INDUSTRIAL HEATING

CONTENTS
INTRODUCTION ......................................................................................................................1

I- COMMON TYPES OF HEATING SYSTEM ......................................................................1

I-1- Hot water heating ..........................................................................................................1

I-1-1- Heat transmission ...................................................................................................2

I-1-2- Factors affecting system efficiency ........................................................................2

I-1-3- System efficiency ...................................................................................................3

I-1-4- Hot water arrangement. ..........................................................................................3

I-2- STEAM HEATING ......................................................................................................6

I-2-1- Advantages and disadvantages ...............................................................................6

I-2-2- Heat flow to a steam ..............................................................................................7

I-2-3- Factors affecting system efficiency ........................................................................7

I-2-4- System efficiency ...................................................................................................9

I-3- ELECTRICAL HEATING ............................................................................................9

I-4- FORCED AIR HEATING........................................................................................... 10

I-4-1- Factors affecting system efficiency ...................................................................... 10

I-4-2- Efficiency of the system ....................................................................................... 11

I-5- SOLAR HEATING ..................................................................................................... 11

I-5-1- Active system ...................................................................................................... 11

I-5-2- Passive systems .................................................................................................... 12

II- BASIC PROCESS HEATING OPERATIONS .................................................................. 12

II-1- AGGLOMERATION AND SINTERING ................................................................... 12

II-2- CALCINING .............................................................................................................. 12

II-3- CURING ..................................................................................................................... 12

II-4- DRYING .................................................................................................................... 13

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II-5- FLUID HEATING ...................................................................................................... 13

II-6- FORMING .................................................................................................................. 13

II-7- HEATING AND MELTING: HIGH-TEMPERATURE .............................................. 13

II-8- HEATING AND MELTING: LOW-TEMPERATURE ............................................... 14

II-9- HEAT TREATING ..................................................................................................... 14

II-10- INCINERATION/THERMAL OXIDATION .......................................................... 14

II-11- METALS REHEATING.......................................................................................... 14

II-12- SEPARATING ........................................................................................................ 14

II-13- OTHER HEATING PROCESSES ........................................................................... 14

CONCLUSION ......................................................................................................................... 16

REFERENCES ......................................................................................................................... 17

LIST OF FIGURES
Figure 1: series loop piping .......................................................................................................4
Figure 2: single loop with diverting tees ...................................................................................4
Figure 3: The two pipe parallel connection system ..................................................................5
Figure 4: Primary-secondary pumped system .........................................................................6

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INTRODUCTION
Industrial process heating operations are responsible for more than any other of the
manufacturing sectors energy demand, accounting for approximately 70% of manufacturing
sector process energy end use. There are a wide range of process heating unit operations, and
associated equipment, that are to achieve important materials transformations such as heating,
drying, curing, phase change, etc. that are fundamental operations in the manufacture of most
consumer and industrial products including those made out of metal, plastic, rubber, concrete,
glass, and ceramics. Energy is supplied from a diverse range of sources, and includes a
combination of electricity, steam, solar and fuels such as natural gas, coal, biomass and fuel oils.
In 2010, process heating consumed approximately 330 TBtu of electricity, 2,290 TBtu of steam,
and 4,590 TBtu of mostly fossil fuels. We can divide process heating systems into five categories:
fuel based process heating; electric based process heating, steam based process heating; solar
based process heating, hybrid based process heating.

I- COMMON TYPES OF HEATING SYSTEM

Systems commonly used to provide heating energy in an industry include hot water, steam,
electric, forced air, and solar (Division, 1999).

I-1- Hot water heating

Hot water heating systems deliver heat energy from a boiler or heat exchanger to the
terminal heating units by circulating water through a piping system. Circulation is usually
maintained by an electrically driven circulating pump or pumps. The rate of circulation is designed
to provide the maximum required heat transmission with approximately an 11C temperature
difference between the supply and the return at the boiler or heat exchanger. The required supply
water temperature is determined by the output capacity of the terminal heating units. Most systems
require 80 to 100C supply water. Systems designed to utilize condenser heat from refrigeration

systems operate with a supply water temperature as low as 38C.

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I-1-1- Heat transmission

Heat transmission by water at normal heating system temperatures may be approximated
by the equation:

= ( )
Where, Q= total heat load (MJ/h);
fw= water flow (L/s);
T1 = heating water supply temperature (C)
T2= heating water return temperature (C)
k = a multiplier which accounts for the specific heat of water and conversion to
common units.

I-1-2- Factors affecting system efficiency

System efficiency is affected by three factors:

Boiler or heat exchanger efficiency;

Heat loss from the piping system;
Pumping energy required to maintain the water flow.

a) Boiler or heat exchanger efficiency

The boiler efficiency of a hot water boiler is a function of combustion efficiency and boiler
shell heat losses. The heat input to a boiler is determined by the quantity of fuel consumed and the
heat value of fuel. Operating efficiency can be over 80 per cent for a well maintained at full load
to less than 60 per cent for a poorly maintained boiler at part load.

The fuel consumption by a boiler can be determined by the equation:

=

Where: Fuel consumption = fuel input(L/h);
Q = total heat transmitted (MJ/h);
Hv =heat value (MJ/h);
Ef = boiler efficiency expressed as a decimal fraction.

The efficiency of a heat exchanger is mainly a function of shell losses since the efficiency

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of the heat source system is normally considered separately. Heat exchanger efficiency of 100 per
cent can be used for estimating purposes.

b) Heat loss from the piping system

Heat loss from the piping system is a function of the water temperature and the amount of
pipe insulation. However, average piping heat loss of 3% of the peak heat delivery rate can be used
for estimating purposes.

c) Pumping energy required to maintain the water flow

Pumping energy requires to maintain water flow refer to the energy use by pump to
circulate water through the system. It affected efficiency in such a way that: if the pumping energy
is too down, the heat transfer time increase and it can result the loss of the heat, and if it too fasts
the heat transfer dont have the time to be effectively done.

I-1-3- System efficiency

System efficiency is determined by the equation:

=
+ [( + ) . ]

Where: Ef = overall system efficiency expressed as a decimal fraction

Qh = Heat output by the terminal heating units (MJ/h);
Qb= Heat input to the boiler or heat exchanger (MJ/h);
Wp = power input to the circulating pump (kW);
Wb = power input to boiler components (kW).

I-1-4- Hot water arrangement.

The following are typical hot water arrangement.
a) The series loop arrangement
The series loop arrangement (figure 1) is a low cost method of connecting a series of
heating unit to the heat source, but provides no opportunity for individual control of the heat output
from each heating unit. The heat output of small system can be controlled by starting and stopping
the pump in response to a building thermostat. The heat output of larger systems is usually
controlled by the supply water temperature in relation to outdoor air temperature or a selected
building space temperature. If the individual heating unit outputs are not matched precisely with

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the requirement of each space, fluctuation of local space temperatures and possible conflict with
the air conditioning systems serving the same space could occur. Successive heating units in the
loop receive a lower temperature because of the heat lower supply water temperature because of
the heat removed by preceding units.

Figure 1: series loop piping

b) The single pipe loop

The single pipe loop with the diverting tees system (figure 2) is an adaptation of the series
loop system, and provide the opportunity for control of the heat output from each unit may be
connected to one diverting tee branch. Like the series loop system, each succeeding heating unit
receives a lower supply water temperature than the preceding units.

Figure 2: single loop with diverting tees

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c) The two pipe parallel connection system

The two pipe parallel connection system (figure 3) is the most commonly used hot water
heating arrangement and provides the opportunity for individual control of heating units. Where
two-way control valves are used at the heating units, some method of regulating the circulation
flow rate is usually employed. The circulating pump speed may be regulated, or a pressure relief
by pass may be used to permit constant pump operation. An alternate three-way by pass control
at each heating unit allows a constant water circulation rate and fast heating response at the heating
units. The reverse return arrangement provides equal-length piping to all heating units for case of
system balancing. Small systems often use the alternate direct return arrangement for economy
piping.

Figure 3: The two pipe parallel connection system

d) Primary-secondary pumped system

In a primary-secondary pumped system (figure 4) the primary loop flow is unaffected by
variations in the secondary loop flow. This system allows stable control of secondary loop water
temperature below that of the primary loop. For widely distributed systems it allows the use of
smaller piping with higher than normal temperature drop in the primary loop. It also allows
individual secondary loops to be shut off when not in use. This sytem may be found in combination
with any previous piping systems and may be used to add new secondary loops to an existing
system.

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Figure 4: Primary-secondary pumped system

I-2- STEAM HEATING

A steam heating system uses the vapor phase of water to transport heat from a boiler to the
terminal heating devices. Steam is propelled through the supply piping system by the pressure
generated at the boiler. The steam condenses in terminal heating devices, giving up its latent heat
of vaporization, and the condensate is returned to the boiler. The condensate may return to the
vicinity of the boiler by gravity flow, but it must be pumped into the boiler to complete the circuit.

I-2-1- Advantages and disadvantages

Steam systems have advantages and disadvantages compared to water systems.

a) Advantages
Advantages include:
A higher heat transfer rate per unit of surface area is produced at the terminal device,
allowing the use of smaller devices.
Smaller piping can be used for a given rate of energy transmission.
Less pumping energy is required than for a hot water system.

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The system flow is self-regulating, being dependent upon the condensation rate (heat
output) at the terminal devices and condensation (heat loss) in the supplying piping.
Steam can be used directly for humidification of building air.

b) Disadvantages
Disadvantages include:
Condensate may be released from the terminal heating devices at a temperature higher
than the saturation temperature at the return system pressure. This results in the generation of flash
steam is often discharged outdoors from vented condensate receivers, resulting in a significant
energy loss.
Because the saturation temperature of stem at atmospheric pressure is 100 C, a partial
vacuum is necessary to operate at lower steam temperature.
System maintenance cost is high owing to the number of distribution system
components such as steam traps and condensate pumps.

I-2-2- Heat flow to a steam

For normal HVAC system steam pressures up to 200 kPa (gauge), the heat flow to a steam
heated device can be approximated by the equation:

= .

Where: Q = Heat flow (MJ/h);

Fs = steam flow (kg/h);
2.2 MJ = 1 kg of steam.

I-2-3- Factors affecting system efficiency

System efficiency is affected by several factors.

Boiler efficiency;
Heat loss from the steam and condensate piping;
Flash stem loss in the return system;
Condensate loss;
Steam or condensate leaks;
Condensate and feed water pump energy.

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a) Boiler efficiency
Boiler efficiency is similar for both steam and hot water boilers. However, a typical steam
boiler plant has other losses which affect the overall plant efficiency: condensate receiving tanks
and condensate treatment equipment have surface heat losses, and chemical treatment of boiler
feedwater requires boiler blowdown. These losses may reduce the overall plant efficiency by 1 to
5 per cent below that of an equivalent hot water plant, a typical annual efficiency range for steam
boiler plants is 60 to 80 per cent. Careful attention to minimizing heat losses from boiler plant
equipment can result in a steam boiler plant achieving the same efficiency as an equivalent hot
water boiler plant.

b) Heat loss from steam and condensate piping

Heat loss from steam and condensate piping is a function of the amount of pipe insulation,
the length of the piping system, the pressure of the steam and the temperature of the the return
condensate.

c) Flash steam loss

Flash steam loss in the return system is affected by the operating temperature of the
terminal heating units, and the effective operation of the steam traps to prevent by passing of steam
to the condensate return system.

d) Condensate loss
Condensate loss results from certain system conditions and methods of using steam.

The direct use of steam for humidification;

Heating of water by direct injection of steam;
Overflow at undersized condensate receivers;
Steam and condensate system leaks.

e) Steam or condensate leaks

The loss of steam and condensate from direct steam use, leaks and overflow requires the
heating of an equivalent amount of cold water make-up at the boiler plant, an increased make up
rate requires the heating of an equivalent amount of cold water make up at the boiler plant. An
increased make up rate requires increased chemical treatment and a higher blow-down rate at the
boiler.

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Steam leaks represent a total loss of both condensate and heat energy of the steam. A
relatively small opening can result in very significant annual losses because it leaks continuously.

f) Condensate and feed water pump energy

Condensate and feedwater pumping energy can be estimated using the general pump
energy equation previously given for hot water heating pumps.

I-2-4- System efficiency

System efficiency is given by the equation:

=
+ [( + ) . ]

Where: Ef = overall system efficiency expressed as a decimal fraction

Qh = Heat output by the terminal heating units (MJ/h);
Qb= Heat input to the boiler or heat exchanger (MJ/h);
Wp = power input to the circulating pump (kW);
Wb = power input to boiler components (kW).

I-3- ELECTRICAL HEATING

Electrical power allows a simple and efficient system of energy distribution within a
building, it is used in areas where electrical energy costs are competitive with the cost of fossil
fuel energy. Electricity can be used as the energy source for steam or hot water boilers, but the
distribution losses of such systems reduce the efficiency advantage. Heat is most commonly
generated at the terminal device by resistance elements which operate at 100 per cent efficiency.
Control is achieved by switching off the entire element, by staged switching of multiple elements,
or by high speed solid state switching of the alternative current in such a way as to modulate the
power input the element.

Terminal heating devices utilize several types of electric heating elements.

Direct resistance element in contact with the air or fluid;

Embedded resistance element to produce low temperature radiant heat;
Exposed infrared-producing element to produce high temperature radiant heat;
Submerges electrodes using water as the resistance medium.

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The heat output by an electric heating can be determined by the equation:

= .

Where: Q= Heat output (MJ/h);

Wi = power input (kW)
1kW = 3600 MJ/h

NB: Overall efficiency is affected only by transformer energy loss and spall resistance
losses in the distribution wiring.

I-4- FORCED AIR HEATING

Forced heating systems use air as the transport medium between the heat source and the
space to be heated. The heat source may be direct fired with the fossil fuel or orther combustible
materials, electrically heated, supplied with heat rejected by processes such as refrigeration
systems, or a combination of two or more of these sources. Forced air heating systems are found
in single zone applications such as small commercial facilities, supermarkets, and repeir garages.
In these applications the air system is often the only source of space heating.

The air circulation system provides an opportunity to perform several other functions in
addition to heating or cooling.

Filtering of the air stream for removal of air borne dust and other contaminants;
Humidification;
Controlled injection of outdoor air for ventilation,
Air redistribution.
NB: The total heat energy required for a forced air heating system includes the sensible
heat required to raise the air temperature, and the latent heat required to provide
humidification.

I-4-1- Factors affecting system efficiency

Efficiency of a forced air heating system is affected by several factors.

Efficiency of a forced air heat source unit;

Heat loss and air leakage from ducts located outside the heated space;
Fan energy required to maintain the air flow;

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The effectiveness of the air distribution in the heated space.

I-4-2- Efficiency of the system

The system efficiency can be determined by the equation:

+
=
+ [ . ]

Where: Ef = overall system efficiency expressed as a decimal fraction

Qv = Heat input required at the occupied level of the space being heated (MJ/h);
Qr= Heat required to heat the ventilating air to room temperature (MJ/h);
Qf= Heat input to the warm air source (MJ/h);
Wp = power input to the circulating fan (kW);

I-5- SOLAR HEATING

Solar heating system is used mainly as a supplementary heat source to reduce the
consumption of fossil fuels or electricity.

Solar systems fall under two general classifications:

Active systems collect solar heat into an air or liquid and transport it to storage or to a
terminal heating device.
Passive systems collect solar heat directly into the space or process to be heated.

I-5-1- Active system

Active solar heating systems usually circulate the heating air directly through a solar
collector. A thermal storage medium is often provided to store heat collected during peak sunshine
hours for use during other heating periods.

Active solar water-heating systems include direct and indirect systems. Direct systems
circulate the heated water through the solar collector. Indirect systems circulate a secondary fluid,
such as an antifreeze solution, between the solar collector and a heat exchanger. In all cases care
must be taken to ensure that circulation through the collector takes place only when the collector
temperature is above that of the receiving water system.

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I-5-2- Passive systems

Passive systems involve the arrangement of building windows and shading to allow
maximum solar radiation to the building interior during the low sun angles of cold weather moths,
while shading out the sun during the high sun angles of summer. Large building masses, such a
heavy masonry walls and concrete floor slabs, are located to absorb solar heat and minimize
heating requirements during hours when the sun is not shining.

II- BASIC PROCESS HEATING OPERATIONS

Process heating is used in many industries for a wide range of applications, which often
comprise multiple heating operations. The manufacture of steel often involves a combination of
smelting, metal melting, and various heat treatment steps. The fabrication of polymers typically
employs fluid heating to distill a petroleum feedstock and to provide heat for a curing process to
create a final polymer product. Common to all process heating applications is the generation and
transfer of heat. In general, they can be grouped into 13 major categories (IHEA & ITP, 2007):

II-1- AGGLOMERATION AND SINTERING

Agglomeration and sintering refers to the heating of a mass of fine particles (e.g., lead
concentrates) below the melting point to form larger particles or solid parts. Sintering is commonly
used in the manufacturing of advanced ceramics and the production of specialty metals.

II-2- CALCINING
Calcining is the removal of chemically bound water and/or gases, such as carbon dioxide,
through direct or indirect heating. Common applications include construction materials, such as
cement and wallboard, the recovery of lime in the kraft process of the pulp and paper industry, the
production of anodes from petroleum coke for aluminum smelting, and the removal of excess water
from raw materials for the manufacture of specialty optical materials and glasses.

II-3- CURING
Curing is the controlled heating of a substance to promote or control a chemical reaction;
in the manufacture of plastics, curing is the cross-linking reaction of a polymer. Curing is a
common process step in the application of coatings to metallic and nonmetallic materials,
including ceramics and glass.

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II-4- DRYING
Drying is the removal of free water (water that is not chemically bound) through direct or
indirect heating. Drying is common in the stone, clay, and glass industries, where the moisture
content of raw materials, such as sand, must be reduced; and in the food processing, textile
manufacture, and chemical industry, in general. There are several types of dryers, including
conveyor, fluidized bed, rotary, and cabinet dryers.

II-5- FLUID HEATING

Fluid heating is used to increase the temperature of a liquid or gas, including the complete
or partial vaporization of the fluid, and is performed for a wide range of purposes in many
industries, including chemicals, food processing, and petroleum refining. In chemical
manufacturing, fluids are heated in both batch and continuous processes to induce or moderate a
chemical reaction. Food processing applications include cooking, fermentation, and sterilization.
In petroleum refining, fluid heating is used to distill crude oil into several component products.

II-6- FORMING
Forming operations, such as extrusion and molding, use process heating to improve or
sustain the workability of materials. Examples include the extrusion of rubber and plastics, the
hot-shaping of glass, and plastic thermoforming.

II-7- HEATING AND MELTING: HIGH-TEMPERATURE

High-temperature heating and melting is conducted at temperatures higher than most
steam-based systems can support (above 400F, although very high-pressure steam systems
support higher temperatures and are used in applications like petroleum processing). High-
temperature heating is typically performed on metals, but this category does not include metals
reheating or heat treating (see below). High-temperature melting is the conversion of solids to a
liquid by applying heat, and is common in the metals and glass industries. Melting can be combined
with refining processes, which demand the increase of temperature to remove impurities and/or
gases from the melt. Metal melting processes comprise both the making of the metals, such as in
the conversion of iron into steel, and the production castings. Energy-intensive nonmetal melting
applications include container and flat glass production.

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II-8- HEATING AND MELTING: LOW-TEMPERATURE

Low-temperature heating and melting is done at temperatures that steam-based systems
can support (less than 400F), although not all applications are steam-based. Nonmetallic liquids
and solids are typically heated or melted.

II-9- HEAT TREATING

Heat treating is the controlled heating and cooling of a material to achieve certain
mechanical properties, such as hardness, strength, flexibility, and the reduction of residual stresses.
Many heat treating processes require the precise control of temperature over the heating cycle.
Heat treating is used extensively in metals production, and in the tempering and annealing of glass
and ceramics products.

II-10- INCINERATION/THERMAL OXIDATION

Incineration refers to the process of reducing the weight and volume of solids through
heating, whereas thermal oxidation refers to heating waste (particularly organic vapors) in excess
oxygen at high temperatures. The main application is the treatment of waste to render it disposable
via landfill.
II-11- METALS REHEATING
Metals are reheated to establish favorable metalworking properties for rolling, extrusion,
and forging. Metal reheating is an important step in many metal fabrication tasks.

II-12- SEPARATING
Separation involves dividing gaseous or liquid streams into various components.
Separation can be accomplished through distillation, membranes, or by other means.
II-13- OTHER HEATING PROCESSES
Many process heating applications do not fall in the preceding categories; however,
collectively, they can account for a significant amount of industrial energy use. Common
applications that use process heating include controlling a chemical reaction, cooking foods, and
establishing favorable physical or mechanical properties, such as in plastics production. In the food
products industry, process heating is used in preparation tasks, particularly baking, roasting, and
frying. In the textile industry, process heating is used to set floor coverings and to prepare fabrics
for various types of subsequent treatments. This category includes fuel, electric, and steam-based
applications.

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Table 1: Summary of Process Heating Operations

Process Application Equipment Industry

Various Furnace
Agglomeration
Metals Production Types, Kilns, Primary Metals
Sintering
Microwave
Various Furnace Various Furnace
Calcining Lime Calcining
Types Types
Various Furnace
Ceramics, Stone,
Types, Ovens,
Coating, Polymer Glass, Primary
Kilns, Lehrs,
Curing and Forming Production, Metals,
Infrared, UV,
Enameling Chemicals, Plastics
Electron Beam,
and Rubber
Induction
Stone, Clay,
Fuel-Based Dryers,
Water and Organic Petroleum Refining,
Infrared, Resistance,
Drying Compound Agricultural
Microwave, Radio-
Removal and Food, Pulp and
Frequency
Paper, Textile
Various Ovens and Rubber, Plastics,
Forming Extrusion, Molding
Furnaces Glass
Food Preparation, Various Furnace
Chemical Types, Reactors,
Production, Resistance Agricultural and
Reforming, Heaters. Food, Chemical
Fluid Heating
Distillation, Microwave, Manufacturing,
Cracking, Infrared, Fuel-based Petroleum Refining
Hydrotreating, Fluid Heaters,
Visbreaking Immersion Heaters
Fuel-Based
Heating and Casting, Furnaces, Kilns,
Melting Steelmaking, Glass Reactors, Direct Primary Metals, Glass
High-Temperature Production Arc, Induction,
Plasma, Resistance
Heating and Softening, Ovens, Infrared,
Plastics, Rubber,
Melting Liquefying, Microwave,
Food, Chemicals
Low-Temperature Warming Resistance
Various Fuel-Based
Furnace Types,
Primary Metals,
Hardening, Ovens,
Fabricated Metal
Heat Treating Annealing, Kilns, Lehrs, Laser,
Products,
Tempering Resistance,
Glass, Ceramics
Induction,
Electron Beam

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Incinerators,
Fabricated Metals,
Incineration/Thermal Waste Thermal Oxidizers,
Food, Plastics and
Oxidation Handling/Disposal Resistance,
Rubber, Chemicals
Plasma
Forging, Rolling, Various Furnace
Extruding, Types, Ovens, Primary Metals,
Metals Reheating Annealing, Kilns, Heaters, Fabricated Metal
Galvanizing, Reactors, Induction, Products
Coating, Joining Infrared
Air Separation, Distillation,
Separating Refining, Membranes, Filter Chemicals
Chemical Cracking Presses
Steelmaking and
Various Furnace
Smelting Other Metals Primary Metals
Types
(e.g., Silver)
Food Production Various Furnace
(including Types, Ovens, Agricultural and
Baking, Roasting, Reactors, Food, Glass,
Other Heating
and Frying), and Resistance Ceramics,
Processes
Sterilization, Heaters. Plastics and Rubber,
Chemical Microwave, Steam, Chemicals
Production Induction, Infrared

CONCLUSION
At the end of this work, we can say that, the industrial heating is a large field, which can
take many paper to explain it from one size to other. Also, we are focus our work in its different
systems which depend both of the medium like (air heating system, water system, steam system)
used to transport heat through the process; and the energy used like (fuel, gas, solar, and electrical)
used to give heat to the medium or not used to carry heat through process. We can also pay attention
to the different process involve heating in an industry and the different equipment used by them.
We can cite for these processes: forming, corning and many others.

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REFERENCES
Division, I. E. (1999). Heating Ventilation and Air conditionning. Ottawa, Ontario: Department of
Energy, Mines and resources Canada.

IHEA, & ITP. (2007). Improving Process Heating System Performance:A Sourcebook for
Industry. California: the National Renewable Energy Laboratory.

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