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TRANSCRIPT
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.
Radiant System Innovation
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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.
Radiant System Innovation
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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
FRI200S2 150-200 kW 2 STAGE 165 mm 230 V – 50 Hz
FRI300S2 200-300 kW 2 STAGE 204 mm 230 V – 50 Hz
FRI400S2 300-400 kW 2 STAGE 204 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
Radiant System Innovation
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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
IEM20 B ON-OFF 20 kW
IEM20S2 B 2 STAGE 14-20 kW
IEM35 B ON-OFF 35 kW
IEM35S2 B 2 STAGE 30-35 kW
IEM40 B ON-OFF 40 kW
IEM40S2 B 2 STAGE 28-40 kW
IEM60S2 B 2 STAGE 45-60 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%;
Radiant System Innovation
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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.
Radiant System Innovation
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COMPARING EFFICIENCIES WITH TRADITIONAL BLOWN AIR BURNERS:
Traditional burners (82% efficiency):
Fraccaro air-stream gas burner ( 92% efficiency):
Radiant System Innovation
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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:
Radiant System Innovation
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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:
Radiant System Innovation
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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):
Radiant System Innovation
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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.
Radiant System Innovation
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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:
Radiant System Innovation
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Other examples of tank heating installations (beer production tank, anodic oxidation
systems, degreasing systems):
Radiant System Innovation
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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:
Radiant System Innovation
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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.
Radiant System Innovation
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Examples of dynamic and static radiant curing ovens, and paint booths:
Radiant System Innovation
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Vertical aired radiating furnaces:
Radiant System Innovation
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Other examples of dynamic and static curing ovens for the coating industry:
Radiant System Innovation
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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).
Radiant System Innovation
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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.
Radiant System Innovation
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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.
Radiant System Innovation
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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:
Radiant System Innovation
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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:
Radiant System Innovation
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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.