Radiant Heaters for industrial processes - Fraccaro process heaters - by... · Radiant heating...

Radiant Heaters for

industrial processes

IGRAF Process heaters

SUNRAD Infrared emitters

Reference book

Radiant System Innovation

www.fraccaro.it - e-mail: [email protected] Via Sile, 32 - Z. I. - 31033 Castelfranco Veneto (TV) – ITALY Tel. +39 0423 721003 - Fax +39 0423 493223

Innovation, Technology and Quality Radiant heating systems for industrial processes

Fraccaro S.r.l. is the European leader in manufacturing radiant heating systems. For many

years it has been successfully moving its relevant know-how to the production of radiant

heaters for industrial drying processes. Radiant heaters include the exchange circuits of

the IGRAF commercial line and the incandescence emitters of the SUNRAD line.

IGRAF - Heat exchanger circuit

SUNRAD - Infrared Emitter

The heaters of the IGRAF line are

composed by a burner with gas sucked

into an air vein with atmospheric mixing

and premixing, by an intake unit and a

special steel heat exchanger resistant to

high temperatures and to the aggression

of external chemical agents.

The products indicated below run with

methane gas or LPG.

SUNRAD infrared emitters are composed by

a radiant unit with a series of honeycomb

ceramic plates that reach a temperature of

900°C, by a control unit that guarantees

maximum safety and by a reflector that

concentrates the radiant heat in the areas

to be heated.



1. APPLICATIONS____________________________________________________

FRACCARO radiant heaters are a very flexible and reliable solution designed to be

installed in many different industrial processes that requires supply of heat, like the

following applications:

Marble processing

Wood drying and wood processing

Coating ovens, static and dynamic drying ovens

Metal oxidation processes

Degreasing processes

Food machinery industry

Industrial washing

Textile industry

Drying plants

Foundry industry

Many other heating applications

Many industrial processes require a consistent contribution of heat during intermediate

working and this is often complicated due to the need for space or the compact

production line. Furthermore, incorporating economic, clean and efficient heaters into the

process lines can become a great problem if the necessary skills and experience are

lacking. Fraccaro products, which use radiant technology, guarantee exceptional

thermal exchange qualities and therefore high thermal efficiency in small spaces.

Fraccaro radiant heaters can be incorporated in compact size inside any industrial

process where heat is required.

HEATING OF SURFACES:

Heaters from the Fraccaro line are widely used for heating surfaces and the features of

radiant heating are exalted in this type of application. In fact radiant heat exchangers

produce direct heating of the surfaces without using intermediate thermal carrier fluids (for

example, air), therefore reaching an extremely high thermal exchange yield. Moreover,

maximum cleaning of the surfaces treated is guaranteed since there is no movement of

air or dust. IGRAF gas heaters with radiant heat exchanger are the ideal solution for the

heating and drying of marble slabs, resin-bonded surfaces, scrap iron; for all drying ovens

and cockles for wood and minerals.

HEATING OF LIQUIDS:

Another field of application for Fraccaro radiant heaters is the heating of liquids using an

exchange circuit inside the basins containing the liquid to be heated. In this way the

thermal exchange is direct, without using any intermediate thermal carrier fluids. The

exchange tubes are made of stainless steel resistant to high temperatures and external

chemical aggression. Fraccaro liquid heaters can be used in the heating of liquids for

industrial degreasing processes, food industry processes and many other applications.



2. TECHNICAL CHARACTERISTICS_____________________________________

IGRAF – Radiant heaters with heat exchanger circuit

Burner:

The IGRAF burner includes a venturi type burning unit with

stabilized multiple flames. A good air/gas mix optimizes burner

performance with very low CO and NOx emissions. The power of

each unit ranges from 10 to 400 kW with 2 power stage

operations. The heating unit is manufactured in a standard

version with comburent air aspiration filter, and in a tight version

with comburent air aspiration from outside. An electric control

panel with capillary thermostats and control leds is included.

MODEL POWER OPERATION EXCHANGER MIN Ø SUPPLY

FRI30 30 kW ON-OFF 90 mm 230 V – 50 Hz

FRI 30S2 20-30 kW 2 STAGE 90 mm 230 V – 50 Hz

FRI50.1 50 kW ON-OFF 90 mm 230 V – 50 Hz

FRI50.1S2 40-50 kW 2 STAGE 90 mm 230 V – 50 Hz

FRI100 100 kW ON-OFF 114 mm 230 V – 50 Hz

FRI100S2 50-100 kW 2 STAGE 114 mm 230 V – 50 Hz




Exchanger circuit:

The exchanger circuit is made of nickel-copper steel or stainless steel pipes, with diameter

and length based on the thermal power to be provided. Shape and size are customizable

on process request. Min-Max tube diameter: from Ø90mm to Ø204mm.

Aspiration Unit:

The aspiration unit includes centrifugal aspirators with aluminium casting scroll resistant to

high temperatures and with power depending on exchanger circuit and chimney length.

MODEL POWER OPERATION SUPPLY

S205.1MF 0.18 kW Single-phase 230 V – 50 Hz

S205.1TF 0.18 kW Three-phase 4000 V – 50Hz

S206.1MF 0.24 kW Single-phase 230 V – 50 Hz

S206.1TF 0.24 kW Three-phase 400 V – 50Hz

S207.1MF 1.1kW Single-phase 230 V – 50 Hz

S207.1TF 1.1kW Three-phase 400 V – 50Hz

S215.1TF 1.5 kW Three-phase 400 V – 50 Hz

S221TF 2.20 kW Three-phase 400 V – 50Hz

S230TF 3 kW Three-phase 400 V – 50Hz



SUNRAD – Infrared emitters

With thermal powers of single burners from 5 to 60 kW, the applications of SUNRAD

EMITTERS are designed, depending on customer’s specific needs.

The emitter consists of a venturi tube and a gas injector: the speed of the gas injection

causes a depression that takes in the amount of air needed for correct combustion. The

air-gas mix is emitted in the mixing chamber and is spread out on the entire surface of the

heat exchanger. The latter consists of a series of ceramic plates, the number of which

varies according to the power of the machine which, when brought to high temperatures,

overheat and radiate the surface below. The SUNRAD emitter is outfitted with a reflector

which reflects that radiating heat which would otherwise be dispersed in useless

directions. The emitters can be supplied also without reflectors, especially when, in an

industrial process, the distance between the emitter and the heated product is small.

The control apparatus, solenoid valve and the electrical circuits are assembled in

sequence on the gas feeding tube of the emitter. When the control system gives the ok

the flame is lit by a block of electrodes which act also as an ionized flame control. The

combustion products are expulsed at the sides of the emitter.

MODEL OPERATION POWER

IEM10 B ON-OFF 10 kW

IEM10S2 B 2 STAGE 7-10 kW








3. COMPARISON WITH OTHER SYSTEMS_______________________________

Unlike traditional systems which require big, complex equipments, Fraccaro industrial

heaters provide high performance with a compact, functional technology. Fraccaro

heaters has the following benefits:

Start up in extremely short time;

No air movement, if required;

No thermal power unit;

Reduced dimensions;

Much lower operating costs;

Easy installation;

Simple maintenance;

Eco-friendly;

Very low CO and NOx emissions;

Durable and reliable;

Yield higher than 90%;



Comparison with traditional systems:

RADIANT HEATERS

AIR HEATERS

STEAM HEATERS

ELECTRIC HEATERS

- Clean heating

process (no

combustion

products inlet in the

process);

- High reliability with

multiple smaller

burners: the

production process

can continue

without stopping

even if one burner is

out of use;

- Highest efficiency

(95%);

- Direct heat

exchange;

- High thermal

emission: so low

installation thermal

power is needed;

- No use of

intermediate

thermal fluids;

- Very high energy

savings in gas fuels;

- Very low electric

consumption;

- Almost no

maintenance.

- Low efficiencies

(around 60%);

- Very low

thermal inertia

of the air;

- Need to switch

on the system

very often in

order to

maintain a

constant

heating

temperature.

- Very high thermal

power needed;

- Complex solution

to design and to

install (minimum 2

heat exchangers

needed, need of

an external steam

generator, need

of insulated pipes,

circulation pumps,

valves, etc. );

- Low efficiency;

- Very expensive

installation cost.

- Very high electric

power needed;

- Expensive running

costs compared with

gas systems;

- Dangerous if some

water is involved in

the heating process;

- Maintenance

needed very often

to substitute

electrical resistors.



COMPARING EFFICIENCIES WITH TRADITIONAL BLOWN AIR BURNERS:

Traditional burners (82% efficiency):

Fraccaro air-stream gas burner ( 92% efficiency):



4. MARBLE DRYING APPLICATIONS__ ______________________

The following system is an example of customized radiant oven for drying marble slabs

in a long industrial process. It consist of 3 burners working in depression conditions with

one aspiration fan at the end of the heat exchangers tube circuit. Then 2 extra fans

provide the air recirculation to take away the steam produced in the drying process.

Drawing of a linear oven with IGRAF system to dry marble slabs (maximum length of

the slab: 2200 mm). The oven includes 6 burners, 2 aspirators fan and a special device

for air ventilation:



Oven for drying marble slabs in an industrial process formed by a 50 kW burner and a

process hot air fan at 7600 m3/h.

.

Drawing and realisation of Fraccaro IGRAF radiant systems installation in an industrial

processes for drying marble slabs:

View of exchangers tubes in a drying marble oven. N.4 burners: 4 x 40 kW +

N.1aspirator:



The following pictures shows a few examples IGRAF radiant heaters installations in floor

tile drying systems, which are customized according to customers and process

requirements.

Specific application on water drying system for 2000x3000 mm. marble slabs (thermal

power installed: 320kW):



5. LIQUIDS HEATING SYSTEMS_________________________________________

Traditional fluid heating systems require a heat carrying fluid inside boilers operating with

multiple fuels. In these cases a thermal power unit and several devices for regulation,

control and distribution of the heat carrying fluid are required. These systems must comply

with industry and legal standards. The path from the boiler to the tank is subject to thermal

dissipation, leading to higher costs. Direct heat exchange IGRAF heaters avoid these

issues and ensure lower operation and maintenance costs. If needed, the inner exchange

circuit is built with stainless steel pipes to avoid corrosion issues due to water or corrosive

agents.

The picture below is an installation of 4

burners, 4 heat exchangers circuits and 4

aspiration fans. Every heating unit consist of

a 100kW burner with 12m heat exchanger

circuit to heat the water up to 100°C in a

few minutes.



Heat exchanger circuits used for pre-heating liquids used for washing in an industrial

process. A 100 kW burner and 14m of heat exchanger circuit + fan were engineered.

Other examples of tank heating installations up to 80°C-100°C liquid temperature:



Other examples of tank heating installations (beer production tank, anodic oxidation

systems, degreasing systems):



6. TEXTYLE INDUSTRY APPLICATIONS___________________________________

Depending on the process requirements, Fraccaro can suggest when to adopt heating

solutions with IGRAF heat exchangers circuits or with SUNRAD infrared incandescent

emitters. The following drawing are examples of various Fraccaro ovens used in the Textile

industry processes.

Example of radiant heating circuit for leathers processing: 100kW burner + 21m of heat

exchanger circuit + fan.

Incandescent Sunrad emitters adopted to dry fabrics passing through the rollers in a

textile process:



Oven designed for industrial ironing processes: 100kW of burners power with 32mt of

heat exchanger circuit.

Drawing and realisation of an Igraf radiant circuit designed for heating processes in a

leathers drying process.

7. DRYING OVENS FOR COATING PLANTS & COATING BOOTS___________

Fraccaro IGRAF ovens are often used in ovens in the industrial powder & liquid coating

plants. Igraf ovens are used in after-washing drying ovens, in dynamic curing processes

and also in closed static ovens.



Examples of dynamic and static radiant curing ovens, and paint booths:



Vertical aired radiating furnaces:



Other examples of dynamic and static curing ovens for the coating industry:



8. WOOD DRYING ___________________________________________________

Igraf radiant heat exchanger circuits are suitable for air static drying ovens applications,

like wood drying and phyto- thermic processes for example. The heat exchanger circuit is

engineered to operate as a heating battery that heat the air which is blown-through by

ventilation fans. In this case the heat exchange between the circuit and the air happens

via the conduction principle.

The two pictures below represents the convection fans connected with the

exchanger circuit (left) and the burners & fumes aspiration fans installation (right).



A few examples of outdoor wood drying static ovens:

Static oven designed for wood processing: 2 burners of 30kW with 27 m of heat

exchanger circuit each.



9. INDUSTRIAL WASHING___________________________________________

Igraf burners are often used for heating liquids in industrial washing machines.

The rotating platform washing machine is used to obtain a perfect cleaning of big

dimension pieces up to 7,000 kg in weight. Technical features: closed cycle washing

with detergent and water up to 80°C; heating with burners connected to the tanks;

automatic feed of the cleaning solution with water taken from the rinse;

computerized anagement and control system; overall dimensions 7,000 x 6,000 mm.

Washing plant for the cleaning

and/or paint removing of bogies,

frames and pieces of big dimensions:

closed cycle spray washing with warm

water and detergent; cold or warm

water rinsing; Working cycles

programmed in time and phases;

Control and management

computerized system

Washing plant for train cleaning.

Igraf burners and heat exchangers can

be installed in the external hot water

tanks to obtain continuous hot water at

a temperature of 80°C used in the

cleaning processes.



10. FOOD PROCESSING_____________________________________________

IGRAF radiant heat exchanger circuits are used in food processing machines. In the

picture on the left they were installed in baking ovens, while in the picture of the right the

system was used for heating the water needed for cooking pasta. The tank capacity was

500 liters, operating temperature 100 °C, reached within 1 hour. Total power installed was

150 kW, shared between two burners, each one with 75 kW power. As you can see in the

picture, the burners are built with a stainless steel cover to avoid corrosion issues due to

the water.

11. SUNRAD - INFRARED EMITTERS___________________________________

SUNRAD incandescent emitters are used in many different processes, especially when

high product temperatures or a quick drying are required. SUNRAD emitters are suitable

for all these applications since are made with honeycomb plates that reach temperatures

up to 900°C, providing a very strong thermal emission.

Example of infrared emitters oven designed for a Textile industrial drying process:



Example of oven for drying brake pads. It is

made with 6 Sunrad emitters of 30kW each in

line, the requirement was to reach 350°C

product final temperature in a few minutes.

SUNRAD emitters installation in two dynamic curing ovens. The required piece

temperature was 150°C and the curing process time was 5 minutes.

N.8 Sunrad infrared emitters installed in marble slabs processing:


www.fraccaro.it

REFERENCES_________________________________________________________

Marbol processing

Simec

Ritec

Breton

Fiam

Barsanti macchine

Wood drying

Baschild

Bigondry

Copcal

Incomac

Incoplan

Secal

Textyle

Triveneta Grandi Impianti

Primec

Industrial washing

Raimondi Impianti

Food industry

Tecnoalimentare

Velo

Gambarelli impianti

Coating Plants

Euroimpianti

Oxidation processes

Aluengineering

Aluplant

Biemme Impianti

Italtecno

Raimondi

CIE International

Mart

Ceramic industry

Barsanti Macchine

Gambarelli Impianti

Breton_______________________________________________________________________

We work in these countries:

The best companies around the world have been choosing the quality of

FRACCARO products for over 50 years.

Radiant Heaters for industrial processes - Fraccaro process heaters - by... · Radiant heating...

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