Airtorch® Applications

The Electric Airtorch® is a unique low pressure-drop patented device that is used to quickly heat air and other process gasses to a temperature ranging from 20°C  to 1300°C.  They find use in simulating heating in test rigs, in running power plants, large die heat-up, chemical, and metallurgical processes, fuel production, 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, 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.   Large Airtorch® uses from KW to MW are seen in Jet Engine Test Beds,  Automotive Engine Test Beds, Chemical Synthesis, or Direct Reduction Processes.  MHI offers low KW to high MW Airtorch® systems.

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 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.

Why Use Electric Process Gas or Steam Heaters?

  • Precise temperature control with fast response times.
  • Very low-pressure drops save considerable energy
  • Ideal for heating gases and other fluids uniformly to high temperatures.
  • Unlimited turndown is feasible with precision.  For example, MHI Airtorch® units of 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 can benefit from high-efficiency electrical energy.
  •  Contact MHI.

Home Page: Process Air and Process Gas Airtorch® Models.

Did you know that devices that can be used to say 1000°C could last exponentially longer at 700°C than devices rated to only 700°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 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 with the rapid heating of profitable gases to optimize the output gas? For example, Methane can be heated to have the least residence time to prevent coke formation.

Home Page: Process Air and Process Gas Airtorch® Models

.World Logo No-gas Use Clean Electric

Uniformity with Airtorch

Uniformity with Airtorch®

Process Air and Process Gas Airtorch® Models.

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) classes. The well-trained MHI staff and technicians are committed to excellence.

Megawatt Airtorch

To help with the COVID-19 process, we encourage our customers to consider helping front-line workers at hospitals, testing clinics, and other healthcare facilities 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.

Case Study:  An example of one company saving significant energy costs by converting from combustion to electricity is discussed below.  This is without considering social costs.  Did you know that the social cost of producing one ton of CO2 can additionally be very high? 

Typical Applications for Airtorch®:

  • 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.
  • Applications in comfort heating.  Hot air generators are used to heat commercial and industrial environments. 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 and others.  Combined catalysis action is enabled.

Each type of application has its unique control system designed for that market.

Case Study: 

A customer replaces his 16.5 MW natural-gas hot-air generator, with an 11.5 MW electric hot-air generator (Airtorch®).  What are his energy-saving, and CO2 production savings?  Both units convert 28000 SCFM from room temperature to 700°C.

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.

Summary:  The MHI Airtorch® can possibly save 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

Customer Testimonials for MHI

Testimonials MHI

GTA

GTA SH

Duct Heaters

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 several 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 – 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 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.

Or say:

CO2  + CH4  = 2CO + 2H2  Feasible above ~660C or via the steam reforming and water shift shown here.  Unique combinations may be used for advantageous reaction engineering.

2H2  + CO2  = C + 2H2O  is feasible below 600C

H2  + CO2  = CO  + H2O is feasible above  900C

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 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)

2CH4= H2 + C2H6  (At 1000C K= 4.2 x 10^-3, Delta (H)= positive)

Syngas production in laboratory

Syngas Production.  For laboratory KW and Commercial, MW MHI is the source.

Heat Methane and CO2

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SH

SH

 

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 generator products are considered for such use.

For 1 kWh of energy use or energy conversion by electric methods instead of by burning carbon-containing fuel, about 0.8-2 lbs of CO2 production is prevented,   What more can we do to convert CO2.

Let us help with Industrial Decarbonization.

Yes, there is a 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 about 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 address 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 steel with useful properties of strength, ductility, and toughness.  The chart below shows the strength of important carbon-containing steels and some without carbon.

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Chronology of Steel Developments

Packaging, Sealing, Chemical Reactions, Cracking and Hot CO2 or CO reactions

       

Looking for a very low-pressure drop high efficiency compact Duct-Heater?

Convert any over to an electric oven with the highly compact SH duct heater module.

Extremely Compact High Power  Duct Heater Airtorch®.

Extremely Compact High Power

General comparison of gas and electric heating for duct heating. 
Maintenance and Safety. Gas furnaces need to be maintained regularly since smaller particles are produced by the burner, which then accumulates within the heater. If these particles are not cleaned off regularly, the entire heater could malfunction. Corrosion is also a common occurrence in gas heaters, which plays a part in the shorter lifespan that these heaters have. 
Since electric heaters don’t contain a gas burner, the system itself doesn’t require regular maintenance. The lower maintenance requirements mean that electric heaters are less expensive to maintain when compared to gas heaters.

Energy Efficiency.  Because of the controlled temperatures feasible from an electric heater they tend to be considerably more efficient compared to gas heaters.

            MVTA Airtorch 72 kWGTA

1- 15 Kw 36 KW, 72kW , 144kW,  402 Kw, 900KW, 3 MW, 4 MW (PV)

Other MHI products like OAB® and Cascade e-ion also may be used for such applications.

Combustion and Scorching/Burn off/Curing

Airtorch® can be used for curing, surface burning, and 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 100°K rise in air temperature. Arrhenius equation and influence of Temperature.
Scorching/burn-off/curing

Airtorch for Combustion Studies and Simulation

Conversion

for

N2

Weight Volume
Pounds
(lb)
kilograms
(kg)
Cubic feet
(SCF)
Cubic meters
(Nm3)
1 pound 1.0 0.454 13.80 0.363
————— ————– —————- ————- —————
1 kilogram 2.205 1.0 30.42 0.7996
1 SCF gas 0.07245 0.03286 1.0 0.02628
1 Nm3 gas 2.757 1.2506 38.04 1.0
Scf (Standard cubic foot) gas measured at 1 atmosphere and 70°F.
Nm3 (Normal cubic meter) gas measured at 1 atmosphere and 0°C.

44.01 kg is the mass of one kilo-mole of CO2 

14.0067 kg is the mass of one kilo-mole of N2 

The average molar mass of dry air is 28.97 kg/kilo-mole.

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Easy Design and Selection

Choose KW, MW, and even MW/m2 flux

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 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 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

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

Large Die Heating/ Rapid Dry of Ores and Lithium Salts

Comfort Air Heating

The Airtorch® allows large room heating along with humidity provided by the Steam Generators.

Comfort Airtorch®

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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 for 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. 

Die heating Studies

Ceramic Drying Studies

Click to see the Die Heating Applications Presentation

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Please contact MHI for ROI calculations for typical Die Heating