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Precision Electric Heat and Control Systemsfor the Chemical industry

ASSURING YOUR PROCESS PERFORMANCE WITH CHROMALOXWE SERVICE MOREINDUSTRIESNO OTHERMANUFACTUREROF HEAT ANDCONTROL PRODUCTSSERVES CHEMICALPROCESSING BETTERWith the broadest productline and experienceunmatched in the industry,Chromalox providesprecision heat and controlsystems for more processesthan anyone in the world.We provide solutions forindustries as diverse astransportation,pharmaceuticals, powergeneration, the military, . . .and chemical processing.The Chromalox DifferenceSome companies simply build heaters and controls.Chromalox does more. We provide custom-engineeredprecision heating technologies for diverseprocess industries by designing equipment specificallyfor customers’ needs.The difference between these two approaches isthe difference between uncertainty and assurance.Chromalox offers full design and engineering forvirtually any electric process heat and controlapplication. We become a partner who workswith you to save time and moneybefore startup, who works withyou to maximize efficiency andminimize downtime, and whoprovides the field serviceand technical support youneed to get the job done.2

TECHNOLOGIES THAT REFLECT AN UNDERSTANDING OFCHEMICAL PROCESSINGChromalox Has the Products That Are JustRight for Your ProcessFrom explosion-proof heaters for hazardous locationsto self-regulating heat trace to maintain processtemperatures in piping. From circulation heatersthat superheat steam to large tank heaters thatwarm viscous materials for pumping. Our expertise,combined with the most stringent materialand manufacturing standards you'll find in theindustry, provides you with an array of productsyou can count on to perform at each criticalprocess phase.The illustration on pages 4 and 5 shows a number ofapplications in chemical processing where Chromaloxhas the best choice for achieving precise heat andcontrol. Others include fuel oil heaters, amine gasheaters for sulfur removal, tail gas heaters, and PSAheaters. Chromalox immersion heaters in aqueousammonia solution tanks can provide reliable heat forthe vaporization of ammonia injected into selectivecatalytic reduction (SCR) systems, which can play avital role in reducing nitrogenoxide (NOx) emissions. And withthe trend toward point-of-useboiler and heat transfer systems,you’ll find that Chromalox has theright product to meet yourspecific needs.Chromalox Meets Your SpecificChallengesWith that kind of experience behind us,Chromalox understands the unique challengesthat chemical plant engineers, builders, managers,and maintenance personnel face. Andwe have the knowledge, experience base, localsupport, and technical skills to meet thosechallenges with you.3LONG HISTORYOF INNOVATIONA LONG HISTORY OFINNOVATION IN THECHEMICAL PROCESSINGINDUSTRYChromalox has beendeveloping better means ofapplying electrical heat forthe chemical processingindustry since 1915. Thatyear, we introduced theworld's first metal-sheathedheating element.

4CHEMICALPROCESSINGPRECISE HEAT ANDCONTROL FORACCURACY ANDREPEATABILITYChromalox heaters andcontrols are engineered andmanufactured to provideprecise heat and control tohelp ensure the accuracy andrepeatability that is expectedof your process.We control the manufacturingprocess from the firstcomponent to the finishedproduct. Our verticalintegration of productmanufacturing allows tightcontrol of all procedures.We can adjust to meetcustomers’ criticalrequirements. Having controlfrom the very beginning ofevery step of the process,Chromalox can ensure thatthe highest quality isdesigned and manufacturedinto each product and allowsus to produce systems thatare tailored to our customers’needs and requirements.Distillation Column HeatingHeat transfer systems and package electricsteam boilers can be used to indirectly heatdistillation columns. Hot oil systems can achievehigh temperature at very low pressure. Fordirect heating, corrosion-resistant immersionheaters are used.Product Transfer LinesElectric heat trace provides pipe temperaturemaintenance for temperature-sensitive materials.Chromalox offers self-regulating cable andcontrol systems for general-purpose andhazardous locations. Mineral-insulated cableis available for pipe temperatures up to1,100ºF (595ºC).Wastewater TanksLTFX-style immersion heaters providefreeze protection on chemical wastewaterstorage tanks. LTFX heating elements canbe removed without draining the tank.Pump House HeaterUnit heaters ensure that temperatures stayabove freezing in the pump houses. Class 1,Division 1 designs available.Caustic and Cleaning Solution TanksStorage tanks containing chemical cleaningagents are heated with immersion and circulationheaters.Immersion HeatersStainless steel sheathed elementsand thermowells are ideal forprocess water applications.A wide variety of ANSI andcustomized flanges and elementlengths is available with ratingsup to 500 kW. Custom wattdensities available for heat-sensitivematerials. Patented 360ºrotatable housing is availableon to facilitate easyconduit connections.Class 1, Division1 rated.Circulation HeatersHigh-energy efficiency, fast heating,and uniform heat distributionfor numerous plant heating applications.High turn-down capability,tight outlet temperature control,and variable flow rates. Varietyof electrical terminal enclosuresis available to meetthe requirements ofyour application.Class 1, Division1 rated.Evaporator HeatingHeating jackets are heated with thermal fluid orsteam to maintain process-specific temperatureson the inner wall of the evaporators.Chemical Feed TanksImmersion heaters with lowwatt densities preheat chemicaladditives.Electric Steam BoilersConstructed of carbon or stainlesssteel with fiberglass insulation toASME or PED code. Safe, versatile,and efficient energy managementsystems that provide low- or highpressurehot water or steam.Packaged units are completelyassembled and ready to install,needing only a water feed-sourceand electric power hookupto operate fromexisting distributionvoltages, makinginstallation simple.Class 1, Division1 rated.Heat Transfer SystemsOur hot oil and water/glycol systemsare safe, versatile, user-friendlyself-contained heating and coolingpackages that provide direct orindirect process heating. Preengineeredand constructed withcarefully matched components,these systems eliminate componentselection andassembly, andprovide easyinstallation andtrouble-freeoperation.

Electrostatic Precipitator Purge HeatingDuct and circulation heaters warm air to heat thewalls of the precipitator to keep particulate fromaccumulating on the ESP walls.Process Heat ExchangerHeat transfer systems and packaged boiler providethe heat source for process heat exchangers.Heat Trace and ControlsCounteracts the heat loss fromprocess equipment and piping, preventssolution precipitation and theincrease of viscosity or solidificationof product, and provides freeze protection.Chromalox offers a varietyof heat trace cable; temperaturecontrol, monitoring, and managementin one, modular package; andall of the necessary componentsneeded to complete the installation,including splices, power connectionboxes, and waterresistantend-sealterminations. Class 1,Division 1 rated.Control SystemsBasic, low-cost temperature andprocess controllers; monitors andovertemperature controls; sophisticatedcontrol systems. Chromaloxcan design the right system foryour plant’s needs, includingintegration with DCS and PLCprograms. We are the only heatingelement supplier offering acomplete line of controls, controlpanels, and accessories.Boiler Feedwater PreheatingImmersion heaters and circulation heaters preheatincoming water supply to reduce cycling ofboiler, increasing efficiency.Reactor Temperature ControlThermal fluid heat transfer systems provide heating and coolingfor various reactions that require tight temperature control.Temperature ranges from -148ºF to 752ºF (-100ºC to 400ºC),depending on the heat transfer fluid used.Eye Wash and Safety Shower HeatingCirculation and immersion heaters heat andmaintain the temperature of heated water loopsfor eye wash and safety shower stationsthroughout the plant.VaporizersChromalox can design speciallyengineered vaporizers for the mostcorrosive and difficult applications.These vaporizers can heat anythingfrom raw materials, such assilane-based materials, to ammoniafor cell processing, to specialtyheat transfer fluids. Chromaloxvaporizers can be design up toseveral MW.Tank HeatersSpecially designed to fit hightemperatureand corrosiveapplications. Multiple productsdesigned to fit large stationary,small portable, and undergroundtanks for just about any materialsand location.5CHEMICALPROCESSINGBROADESTTHIRD-PARTYAPPROVALWith manufacturinglocations in the U.S.and Europe, Chromaloxhas earned world-wideapprovals andcertifications including,but not limited to,CE, NEC, UL, VDE, cUL, FM,CSA, MSHA, BASEEFA,Cenelec, ASME, PED, ATEX,GOST, and ISO 9001:2008.

ELECTRIC HEAT OFFERS SIGNIFICANT BENEFITS ANDADVANTAGES OVER OIL- OR GAS-FIRED SYSTEMSSIGNIFICANT BENEFITSAND ADVANTAGESThere are a lot more "green" reasons beyond environmental concerns to choose electric heat overoil- and gas-fired heat systems. Electric heat offers a number of advantages that can benefit manufacturersin saving or reducing manufacturing, installation, operating, maintenance, and capital costs.Improved safety and the ability to meet or exceed regulatory issues are important considerations, too.Consistent PricingElectric utility prices have been very consistent,averaging only four percent yearly increases.This allows customers to accurately determineoperating cost without gambling on the volatileprices of gas or oil. Gas and oil prices tend tobe erratic, with prices surging every winter.Clean-Running OperationWith electric heat there is no additionalexpense of installing exhaust piping, fuel orgas inlet lines, storage tanks for fuel oil, or airinlet lines–not to mention the factory spacelost to accommodate such a system.No PollutionElectric converts 100 percent of the powerinput into heat energy with no pollutantsgenerated. Fuel- and gas-fired systems producepollutants that must be monitored andcontrolled in accordance with EPA regulations.Quiet OperationElectric heaters have no combustion noiseand minimal moving parts. This greatly reducesconcerns over meeting OSHA noise regulations.Reduced Footprint and Envelope SizeCompared to some similar oil and gas heatingsystems of similar outputs, electric heatersare typically one-quarter to one-half the size.This saves valuable plant floor space.Minimal MaintenanceDue to the simpler operation of electric heaters(i.e., no combustion controls) very little maintenanceis needed. In addition, electric elementscan be easily replaced by service personnel.Lower Operating CostDue to the complexity of controlling a fuel/airmixture in a fuel or gas system, a full-time,trained technician may be needed for its operation.In addition, without continual tuning, gasand oil units can have reduced efficiencies.Safety ConcernsElectric heaters have no open flames. Flameoperatedsystems may require installationaway from any potentially combustible areas.Large Turndown / Precise ControlWith multiple staging or an SCR powercontrol, electric heaters can respond rapidlyand precisely to varying process conditionsfor operating cost savings. The large turndownratios possible with electric heat dropsoperating costs proportionally, while turndownratios of other heat technologies, e.g. steam,deliver a diminishing return of operatingcost reduction.6

UNRIVALED DESIGN, ENGINEERING, AND MANUFACTURINGCAPABILITIES FOCUSED ON YOUR CUSTOM ALTERNATIVEENERGY PROCESSFront-End Engineering Design AssistanceChromalox has more experience in processdesign than anyone else in the industry. Priorto construction let us put that experience towork for you.Accurate planning and sound engineering arekeys to any process. Our engineering supportstaff can help to properly specify equipment thatwill get the job done right the first time so whenyou enter the construction phase, you can besure that the specified equipment will operateas desired.Comprehensive Engineering CapabilitiesFrom heater assemblies and skid fabricationto integration with controls and sensors, ourcomplete engineered systems reduce installationlabor, reduce startup time, and ensure properoperation to specification. Chromalox providesengineering assistance with integrating ourproducts into your application, offering a fullrange of engineering capabilities.Our in-house engineering and software capabilitiesallow us to design simple operator interfaces.These advanced designs can reduce your business’training time and expense, as well asincrease repeatable operation. In addition,Chromalox has training tools and resources toassist you with installation, startup, and operation.Manufacturing That Leads the IndustryChromalox maintains four state-of-the-art manufacturingplants in the United States, Mexico, Europe,and Asia. In the U.S. alone, Chromalox has morethan 325,000 square feet (30,000 square meters)of manufacturing and warehousing space in Utahand Tennessee.Our manufacturing capability features computercontrolled,automated machinery to help achievethe highest in quality. With ASME welding capabilityin-house since 1953, Chromalox has gainedmore in-plant experience than any other electricheater manufacturer for high-quality welding. Ourlarge-volume ASME production of high-qualitypressure systems enables us to perform ASMEwelding at a level unsurpassed in our industry.Comprehensive On-Site EngineeringService and SupportChromalox will provide highly qualified personnelfor site commissioning and operational servicinganywhere in the world. Our engineers have beencomprehensively trained and possess the requiredmedical and safety certificates. If necessary,they are available to commission the mechanical,electrical, instrumentation, and control equipmentfor any system we have built.Custom Design for Special NeedsChromalox can design heating solutions for anyunique requirement. Our engineers will customdesignthe right product to meet your applicationneeds. If an element, sensor, control, or packagedsystem that we carry in stock doesn't exactlyfit your needs, we'll custom-build it–either byexpertly adapting an existing product or bydesigning and manufacturing a completely newone. Chromalox will help you produce prototypesfor new products and systems, developing aninnovative design in the shortest possible turnaroundtime.7DESIGN, ENGINEERING, ANDMANUFACTURING

Chromalox Value-Added Products and ServicesAre Available Worldwide103 Gamma DrivePittsburgh, PA 15238USAPhone: (412) 967-3800Fax: (412) 967-5148Toll-Free: 1-800-443-2640email: sales@chromalox.comwww.chromalox.comChromalox-UKUnit 122, Lombard House2 Purley WayCroydon, Surrey, CR0 3JP,UKTel: +44 (0)20 8665 8900Fax: +44 (0)20 8689 0571email: uksales@chromalox.comwww.chromalox.co.ukChromalox-FranceRoute de Château-ThierryNoyant et AconinF-02203 SOISSONS Cedex,FranceTel: +33 (0)3 23 74 39 39Fax: +33 (0)3 23 74 39 00email: francesales@chromalox.frwww.chromalox.frChromalox-Germany GmbHIm Defdahl 10 B44141 DortmundHRB 24583 AG DortmundGermanyTel: +49 (0) 231-58 44 990-0Fax: +49 (0) 231-58 44 990-9mail: Kontakt@chromalox.comwww.chromalox.deChromalox-ChinaChromalox (Shanghai) Precision Heatand Control Co., Ltd.Suite A2, 4th Floor, Fenggu Building88 Taigu RoadWaigaoqiao Free Trade ZoneShanghai 200131People’s Republic of ChinaTel: +86 (0)21-5866-8802Fax: +86 (0)21-5866-8803email: shanghai.office@chromalox.comwww.chromalox.cnChromalox-India1st Floor, 6 UNICOM HouseA-3 Commercial ComplexJanakpuriNew Delhi-10058IndiaTel: +91-11-25623134Fax: +91-11-25623480email: indiasales@chromalox.comwww.chromalox.inChromalox-Thailand75/57, 75/237-240, Moo 10Sukhumvit RoadThung SukalaSrirachaChon Buri, 20230ThailandTel: +66 (0)38 492944/5Fax: +66 (0)38 492946email: asiasales@chromalox.comwww. chromalox.comCopyright © 2008, 2013. Chromalox, Inc. All rights reservedPX119-1