Thermaflow vs. Boiler

COMPARISON OF THERAMFLOW HEATING SYSTEM TO BOILER AND HEAT EXCHANGERS

Boilers have been in the hot dip galvanizing industry for at least a hundred years. They are typically fired with natural gas, and transfer steam or hot water through pipes to heat exchangers submerged in the tanks to be heated. They are a reliable, time proven method of heating. The Thermaflow heating system also uses natural gas, and is submerged in the tanks to facilitate transfer of heat to the liquid baths as well. This is where the similarities end and the uniqueness of the Thermaflow heating system begins.

Boiler:

Boilers – Boilers and hot water heaters are like a separate operation located remotely in close proximity to the tanks to be heated. They require that water be heated in a furnace and then transferred through pipes to the process tanks. Energy losses begin at the boiler, continue through the piping to the tanks, ending with the heat transfer through coils submerged in the process liquid. Even though many boilers manufactured in recent years may have efficiencies up to 80%, by the time the heated water gets to the tank, it has dropped to below 60%. Older systems can be even less efficient.

Thermaflow heaters – The Thermaflow heating system is located directly in the process tank. There is no separate furnace, no piping of water/steam, and no heat exchangers.
The Thermaflow heater utilizes a proprietary design (there is a patent pending) which
uses submerged combustion as the way of transferring heat to the liquid in the tank.
This is accomplished by attaching a burner to the end of a machined carbon tube and
firing directly under the surface of the liquid, allowing the gases to completely burn and then exhaust directly into the liquid. The air/gas ratio is adjusted to precise levels based
on empirical data on the burner and the BTU output desired for that particular heater.
The transfer of heat is accomplished through intimate contact of the exhausting gases
to the liquid to be heated. Over 90% of the available heat goes directly into the liquid!

Heat exchanger:

Boilers – Most boilers and hot water systems use heat exchangers in the process tanks. There are several types available, but all seem to have limited life expectancy due to the corrosiveness found in the process. Elevated levels of chlorides and other impurities can cause rapid failure in some systems.

Thermaflow heaters – Thermaflow heaters are constructed of graphite and thermal plastics in the submerged portion of the heater. Since both products are inert to the corrosive chemicals, there has been little to no evidence of water with heaters in over 18 months of service.

Boiler monitoring:

Boilers – Most localities require that boilers over a certain psi or horsepower have 24 hour monitoring which requires that personnel always be present. This is just another source of permitting and paperwork to be maintained and then scrutinized by authorities.

Thermaflow heaters – Thermaflow heaters do not require any type of special boiler permits or monitoring.

Chemicals and maintenance:

Boilers – Boilers require special additives to be injected into the feed water to help prevent buildup of scale inside the boiler tubes and piping. Annual inspections are usually required for permitting purposes, requiring scheduled shutdown of the system.

Thermaflow heaters – Because the process liquid is directly heated, the need for chemical additives does not exist. There are no annual inspections.

In summary, the Thermaflow heating system is over 90% efficient, reliable, and durable, making it likely the most efficient means available to heat your process tanks.