Advanced Process Heater

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The Roadmap for Process Heating Technology (March 16, 2001), identified the following priority R&D needs: Improved performance of high temperature materials; Improved methods for stabilizing low emission flames; Heating technologies that simultaneously reduce emissions, increase efficiency, and increase heat transfer. This Category I award entitled ''Proof of Concept of an Advanced Process Heater (APH) for Steel, Aluminum, and Petroleum Industries of the Future'' met the technical feasibility goals of: (1) Doubling the heat transfer rates (2) Improving thermal efficiencies by 20%, (3) Improving temperature uniformity by 100 degrees F and (4) simultaneously reducing NOx and CO2 emissions. The APH address ... continued below

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Tom Briselden, Chris Parrish March 7, 2005.

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Description

The Roadmap for Process Heating Technology (March 16, 2001), identified the following priority R&D needs: Improved performance of high temperature materials; Improved methods for stabilizing low emission flames; Heating technologies that simultaneously reduce emissions, increase efficiency, and increase heat transfer. This Category I award entitled ''Proof of Concept of an Advanced Process Heater (APH) for Steel, Aluminum, and Petroleum Industries of the Future'' met the technical feasibility goals of: (1) Doubling the heat transfer rates (2) Improving thermal efficiencies by 20%, (3) Improving temperature uniformity by 100 degrees F and (4) simultaneously reducing NOx and CO2 emissions. The APH address EERE's mission priority of increasing efficiency/reducing fuel usage in energy intensive industries. One component of the APH, the SpyroCorTM, was commercialized by STORM Development's partner, Spinworks LLC. Over 2000 SpyrCorsTM were sold in 2004 resulting in 480 million BTU's of energy savings, 20% reduction in NOx and CO2 levels, and 9 jobs in N.W. Pennsylvania. A second component, the HeatCorTM, a low-cost high-temperature heat exchanger will be demonstrated by Spinworks in 2005 in preparation for commercial sales in 2006. The project occurred in the 21st Congressional District of Pennsylvania. Once fully commercialized, the APH energy savings potential is 339 trillion BTUs annually in the U.S. and will process 1.5 million more tons annually without major capital equipment expenditures. Spinworks will commercialize the APH and add over 100 U.S. workers. To accomplish the objective, STORM Development LLC teamed with Penn State University, SyCore, Inc, Spinworks LLC, and Schunk-INEX, Inc. The project consisted of component engineering and integration of the APH followed by parametric testing. All components of the system were tested in a lab furnace that simulates a full scale industrial installation. The target areas for development include: (1) Scale up STORM's Finned Stabilized Combustion, (2) Optimization of SyCore's SiGr Inserts such that the heat transfer on the exhaust leg will match the high luminosity burner leg., (3) Evaluation of the heat transfer characteristics of Schunk-INEX's finned composite tubes as a heat exchanger, and (4) Design of a system to monitor all components of the APH and control its performance such that the objectives are met.

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  • Report No.: DOE/GO/13016-1
  • Grant Number: FG36-03GO13016
  • DOI: 10.2172/850298 | External Link
  • Office of Scientific & Technical Information Report Number: 850298
  • Archival Resource Key: ark:/67531/metadc779735

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Office of Scientific & Technical Information Technical Reports

Reports, articles and other documents harvested from the Office of Scientific and Technical Information.

Office of Scientific and Technical Information (OSTI) is the Department of Energy (DOE) office that collects, preserves, and disseminates DOE-sponsored research and development (R&D) results that are the outcomes of R&D projects or other funded activities at DOE labs and facilities nationwide and grantees at universities and other institutions.

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  • March 7, 2005

Added to The UNT Digital Library

  • Dec. 3, 2015, 9:30 a.m.

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  • Aug. 30, 2016, 6:25 p.m.

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Tom Briselden, Chris Parrish. Advanced Process Heater, report, March 7, 2005; United States. (digital.library.unt.edu/ark:/67531/metadc779735/: accessed November 24, 2017), University of North Texas Libraries, Digital Library, digital.library.unt.edu; crediting UNT Libraries Government Documents Department.