MEGA CLEAN FLOW Heater: Minimizing Toxic Emissions for Cogeneration

BACKGROUND

Using a small (~25HP) lean burn natural gas motor for cogeneration, our customer wanted to mitigate toxic emissions on the exhaust. The challenge is reducing Formaldehyde and Benzine output levels as well as reducing all other toxins without air-flow exposure to ni-chrome resistors.

The MEGA CLEAN FLOW HEATER needed to satisfy the following criteria:

• Exhaust air flow rates from 15cfm to 30cfm
• Inlet 2” NPT, outlet 2” NPT
• Engine loads for 25% to 100%
• Insulation of all inlet & outlet entries as well as process chamber
• Air-flow exposure to 304 or 316 stainless steel only
• Outlet temperature must be <288°C at ALL flow rates
• BCE Controllers needed for operating temp and
• 50 Meg-ohm isolation at 500 VDC
• Hi-pot 2E + 1K at 3mAmp
• ALL TESTS PERFORMED AT ROOM TEMPERATURE 

OUTCOME

The Mega Clean Flow Heater proved to be the most optimal design for Cogeneration. The temperature, watt density, and variable flow rates assured success when operating the instrument. BCE’s proprietary design was essential in the application.

Download the PDF version of the MEGA CLEAN FLOW Heater: Minimizing Toxic Emissions for Cogeneration case study here. For more information, visit https://bcemfg.com or call 510-274-1990.

Vacuum Feedthroughs the Way You Want Them

Equipment manufacturers and scientific researchers are continually challenged with supplying power, fiber-optic, control, and monitoring cables into sealed vacuum vessels. Whether due to space restrictions, special geometries, or number and type of conductors, standard glass-to-metal or ceramic feedthroughs never quite fit the bill. Unfortunately, because of limited options, many designers are forced to compromise and go for an off-the-shelf solution.

Until now. 

BCE designs, engineers, and manufacturers feedthroughs that can handle custom shapes, tight angles, curves, shielded wire and still provide a tight seal.

Why You Need to Consider BCE:

• Feedthroughs Designed to Your Specifications
• 24 Hour Turnaround on Custom Drawings & Quotations
• Custom Feedthroughs Ship in 2 Weeks

Call today. 510-274-1990

Basic Wattage Requirement Calculations for Metals, Non-metals, and Gases

Accurately heating various materials such as metals, non-metals, liquids and gases is complex. There are many variables to consider. Material properties such as density, thermal conductivity, specific heat and time all must be known to calculate a correct wattage value. Phase change (solid to liquid, liquid to gas) requires additional calculations to account for latent heat of vaporization and latent heat of fusion.

BCE, a manufacturer of custom heating elements and thermal systems, has a page on their website providing basic wattage requirement calculations for your reference. These calculations will assist you in determining the amount of power your heater will require, but it is strongly suggested you consult with a heater application expert before designing, specifying, or purchasing. Their expertise and knowledge will assure a safe, efficient, and economical heating solution.

Visit the BCE Basic Wattage Calculation page.

Epoxy-based Feedthroughs Provide Design Flexibility, Rapid Prototyping and Cost Savings

Multi-conductor, flanged feedthrough.

The point of view that epoxy-based feedthroughs are inferior to glass-to-metal feedthroughs in terms of sealing and outgassing may have once been true, but modern manufacturing techniques and new epoxy compounds have all but eliminated those concerns. Modern epoxy formulations are more capable of enduring greater mechanical stresses, operating under wider temperature ranges, and sustaining exposure to harsher chemicals than ever before. Today's epoxy-based feedthroughs are excellent choices for even the most challenging feedthrough applications.

Take BCE's proprietary epoxy compound for instance. It seals to 1 X 10E-9 cc/sec of Helium under high vacuum and high pressure. Concerns of outgassing have been erased with the formulation meeting NASA’s ASTM E-595 low-outgassing specification, the industry standard test for measuring outgassing in adhesives and other materials. Developed to screen for low outgassing materials for use in deep space, the test determines the volatile content of material samples placed in a heated vacuum chamber under tightly controlled humidity, temperature, and vacuum conditions.

PCB feedthrough with clear epoxy feedthrough.

Epoxy feedthroughs allow designers and engineers to procure a feedthrough built for the specific task, rather than to accommodate off-the-shelf connectors that are rarely ideal for the specific requirement. Off-the-shelf connectors and feedthroughs impose restrictions on the number and gauge of conductors, as well as the geometry of the device. The use of epoxy-based feedthroughs opens the door for virtually any combination of conductors, tubes, fiber optic cables, sizes and geometries.

It’s important to use the right feedthrough for a given application. Epoxy feedthroughs are not always the right choice, and consultation with an applications expert is always recommended.  But from the viewpoint of engineers and designers, epoxy-based feedthroughs usher in design freedom, prototyping, and cost advantages that once didn't exist. 

Clean Gas and Liquid Stream Heating

Clean gas and liquid heater
(BCE Mini Clean Flow)

As demand for purity increases throughout the medical, analytical, and semiconductor industries, equipment manufacturers continuously require new tools to reach the next technology threshold. In these industries electric heating applications for clean gases and liquids abound. Just a few examples are; clean air circulation, nitrogen heating, product drying, dehumidification, analytical instrument sample prep, incubation, DI water heating, solvent removal, wafer drying and processing.

High purity gas and liquid heating is challenging. Heater designs have to address problems and concerns involving contamination, thermal efficiency, electrical isolation, controllability, size, and packaging. Gas and liquid heating applications can vary dramatically. Some applications are very difficult to control and size is always a concern. One of the toughest issues to overcome is the seemingly mutually exclusive requirement for smaller size and higher power.

General diagram of "clean flow" heater.

Driven by innovation and competition, the need for hotter, cleaner, smaller and more efficient electric heaters is unceasing. One type of heater known as the "clean flow" has broad adaptability to many clean gas and liquid heating needs. It utilizes an internal heating element isolated from the process flow chamber, both electrically and physically. Best described as a "mini circulation heater", the heater's flow chamber, with inlet and outlet connections, completely protects the clean gas or liquid from external exposure and contamination.  The internal heating element can run at fairly high watt densities to accommodate fast changing flow rates, while still maintaining a compact and efficient package.  Internal RTDs or thermocouples can be incorporated to monitor temperature closely, or to protect the heater from over-temperature.

If you have questions about electrically heating clean gases or liquids, contact BCE by either visiting https://bcemfg.com or by calling (510) 274-1990.

BCE ISO 9001: 2015 Update

BCE is very pleased to announce the company has been awarded ISO 9001: 2015 approval.

July 23, 2018 - BCE, Inc., a California based designer and manufacturer of electric thermal systems and vacuum feedthrough devices, announced today that it has been recognized for its commitment to quality and excellence by being certified in accordance with ISO 9001:2015.

For more information, contact BCE by calling 510-274-1990 or visiting https://bcemfg.com.

The SMARTFLOW Circulation Heater - Highly Efficient Electric Heater Design for Heating Liquids

The SMARTFLOW liquid heater is designed for applications where fast heating of liquids is required. All parts exposed to liquid flow are constructed of 304/316SS (other materials available). All units have built-in Type J or K TC with potential of added adapter for outlet flow.

• Wetted parts constructed of 316 stainless steel (other material available) 
• Liquid flow passes over an enclosed heated body.
• All threaded fittings are available as NPT, SAE, BSP & VCR
• Internal heater provides uniform heating.
• Made in U.S.A.

https://bcemfg.com
510-274-1990