THERMIC FLUID HEATERTHE UNITHERM SYSTEM : The UNITHERM Thermic Fluid Heating System essentially comprises of A hilly automatic 3-pass, wet-back package, ol or gas fied heater in which the thermic fluid can bee heated up to 300°C at neor atmospheric pressure ‘The hot thermic fli is circulated in a closed cycle by high temperature centifugel pump and the heat is dissipated to the process through appropriate heat exchangers inthe user equipment circuit ‘A combined dearator cum expansion tank incomporated in the system, elficiently removes any liberated gases as well as absorbes the thermic fluid expansion during heating proces. Due to drain tank and top up pump, the plant can be patially drained for servicing. A contol panel consist all the necessary control and switching elements as well the necessary indications for safe and automatic operation of UNITHERM plant. 1 UNTHER HEATER 10 OVER FLOW LINE W SAFETY DEVICE 2 BURNER 11, ARENT 19 HIGH FEED TEMPERAT 3 CIRCULATING PUMP 19 FEED LINE 20 BURNER SAFETY CU {4 TOPUP PUMP (MOTORISED OR MANUAL) 13 RETURN LINE 21 STACK TEMPERATURE 5 SEPARATOR 14 TEMPERATURE INDICATOR CUM CONTROLLER 92 LOW LEVEL CONTROLLE {6 EXPANSION TANK 15 TEMPERATURE INDICATOR CUM CONTROLLER 23 OIL LEVEL G/ 7 DRAIN TANK 116 CIRCUIT PRESSURE GAUGE 124 SAFETY VALVE #8 EXPANSION LINE 17 PUMP PRESSURE GAUGE 125 HEAT CONSUM 9 DEARATOR LINEUnilherm-tk 3-PASS WET BACK THERMIC FLUID HEATER The liquid phase thermic heater has Isotex have manufactured liquid phase thermic established as the most economical indirect fluid heater since 1979 and have over 1000 heating system for industrial process heating. Its installations in continous operation throughout India The Unitherm TK series incorporates the new technology for higher efficiency and better ‘operational economy. superiority as a heat source over steam, hot water, hot air, and electricity has established it as the best alternative. i Burner 2 Flame of Burner 3 Combustion Chamber 4 Tube coil of radiation section 5 Tube coil of convection section 6 Oil cooled chamber 7 Internal Casing ‘BRetum Oil inlet 8 Mineral wool insulation 14 ‘st pass of the Flue gas 9 External casing 15 Snd pass of the Flue gas 10 Front hinged door 16 3rd pass of Flue gas TiRefractory insulation 17 Flue gas outlet 19 Forward Oil OutletDESIGN AND OPERATION THE HEATER : THE BURNER : The UNITHERM is a fully automatic horizontal or vertical coil type, 3-pass, wet-back oil/gas fired, forced draft heater. It embodies an integral combustion chamber arranged as a nest of Concentric helical tube coil manufactured from the seamless tubes recommended for high temperature service. The concentric coils are placed within a shell of Mild Steel assembly. The. Concentric coil and oil cooled jacket (wet back) allow three flue passes to ensure low rate of heat release and maximum heat transfer. The design incorporates very litle refractory work on the front hinged door to keep thermal inertia low. This new 3-pass wet back design ensures maximum absorption of heat and flue gas temperature at less than 300°C in a standara heater. Heater of larger size (above 1 milion kcals/he) is provided with suitable air pre-heater 50 as to reduce stack temperature upto 170°C. ‘The heater is equipped with a fully automatic pressure-atomising type 2-stage or modulating ‘oil/gas burner. The bumer is of monoblock construction and can be hinged to left or right. This simplifies the work on combustion head, diffuser, nozzles and ignition electrodes, The bumers for heavy oil are equipped with electric or media oil preheaters, heated nozzle head, pump and solenoid valves, (During prepurge heated cil flows through the nozzle head oil line system. This ensures that for flame. establishment evenly heated oil is available). This nozzle recirculation and positive shut off at nozzle tip ensures trouble free opeation even if temperature drops down to below zero degree. celsius. Special burners are available for any other kind of liquid/gas fuels.UNIT WITH INDUSTRIAL BURNER (Preheated Version) Combustion ar muss _/ Unit offering 92 + 9% efficiency is incorporated with preheated version of burners developed for special industrial and commercial application. In certain industrial process (ie. thermic fluid boilers) very high rate of flue gas temperature occurs due to the high heat transfer medie temperature, ‘A tremendous amount of energy can be retrieved by installing a heat exchanger (air preheater) inthe fiue gas path which otherwise being lost thru stack. In the process of cross~mixing the hot flue gas and primary combustion air in the heat recovery device (APH) the primary air recovers the excess heat from flue gas and goes to burner block and the temperature of flue gas exhaust will not be more than T70°-190° c This technology application results in an improvement of efficiency upto 8-10%. BURNER FUEL SYSTEMS Two stage and modulating regulation A ®t Oilis released at start when solenoid valve opens. 1m Full load is reached when solenoid valve 2 opens. The capacity is regulated by opening and closing solenoid valve 9. Bm Tre oil quantity forthe starting load is released when the nozzle needle opens A slow running servomotor acs the ol regulator up to ful capacity ® Regulation of burner capacity between partial and ful load by opening and closing ti ol regulator. AC el G-full load K-Partial load Z-lgnition load Graph A : Two stage Graph B : Modulating Fuels Light Oil : Upto 45 secs R.1/100°F Heavy Oil : Upto 3500 secs R.1/100°FThe thermic fluid circulation pump of centrifugal type circulates the thermic fluid at the reauired capacity and head. This pump meets all the API specification. Its Cast Steel construction, water cooled legs, water jacketed stuffing box and water cooled heavy duty reinforced bearings ensure longer service life. It can be equipped with suitable mechanical seal for zero leakage The back pull design of pump ensures easy maintenance. The rotating parts can be replaced with minimum down time without disturbing motor and casing. The reassembly operation requires a minimum of effort in realigning the coupling since the motor and casing are undisturbed and remain in good alignment. EXPANSION CUM DEARATOR TANK : ‘The combined dearator cum expansion tank effectively removes any liberated gases to prevent cavitation in the pump and accomodates expansion of thermic fluid. Design ensures very low temperature in the expansion tank to prevent ‘oxidation of oil to ensure longer life to the costly thermic fluid. ‘More than 15 different sizes are available, from 200 ltrs, to $000 Itrs. so that correct size can be selected to suit individual requirement. Expansion cum dearator tank is hydraulically tested to 150 psig. FILL AND DRAIN SYSTEM Comprises a Thermic Fluid Storage Tank of suitable capacity, a motorised thermic fluid top up pump and inter connecting pipings and fittings. In this system the thermic fluid overflow line from Expansion tank is directly connected to the storage tank and hence in case of over flow the costly thermic fluid will not go waste. This system is an optional feature. INSTRUMENTATION & CONTROLS The UNITHERM-TK is fully automatic and safe for unattended operation. The normal operation of the system is governed by a master sequence controller which, in the event of abnormal operating conditions sounds and audible alarm and trips the unit to stop. Symbols are provided (on the lock out indicator which indicates the kind of fault. Once the fault is cleared the controller automatically restarts the unit. The full complement of safety interlocks, indicators and alarm are mounted in modular control panel boxes AUTO CONTROLS & SAFETIES Thermic fluid feed temperature indicator cum controller Automatic ourner cut off and temperature: indication Thermic fluid return temperature indicator cum controller Automatic burner cut off and temperature indication. High feed temperature controller ‘Audio-visual alarm and automatic burner cut off. Low flow of thermic fluid Differential pressure switch actuated audio-visual alarm and bumer cut off. Low thermic fluid level in expansion tank Level switch actuated audio visual alarm anc ‘automatic system cut off. High stack temperature controller ‘Audio-visual alarm and automatic burner cut off. Fuel oll temperature monitor Allows the burner to start only if set temperature is reached at nozzle tip for perfect ‘atomisation of fuel oil Flame failure Photo-resistor actuated audio-visual alarm and ‘automatic burner cut-off ‘Additional safety through synchronisation of burner and circulating pump. The burner cannot bbe cut in before the pump has reached full speed.TYPICAL ADVANTAGES © 300°C temperature at near atmospheric pressure «© No corrosion o scale formation Fully automatic operation Adjustable temperature at heater outlet upto 300°C with + 196 accuracy High efficiency level No explosion hazards Exempt from Indian Boller regulation act, Rapid heating-up time Heating and cooling possible Thermic fluid can be used for many years No heater engineer required Lower servicing costs OPTIONAL FEATURES © Stand-by thermic fuid pump with motor (© Mechanical Seal for thermic fluid cteulating pump © Heat Recovery device © Media oil pre heater using thermic fluid or steam © Diain tank and top up pump © Temperature regulating device for user equipment STANDARD UNITS UNITHERM TK for standard application are available in il fired models with output ranging from 2,00,000 kcals/hr to 25,00,000 keals/he LUNITHERM TSP for standard application are avilable in ol fired package models with ‘output ranging from 50,000 calf to 1,50,000 keals/hr UNITHERM CX. for standard application ore available in coal/woodshusk fired models with output ranging from 2,00,000 keal/hr to 25,00,000 keals/hr. For futher details please ask for specification sheet TYPICAL APPLICATIONS All heat consumers, which need a temp, upto 350°C As Textile industry Driers, Hot ponds ete Vegetable Oil Deodorisr bleacher Industry neutalser Catering industry Dries inthe milk production, Friers, drying & baking ovens Metal industry Galvanizing, Hot ponds, Washing plants, dies Chemical industry Reactors for plastics, hot ponds for paints, rubber presses, autockaves, heating of tanks, distilation process Paper & Pinting Driers, Calender, Hot ponds, industry Printing machines Plywood & Veneer presses & dies, Laminate industry timber drying Building industry Bitumen tank, concrete forms drying tunnels, storage silos, brick work driers Ship Building: Exploitation of exhaust gas heat, heating of tanks and cargo. Petroleum Distillation of various fractions, Industey heavy oil heating and bitumen heating ete Soap and For autoclaves, boiling vessels, detergent Spraying and drying towers 235 well as sosponifcation lines Miscellaneous Insulation drying, sealing batteries, perfume manufacture, steam generation and hot water generation etc NON-STANDARD UNITS Custombuilt units are designed and manufactured to suit special process needs. Non standard UNITHERM TK are available from capacity range 200,000 kcal/hr to 2,50,000 heealfhe * For temperature above 300°C and upto 375°C + For wide variety of fuels like LSHS, Gas, solid fuels and agricultral wastes with flexibility of change-over from one fuel to other with imum down time ** Wide range of thermic fluid flow and head + Differentail temperature range 10°C to 60°C + With penumatic and electronic instrumentat + For other speci requirements