The Ultimate in Direct Contact Water Heating. by Thermal Engineering of Arizona, Inc. An Inc. 500 Company

Transcription

1 SWERHMTER The Ultimate in Direct Contact Water Heating - by Thermal Engineering of Arizona, Inc. An Inc. 500 Company

2 TEA'S "S U P E R H E ATE R" When high volumes of hot water are needed, Thermal Engineering's "SUPERHEATER" Direct Contact Water Heater should be your first choice. The 99% plus thermal 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, hundreds of these heaters have been installed and have resulted in unmatched levels of performance. This Is How The "S U PER H EATER' Works The heater itself is a vertical all stainless steel vessel which consists of the following: the exit cone which discharges the cool gases to the exhaust stack an inlet water flow distributor which spreads the water out over the packed mass heat exchanger the upper heat transfer zone which consists of a "packed mass" heat exchanger a lower heat transfer zone where the hot gases contact the water droplets falling through a bottom heated water storage reservoir 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 thru the packings readily releases its heat to the water film rapidly raising 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 thru 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 are generated to maintain the desired hot water discharge temperature. STRUCTURAL COOLING: "the key to long heater I if e" 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 at 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. The Energy Bonus How can the "SUPERHEATER" claim 99% plus thermal efficiency? It's done by 'lover-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. TEA is not making exaggerated claims when it says its "SUPER ZEATER" operates at nearly 100% thermal eficiency. Simply stated, it combines the very high heat transfer eficiency of the packed mass heat exchanger with the extra heat of the recovered almost water temderatures. This n *. -., water oj combustzon. 1 be bottom controlled wall temperature is the key to long heater life. Thermal stresses are line is the most eficient water controlled eliminating the resulting heater on the market. ~ cracking and distortion so common in other heaters.

3 Thermal Engineering's "SUPERHEATER' Direct Contact Water Heater makes use of a very old engineering principle for removing entrained solids from an air stream, the wet scrubber. The products of combustion when using natural gas-minute as they are-are removed from the gas stream to some degree. Fortunately, the volumes of water in relation to the volumes of solid particles resulting from the combination process are such that the combustion products are almost undetectable. Normal operation produces a hot water supply as clear and pure as water heating would from any other kind of heater. No odors can be detected nor are floating or suspended particles visible. Generally the slight decreade in ph is more beneficial than the higher ph values formed in most water supplies. Direct contact water heaters have been used for years in food preparation plants and hospital laundries with no apparent problems. Just the benefits of a very Graphic display and motor controlpanelh$+ visible fiom a distance for quick reference. economical heater water have resulted. In fact, the United States Department of Agriculture has issued the following statement: "Equipment such as a direct contact hot water heater may be used in federally inspected meat and poultry plants without a formal letter of acceptance provided: I) it created no adverse conditions or safety hazards; and 2) It is installed, maintained and operated in a manner acceptable to the inspector in charge." For those desiring more definitive information on a typical analysis that could be expected, the follow is offered: 70" F. 160" F. Inlet Outlet PH Total Suspended Solids Residue or Evaporate Total Hardness (Ca C03) Total Alkalinity (Ca C03) Calcium Sodium Chloride B.O.D. (5 day) Dissolved NOx NOTES: Values shown are in milligrams per liter (1 Mg/L=I PPM). Results will vary depending on source of water. Ratings and Approvals All burner and control components are U.L. approved. Additional approvals (EM., C.S.A., etc.) can be supplied at additional costs. Contact TEA directly for specifics. To fall under the jurisdiction of the A.S.M.E. Boiler and Pressure Vessel code, either Section 1-Power Boilers or Section IV-Heating Boilers or Section VIII-Pressure Vessels, the operating pressure of a water heater must exceed 15 PSIG. The TEA "SUPERHEATER" is a Fresh water control piping-assembled, tested and heater mounted. vented non-pressurized water heater (atmospheric water pressure) and as such does not fall within the scope or jurisdiction of the A.S.M.E. Boiler Code and requires no approvals. It is strictly the responsibility of the installer and/or customer to obtain any local or state approvals or permits for the installation of TEA supplied equipment. It is strongly recommended that these approvals be obtained before ordering the equipment. 'ya man can write a better book, preach a better sermon. or make a better mouse trap than his neighbor, though he may live in the woods [Tucson], the world will make a beaten path to his door." -Ralph Waldo Emerson

4 ~~ I- r m Y - Typical Superheater Installation Arrangement HOT WATER REHEAT LINE A "-HOT WATER DELIVERY LINE HOT WATER TOPROCESS it I I COLD FRESH WATER SUPPLY / SUPERHEATER TEA STAINLESS OPTIONAL TEA \ DIRECT CONTACT STEEL HOT WATER HEAT RECOVERY HOT WATER HEATER STORAGE TANK SYSTEM D.C.- 1 Superheater Sizing and Performance Data i 7111) nnn 43" 130" I C" 'Normal high fire output- turndown ratios of 4:1 are standard without modification. Other Products by Thermal Engineering: WASTE WATER HEAT RECOVERY SYSTEMS WATER STORAGE AND PUMPING SYSTEMS D.C.-2 BOILER STACK ECONOMIZERS THERMAL 2250 W. Wetmore Tucson, Arizona Telephone: (520) Fax: (520)

5 The Ultimate in Direct Contact Water Heating UNBELIEVABLY LOW EXHAUST GAS TEMPERATURE Typically 10 to 15 degrees F. above inlet cold water temperature. FULLY REMOVABLE TOP Allows fast removal for easy internal access. Anatomy of a SUPERHEATER In ternully Superior 1 INLET FRESH WATER FLOW DISTRIBUTOR Eliminates pressure sensitive spray nozzles -the major cause of heater shut down. Larger droplets all but eliminate mist discharge from stack. Excellent water distribution over packed bed through entire burner range. No flow rate changes due to nozzle restrictions or pressure fluctuations. Changing hot water demands - 100% down to 25% are easily handled automatically. BURNER NOZZLE COOLING High velocity water cooling channels maintain inner liner at near cooling water temperature. No expensive heat shields or burner shrouds are required. Competitive heaters with poor cooling use a failure prone heat shield which requires periodic replacement. FORCED DRAFT BURNER Completely wired and tested at the factory. The U.L. approved gas train is completely assembled and wired (Optional ratings F.M., I.R.I., C.S.A., ETC. are available). COMBUSTION ZONE COOLING High velocity water cooling ensures metal liner remains at cooling water temperature for outstanding durability. Competitive heaters lack high velocity cooling and require special stainless steel rating for 1800 degrees F. to overcome high metal temperature operating conditions. PRE-MOUNTED TRANSFER PUMP for rapid heater installation. FRESH WATER MAN I FOLD Shipped fully assembled, tested and mounted. The control valves allow full rangeability from high demand conditions (100%) to low hot water needs (25%) for a true 4:l turndown ratio of plants flow-rate with full burner temperature control. Competitive heaters can only operate at rated water flows of the spray nozzle. A change of flow results in thermal cycling, a major cause of metal failure. superior acid and heat resistant material.

6 Some very good reasons to seriously consider TEA'S "SUPERHEATER": A superior design-overcomes other heater wall hot spot problems. Combustion zone and burner nozzle high velocity jacket cooling - unmatched in the industry, All stainless steel construction-long term service with low maintenance. Includes fresh water control piping-assembled, tested and heater mounted. Transfer Pump-assembled, tested and heater mounted. Control Center-wired, tested and heater mounted. Graphic Display Panel-highly visible status and fault lights. Structural base mounting ring-strong enough for earthquake restraints to rating if needed. Factory piped and tested-only needs minor assembly, utility and stack connections to be operational. Direct reading fresh water flow-rate meter-insures precise flow settings for maximum performance. Flow rated pump-half the horsepower of other heaters which reheat water through main delivery spray nozzles. Atmospheric pressure operation-eliminates full time boiler operator and A.S.M.E. Boiler Code approvals and restrictions. High temperature alloy stainless steel in combustion zone for longest trouble-free service. Quick heating-high volumes of hot water within 3 minutes of starting. Easily removed discharge cone-provides full access to heater internals. Internal components fully removable-provides top to bottom access. Full modulating heaters available for highly variable plant demands and no plant water storage capabilities. Fully self contained-all major operating parts, valves, controls included. USDA acceptable water heating process. Super efficient-heat output will exceed 100% (high ambient-low water temperature conditions.) Simple exhaust stack installation-low temperature exhaust gases and forced draft reduce stack size and costs. Floor space-about 1/3 of floor space of conventional water heaters. Direct contact heat transfer eliminates scaling and fouling-just about eliminates internal maintenance. Water quality or mineral content does not affect the thermal performance-untreated city water is satisfactory. To estimate fuel savings-use 100% thermal efficiency for the Superheater and compare it to your present heater using a realistic fuel to hot water heat transfer efficiency. Digital temperature readout and over temperature alarm for instantaneous evaluation. Inlet fresh water flow distributor eliminates pressure sensitive spray nozzles-the major cause of heater shutdowns. A 2250 W. Wetmore Tucson, Arizona Telephone: (520) Fax: (520) HDXDF