Comments Off on Schafer Joins Enerquip as a Design Engineer
Enerquip is excited to introduce Emily Schafer as its newest Design Engineer.
As an Enerquip Design Engineer, Schafer crafts detailed fabrication drawings for various equipment, ranging from heat exchangers to condensers and bayonet heaters. Proficient in managing intricate thermal calculations and interpreting blueprints and specifications, she and the rest of Enerquip’s talented designers design thermal process solutions that optimize our clients’ manufacturing processes.
With a strong interest in engineering, Schafer began her journey with Enerquip as a mentorship student back in 2020 as a Medford High School Senior. Throughout her college years, she further developed her skills at Enerquip during winter and summer breaks away from college. Now, as a recent graduate of UW-Stout’s engineering technology program and armed with her completion of the SolidWorks Associate’s Exam, she’s joined Enerquip full-time as a Design Engineer.
Cameron Diedrich, Design Engineering Manager, shares his enthusiasm about Emily Schafer joining the team, stating, “Emily brings a wonderful blend of talent, dedication, and fresh perspective to our design team. Her passion for engineering and commitment to excellence make her a valuable addition to Enerquip.”
A native of Medford, Wisconsin, Schafer is thrilled to kickstart her career at Enerquip. “Returning home to launch my career is incredibly exciting,” remarks Emily Schafer, Enerquip Design Engineer. “I chose Enerquip for its collaborative atmosphere, team of talented colleagues, fantastic work/life balance, and the opportunity to tackle custom projects that push my boundaries.”
Outside of work, Schafer enjoys spending time with family and friends, doing outdoor activities, going for walks, discovering new coffee shops, and nurturing her love for gardening. Schafer is also a lifelong hockey player and was ranked number one in the state of Wisconsin during her senior year of high school.
Comments Off on Maintaining Your Shell and Tube Heat Exchanger
Editor’s note: This content was last updated 5/14/24.
A pivotal component across various operations, the shell and tube heat exchanger stands out as a cornerstone in many processes. In sectors like food, beverage, and dairy, its role in safeguarding consumers from contaminated products is paramount. Similarly, within the pharmaceutical realm, heat exchangers play a vital role in upholding the quality of medications.
The ramifications of a heat exchanger malfunction are significant. Contaminated products result in potential decreases in productivity and, in severe cases, damaging recalls that tarnish reputations. To avert such scenarios, regular review and servicing of the heat exchanger are imperative. Neglecting maintenance leaves heat exchangers vulnerable to corrosion and fouling, which in turn heightens the risk of leaks. These leaks can lead to undesirable mixing of product with cooling or heating fluids, rendering entire batches unusable. Additionally, the accumulation of corrosion and deposits within the exchanger compromises its efficiency, hindering the attainment of desired temperatures.
Corrosion leads to bigger problems
Like any piece of equipment, a shell and tube heat exchanger requires periodic maintenance, including cleaning, repairs, and ultimately replacement. Continuous use will inevitably lead to wear and, potentially, corrosion. The objective is to prolong the exchanger’s operational lifespan for as long as possible. Proper maintenance can extend its longevity for decades, involving meticulous and regular inspections of all components.
Ensuring the heat exchanger’s cleanliness is paramount throughout its lifespan. Prior to initial use, a thorough examination is necessary to confirm proper assembly and to prevent contamination of the tubes and shell by dirt, dust, or other contaminants.
Corrosion is an inevitable process that occurs over time, despite adhering to maintenance schedules. It arises from chemical reactions within or surrounding the heat exchanger. Different metals react differently with various substances. Stainless steel is an optimal choice for exchangers, particularly when handling potentially corrosive substances that could harm other metals like copper alloys. High-alloy grade stainless steel can withstand corrosion from most acidic, alkaline, and chlorinated substances. However, even though the metal exhibits high resistance to corrosion, it will gradually deteriorate with time.
The best way to prevent corrosion is to make sure only the best substances for the exchanger’s material makeup enter the machine. Using the correct chemicals to treat and clean the tubes is essential. This information should be obtained before you begin using your heat exchanger to ensure you are prepared for its maintenance from the get-go.
Many heat exchangers use water as the heat transfer liquid. Tap water is generally of an acceptable quality to use in the machine. However, it is important to double check the water before putting it into the exchanger. The pH should be neutral, and the water shouldn’t be polluted or have any bacteria or other contaminates in it. If the water comes from a natural source, is should be treated before entering the tubes.
If the water isn’t treated or inspected before entering the exchanger, debris could enter the machine and block the chambers. To prevent this from happening, screens or filters can be installed to keep particles out. If they do enter, they will wear against the tubes and cause corrosion.
Regular monitoring of the heat exchanger’s condition aids in early detection of potential failures before fouling or contamination exacerbate the issue. Assessing water quality serves as an indicator of potential or ongoing failures; cloudy water suggests impurities. Additionally, recording temperature and pressure fluctuations can reveal emerging issues. Reduced efficiency may signal scaling, a solid precipitate formed from chemical reactions, which, over time, leads to fouling and corrosion. Monitoring other parameters such as tube thickness also provides insights into emerging problems.
Comments Off on Addressing the Impacts of Maldistribution in Heat Exchange
Editor’s note: This content was last updated 5/13/24.
In the realm of processing liquids with shell and tube heat exchangers, maintaining impeccable conditions is paramount. Even the slightest flaw, breakage, or contamination within the exchanger can jeopardize the entire liquid batch’s suitability for consumption.
One challenge faced in shell and tube heat exchanges, though, is maldistribution, characterized by an uneven flow of liquid through the tubes. This issue can lead to tubes pulling out of their designated spaces on the tube sheet, risking contamination of the processed solution and compromising product integrity. Repairing such damage can be costly and time-intensive, underscoring the importance of preventing maldistribution.
Thermal expansion exacerbates maldistribution, particularly when there’s uneven heat distribution between the shell and tube sides of the exchanger. Installing expansion joints can mitigate this risk, ensuring the components can expand and contract uniformly. Additionally, maintaining evenly dispersed flow within the exchanger, especially as the flow rate increases, is crucial for averting maldistribution. Employing liquid distribution systems with adequate pressure and temperature control can further enhance uniformity across tubes.
Understanding these potential causes of maldistribution underscores the importance of investing in high-quality, customized shell and tube heat exchangers. By incorporating features like expansion joints and bottoms recirculation systems, companies can safeguard against maldistribution and its detrimental effects on product quality.
For tailored solutions and expert guidance on process equipment, contact Enerquip today.
Comments Off on Oil and Gas Industry Helping Drive Heat Exchanger Market
Editor’s note: This content was last updated 5/13/24.
The oil and gas industry has been advancing the heat exchanger market in various capacities, according to several reports. MarketsAndMarkets explains that heat exchangers are an integral part of the petrochemical and oil and gas industry. The chemical industry is the most influential driver of heat exchanger business.
Get cracking
The global market for oil and gas equipment is expected to be worth USD $134.20 billion in 2024 and $156.18 billion by 2029, according to Mordor Intelligence.
Oil and gas equipment can be categorized in two parts: rotating and static equipment. Rotating equipment is comprised of valves, pumps and turbines, while static equipment includes valves, furnaces, boilers and heat exchangers.
Heat exchangers play an important role in processing oil and gas. They are used in the refining process in cracking units as well as in the liquefaction of natural gas. Cracking is the process of breaking the hydrocarbons that compose crude oil into smaller pieces, according to Chemguide.
Cracking takes place after the first round of distillation. Then, lubrication and heavy gas oils go through a cracking process. After cracking, a second round of distillation separates the pieces into groups. Heat exchangers come into play to separate oil from any water that is produced during the process.
The BBC explains that cracking is a thermal decomposition reaction, which means heat is used to break apart the hydrocarbons. Once the hydrocarbons are in smaller, more applicable pieces, they can be used to make fuels and polymers.
Still distilling
Heat exchangers play a vital role in the diabatic distillation process, facilitating heat transfer both within the reboiler and throughout the distillation column.
During this process, water is propelled through a sequence of trays to regulate the temperature of the oil, while steam from the reboilers circulates through another set of trays. Each tray incorporates a heat exchanger, which significantly enhances the speed and efficiency of the process. By accelerating the reboiler’s temperature rise, heat exchangers expedite the distillation process. Additionally, they optimize the cooling efficiency of the condensers, contributing to overall process enhancement.
Heating up
According to MarketsAndMarkets, the oil and gas industry is also boosting the global waste heat recovery market. It is expected to grow 7.1% CAGR from 2022 to 2027. Waste heat recovery is primarily done through the use of heat exchangers and other equipment such as turbines and industrial heating boilers.
“Between 20 and 50 percent of industrial energy output is wasted.”
A report from the World Economic Forum said up to half of industrial energy input is wasted. The way to utilize this wasted energy is through waste heat recovery. A U.S. Department of Industry report stated the converted heat can usually be used for generating electricity, heating and absorption cooling. Heat exchangers in this process are typically most useful for preheating air before it enters a furnace system. This takes some of the stress away from the furnace, allowing it to use less fuel and energy to heat the air itself.
The World Economic Forum reported governments and industries around the world begin to make environmentally friendly changes, and many have focused on striking a balance between three concepts: energy security, energy affordability and environmental sustainability. Large industries, such as oil and gas, have especially been looking into ways to achieve an ideal energy triangle.
According to the Department of Industry, low-temperature heat recovery, which is identified as being between 100 and 400 degrees, can use shell and tube heat exchangers to condense water vapor in the discharged gases.
In a report, Research and Markets explains that government regulations on greenhouse gas emissions have inspired the use of heat exchangers and other heat recovery equipment. Reusing wasted heat not only cuts down on emissions, but also reduces the amount of fuel needed to run oil and gas facilities. The report predicts that continued regulations on how environmentally friendly facilities need to be will keep driving the need for heat exchangers.
Contact Enerquip to learn more about high-efficiency process equipment for the oil and gas industries.
Comments Off on Enerquip Uses Augmented Reality to Help Train and Educate the Next Generation of Welders
According to the Bureau of Labor Statistics, the U.S. has approximately 43,000 open welding jobs to fill each year. To help fill these vital roles and open students to the challenging but exciting world of welding, Enerquip has introduced augmented reality welding simulators to its internal and external training programs. With the purchase of the robust AugmentedArc® and the smaller MobileArc™ Augmented Reality Welding Systems from Miller, Enerquip is set to amplify welding education in central Wisconsin by offering safe, life-like, hands-on learning experiences for both student education and internal training.
Both welding systems were developed by Miller and tailored for classroom training. These highly realistic multi-process welding simulators cater to students ranging from beginners to advanced-level welders. By seamlessly blending real-world and computer-generated images into a unique augmented reality environment, these welding systems provide immersive learning experiences. Students can interactively explore the fundamentals of welding, fostering a deeper appreciation for the craft.
“Enerquip has invested in welding simulation tools to help advance welding education and training in Taylor County,” said Tim Strebig, Facilities & Operations Manager of Enerquip. “By leveraging this augmented reality, we empower students with the skills and knowledge they need to succeed in the welding industry within a safe, fun, and stress-free environment.”
While Enerquip opened its doors for student opportunities years ago, using virtual welding simulators has added significant value to its tours and school-to-work student programs. While Enerquip only provides the virtual option for student tours, students in its internship and mentorship programs can work with both simulators and actual welding equipment. This addition of simulators provides students with a virtual hands-on experience before they begin welding real materials. Utilizing simulators helps students familiarize themselves with welding techniques and enables Enerquip to significantly reduce costs associated with stainless steel and other consumables.
This spring, Enerquip began demonstrating these simulators with hundreds of area students at various career fairs and speaking engagements. Students were given a firsthand glimpse into opportunities within the welding industry. By leveraging augmented reality technology, Enerquip and Miller are not only preparing the next generation of welders but also inspiring them to pursue fulfilling careers in welding. Furthermore, with the addition of these simulators, Enerquip is in the process of developing a welding curriculum to collaborate with local schools for the upcoming 2024 – 2025 academic year.
A participant at April’s Homegrown Success Career Fair at the Simek Center shows off her welding skills on the AugmentedArc® Augmented Reality Welding System from Miller. Her welds are mirrored on the TV screen in the background.
Brady Loetscher (right), Enerquip Sales Engineer, tries out the MobileArc™ Augmented Reality Welding System from Miller as he receives guidance from Enerquip Welder Troy Komarek (left).
Enerquip Welder Travis Frost helps a student set their hands before trying out the AugmentedArc® Augmented Reality Welding System from Miller.
Comments Off on Enerquip’s Employee Match Supports Beggs Youth Baseball
Enerquip has proudly donated $500 to the Oklahoma DirtBags Youth Baseball program in Beggs, OK. This contribution will assist with the program’s ongoing expenses, including uniforms, athletic equipment, tournaments, and more.
The Oklahoma DirtBags Youth Baseball program is dedicated to supporting dozens of youth participants each summer. Through this program, youth not only have a great time playing the game but also learn the importance of hard work, good sportsmanship, and teamwork.
Enerquip is committed to supporting and encouraging its employees to lift others through giving and service. Therefore, Enerquip provides gifts to organizations at 100% of the employee’s contribution up to $500 per employee per calendar year, including volunteer hours.
This employee match designation from Enerquip Welder & Safety Coordinator Pat Branson (back, left) includes his own volunteer hours and contributions as a 10U AA Oklahoma DirtBags Youth Baseball Coach.
Comments Off on Common Questions About Pharma-Grade Shell and Tube Heat Exchangers
When it comes to pharmaceutical manufacturing, the integrity of equipment is vital. Among the critical components in this industry are shell and tube heat exchangers. Understanding what sets pharma-grade heat exchangers apart is crucial for ensuring product quality, safety, and compliance with stringent regulations.
Here, we answer common questions about pharma-grade shell and tube heat exchangers, shedding light on their functionality, materials, regulatory requirements, and key considerations in selection and maintenance.
Comments Off on Difference Between Parallel Flow, Counter Flow, and Crossflow Heat Exchangers
Flow patterns are a critical design factor in any shell and tube heat exchanger, directly impacting heat transfer efficiency, thermal stress, and overall system performance. Engineers can select from three primary flow patterns—parallel flow, counter flow, and crossflow—but in many cases, combining these patterns leads to optimal results.
Let’s explore the unique characteristics, advantages, and drawbacks of each flow pattern to help you choose the right configuration for your application.
Understanding Flow Patterns
1. Parallel Flow (Cocurrent Flow)
In parallel flow, both the shell side and tube side fluids flow in the same direction. This pattern is commonly found in double-pipe heat exchangers and can be applied to shell and tube configurations as well.
Pros:
Ensures more uniform wall temperatures, reducing thermal stress.
Ideal when a moderate temperature difference between fluids is sufficient.
Cons:
Less thermally efficient compared to counter flow, as the maximum temperature difference occurs only at the inlet.
Risk of thermal stress from dramatic inlet temperature differentials.
2. Counter Flow (Countercurrent Flow)
Counter flow heat exchangers are designed for the tube side fluid to enter from the opposite end of the shell side fluid. This flow pattern is the most thermally efficient and is preferred in many applications where maximizing heat transfer is critical.
Pros:
Delivers the highest temperature change between fluids, enhancing heat transfer efficiency.
More consistent temperature differences across the exchanger reduce hotspots and thermal stress.
Cons:
Can be more complex to design when used in conjunction with multipass configurations.
3. Crossflow
In crossflow heat exchangers, fluids flow perpendicularly to each other. This pattern is commonly used in steam condensers and other applications involving phase changes.
Pros:
Effective in applications involving gas-liquid heat transfer or condensation processes.
Can be customized with baffles and tubes to optimize turbulence and heat transfer.
Cons:
Less thermally efficient than counter flow but often ideal for specialized applications like condensation.
Why Combining Flow Patterns is Often Used
In real-world applications, shell and tube heat exchangers often combine multiple flow patterns to meet complex process demands. A common combination is counter flow and parallel flow, especially in multipass systems. This hybrid approach maximizes thermal efficiency while mitigating risks such as excessive thermal stress or fouling.
Key Considerations for Optimal Flow Pattern Selection
Process Requirements: Determine if your process demands rapid heat transfer, condensation, or phase changes.
Temperature Range: Evaluate the desired temperature change and whether a uniform or variable gradient is needed.
Maintenance & Longevity: Consider fouling potential, thermal stress, and maintenance ease when choosing a pattern or combination.
Optimize Your Heat Exchanger With Enerquip
Selecting the right flow pattern is essential for maximizing heat exchanger efficiency, longevity, and cost-effectiveness. At Enerquip, our experts help you design custom solutions tailored to your specific process needs. Whether you’re looking to optimize a new design or upgrade an existing system, we’re here to help.
Unlocking the intricacies of heat exchange involves navigating through a maze of specialized terminology and cryptic acronyms. In this comprehensive guide, we’ll demystify the language of heat exchange, empowering you with a deeper understanding of the crucial terms and abbreviations that drive this dynamic field.
Whether you’re a seasoned professional or just dipping your toes into the world of thermal management, this resource will shed light on the essential concepts that underpin efficient heat transfer processes.
Comments Off on Enerquip Supports Taylor County First Responders
In support of Taylor County’s frontline heroes, Enerquip proudly donated $500 to the Taylor County First Responders. This contribution, and others, plays a crucial role in supporting emergency services within our community.
Formed in January 2024, the Taylor County First Responders emerged from a collective vision among dedicated emergency personnel. Recognizing the urgent need for expedited emergency response across Taylor County’s rural landscape, these responders embarked on a mission to bridge the gap in life-saving care.
Before their inception, Taylor County grappled with a shortage of emergency personnel, compounded by jurisdictional hurdles that impeded swift assistance. With the advent of the Taylor County First Responders, strategically stationed units in Medford, Rib Lake, and Jump River now stand ready to traverse the county’s expanse at a moment’s notice. While distinct from Taylor County Ambulance services, these responders collaborate seamlessly to deliver crucial on-scene interventions.
Operating without ambulances and emergency vehicles, Taylor County First Responders leverage their personal vehicles to expedite response times. Their interventions provide vital initial care before transitioning patients to specialized transport services, such as Taylor County Ambulance or Medevac.
Ashley Dake, Director of Taylor County First Responders, expresses gratitude for the community’s unwavering support: “Every dollar donated translates into emergency care for those in need. Our dedicated team of responders embodies the spirit of compassion, and we take immense pride in expanding access to life-saving interventions across our rural communities.”
Enerquip matches employee contributions to organizations at 100%, up to $500 per employee per calendar year. This employee match from Enerquip Assembler David Nelson, includes his contributions as a Taylor County First Responder.
For more information on how you can support Taylor County First Responders, visit their Facebook page.
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