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Thermal Fluid Heaters Oil-Matic 2 Thermal Fluid Heaters Series Oil-Matic

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Thermal Fluid Heaters Oil-Matic 2 Thermal Fluid Heaters Series Oil-Matic Technical Book Thermail FluidHeatersOMV THERMAL FLUID HEATERS OIL-MATIC 2 THERMAL FLUID HEATERS SERIES OIL-MATIC 1. General Information about Thermal Fluid Heaters 2. Technical Highlights 3. Competitive Advantages 4. Technical Characteristics and Overall Dimensions 5. P&ID 6. Thermal Oil Circuit Layout 7. Thermal Oil System Elements 8. Installation 9. Thermal Fluid Brands & Types 10. Scope of Supply 11. Appendix 1. OIL-MATIC OMV Special Executions 12. Appendix 2. BONO ENERGIA Product Range 3 1. GENERAL INFORMATION Thermal fluid heathers of the series OIL-MATIC, OIL-MATIC OMV fields of application are typically: type OMV, guarantee a power capacity range typographies, cosmetics, pulp and paper industry, between 200.000 Kcal/h and 5.000.000 Kcal/h, with chemical and petrochemical industry, oil a maximum working temperature of 350 °C. transportation devices, food&beverage, bitumen industry, textile and packaging industry. Models of the series OIL-MATIC include: OIL-MATIC heaters are supplied as packaged • OMV 200: up to 0,2 MW, 200.000 Kcal/h. units, complete with all necessary equipment and • OMV 300: up to 0,5 MW, 300.000 Kcal/h. ready to be connected to site utilities; the selection • OMV 400: up to 0,7 MW, 400.000 Kcal/h. of the oil circulation pumps, expansion tank • OMV 600: up to 0,9 MW, 600.000 Kcal/h. and oil storage tank is strictly depending on the • OMV 800: up to 0,2 MW, 800.000 Kcal/h. system type, anyway our technical and commercial • OMV 1000: up to 1,2 MW, 1.000.000 Kcal/h. specialists are available to select and quote the • OMV 1250: up to 1,5 MW, 1.250.000 Kcal/h. proper equipment case by case. • OMV 1500: up to 1,7 MW, 1.500.000 Kcal/h. • OMV 2000: up to 2,3 MW, 2.000.000 Kcal/h. As an optional, air preheater can be purchased • OMV 2500: up to 2,9 MW, 2.500.000 Kcal/h. additionally to the oil heater. Preheater enables • OMV 3000: up to 3,5 MW, 3.000.000 Kcal/h. the boiler to increase efficiency reaching 90% at • OMV 4000: up to 4,7 MW, 4.000.000 Kcal/h. full load. • OMV 5000: up to 5,8 MW, 5.000.000 Kcal/h. OIL-MATIC model OMV is available both in vertical and horizontal versions; OMV compact design is also suitable for small plants, although always guaranteeing high quality performances. OIL-MATIC OMV heaters are marked and can be produced according to the most important and rigorous directives, such as: - PED Directive 97/23/CE - Machinery Directive (MD) 2006/42/CE - Gas Directive 2009/73/EC according to PED - Low Voltage Directive (LVD) 2006/95/EC - Electromagnetic Directive 89/336/EEC. Figure 1 Thermal Fluid Heaters series OIL- MATIC, type OMV, with ladder and platform. 4 Figure 2 Thermal Fluid Heater OIL-MATIC – OMV AIR FUEL OIL OUTLET BURNER FLAME OIL INLET EXHAUST GAS 1 OIL-MATIC coil 5 Thermal Oil Inlet 2 Heater’s body 6 Thermal Oil Outlet 3 Upper cover 7 Thermal Oil Drain 4 Burner 8 Thermal Oil inner coil/furnace 5 2. TECHNICAL HIGHLIGHTS At first glance, thermal fluid heaters of different equipment producers may appear the same. Deeply analyzing their char- acteristics it is clear that OIL-MATIC OMV has outstanding technical features. OIL-MATIC OMV heaters can be used with a wide range of thermal fluids (both minerals and synthetics) and are available in a wide range of sizes, from 0,2 MW up to 5.8 MW. Thanks to its easy design OIL-MATIC OMV series has found a large and successful application in many heating processes. OMV Design OMV design consists in a well proportioned heating sur- faces dimensioning, where both the sections, radiant and convective, are designed according to recent up-to-date design formulas, taking into consideration of several critical process data such as heat flow density, specific thermal load per unit, max. recommended bulk and max. film temperature. Depending on the thermal output, OMV heaters employ up to 4 concentric coils, containing up to 7 pipes in parallel (see Figure 3); the extended convective section ensures a higher exploiting of the hot gases, a gradual heat ex- change rate and reduced thermal stresses in the whole structure. Figure 3. OIL-MATIC OMV seamless spiral heating coils Thanks to our innovative design, the OMV range also ensures : • Longer fluid life cycle • High safety margin during operation with thermal fluid temperature close to the maximum recommended bulk tem- perature. • Reduced carbon coating and carbon sooty formation at the film layer. • Uniform thermal fluid circulation velocity in each coil. • An innovative and reliable design of tube suspension ensures a free thermal expansion. • Thanks to the correct combination between wide surfaces (radiant and convective) and different fluid speed and flows, OMV ensures lower heat flow if compared with other design, with evident benefits in terms of lower tube wall and fluid film temperatures. Multi Coil Design Properties OMV heater employs several coils pipe seamless type, having a reduced section in order to ensure higher fluid velocity and, consequently, a reduced Delta T between mass and wall fluid temperature. Thanks to the particular restricted section of the coil the fluid in OMV heater circulates in turbulent flow and the fluid speed at any point is in a status of continuous undergoing changes both in magnitude and direction; this implies a more balanced heat flow and increased heat transfer properties. Moderate Delta Temperature between bulk and film In our OMV the fluid flow is in turbulent condition, which is enough to ensure flat temperature profile and a reduced differ- ence between film and bulk temperature along the entire circuit. 6 Figure 4 Right side partially turbulent condition The fluid film, in this thermal flow condition, has a temperature of 30÷35°C higher than the bulk one and this situation leads to a fast flow degradation. Although only a part of the whole fluid volume is present in the film layer, if the fluid temperature exceeds the max. recommended value (as very often happens in the inner coil, called the radiant section), the whole volume of fluid is quickly involved in a larger degradation rate. The rate of degradation generally doubles with an increase of tempera- ture of 10°C. The film temperature is not the only one to be controlled in this process, also the bulk temperature must be under control. A cracking event occurs in a coil heater when the fluid velocity (and con- sequently the turbulence) decreases and the thermal fluid remains in prolonged contact with the heated surfaces. Even though the bulk tem- perature may not change so evidently the film temperature can rise very quickly leading to cracking. Figure 4 Left side turbulent condition This is the best operating condition peculiar of our OMV Coil Heater De- sign, characterized by a reduced difference of temperature between the film and the bulk. Design of Heaters The fundamental principles. In order to minimize the degradation rates when using mineral oils Figure 4 above 600° F (316°C), users should take extra care with a proper heat- Heat exchange in the oil pipes depending on oil speed er selection in terms of combustion chamber dimension choice. A larger volume combustion chamber allows more space around the burner, which minimizes the radiant energy reaching the coil surface. The same thing could be said regarding the space between the coils. The radiant section is the area of the tubing that actu- ally faces the flame; depending on geometry and design, up to 70% of the total heat is transferred in the radiant section. The resulting localized heat flow can be three times the average in the entire heater, with film temperatures ex- ceeding the average fluid temperature by 150° F (83°C) or even more. In some heaters, the maximum recom- mended film temperature of a fluid can be exceeded even if the average temperature is largely within limits. OIL-MATIC employs a new coil design, which, if combined with the fluid’s turbulent flow, guarantees excellent heat transfer conditions and the best fluid temperature pro- file, as per recommendation of all the fluid suppliers. The fluid’s high turbulence and velocity rates in the radi- ant section prevent the formation of fluid stagnation ar- eas that might lead to boiling and hot spot phenomena and, consequently, rapid fluid degradation. Figure 5 Thermal fluid velocity in a OIL-MATIC heater 7 2. TECHNICAL HIGHLIGHTS Moreover higher flow velocity in the coils enables to control the fluid itself with simpler control devices, which are not recommended on heaters with lower flow circulation speed, for the same thermal degra- dation prevention reasons. Reduced Fluid Degradation Rate The reduced fluid degradation rate is achieved thanks to the homogeneous heat flow. On the con- trary, single or dual coil heater design (or fluid flow connected in parallel arrangements) are charac- terised by a wide unbalanced condition between the inner and outer coil where the difference in temperature both film and bulk can be over 35°C from the set point with a consequent reduced safety margin. In OMV Heaters circulates only thermal fluids in liquid phase This condition allows a balanced heat transfer rate between the sections in order to ensure: • High fluid velocity in radiation section. Figure 6 • Reduced fluid degradation rate. Degradation rate vs Operating temperature • Maximum exploiting of the flue gases and high heat transfer rate also in the convection section. • Gradual fluid temperature increases in radiation section and in countercurrent to the gases in order to avoid any thermal shock.
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