Climate change is one of the most significant challenges of our time. The compact Airtorch® can eliminate fossil-fuel heating, rapidly aid deep decarbonization, and create flexible, efficient chemical processes. Changing to efficient electric methods with the zero emission green transition could spur huge economic gains as the world looks to curb climate change.
Industrial Products and Fuels for a Decarbonized Economy.
MHI offers low KW to high MW Airtorch® systems for the industrial sector that can aid in significant decarbonization with improved energy efficiency. The Electric Airtorch® is a unique low-pressure-drop patented device used to quickly heat air and other process gasses to a temperature ranging from 20°C to 1300°C. Use the Airtorch for electrifying high-temperature industrial processes in iron-making, alumina calcination, cement, and lime production. Large Airtorch® uses from KW to MW are seen in Jet Engine Test Beds, Automotive Engine Test Beds, Chemical Synthesis, Clay calcination, Cement Industry, Drying, or Direct Reduction Processes. They find use in simulating heating in replacing combustion burners and preheaters, test rigs, running power plants, large die heat-up, chemical, and metallurgical processes, fuel production, and replacing fossil fuel calcination & kiln firing in several industries, including cement making, system combustion/flow simulation, additions to cement clinker furnaces, curing, drying, or bonding of paper boards, removal of inorganic and organic salts, fuel cells, thermal energy storage, 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 burns off, chemical reactions for environment and sustainability applications, and general uniform heating requirements. With devices like the Airtorch and similar high-value equipment, there is the potential to decarbonize roughly 80% of U.S. petroleum refining subsector CO2 emissions by 2050.
What is a decarbonized economy? A decarbonized modern economy has low greenhouse gas emissions from its industrial, transportation, and power generation sectors. The main impact of decarbonization can come from converting combustion methods to electrical methods. It is straightforward to convert combustion heating and drying to electrical heating and drying. An alternative way to decarbonize is to capture the CO2 and methane emissions and convert them into valuable products, even to CO (a toxic gas) with plasma catalysis. For 1 kWh of energy use or energy conversion by electric methods instead of burning carbon-containing fuels, about 0.8-2.2 lbs. of CO2 production can be prevented. A 100 KW device can prevent 80 – 220 lbs. of CO2 from being made every hour when heating is electrical, i.e., not with combustion heating (fossil fuel use).
Case Study: The price of natural gas per megawatt-hour in Europe decreased by 17% to ~$172 on October 7, 2022, the latest market data shows; a two MW saving by converting a 14.2 MW gas-combustion process air heater to a 12 MW MHI Electric Airtorch is a $3 million per year saving assuming 12 months, 30 days a month, and 24-hour day. (The additional social cost for the CO2 produced by burning natural gas has not been factored in this calculation).
With over 5 billion metric tons of CO2 emissions in the United States in 2017, the utilization and conversion of CO2 into value-added chemicals, fuels, polymers, building materials, and other carbon-based products represents a critical economic opportunity. The MHI Airtorch and MHI steam generator products can be considered for such use.
Thermal processing companies worldwide are feeling the pressure to lower the environmental impact of their operations and make them more sustainable. These pressures come from governmental regulations and societal expectations, resulting in increasingly stringent requirements. Many companies are accelerating their “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 industry, and the building sectors. Cut emissions and decarbonize with MHI products. For energy benefits in any application, from comfort heating to heavy industrial processes, the Airtorch® is a great approach when tackling climate change.
The energy cost produced by electric or combustion methods is not that different when the social cost of harmful CO2 is considered.
Electric heating gives precise temperature control with fast response times.
Very low-pressure drops save considerable energy.
Electric heating is ideal for uniformly heating gases and other fluids to high temperatures.
Unlimited turndown is feasible with precision with electrically heated Airtorch® systems. For example, MHI Airtorch® units of 240 KW or 16 MW offer a 90 % turndown when required.
Suitable for use in hazardous areas, including external use.
No in-plant emissions. The most important crisis facing us is the ecological crisis caused by emissions. Emission control is addressed using the best efficiency (system and rules) and the new technologies that can benefit from high-efficiency electrical energy.
WHY CHOOSE THE BEST AVAILABLE? Did you know that devices that can be used ~1000°C could last exponentially longer at 700°C than devices rated to only 700°C? MHI is often able to provide a full warranty for an Airtoch® that covers the heaters. Check testimonials from customers. Outlet temperature 20°C-1300°C, inlet depending on the 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 production of chemical energy carriers utilizing electrical energy from renewable sources is essential for the future energy system. How can MHI help rapidly heat profitable gases to optimize output? Contact MHI. Substitute for combustion preheating or heat without chemical wastage, e.g., methane or other petrochemical gases can be heated to have the least residence time to prevent coke 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. The smaller KW models are LTA, VTA and MTA925, and GTA925. The larger flow models are MVTA and GTA (high-pressure) classes. MHI staff and technicians are committed to excellence.
To help with the COVID-19 process, we encourage our customers to support front-line workers at hospitals, testing clinics, and other healthcare facilities to 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.
Decarbonizing the industrial sector is very important to address our climate crisis. Almost a third of the greenhouse gas emission is from the industrial sector. CO2 emissions can be reduced quickly, as can emissions from the fuel-making, general industrial heating, and chemical and steam sectors. The first steps in decarbonization are eliminating heat production by fossil-fuel-fired combustion and relying on electrical energy instead for heating. This can significantly impact CO2 emissions; e.g., the cement industry produces about 10% of global human-made CO2 emissions, of which about 60% is from the chemical process, and 40% is from burning fuel.
Although there may be a cost to changing to high-quality clean energy, the benefits are astounding. Greenhouse emissions from American, European, and other regions have already decreased by 23% – between 1990 and 2018, while the economy grew by 61% (click for reference). Not bad. But much more can be done using the Electric Airtorch or the MightySteam(R) steam systems.
Methane emissions are of great concern for global warming and climate change. Did you know that Methane has a global warming potential of almost 25 compared to carbon dioxide? Uses of the Airtorch include cold gas to be cracked (the process of cracking), i.e., for Naphta or Ethane for ethylene production. If one is considering bio-fuels or valuable products like carbon monoxide (CO), formic acid (HCOOH), methane (CH4) and ethylene (C2H4), or ethane (C2H6) from CO2 conversion – please get in touch with MHI with your requirements.
What is Green Steel? Steel that does not contain carbon. Iron ore is reduced at about 850C with hydrogen to make such steels. The carbonaceous (coke) reduction methods commonly used to produce iron are not employed when making green Steel. Consequently, there is no carbon present in such 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.
The microstructure of Steel is conditioned such that it competes with carbon steel with valuable properties of strength, flexibility, and toughness. 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 factors. The chart below shows the power of critical carbon-containing steels and some without carbon.
Electric heating improves energy efficiency. Electric heating prevents CO2, NOx, and SO2 emissions associated with fossil-fuel combustion heating. Recent estimates suggest that global carbon dioxide emissions from fossil fuels will hit a record high of 36.6 billion tonnes in 2022, corresponding to a record high of 442 ppm in the atmosphere.
Several applications are in high-pressure test stands for automotive and jet engines—key Features: Long-lasting, high temperature, high energy conversion, high pressure, and compactness.
Electric hot air generators are often used to heat commercial and industrial environments. Several applications are in energy-efficient comfort heating. Key Features: Compact, long life, and rapid heating.
Several applications in chemical processes and drying. Key Features: Energy efficient, extremely compact, controlled high temperature, and rapid heating. MHI Airtorch® nano-structuring is used for various gas combinations like hydrogen, methane, or syn-gas. Combined catalysis action is enabled.
Use in Ammonia, Cement, Steel, Aluminum, and General Heating Industries
Each type of application has its unique control system designed for that market.
Kilograms of CO2 emissions per million KJ (kilojoules) (Source)
Natural Gas (the main component is methane)
Diesel and Home Heating Fuel (Distillate Fuel Oil)
Gasoline and Ethanol Blends
A customer replaces his 16.5 MW natural-gas hot-air generator with an 11.5 MW electric hot-air generator (Airtorch®). Both units convert 28000 SCFM from room temperature to 700°C. What are his energy-saving and CO2 production savings? Answer: Taking into account 17 psi savings in pressure drop, a unit efficiency from the improved new technology, and the elimination of the combustion process, the user could save ~40% energy. Please contact MHI. for details.
Summary: The MHI Airtorch® can save up to 52800KWhr of energy every day and prevent the production of 57954 Kg per day of CO2 (assuming an 8-hour day). For details Contact MHI.
CO2, SO2, and Nox prevention with energy savings. Did you know that each such unit can cause savings estimated at $44 Million over a ten-year lifetime? Please contact MHI. for details.
Sectors for Decarbonization
The vast majority of the industry’s GHG (Green House Gases) emissions, 90 percent, consist of CO2. Almost 40% of the industry’s CO2 emissions today (2018) result from manufacturing the four industrial commodities—ammonia, cement, ethylene, and steel. A significant amount also comes from the general heat-treating industry.
Low-carbon energy inventions and innovations are essential to combat climate change, promote economic competitiveness, and achieve strong energy security. MHI’s rapid heat and high-temperature gas and steam systems are tested for several uses, like eliminating combustion heating and enabling new chemical 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, ore drying, rapid heat treatment, and surface treatments like finishing to hardfacing are the future. The C, CO, and CO2 gas reactions, including the Boudouard reaction, Fischer-Tropsch, DMR, and variations, can be manipulated with hot process gases – including 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 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 cost-competitive?
Pyrolysis of Methane at high temperatures can 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. The diagram below relates to iron ore reduction without catalyst with some of the reduction with carbon monoxide or hydrogen. Contact MHI for nozzles supplied.
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.
Chronology of Steel Developments
Packaging, Sealing, Chemical Reactions, Cracking and Hot CO2 or CO reactions
Large Die Heating/ Rapid Dry of Ores and Lithium Salts/Furnace Preheating
Drying is best done with hot air or hot steam. This prevents the toxic use of drying salts (chemicals) and reduces sulfuric and hydrochloric acid emissions. In one application the return on expenditure was very high – the cost of the capital equipment was recovered in two years. When using salts or desiccants they have to be dried for reuse. Using salts could create a very high energy/material recovery cost.
The Airtorch® allows large die heat-up, including reclaiming dies and aluminum. Attempt the removal of inorganic and organic salts, fuel cells, general heat treatment for bending and de-flashing/deburring, drum heating, plastic rolls, welding organics like plastic soldering disinfection, drying, and rapid paper and pulp dry: combustion/flow simulation, curing, drying, or bonding of paper boards.
With a 4 kW machine, plan to dry 2-4 Kg/hr. of desiccant.
Decarbonize the melting of tin, zinc, and aluminum with the Airtorch products. In a tin melting plant, it became costly to get new gas lines. The plant is considering melting with low-pressure drop Airtorches. It hopes to recover its expenditure in two years because of the enormous energy benefits of melting with an electric airtorch. MHI can assist with energy calculations.
Other MHI products like OAB® and Cascade e-ion also may be used for such applications.
Combustion and Scorching/Burn off/Curing
Arrhenius equation and influence of Temperature. Airtorch® can be used for curing, surface burning, sealing, and simulation operations. The possibilities are endless, as Air, Nitrogen, Helium, and Argon can be used. During combustion, the time for 98% combustion can change by several orders of magnitude for a 100°K rise in air temperature. Scorching/burn-off/curing
1 SCF gas
1 Nm3 gas
SCF (Standard cubic foot) gas was measured at 1 atmosphere and 70°F.
Nm3 (Normal cubic meter) gas was measured at 1 atmosphere and 0°C.
If the flow is higher than 40 SCFM, please choose from MVTA models
If the temperature required is above 1150°C, please choose PDF models
If the flow rate needed is of the order of 2-40 SCFM, please select 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 and a compressed air/gas input.
Large Flow MVTA.For 1000-1100°C. These are sealed process gas heaters (THN or DNA class) with a 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
CONVERSION TABLE OF MBtu/h to KW
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
Comfort Air Heating
The Airtorch® allows large room heating along with humidity provided by the Steam Generators.
The application of the Airtorch™ in Fluidized Beds! Please call MHI for details.
The Airtorch® has opened up new possibilities in the brazing and joining technologies. Whereas brazing furnaces were cumbersome and expensive in the past, Airtorch® allows for inexpensive processes.
The Airtorch® can be used for curing, surface burning, and sealing operations. The possibilities are endless as Air, Nitrogen, Helium, and Argon can be used.
Large Die Heating
Direct Ceramic Drying
The Airtorch® allows large die heat-up; reclaim dies and aluminum.
The Airtorch® can achieve very high temperatures without contamination. Therefore direct drying is a natural application. Free and bonded water can be easily removed. MHI also manufactures several Airtorch® Continuous ovens.
Binder Burn Off
Heating for Tensile Testing
Easy, uniform, safe, and collectible binder burn-off. Substantially improve quality and productivity for ceramics, nitrides, powder metals, etc.
When high temperatures are needed in spaces where resistance heating elements cannot be used, the Airtorch® provides the solution.
Packaging or Sealing
Designed for long life and high temperatures, the non-contaminating Airtorch® is an ideal solution for inline packaging or sealing processes.
Use the Airtorch® as a preheating device for dies in the metal forging and rolling industries.
Soldering, Melting, and Dental
Use the Airtorch® for softening, soldering, and melting of precious metals and glass. Use for rapid glazing, burnout, and quick melts. This feature applies to the dental, jewelry, and glass industries.
The glass industry uses the high-temperature Airtorch® to enable uniform flow and reflow of molten glass. The air temperature can be as high as 1200°C with a meager flow rate.
Airtorch® can rapidly heat various atmospheres: Air, Nitrogen, Argon, Helium, etc. Call MHI for more information.
Light Fiber Processing
Unique heating from 500°C to 1000°C. The Airtorch® produces laser-like heat to small areas down to 5mm in diameter with stable and accurate control.
Uniformly free carbon from woven fibers with true convection. The Airtorch® creates hot turbulent air that passes through the substrate for uniform and accurate heating. As carbon is released, the natural flow of clean hot air flushes the airborne carbon away from the part and up the chimney.
Effective Heat Treating
Preheating for Welding
Uniform rapid heating. The Airtorch® offers uniform high temperature and heat transfer to rapidly heat parts. Very effective for metals when increasing hardness.
With high accuracy and temperatures, the Airtorch® reduces the guesswork of preheating for welding applications. Offers accurate temperature read-out.
Spot Decarborinzing (reducing hardness)
Over carbonizing causes hardness above most machining capabilities. The Airtorch® offers locatable, accurate, rapid heat-up and cool down to efficient diffuse carbon allowing the metal’s tempering.
Develop your application. The Airtorch® is capable of many applications where accuracy, uniformity, power, and high temperatures are required. Also benefit from whisper-like operations, energy efficiency, and ease of use.