Thermal processing companies around the world are feeling the pressure to lower the environmental impact of their operations and make them more sustainable. These pressures are coming from both governmental regulations as well as societal expectations, resulting in increasingly stringent requirements that are expanding globally. Many companies are accelerating their own “green” initiatives and programs to leap ahead of these regulations and lead this transformation for their industry. MHI Airtorch® and MightySteam® can assist your various initiatives. Decarbonize the industrial sector, the agricultural sector, and the building sectors. Cut emissions and decarbonizing with MHI products.
Why Use Electric Process Gas and Steam Heaters?
Precise temperature control with fast response times.
Ideal for heating gases and other fluids uniformly to high temperatures.
Unlimited turndown is feasible with precision. For example MHI Airtorch® unitsof say 240 KW or 1 MW, offer a 90 % turndown when required.
Suitable for use in hazardous areas including outside use.
No in-plant emissions. The most important crisis facing us is the ecological crisis. This is addressed by using the best efficiency (system and controls) and the new technologies that are able to benefit from high-efficiency electrical energy.
Often the capital cost of an electrical system is higher than using a combustion burner but the payback is extremely attractive. Contact MHI.
Did you know that devices that can be used to say 1300°C could last exponentially longer at 900°C. This is why MHI is often able to provide a full warranty for an Airtoch® that covers the heaters. Check testimonials from customers. Outlet temperature 400°C-1300°C, inlet depending on model -40°C, 100°C, 450°C, 800°C, choice of shell pressure. New high value duct modules for transforming combustion ovens to electrically powered air heating. As MHI for the best warranty on heating systems.
The Airtorch® is a unique low pressure-drop patented device that is used to quickly heat air and other process gasses to temperature ranging from 200C to 1300°C. They find use in simulating or running power plants, large die heat-up, chemical process for fuel production, combustion/flow simulation, additions to cement clinker furnaces, curing, drying or bonding of paper boards, removal of inorganic and organic salts, fuel cells, general heat treatment for bending and de-flashing/deburring, drum heating, plastic rolls, welding of plastics, soldering disinfection, drying, rapid paper and pulp production, binder burn off, chemical reactions for environment and sustainability applications, and general uniform heating requirements. Large Airtorch® uses from KW to MW are seen in Jet Engine Test Beds, Automotive Engine Test Beds, Chemical Synthesis or Direct Reduction Processes.
The production of chemical energy carriers utilizing electrical energy from renewable sources is essential for the future energy system. How can MHI help with rapid heating of pyrolizable gases to optimize the output gas? For example Methane can be heated to have the least residence time to prevent cole formation.
MHI Airtorch® models offer extremely high energy efficiencies. Where required they are manufactured to ASME specification-compliant pressure vessels/ schedules – built by an experienced company with patented technologies. Airtorch® models range from 1 KW to several MW (120/240/400/480/600V). The smaller KW models are LTA, VTA and MTA925 and GTA925. The larger flow models are MVTA and GTA (high-pressure) class. The trained MHI staff and technicians are committed to excellence.
To help with the COVID-19 process we are encouraging our customers to consider helping front-line workers at hospitals, testing clinics and other health-care facilities in their fight against the coronavirus and the COVID-19 disease it causes with innovative uses of the steam products and Airtorch Products. We have placed many such products in the ‘Sale’ section of the MHI web-store.
Climate change is one of the greatest challenges of our time. The Airtorch® can help.
Low-carbon energy inventions and innovations are essential to combat climate change, promote economic competitiveness, and achieve strong energy security. The MHI rapid heat and high temperature gas and steam systems are being tested for a number of reactions. Closing the carbon cycle by utilizing the excess CO2 is an appropriate intermediate step towards a carbon-free future. Use the powerful Airtorch for continuous VOC removal, conversions, or use for rapid heat treatment and/or surface treatments like finishing to hardfacing. The C, CO and CO2 gas reactions including the Boudouard reaction, Fischer-Tropsch, DMR and variations can be manipulated with hot process gases – includes Air, N2, O2, CO2, Ar and more. Examine other reactions below and do not hesitate to contact MHI for guidance:
2CH4 + H2O +CO2 = 3CO + 5H2 Well feasible above ~(760-860C) with easy methods for enabling all forms of downstream reduction. MHI reaction.
E.g. products that are reducing gases that can be used for various reducing reactions including cleaning and shiny metal production such as Fe2O3 + 3CO = 2Fe + 3CO2 (weak) or Fe2O3 + 3H2 = 2Fe + 3H2O above 520C. Note also that CO2 + CH4 =2C + 2H2O is always feasible at >100C but is extremely weak. Fe2O3 + 2CO + H2 = 2Fe + 2CO2 + H2O is always feasible but best above 1100C. The reaction Fe2O3 + 3H2(g) = 3H2O(g) + 2Fe is feasible above 600°C but requires a higher temperature than that for proper kinetics. Fe3O4 + 4H2(g) = 4H2O(g) + 3Fe is feasible above 1100°C. FeO + H2(g) = H2O(g) + Fe is a difficult reaction. Some green steel processing could use a mixture of Fe2O3 and nano-FeO which when reduced can yield a metal-ceramic composite of Fe/FeO.
MHI offers up to 1-10 Mega-Watts, easy on off reactors and Airtorch® models. Contact MHI.
Is sustainable CO2 reuse via the Dry Methane Reforming (DMR) process actually cost competitive?
Pyrolysis of methane at high temperatures can be used to produce hydrogen and other carbon hydrogen compounds or various morphologies of carbon like C12, carbon -fibers and other useful high energy products and materials. Several reactions are possible that can be manipulated with pressure and catalysts:
CH4=2H2+ C (At 1000C K= 1 x 10^2, Delta(H)= positive)
2CH4= 3H2+C2H2 (At 1000C K= 1.2 x 10^-3, Delta(H)= positive)
Syngas Production. For laboratory KW and Commercial MW MHI is the source.
Heat Methane and CO2
Fuel Cells, High velocity drying and surface heating including simulation. Contact MHI for nozzles supplied. The diagram below relates to iron ore reduction without catalyst with some of the reduction with carbon monoxide or hydrogen.
Catalytic Bed Heating/ See also Fluidized Bed. See also Quasi-R(R). Airtorch® units can have a high temperature input and may be supplied with high pressure shells/schedules. Various types of supplemental heating can be included. MHI specializes in custom units. Please be aware that customization adds a considerable degree of cost. Use also for aseptic and antimicrobial processing.
With over 5 billion metric tons of CO2 emissions in the United States in the year 2017, the utilization and conversion of CO2 into value-added chemicals, fuels, polymers, building materials, and other carbon-based products represents a key economic opportunity. Both the MHI Airtorch and MHI steam generators products are considered for such use.
Yes there is cost to change over to high quality clean energy but the benefits are astounding according to American and European and other blocks- between 1990 and 2018, greenhouse gas emissions in some blocs have already decreased by 23%, while the economy grew by 61% (click for reference). Not bad. See below for more CO2 conversion reactions. Use in refineries for hydrotreating and methanol/alcohol production.
If one is considering bio-fuels or useful products like carbon monoxide (CO), formic acid (HCOOH), methane (CH4) and ethylene (C2H4) or ethane (C2H6) from CO2 conversion – please contact MHI with your requirements. Methane emissions are of primary concern with regard to global warming and climate change. More Usage: Cold gas to cracked (process of cracking) gas for Naphta or Ethane for production of ethylene and more…
Did you know that Methane has a global warming potential of almost 25 when compared to carbon dioxide?
Decarbonizing the industrial sector is very important to addressing our climate crisis.
What is Green Steel? Steel that does not contain carbon. To make such steels, iron ore is reduced at about 850C with hydrogen. The carbonaceous (coke) reduction methods that are commonly used to produce iron are not used. Consequently there is no carbon present in the iron or steel. Hydrogen-based direct reduction uses hydrogen instead of coal as a reagent to reduce iron ore to pig iron, eliminating the CO2 emissions from the equivalent process in a traditional blast furnace.
Green steel production also avoids secondary carbon reducing processes like the Basic Oxygen Process. Green steels could include alloying elements like hydrogen, oxygen (see above for Fe/FeO composites), nitrogen or boron, aluminum, manganese, vanadium, molybdenum and other elements. The microstructure of steel is conditioned such that it competes with carbon steels with useful properties of strength, ductility and toughness. The chart below shows the strength of important carbon containing steels, and some without carbon.
If the flow is higher than 40 SCFM, please choose from MVTA models
If the temperature required is above 1150°C please choose DPF models
If the flow rate required is is of the order of 2-40 SCFM please choose from MTA, VTA or LTA models or MVTA925 for flanged units
DPF – Up to 1150°C-1250°C/~2200°F. DPF models can take fan or blower input as well as a compressed air/gas input.
Large Flow MVTA. For 1000-1100°C. These are sealed process gas heater (THN or DNA class) with blower or inline capability. High KW – High Flow.
Large Flow GTA – For high pressure vessel Airtorch®use. Custom engineering. Please contact us directly for assistance.
Continuous ovens with Airtorch® heating
CONVERTING FLAME SYSTEMS TO ELECTRIC AIRTORCH
MBtu/hour [MBtu/h] Kilowatt [kW]
0.01 MBtu/h 2.93 kW
0.1 MBtu/h 29.30 kW
1 MBtu/h 293.07 kW
2 MBtu/h 586.14 kW
3 MBtu/h 879.21 kW
5 MBtu/h 1465.35 kW
5.8 MBtu/h 1700 kW
8.54 MBtu/h 2500 KW
10 MBtu/h 2930.71 kW
Large Die Heating/ Rapid Dry
The Airtorch™ allows large die heat-up; reclaim dies and aluminum. Combustion/flow simulation, curing, drying or bonding of paper boards. Removal of inorganic and organic salts, fuel cells, general heat treatment fr bending and de-flashing/deburring, drum heating, plastic rolls, welding organics like plastic soldering disinfection, drying, rapid paper and pulp dry. With a 4 kW machine plan to dry 2-4 Kg/hr of desiccant.
Mineral or ceramic material curing, transformation or drying with hot clean gas
E.g. Free and bonded water can be easily removed. The Airtorch® can achieve very high temperatures without contamination, therefore direct drying is a natural application. Cure or phase transform minerals with clean hot air. For very special cases MHI also manufactures several Airtorch® Continuous ovens. It is also easy for us to work with you kiln fabrication shop. Airtorch Augmentation for Heat Treatment Furnaces – typical ROI.
Binder Burn-Off. Heating for Tensile and Fatigue Testing
Easy, uniform, safe, and collectable binder burn off. For ceramics, nitrides, powder metals, etc. Substantially improve quality and productivity.
Binder Burn Off
When high temperatures are needed in spaces where resistance heating elements cannot be used, the Airtorch™ provides the solution. Temperature variations matter during adhesive resin curing. Temperature profiling is particularly is important with an 8 Data Log during start up and cool down. Airtorch is instantaneous and uniform. OAB steam is instantaneous. Hybrid.
Producing CO2(g) and want to recycle- try this — CO2(g) + H2(g) = CO(g) + H2O(g) Water Shift. Feasible above ~820C.
H2(g) can be obtained by electrolysis of water – use 800C steam.
* Estimate only- subject to change. The estimate will vary by application, VOC removal consideration price is considered primarily from gas stream only. All ROI’s require a 30 day assessment as the assessment may not be current.
Hot CO2 or CO can easily be reacted with azides of Na, Ca, Li etc based) and other reactive compounds to make useful solids or liquids and the oxides of the alkali metal can be recovered.
NaN2 +CO2 or Ca-N or Li-N compounds can be reacted with hot CO2; or oxides with hot CO for clean metal production.
Hot CO2(g) + NaN3 = C + NaO2 + 1.5N2(g)
is negative free energy and good kinetics at 980C.
Similarly Fe203 + hot CO(g) can yield clean Fe.
Combination of Greenhouse-gases (also called high temperature greenhouse gas reactions):
CO2(g) + CH4(g) = 2CO(g) + 2H2(g) Feasible above ~650C or via the steam reforming and water shift shown above. Again the products are reducing gases that can be used for various reducing reactions including cleaning and shiny metal production such as Fe2O3 + 3CO(g) = 2Fe + 3CO2(g) (weak) or Fe2O3 + 3H2(g) = 2Fe + 3H2O(g) above 515C. Note also that CO2(g) + CH4(g)=2C + 2H2O(g) is always feasible at >100C but is extremely weak. Someof the most potent greenhouse gases like Methane can be converted to Non-greenhouse gases CO and H2. These reducing gases can be used for reducing reactions like reducction of metal oxides. So either the OAB or Airtorch may be used. At this point catalysts become become important.
Note that several gases can be toxic and only professional use is recommended.
Heating: Create a convective cavity around the assembly using multiple Airtorch® units. Fixture Airtorches™ behind mold and electrodes at angles to create air movement. This should improve the overall heating of the mold.
Insulation: The assembly is surrounded by refractory blankets (all 5 sides) to retain as much heat inside as possible. Blankets can be supplied by MHI at customer’s request.
Solution: By supplementing the existing electrodes with the Airtorch® and blankets, the watt density is increased on the mold thus reducing the workload of the existing electrodes which should improve performance and life. Other results include an increase of uniformity across the mold surface. Call MHI for more information.
Soldering, Blanketing, Melting, Molten Salt and Dental
Use the Airtorch® for softening, soldering, and melting of precious metals, molten salt processes and glass. Please do not use wet metal specially wet aluminum in a furnace, instead optimize by heating or preheating with a versatile Airtorch®. This feature is very applicable to the dental, jewelry, and glass industries. Use for rapid glazing, burnout and quick melts.