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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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Start up and Commissioning
Chromalox and Eastman Therminol Meet High-Temperature Demands
Chromalox helps production plant meet third-party standards.
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Chromalox Case Study: Terephalate - 500
Chromalox Enables Whole Range of Precise Temperatures for Resin Products
A new production plant was being built for the manufacture of polyester resins used in a multitude of products. The Chromalox engineers developed a solution and installation plan for both accurate heating of a variety of precise temperatures and to save on overall costs.
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Chromalox Case Study: Chlor Alkali - 500
Chromalox Site Services and Process Heating Solutions Safely Warms Caustic Chemicals
Chromalox reviews and troubleshoots existing situation at Chlor Alkali processing plant to bring the best process heating solution, insulation and start-up parameters.
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chemical processing
Pilot Reactor Requires Maximal Polyvalence
TPCI generator helps to regulate and stabilize heat transfer fluid temperature.
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aerospace weapon systems
Testing Missile Components Required Accuracy and Reliability
Components for interceptor and ICBM rockets must be tested for reliability prior to deployment. 
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aircraft industry process heating and controls
Rigorous Testing of Throttling Equipment Prevents Dangerous Freeze-Ups
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. 
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natural gas industry process heating and controls
Chromalox Creates “Virtual Factory” for Field Factory Acceptance Testing
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.
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gas turbine operationg temperature controls
Chromalox Engineers Safe and Efficient Pre-Heaters of Natural Gas
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.
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industrial process heating and controls 4
Chromalox Hot Oil and Advanced Control Systems Protect Costly Glass-Lined and Hastelloy Jackets
Glass-Lined and Hastelloy® Jackets used in hazardous chemical manufacturing are extremely sensitive to changes in temperature and can easily crack and be destroyed.
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faux rock wall
Electrically Heated Oil in Molds Produces Uniform Imitation Stone
For consistent production of imitation landscaping stones, their molds must be heated uniformly.
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outdoor storage tank heating and controls
Chromalox Monitors Tank Levels and Temperatures
Chromalox control panels are easily configured to accept a signal of current level status from a level controller installed within tanks.
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nuclear power plant process heating
Chromalox Circulation Heater Accelerates the Search for New Competitive Nuclear Power Sources
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.
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nuclear power plant
Controls of Feed-Water Temperature to Test Nuclear Elements
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.
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Cryogenic Methane System
Custom Heating System Designed for Cryogenic Methane System
A manufacturer of cryogenic systems for use in the aerospace industry had a critical need for a methane conversion system. 
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engine preheating
Custom Heating System Design Puts Locomotive Engine Preheating On-Track
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.
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silicon wafer production process heating and controls
Custom Modular, Dual-Chamber Circulation Heater Protects Polysilicon Process

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.

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aerospace industry jet turbine
Electrically Heated Compressed Air Tests Jet Engine Parts
In an aerospace testing lab, air was to be heated to simulate temperatures from jet engines for the purpose of testing aircraft turbine units.
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metal forging heating
Electric Heat is Safe, Accurately Controlled for Triclorethylene Vapor Degreaser

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

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oil industry temperature controls
Electric Heat is Used in Stand-By Operation to Preheat Fuel Oil

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.

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textile industry process heating
Electric Preboarding Oven Improves Production Efficiency
An old steam preboarding machine used for shaping hosiery needed to be replaced.
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bottle assembly line process heating and controls
Circulation Heaters Remove Moisture From Bottles Before Filling
In a continuous straight-line bottling facility, bottles are loaded into the line along which a pneumatic cleaning machine automatically removes all foreign matter. 
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hydroelectric power generation heating and controls
Freeze Prevention Saves Millions Downstream From Hydro-Electric Dam

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.

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industrial painting heating
Fast Paint Bake Required to Speed Production

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

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synthetic fiber production heating and controls
Heat and Control System Provides Precision Needed for Quality Control
A North Carolina manufacturer of specialty synthetic fibers used in both home and industrial applications required a custom autoclave for a drying application. 
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wastewater processing heaters and controls
Heater and Control Unit Prevent Freezing in Wastewater Tanks

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

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pasteurization process heating and controls
Heaters, Control Panels and Boilers Combine to Provide Cost-Effective Food Processing Solutions
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.  
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asphalt production process heating and controls
Heating System Increases Product Integrity and Enhances Plant Reliability

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

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chemical processing systems
Hot Oil Control System is Key to Maintaining Product Temperature
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.
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solar energy process heating and controls
Hot Oil System Meets Strict Emission Standards
This solar energy producer uses hot oil and heat exchangers to heat various process materials in the manufacture of polysilicon for solar applications. 
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textile industry process heating and controls 3
HTM Generator Reinstalled Without Production Shutdown

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

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Reactor Vessels
Immersion Heaters Provide High-Temperature Heating Flexibility

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. 

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gold mining industry heating and controls 3
Immersion Heaters with Replaceable Elements Improve Safety of Harsh Chemicals Needed To Mine Gold

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.

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train comfort heating 3
Chromalox Keeps Railway Commuters Safe and Warm
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.
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coal train
Clean Water Heater System Reduces Coal Dust, Eliminates Freezing and Keeps the Lights On
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.
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metal chain
Lubricates and Protects with Hotter Heavier Oil
Steel chains must be "oil coated" to ensure lasting strength and rust-free delivery. 
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industrial press process heating
Maintaining Processing Temperatures in Micarta Strips Until Reaching Press
Maintaining a temperature of 250° F on Micarta strips after after removal from a pre-heating oven.
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electric motor machine tooling
New Heating and Control System Increases Reliability of Resin Impregnation System
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.
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metal grinder
Oil Circulation Heater Contols Expansion of Jet Hubs, Eliminates Rejects
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.
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salt mine process heating and controls
Oil Tanks, Recirculation and Offload Lines All Benefit
A Chromalox solution for maintaining correct temperatures in oil tanks for lightweight and thick viscous oil using an electric heat trace system.
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power generation heating and controls 2
Pocket Heater Reduces Costs and Downtime
A large South Dakota electric power plant needed to upgrade the 10-year-old heating system on an external storage tank.
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hot steel ingot
Salt Bath Converted from Natural Gas to Electric Heat

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

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vacuform machine process heating
Preheating to Vacuum-Form Thermoplastic Requires Consistent Heat
To heat thermoplastic sheet material for vacuum forming, heating must be rapid, uniform and controllable. 
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chemical reactor process heating and controls
Seal-less Pump Achieves Chemical Reaction

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

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parts manufacturing assembly line
Used Steam-Heated Cleaning Machine Converted to Electric Heat
Parts are produced by the hundreds of thousands yearly and require fast cleaning to keep pace with the milling. 
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asphalt pavement
Customer Saves Two Hours Per Load of Road Oil With Electric Heat
Heating viscous fluids speeds loading time of tanker trucks.
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military marine heating and temperature controls
Warmth at >800 Feet Below Sea Level, Made Possible by Chromalox.
Working on a submarine in the depths of the ocean would be cold and damp without Chromalox radiant comfort heaters.
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packaging industry process heating and controls
Starch Temperature Not Too Hot or Cold
Chromalox packaged heating system provides tight control of temperature sensitive process.
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Dolomite
Consistency of Dolomite Quality is Achieved After Converting to Electric Pre-Heating

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.

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rental construction industry
Blower Heater Meets Diverse Rental Needs

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

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petroleum industry heating and controls 2
Tank Heaters Keep Gas Drilling Operation on Track Through Reliable Service

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

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chemical industry process heating and controls
The Heat is On: Durable Sheathed Element Duct Heater Reduces Downtime and Costs
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.
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diesel generator heating
Timely Response and Product Availability Wins the Day
A load bank manufacturer was not receiving timely delivery of screw plug and straight tubular heaters from its current supplier.
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chocolate molds process heating
Warm Molds Produce Better Chocolate
For best results when molding chocolate, it is necessary to temper the molds to 90° F before filling with syrup.
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zoo comfort heating
Warm Pools and Rocks Help To Keep Zoo Exhibit Open Year-Round
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. 
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printing press image
Wax Maintained at Steady Laminating Temperature in Converted Press Tank
In this lamination process, up to four sheets of paper are laminated at one time by a press.
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agriculture industry process heating and controls

Chromalox Heater Enables Farming Sustainability
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.
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food processing heating
5,000 Lbs. of Fish Fried Per Hour with Help of Heat Transfer System
The cleanest and most efficient semi-automated system for deep fat frying of fish was desired by this customer. 
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metal forging heating
Infrared Oven Key to New Business
With metal, the finishes required must be baked on, which meant they needed to install a baking oven.
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lipstick beauty industry process heating
Heat Transfer System Increases Quality of End Product
Keeping lipstick mixture at optimum temperature during forming process was difficult. 
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hardwood flooring

Edge-Gluing of Peeled Wood Laminations Improves Quality
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.
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church exterior
Chromalox Electric Baptistery Heater Ends Cold Water Troubles
The previous method of heating the baptismal font use at a church was to draw hot water from church's hot water heating system.
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fuel gas conditioning system heating and controls
Chromalox Keeps Alternative Fuels Flowing, No Matter the Weather
Explosion-proof heat trace system provides safe, reliable freeze protection of pipes, valves, tanks in hazardous locations.
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rubber pellets
Circulation Heater Dries Steam for Dust Contol in Plastic De-Burring Tumbler
De-burring the flashing from molded plastic parts is performed in a tumbler. Steam is used as a pickup medium for dust control.
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Chromalox bottle sterilization
Circulation Heaters Used in Thermal Shock Tests of Glass Bottles
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. 
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biodiesel production heating and controls
Custom Circulation Heater Enhances Biodiesel Plant's Productivity
Due to this caustic nature of the biodiesel production feedstock, this customer was experiencing process heater failures at a frequency that was unacceptable.
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printing press image
"Dry" Steam From Chromalox GCH Steam Superheaters Used to Set Ink on Paper Bags
Dry steam prevents excessive paper moisture in printing process.
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road construction painting process heating
Safe, Economical Way to Achieve High Quality Asphalt Paint Coating
Controlling the viscosity of asphalt paint is paramount to the quality of the end product.  
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