Case Studies - Process Heating Solutions

Custom Solutions. Customer successes.

Chromalox has been finding elegant solutions for demanding applications across a wide range of industries for nearly a century. Take a look through our case studies for a clearer idea of what we’ve done for customers like you – and see how we can help with your Process Heating needs. 

 
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chemical processing
TPCI generator helps to regulate and stabilize heat transfer fluid temperature.
aerospace weapon systems
Components for interceptor and ICBM rockets must be tested for reliability prior to deployment. 
aircraft industry process heating and controls
A Virginia aircraft testing facility utilizes compressed air to test aircraft devices, throttling it from the source starting at 3,800 psi down to 1,650 psi down to 5 psi. 
natural gas industry process heating and controls
A manufacturer who designs, builds and markets natural gas, drying, filtering and conditioning skids required assistance in Factory Acceptance Testing on entire integrated skid in addition to the Acceptance Testing of each component.
gas turbine operationg temperature controls
A 92 MW co-generation power plant fueled by natural gas utilized two 46 MW gas turbines that required fuel gas treatment and preheating for increased efficiency.
industrial process heating and controls 4
Glass-Lined and Hastelloy® Jackets used in hazardous chemical manufacturing are extremely sensitive to changes in temperature and can easily crack and be destroyed.
faux rock wall
For consistent production of imitation landscaping stones, their molds must be heated uniformly.
outdoor storage tank heating and controls
Chromalox control panels are easily configured to accept a signal of current level status from a level controller installed within tanks.
nuclear power plant process heating
To test simulated fuel components, it was necessary to pre-heat carbon dioxide gas, CO2, used as a coolant in a high temperature gas-cooled nuclear reactor.
nuclear power plant
Inlet temperature of demineralized feed-water must be controlled to properly test heating element. Required temperatures range from not less than room temperature up to 600° F.
Cryogenic Methane System
A manufacturer of cryogenic systems for use in the aerospace industry had a critical need for a methane conversion system. 
engine preheating
Chromalox helped this transportation industry customer solve an unusual heating system design challenge. A heated water/glycol mixture is used to preheat the engines of the customer's locomotives.
silicon wafer production process heating and controls

An intricate part in the manufacture of electronic components and solar panels, the polysilicon process, requires high temperatures, high pressure and a low flow rate to succeed.

aerospace industry jet turbine
In an aerospace testing lab, air was to be heated to simulate temperatures from jet engines for the purpose of testing aircraft turbine units.
metal forging heating

Metal parts must be thoroughly cleaned so that paint adheres for a good, lasting finish. This process uses a triclorethylene vapor degreasing method.

oil industry temperature controls

To reduce risk, it was important to preheat fuel oil used for stand-by power in case there was an interruption of natural gas supply.

textile industry process heating
An old steam preboarding machine used for shaping hosiery needed to be replaced.
bottle assembly line process heating and controls
In a continuous straight-line bottling facility, bottles are loaded into the line along which a pneumatic cleaning machine automatically removes all foreign matter. 
hydroelectric power generation heating and controls

If dam gates freeze or suffer from ice or snow build-up, it interferes with the operation of the dam to open and close the flood gates as necessary to control the water levels.

industrial painting heating

An infrared lamp paint baking oven was a bottleneck, slowing all production, because it was unable to produce sufficiently high temperatures.

synthetic fiber production heating and controls
A North Carolina manufacturer of specialty synthetic fibers used in both home and industrial applications required a custom autoclave for a drying application. 
wastewater processing heaters and controls

Filtration membranes in two waste water treatment tanks at an Iowa ethanol producer were susceptible to damage from freezing temperatures. 

pasteurization process heating and controls
Several U.S. processors of nut meats required a processing system to pasteurize these nut products to meet validation requirements for proper log-kill doses of salmonella and other bacteria.  
asphalt production process heating and controls

A Wyoming manufacturer of road repair “crack-filling” mixtures takes refinery byproducts and processes them into a variety of road crack filling mixtures.

chemical processing systems
A manufacturer of specialty automotive fluids and lubricants located in the southeastern U.S. was in the process of transferring an existing production line to another facility.
solar energy process heating and controls
This solar energy producer uses hot oil and heat exchangers to heat various process materials in the manufacture of polysilicon for solar applications. 
textile industry process heating and controls 3

Impedance heating technology maintains uninterrupted process temperature during generator replacement installation.

Reactor Vessels

The installed system for heating reactors and stills with hot tempering oils was limited in temperature range and could be troublesome. A growing diversity of products required a greater degree of flexibility in temperature range than the hot-oil system could provide. 

gold mining industry heating and controls 3

When mining for gold, hazardous chemicals are held and heated within large storage tanks. Immersion Heaters with replaceable elements avoid the necessity and expense of draining tanks to maintain heaters.

train comfort heating 3
An OEM customer in railway car HVAC systems required both overhead heaters with open coil and tubular elements, as well as custom duct heaters to provide safe, reliable and comfortable heat on passenger railway cars.
coal train
A Missouri coal-fired generating station needed to reduce coal dust in an onsite tunnel.  Approximately 9,000 rail cars of coal pass through the tunnel each month, dumping coal for power generation.
metal chain
Steel chains must be "oil coated" to ensure lasting strength and rust-free delivery. 
industrial press process heating
Maintaining a temperature of 250° F on Micarta strips after after removal from a pre-heating oven.
electric motor machine tooling
A machining and tooling company was asked to retrofit an existing conveyor system that used a quartz bulb heating design in a two-stage oven.
metal grinder
One of the most critical production operations at this plant is the finish-grinding of the hubs and shafts for J57 and J75 jet engines.
salt mine process heating and controls
A Chromalox solution for maintaining correct temperatures in oil tanks for lightweight and thick viscous oil using an electric heat trace system.
power generation heating and controls 2
A large South Dakota electric power plant needed to upgrade the 10-year-old heating system on an external storage tank.
hot steel ingot

In this plant, the salt bath heating operation is initiated each working day at 3:00 a.m. by a time clock.

vacuform machine process heating
To heat thermoplastic sheet material for vacuum forming, heating must be rapid, uniform and controllable. 
chemical reactor process heating and controls

Chromalox Hot Oil System maintains high temperatures necessary to heat jacketed reactors with customized seal-less pump.

parts manufacturing assembly line
Parts are produced by the hundreds of thousands yearly and require fast cleaning to keep pace with the milling. 
asphalt pavement
Heating viscous fluids speeds loading time of tanker trucks.
military marine heating and temperature controls
Working on a submarine in the depths of the ocean would be cold and damp without Chromalox radiant comfort heaters.
packaging industry process heating and controls
Chromalox packaged heating system provides tight control of temperature sensitive process.
Dolomite

Dolomite is composed of 60% calcium and 40% magnesium and tends to pick up moisture from rain and fog. The previous evaporation method was air-drying which left the company at the mercy of the weather.

rental construction industry

Chromalox blower heater is rugged and built to operate at various voltages without rewiring.

petroleum industry heating and controls 2

A Colorado natural gas driller performs hydraulic fracture drilling, using water and steam mixtures.

chemical industry process heating and controls
A worldwide leader in specialty chemical production has been using open coil duct heaters for many years to heat the air for some of its chemical applications.
diesel generator heating
A load bank manufacturer was not receiving timely delivery of screw plug and straight tubular heaters from its current supplier.
chocolate molds process heating
For best results when molding chocolate, it is necessary to temper the molds to 90° F before filling with syrup.
zoo comfort heating
A zoo’s plans for a new exhibit for mountain lions, lynx, otters, snow fox and grizzly bears called for keeping the animals as close to the public as possible. 
printing press image
In this lamination process, up to four sheets of paper are laminated at one time by a press.
agriculture industry process heating and controls
Chromalox helps OEM client in farming industries create custom machinery to dry out farming by-products such as corn husks and animal refuse into FDA approved fertilizer and other soil enrichments.
food processing heating
The cleanest and most efficient semi-automated system for deep fat frying of fish was desired by this customer. 
metal forging heating
With metal, the finishes required must be baked on, which meant they needed to install a baking oven.
lipstick beauty industry process heating
Keeping lipstick mixture at optimum temperature during forming process was difficult. 
hardwood flooring
The tremendous increase in building construction in past years and the wider use of laminated plywood has brought about an improvement in the art of making the plies for laminating into plywood.
church exterior
The previous method of heating the baptismal font use at a church was to draw hot water from church's hot water heating system.
fuel gas conditioning system heating and controls
Explosion-proof heat trace system provides safe, reliable freeze protection of pipes, valves, tanks in hazardous locations.
rubber pellets
De-burring the flashing from molded plastic parts is performed in a tumbler. Steam is used as a pickup medium for dust control.
Chromalox bottle sterilization
For accurate results, maintaining the temperature of hot water, used in thermal shock tests, at a constant temperature of 90° F above incoming cold water. 
biodiesel production heating and controls
Due to this caustic nature of the biodiesel production feedstock, this customer was experiencing process heater failures at a frequency that was unacceptable.
printing press image
Dry steam prevents excessive paper moisture in printing process.
road construction painting process heating
Controlling the viscosity of asphalt paint is paramount to the quality of the end product.