Fraccaro radiant heaters is the heating of liquids using an exchange circuit inside the basins containing the liquid to be heated. In this way the thermal exchange is direct, without using any intermediate thermal carrier fluids. The exchange tubes are made of stainless steel resistant to high temperatures and external chemical aggression. Fraccaro liquid heaters can be used in the heating of liquids for industrial degreasing processes, food industry processes and many other applications.

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Radiant System Innovation

2. TECHNICAL CHARACTERISTICS_____________________________________ IGRAF – Radiant heaters with heat exchanger circuit Burner: The IGRAF burner includes a venturi type burning unit with stabilized multiple flames. A good air/gas mix optimizes burner performance with very low CO and NOx emissions. The power of each unit ranges from 10 to 400 kW with 2 power stage operations. The heating unit is manufactured in a standard version with comburent air aspiration filter, and in a tight version with comburent air aspiration from outside. An electric control panel with capillary thermostats and control leds is included.

MODEL

POWER

OPERATION

EXCHANGER MIN Ø

SUPPLY

FRI30

30 kW

ON-OFF

90 mm

230 V – 50 Hz

FRI 30S2

20-30 kW

2 STAGE

90 mm

230 V – 50 Hz

FRI50.1

50 kW

ON-OFF

90 mm

230 V – 50 Hz

FRI50.1S2

40-50 kW

2 STAGE

90 mm

230 V – 50 Hz

FRI100

100 kW

ON-OFF

114 mm

230 V – 50 Hz

FRI100S2

50-100 kW

2 STAGE

114 mm

230 V – 50 Hz

FRI200S2

150-200 kW

2 STAGE

165 mm

230 V – 50 Hz

FRI300S2

200-300 kW

2 STAGE

204 mm

230 V – 50 Hz

FRI400S2

300-400 kW

2 STAGE

204 mm

230 V – 50 Hz

Exchanger circuit: The exchanger circuit is made of nickel-copper steel or stainless steel pipes, with diameter and length based on the thermal power to be provided. Shape and size are customizable on process request. Min-Max tube diameter: from Ø90mm to Ø204mm. Aspiration Unit: The aspiration unit includes centrifugal aspirators with aluminium casting scroll resistant to high temperatures and with power depending on exchanger circuit and chimney length. MODEL S205.1MF S205.1TF S206.1MF S206.1TF S207.1MF S207.1TF S215.1TF S221TF S230TF

POWER 0.18 kW 0.18 kW 0.24 kW 0.24 kW 1.1kW 1.1kW 1.5 kW 2.20 kW 3 kW

OPERATION Single-phase Three-phase Single-phase Three-phase Single-phase Three-phase Three-phase Three-phase Three-phase

SUPPLY 230 V – 50 Hz 4000 V – 50Hz 230 V – 50 Hz 400 V – 50Hz 230 V – 50 Hz 400 V – 50Hz 400 V – 50 Hz 400 V – 50Hz 400 V – 50Hz

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Radiant System Innovation

SUNRAD – Infrared emitters With thermal powers of single burners from 5 to 60 kW, the applications of SUNRAD EMITTERS are designed, depending on customer’s specific needs. The emitter consists of a venturi tube and a gas injector: the speed of the gas injection causes a depression that takes in the amount of air needed for correct combustion. The air-gas mix is emitted in the mixing chamber and is spread out on the entire surface of the heat exchanger. The latter consists of a series of ceramic plates, the number of which varies according to the power of the machine which, when brought to high temperatures, overheat and radiate the surface below. The SUNRAD emitter is outfitted with a reflector which reflects that radiating heat which would otherwise be dispersed in useless directions. The emitters can be supplied also without reflectors, especially when, in an industrial process, the distance between the emitter and the heated product is small. The control apparatus, solenoid valve and the electrical circuits are assembled in sequence on the gas feeding tube of the emitter. When the control system gives the ok the flame is lit by a block of electrodes which act also as an ionized flame control. The combustion products are expulsed at the sides of the emitter. MODEL IEM10 B IEM10S2 B IEM20 B IEM20S2 B IEM35 B IEM35S2 B IEM40 B IEM40S2 B IEM60S2 B

OPERATION ON-OFF 2 STAGE ON-OFF 2 STAGE ON-OFF 2 STAGE ON-OFF 2 STAGE 2 STAGE

POWER 10 kW 7-10 kW 20 kW 14-20 kW 35 kW 30-35 kW 40 kW 28-40 kW 45-60 kW

3. COMPARISON WITH OTHER SYSTEMS_______________________________ Unlike traditional systems which require big, complex equipments, Fraccaro industrial heaters provide high performance with a compact, functional technology. Fraccaro heaters has the following benefits:

          

Start up in extremely short time; No air movement, if required; No thermal power unit; Reduced dimensions; Much lower operating costs; Easy installation; Simple maintenance; Eco-friendly; Very low CO and NOx emissions; Durable and reliable; Yield higher than 90%;

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Radiant System Innovation

Comparison with traditional systems: RADIANT HEATERS

AIR HEATERS

STEAM HEATERS

- Clean heating process (no combustion products inlet in the process);

- Low efficiencies (around 60%);

- Very high thermal power needed;

- Very high electric power needed;

- Very low thermal inertia of the air;

- Complex solution to design and to install (minimum 2 heat exchangers needed, need of an external steam generator, need of insulated pipes, circulation pumps, valves, etc. );

- Expensive running costs compared with gas systems;

- High reliability with multiple smaller burners: the production process can continue without stopping even if one burner is out of use; - Highest efficiency (95%);

- Need to switch on the system very often in order to maintain a constant heating temperature.

- Low efficiency;

ELECTRIC HEATERS

- Dangerous if some water is involved in the heating process; - Maintenance needed very often to substitute electrical resistors.

- Very expensive installation cost.

- Direct heat exchange; - High thermal emission: so low installation thermal power is needed; - No use of intermediate thermal fluids; - Very high energy savings in gas fuels; - Very low electric consumption; - Almost no maintenance.

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Radiant System Innovation

COMPARING EFFICIENCIES WITH TRADITIONAL BLOWN AIR BURNERS: Traditional burners (82% efficiency):

Fraccaro air-stream gas burner ( 92% efficiency):

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Radiant System Innovation

4. MARBLE DRYING APPLICATIONS__

______________________

 The following system is an example of customized radiant oven for drying marble slabs in a long industrial process. It consist of 3 burners working in depression conditions with one aspiration fan at the end of the heat exchangers tube circuit. Then 2 extra fans provide the air recirculation to take away the steam produced in the drying process.

 Drawing of a linear oven with IGRAF system to dry marble slabs (maximum length of the slab: 2200 mm). The oven includes 6 burners, 2 aspirators fan and a special device for air ventilation:

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Radiant System Innovation

 Oven for drying marble slabs in an industrial process formed by a 50 kW burner and a process hot air fan at 7600 m3/h.

.

 Drawing and realisation of Fraccaro IGRAF radiant systems installation in an industrial processes for drying marble slabs:

 View of exchangers tubes in a drying marble oven. N.4 burners: 4 x 40 kW + N.1aspirator:

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Radiant System Innovation

 The following pictures shows a few examples IGRAF radiant heaters installations in floor tile drying systems, which are customized according to customers and process requirements.

 Specific application on water drying system for 2000x3000 mm. marble slabs (thermal power installed: 320kW):

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Radiant System Innovation

5. LIQUIDS HEATING SYSTEMS_________________________________________ Traditional fluid heating systems require a heat carrying fluid inside boilers operating with multiple fuels. In these cases a thermal power unit and several devices for regulation, control and distribution of the heat carrying fluid are required. These systems must comply with industry and legal standards. The path from the boiler to the tank is subject to thermal dissipation, leading to higher costs. Direct heat exchange IGRAF heaters avoid these issues and ensure lower operation and maintenance costs. If needed, the inner exchange circuit is built with stainless steel pipes to avoid corrosion issues due to water or corrosive agents.  The picture below is an installation of 4 burners, 4 heat exchangers circuits and 4 aspiration fans. Every heating unit consist of a 100kW burner with 12m heat exchanger circuit to heat the water up to 100°C in a few minutes.

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Radiant System Innovation

 Heat exchanger circuits used for pre-heating liquids used for washing in an industrial process. A 100 kW burner and 14m of heat exchanger circuit + fan were engineered.

 Other examples of tank heating installations up to 80°C-100°C liquid temperature:

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Radiant System Innovation

 Other examples of tank heating installations (beer production tank, anodic oxidation systems, degreasing systems):

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Radiant System Innovation

6. TEXTYLE INDUSTRY APPLICATIONS___________________________________ Depending on the process requirements, Fraccaro can suggest when to adopt heating solutions with IGRAF heat exchangers circuits or with SUNRAD infrared incandescent emitters. The following drawing are examples of various Fraccaro ovens used in the Textile industry processes.  Example of radiant heating circuit for leathers processing: 100kW burner + 21m of heat exchanger circuit + fan.

 Incandescent Sunrad emitters adopted to dry fabrics passing through the rollers in a textile process:

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Radiant System Innovation

 Oven designed for industrial ironing processes: 100kW of burners power with 32mt of heat exchanger circuit.

 Drawing and realisation of an Igraf radiant circuit designed for heating processes in a leathers drying process.

7. DRYING OVENS FOR COATING PLANTS & COATING BOOTS___________ Fraccaro IGRAF ovens are often used in ovens in the industrial powder & liquid coating plants. Igraf ovens are used in after-washing drying ovens, in dynamic curing processes and also in closed static ovens.

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Radiant System Innovation

 Examples of dynamic and static radiant curing ovens, and paint booths:

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 Vertical aired radiating furnaces:

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Radiant System Innovation

 Other examples of dynamic and static curing ovens for the coating industry:

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Radiant System Innovation

8. WOOD DRYING ___________________________________________________ Igraf radiant heat exchanger circuits are suitable for air static drying ovens applications, like wood drying and phyto- thermic processes for example. The heat exchanger circuit is engineered to operate as a heating battery that heat the air which is blown-through by ventilation fans. In this case the heat exchange between the circuit and the air happens via the conduction principle.

 The two pictures below represents the convection fans connected with the exchanger circuit (left) and the burners & fumes aspiration fans installation (right).

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Radiant System Innovation

 A few examples of outdoor wood drying static ovens:

 Static oven designed for wood processing: 2 burners of 30kW with 27 m of heat exchanger circuit each.

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Radiant System Innovation

9. INDUSTRIAL WASHING___________________________________________ Igraf burners are often used for heating liquids in industrial washing machines.  The rotating platform washing machine is used to obtain a perfect cleaning of big dimension pieces up to 7,000 kg in weight. Technical features: closed cycle washing with detergent and water up to 80°C; heating with burners connected to the tanks; automatic feed of the cleaning solution with water taken from the rinse; computerized anagement and control system; overall dimensions 7,000 x 6,000 mm.

 Washing plant for the cleaning and/or paint removing of bogies, frames and pieces of big dimensions: closed cycle spray washing with warm water and detergent; cold or warm water rinsing; Working cycles programmed in time and phases; Control and management computerized system

 Washing plant for train cleaning. Igraf burners and heat exchangers can be installed in the external hot water tanks to obtain continuous hot water at a temperature of 80°C used in the cleaning processes.

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10.

FOOD PROCESSING_____________________________________________

IGRAF radiant heat exchanger circuits are used in food processing machines. In the picture on the left they were installed in baking ovens, while in the picture of the right the system was used for heating the water needed for cooking pasta. The tank capacity was 500 liters, operating temperature 100 °C, reached within 1 hour. Total power installed was 150 kW, shared between two burners, each one with 75 kW power. As you can see in the picture, the burners are built with a stainless steel cover to avoid corrosion issues due to the water.

11.

SUNRAD - INFRARED EMITTERS___________________________________

SUNRAD incandescent emitters are used in many different processes, especially when high product temperatures or a quick drying are required. SUNRAD emitters are suitable for all these applications since are made with honeycomb plates that reach temperatures up to 900°C, providing a very strong thermal emission.  Example of infrared emitters oven designed for a Textile industrial drying process:

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Radiant System Innovation

 Example of oven for drying brake pads. It is made with 6 Sunrad emitters of 30kW each in line, the requirement was to reach 350°C product final temperature in a few minutes.

 SUNRAD emitters installation in two dynamic curing ovens. The required piece temperature was 150°C and the curing process time was 5 minutes.

 N.8 Sunrad infrared emitters installed in marble slabs processing:

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Radiant System Innovation

REFERENCES_________________________________________________________ Marbol processing Simec Ritec Breton Fiam Barsanti macchine

Food industry Tecnoalimentare Velo Gambarelli impianti Coating Plants Euroimpianti

Wood drying Baschild Bigondry Copcal Incomac Incoplan Secal Textyle Triveneta Grandi Impianti Primec

Oxidation processes Aluengineering Aluplant Biemme Impianti Italtecno Raimondi CIE International Mart

Ceramic industry Industrial washing Barsanti Macchine Raimondi Impianti Gambarelli Impianti Breton _______________________________________________________________________ We work in these countries:

The best companies around the world have been choosing the quality of FRACCARO products for over 50 years.

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