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Solex Thermal Indirect Plate Heating & Cooling

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cooling, heating and drying a wide …

cooling, heating and drying a wide
variety of free flowing bulk solids such as sugars, fertilizers,
chemicals, plastics, minerals, oilseeds, and many other types of
granules, crystals and powders.

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  • 1. World Leaders in EnergyEfficientTechnology for Cooling, Heatingand Drying Bulk Solids.World leading technology for cooling, heating and drying a widevariety of free flowing bulk solids such as sugars, fertilizers,chemicals, plastics, minerals, oilseeds, and many other types ofgranules, crystals and powders.
  • 2. ContentBULK SOLIDS COOLING TECHNOLOGY Cooling Product from 400ºC ...................................... 4 Cooling Product from 2000ºC .................................... 6BULK SOLIDS HEATING TECHNOLOGY Heating Using Steam, Hot Water, Thermal Oil .......... 8BULK SOLIDS DRYING TECHNOLOGY Drying Bulk Solids, Oilseeds & Grains . . . . . . . . . . . . . . . . . . . . . . . . . 10SOLIDS-TO-AIR HEAT EXCHANGE Indirect Cooling & Heating Using Air/Gas . . . . . . . . . . . . . . . . . . . 14APPLICATIONS Chemicals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Fertilizers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Sugars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Polymers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Dried Biosolids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Minerals and Sands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Oilseeds and Grains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26DESIGN ADVANTAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Discharge Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31TESTING Lab Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Pilot Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33ENERGY EFFICIENCY What Makes Solex Technology So Efficient? . . . . . . . . . . . . . . 34ABOUT SOLEX Experience, Service, and Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Installation Photos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
  • 3. TechnologyTechnology for Cooling, Heating & Drying Bulk Solids thatuses up to 90% less energy.BULK SOLIDS COOLING TECHNOLOGY Cooling Product from 400ºC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Indirect plate cooling technology works by passing cooling water in the plates to cool material by conduction. Cooling Product from 2000ºC . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Indirect plate cooling technology for challenging high temperature applications.BULK SOLIDS HEATING TECHNOLOGY Heating Using Steam, Hot Water, Thermal Oil . . . 8 Indirect heating of bulk solids by passing steam, hot water or thermal oil through hollow heat exchanger plates.BULK SOLIDS DRYING TECHNOLOGY Drying Bulk Solids, Oilseeds & Grains . . . . . . . . . . . . . . 10 Ultra-efficient drying technology combining indirect heat transfer and low volume purge air.SOLIDS-TO-AIR HEAT EXCHANGE Indirect Cooling & Heating Using Air/Gas . . . . . . . . 15 Scan this QR code to view a video about Solex capabilities.
  • 4. Bulk Solids Cooling Technology (Cooling Product from 400ºC)how it works Slow & Controlled Product Flow Bulk solids pass slowly downward between a series of vertical hollow heat exchanger plates. Indirect Plate Cooling Cooling water flows through the plates to cool the material by conduction. Mass Flow Technology The mass flow discharge feeder creates uniform product velocity through the cooler and regulates Specifications Capacity: 100 kg/hr to 150,000 kg/hr the product flow rate. Cooling Medium: Water, Glycol Product Temperatures: up to 400ºCwhy it’s better Uses up to 90% ZERO Emissions, Dust, Less Energy Fines & Odor The Solex cooling technology is The indirect plate cooling design means air ultra-efficient, using up to 90% less energy is not in contact with the product during than technologies such as fluid beds or the cooling process. Emissions, dust, fines rotary drums that require the use of air. and odors are eliminated.. Produces a Superior Final Product Uniform Final T h e s l ow a n d c o n t ro ll e d Product Temperatures movement of the product The mas s f low design through the cooler prevents means the product moves product abrasion and slowly and with uniform degradation so that there ve l o c i t y t h ro u g h t h e is no change in par ticle characteristics or crystal shape. cooler. This enables even temperature distribution producing stable and uniform f inal produc t temperatures. Compact and Modular Design The compact installation footprint makes this design easy to integrate into existing plants, Reduced Installation Costs and is ideal for debottlenecking or revamps. The Since air is not used in the heating process, modular design means additional heat exchanger installed capital costs are reduced due to plate banks can be stacked if increased cooling the elimination of costly and unnecessary air capacity is required in the future. handling equipment. 4 Learn more at www.solexthermal.com
  • 5. Energy Recovery While Cooling Bulk Solids(Cooling Product from 400ºC) energy recovery Indirect Plate Cooling Technology Makes Energy Recovery Easy During the cooling process, the heat from the bulk solids is transferred to the cooling water, producing pressurized hot water that can then be used for other processes, such as building heat, pre-heating air, or pre-heating product. Recovering Heat from Bulk Solids Cooling Process 5 Learn more at www.solexthermal.com
  • 6. High Temperature Bulk Solids Cooling Technology (Cooling Product from 2000ºC)how it works Slow & Controlled Product Flow Bulk solids pass slowly downward between a series of vertical hollow heat exchanger plates. Indirect Plate Cooling Cooling water flows through the plates to cool the material by conduction. Mass Flow Technology The mass flow discharge feeder creates uniform Specifications product velocity through the cooler and regulates Capacity: 100 kg/hr to 150,000 kg/hr Cooling Medium: Water the product flow rate. Product Temperatures: up to 2000ºC Finally, a Solution for Cooling Highwhy it’s better Temperature Bulk Solids Cooling high temperature bulk solids is inherently challenging due to large thermal gradients and high stresses. The Guaranteed Thermal Performance high temperature cooler from Solex is a fit-for-purpose Solex’s proprietary thermal modeling technology engineered specifically for cooling high temperature s of t ware, T her maPro, acc ur ately materials up to 2000ºC. models p ro d u c t temperatures of the material at each point through the heat exchanger. The result is guaranteed thermal performance. Uses up to 90% Advanced Engineering Less Energy Extensive modeling, including finite element analysis (FEA) is The Solex bulk solids cooling carried out to ensure successful operation under extreme conditions. technology is ultra-efficient, using up to 90% less energy than other technologies. Plate Profile Engineered for High Temperature Cooling Specially designed plates for high temperature service are engineered to minimize thermal s tres ses. L o w s t r e s s Recovers High levels are achieved with multiple banks to reduce the Grade Heat temperature gradient over each bank. Precise design ensures The indirect cooling design uniform water distribution which eliminates stagnate zones. enables efficient recovery of heat from high temperature bulk solids during the cooling process. The heat is most easily recovered as pressurized hot water that can be flashed to steam. 6 Learn more at www.solexthermal.com
  • 7. Energy Recovery Technology(Cooling Product from 2000ºC) energy recovery Recovering High Grade Heat from High Temperature Solids Solex Technology can recover the heat during the cooling process in the form of pressurized hot water, which can be flashed to steam and made available as an energy source elsewhere in your facility. Recovering High Grade Heat While Cooling High Temperature Conceptual energy recovery loop for Solids cooling high temperature solids, such as ash, petroleum coke or graphite. Scan this QR code to view a video about Solex high 7 temperature technology. Learn more at www.solexthermal.com
  • 8. Bulk Solids Heating Technology (Using Steam, Hot Water, or Thermal Oil)how it works Slow & Controlled Product Flow Bulk solids pass slowly downward between a series of vertical hollow heat exchanger plates. Indirect Plate Heating Heat transfer media such as steam, hot water or thermal oil flows through the plates to heat the material by conduction. Mass Flow Technology Specifications Capacity: 100 kg/hr to 150,000 kg/hr The mass flow discharge feeder creates uniform Heating Medium: Hot Water, Steam, product velocity through the heater and regulates Thermal Oil the product flow rate. Product Temperatures: up to 300ºCwhy it’s better Uses up to 90% ZERO Emissions, Dust, Less Energy Fines & Odor The Solex bulk solids heating The indirect plate heating design means air technology is ultra-efficient, using up to is not in contact with the product during the 90% less energy than other technologies. heating process. Emissions, dust, fines and odors are eliminated. Uniform Final Produces a Superior Final Product Product Temperatures The slow movement of the The mass flow design means produc t through the heat the product moves slowly and exchanger prevents product with uniform velocity through abrasion and degradation so the heater. This enables even that there is no change in te m p e r a t u re d i s t r i b u t i o n particle characteristics or producing stable and uniform crystal shape. final product temperatures. Compact and Reduced Installation Costs Modular Design Since air is not used in the heating process, The compact installation footprint makes this installed capital costs are reduced due to the design easy to integrate into existing plants, elimination of costly and unnecessary air and is ideal for debottlenecking or revamps. handling equipment. The modular design means additional heat exchanger plate banks can be stacked if increased capacity is required in the future. 8 Learn more at www.solexthermal.com
  • 9. Use Recovered Energy to Heat Bulk Solids energy recovery Indirect Plate Heating Technology Makes Energy Recovery Easy The unique design of the Solex heat exchanger plates makes it possible for the plates to heat the bulk solids by conduction using a variety of recovered heat mediums, such as hot water, steam, thermal oil, or even air. Heating Bulk Solids with Recovered Exhaust Gases Typical energy recovery loop in a glass plant 9 Learn more at www.solexthermal.com
  • 10. Bulk Solids Drying Technologyhow it works Slow & Controlled Product Flow Bulk solids pass slowly downward between a series of vertical hollow heat exchanger plates. Indirect Heating Cross-Flow Air Hot water, steam (or waste heat) flow through the plates to heat the material and evaporate moisture from the product. Cross–Flow Air Removes Product Moisture A small amount of cross-flow air is used to remove moisture from the product. Precise Temperature and Moisture Control Solex dryer/conditioner technology enables both moisture content and the temperature of the final product to be independently and precisely controlled. The combination of the two media - indirect heat and cross-flow air - enables accurate control over the desired outcomes. The indirect method of heating regulates the final product temperature; at the same time, the amount of cross-flow air used regulates the final product moisture content. Ultra-Efficient Technology with 90%+ Efficiencies The indirect method of heating the product serves to heat the product and maintain the temperature of the cross-flow air. Since the temperature of the cross-flow air does not drop, the air maintains its moisture carrying capacity and is capable of carrying larger quantities of moisture. As a result, only a very small amount of cross-flow air is needed to remove moisture from the product. The result is efficiencies of greater than 90%. 10 Learn more at www.solexthermal.com
  • 11. Ultra-Efficient Drying TechnologySolex Technology vs. Conventional Dryers WHY IT’S BETTERThe Problem with Conventional DryersConventional drying technologies utilize hot air to heat the product and remove moisture from the product.In this process the following takes place: Air at ambient temperature Is heated Reaches its saturation point after absorbing moisture from the productThe Solex Drying/Conditioning Process Increases the moisture carrying capacity of the air by using indirect heating technology to keep the temperature of the drying air constant. As a result, only a very small amount of cross-flow air is needed to remove moisture from the product. The efficiency of this technology is greater than 90%. 11 Learn more at www.solexthermal.com
  • 12. Drying Bulk Solids with Recovered Energyenergy recovery Solex Dryer Technology Operates on 100% Recovered Energy. Due to the indirect method of heating, the Solex dryer can utilize waste heat from elsewhere in your facility to indirectly heat the product during the drying process. Drying bulk solids using a combination of recovered heat and steam Use a combination of recovered energy and steam to heat and dry bulk solids 12 Learn more at www.solexthermal.com
  • 13. Conditioning or Heating Oilseeds with Recovered Energy WHY IT’S BETTERReduce Steam Consumption with the Solex Heat ExchangerThe indirect method of heating utilizing plates can operate with low grade waste heat to assist in theheating of oilseeds. The more recovered energy you have available, the greater the savings. STEAM RecoveredSTEAM Energy Recovered STEAM Energy Recovered STEAM Energy STEAM STEAM RecoveredSTEAM Energy RecoveredSTEAM Energy STEAM STEAM STEAM RecoveredSTEAM Energy Scan this QR code to view a video about energy 13 recovery possibilities. Learn more at www.solexthermal.com
  • 14. Technology Possibilities with Indirect Air/Gas Coolinghow it works Slow & Controlled Product Flow Bulk solids pass slowly downward between a series of heat exchange elements. Indirect Heat Exchange Air (or gases), acting as the heat transfer medium, cools or heats the material indirectly by conduction. Mass Flow Technology A mass flow discharge feeder creates uniform Specifications Capacity: 100 kg/hr to 100,000 kg/hr product velocity and regulates the product flow. Heat Transfer Medium: Air/Gases Product Temperatures: up to 2000ºC Pressures: Atmospheric to High Pressure Air/Gasesenergy recovery Recovering Energy with Indirect Air Cooling Technology 14 Learn more at www.solexthermal.com
  • 15. Solids-to-Air Heat Exchange energy recovery The Advantages of Indirect Heat Exchange Indirect air/gas heat exchange provides many advantages. The air used for heat exchange never comes into direct contact with the product, which preserves the integrity of the product and eliminates the need to treat the exiting air. It also makes energy recovery while cooling or heating a viable option. Heating Bulk Solids with Recovered Exhaust Gases 15 Learn more at www.solexthermal.com
  • 16. ApplicationsSolex heat exchange technology is engineered specifically for cooling,heating and drying a variety of free flowing bulk solids such as sugar,fertilizer, chemicals, plastics, minerals, oilseeds, and many other typesof granules, crystals and powders. Following are some of the mostcommon applications.17 Chemicals18 Fertilizers20 Sugar22 Polymers24 Dried Biosolids25 Minerals and Sands26 Oilseeds and Grainspage
  • 17. applicationsCOOLING & HEATING CHEMICALSIndirect Cooling & HeatingTechnology Ideal forChemicalsThe Solex heat exchanger is capable of cooling and heatinga wide range of chemicals and powders, including hightemperature products up to 2000ºC. Cools Chemicals Using up to 90% Less Energy Uses up to 90% less energy than Zero Product Degradation technologies requiring the use The slow and controlled movement of the chemical particles of air. through the cooler prevents product abrasion and degradation ensuring that the characteristics of the product are not changed in the cooling process. Compact Design The vertical configuration gives this heat exchanger a small installation footprint, making it ideal for debottlenecking, revampsZero Emissions or capacity increases.Emissions, dust, fines and odors areeliminated because air is not used todirectly heat or cool the product. Reduced Installation Costs The indirect heat exchange design eliminates the need for costly and unnecessary air handling equipment, significantly reducing installed capital costs.Stable Final Product TemperaturesThe mass flow design means that the chemicals move withuniform velocity through the heat exchanger. This feature, U se scombined with long residence times, enables even temperature less up to 90 e % Find nergy.distribution producing remarkably stable and uniform finalproduct temperatures. on p out mo age r 35. e Scan this QR code to view a video about Solex technology 17 for chemicals. Learn more at www.solexthermal.com
  • 18. applications COOLING & HEATING FERTILIZER Clear Advantages for the Fertilizer Industry The Solex heat exchange technology is widely used in the fertilizer industry due to the many advantages it offers. Cools Fertilizer Using up to 90% Less Zero Product Contamination Typical Electrical Energy Since air is not used to directly cool the product, air is not in Requirements kW.h/tonne contact with the product eliminating the risk of product 6 5.3 moisture content changes or product contamination. 5 4 Zero Emissions kW.h/tonne 3 Emissions, dust, fines and odors are eliminated because air is 2 not used to directly heat or cool the product. (Purge air may be 1 required.) 0.3 0 Fluid Bed Cooler Solex Heat Exchanger *Source: Jacobs Engineering Study 1995 Typical energy requirements for a 50 TPH DAP train Stable Final Product Temperatures The mass flow design means that the fertilizer moves with uniform velocity through the heat exchanger. This feature, combined with long residence times, produces even temperature distribution and remarkably stable and uniform final product temperatures. Compact Design The vertical configuration gives this heat exchanger a small installation footprint, Guaranteed Product Storage Temperatures making it ideal for debot tlenecking, Due to the indirect water-cooled technology, fertilizer can be revamps or capacity increases. efficiently cooled to within approximately 10ºC of cooling water temperatures, which enables lower produc t storage temperatures. Scan this QR code to view a video about18 Solex technology Learn more at www.solexthermal.com for fertilizers.
  • 19. applications COOLING & HEATING FERTILIZER Efficiently Cool Fertilizer Without Caking The problem Fertilizers are hygroscopic, containing a low percentage of water. As they cool, this water will transfer to the air in the void space which can lead to condensation and caking.The Solex SolutionSolex has developed advanced modeling based on the critical relative humidity and the drying characteristic of each type and gradeof fertilizer. Caking is prevented by ensuring that the water temperature is above the dew point of the air in the void space betweenthe prills or granules. In the Solex Fertilizer Cooler, the water temperatures and purge air requirements are carefully selected toprovide optimum cooling performance without the risk of caking.The ResultThe Solex heat exchanger cools fertilizers reliably without condensation or product caking. HOT PRODUCT IN VENT Water temperature must be to the right of the COOLING WATER OUT dew point line to avoid condensation. Product Temperature Dew Point COOLING WATER IN Water Temperature PURGE AIR GATE FEEDER ACTUATOR POSITIONER COLD PRODUCT OUT 20 40 60 80 100 Temperature (ºC) 19 Learn more at www.solexthermal.com
  • 20. applications COOLING SUGAR What Makes Solex Technology Ideal for Cooling Sugar? The ultra-efficient Solex heat exchanger technology is widely used in the sugar industry due to the many advantages it offers sugar producers. Cools Sugar Using up to 90% Less Energy Uses up to 90% less energy than Zero Product Contamination technologies such as fluid beds or Since air is not used to directly cool the sugar, air is not in rotary drums that require the use contact with the product, eliminating the risk of bacterial of air. contamination, odor contamination, and moisture content changes in the sugar. Compact Design Zero Product Degradation The compact installation footprint makes this design easy to integrate into existing sugar plants and can conveniently be installed The slow and controlled movement of the sugar crystals through in conjunction with drum dryers. the cooler prevents product abrasion and degradation ensuring that the characteristics of the sugar crystals are not changed in the cooling process. Easy to Add Future Capacity The clever modular design means that additional plate banks can Guaranteed Storing and Packing Temperatures be stacked if cooling capacity needs to be increased in the future. With Solex technology, cooling water temperatures can be controlled and sugar can be cooled to a specific temperature, U se enabling constant storing or packing temperatures year round, s less up to 90 independent of ambient or weather conditions. e % Find nergy. on p out mo age r 35. e Scan this QR code to view a video about20 Solex technology for sugar. Learn more at www.solexthermal.com
  • 21. applications COOLING SUGAR Solex Technology Ideal for Debottlenecking and Capacity Increases. The Solex sugar cooler can cool large volumes of sugar with a small installation footprint, making it an ideal solution for capacity increases.Designed to Cool Large Volumes of SugarThe Solex sugar cooler solves capacity increase challenges. Existing drum coolers can be easily converted to a second stage drum dryerallowing the compact Solex sugar cooler to be installed downstream as the primary sugar cooler. 40,000 kg/hr Sugar Processing Capacity 60,000 kg/hr Sugar Processing Capacity 21 Learn more at www.solexthermal.com
  • 22. applications COOLING & HEATING POLYMERS Technology Advantages for Cooling and Heating Polymers The Solex indirect cooling and heating technology is ideal for polymer applications due to the many operational advantages it offers. Zero Emissions Air emissions, such as VOC, NOX, dust, fines and odors are eliminated Ideal for Degassing and Conditioning because air is not used to directly The Solex indirect heat exchanger design is a sealed unit, heat or cool the product. designed to operate with blanket gas or a purge gas stream, such as in degassing and conditioning applications. Zero Product Degradation Compact Design The slow and controlled movement of the polymers through The vertical configuration gives this heat exchanger a small the heat exchanger prevents product abrasion and degradation installation footprint, making it ideal for debottlenecking, ensuring that the characteristics of the polymer pellets are not revamps or capacity increases. changed in the process. Stable Final Product Temperatures Superior Design for The mass flow design means that the polymers move with Ongoing Maintenance uniform velocity through the heat exchanger. This feature, The heat exchanger plates are combined with long residence times, enables even temperature configured to enable simple and distribution producing remarkably stable and uniform final complete access for inspection product temperatures. and cleaning. The design makes it possible for individual plates to be isolated or replaced. U se s less up to 90 e % Find nergy. on p out mo age r Scan this QR code to 35. e view a video about22 Solex technology for polymers. Learn more at www.solexthermal.com
  • 23. applications ENERGY RECOVERING OPTIONS - HEATING POLYMERS Indirect Plate Heating Technology Makes Energy Recovery Easy Solex technology makes it easy to capture and use waste heat for preheating polymers. The unique design of the Solex heat exchanger plates makes it possible to heat the bulk solids by conduction using recovered heat from other sources, such as the plastics extruder.Preheating Resin withRecovered Heat 23 Learn more at www.solexthermal.com
  • 24. applications COOLING DRIED BIOSOLIDS Cooling Dried Biosolids The unique indirect plate cooling design of the Solex heat exchanger does not use air in the cooling process which helps solve many of the challenges when cooling products like dried biosolids. Zero Emissions When cooling dried biosolids using the Solex heat exchanger, emissions, dust, fines and odors are eliminated because air is not used to directly Reduced Installation Costs cool the product. There is no need Installed capital costs are reduced due to the elimination of costly for additional dust removal or odor and unnecessary air handling equipment such as large diameter control systems. air ducting, motors, fans, scrubbers, chillers, etc. Prevents Product Degradation Maintenance The slow and controlled movement of the dried biosolids through Friendly Design the heat exchanger prevents product abrasion and degradation The cooling plates in the Solex during the cooling process. heat exchanger are configured to enable easy access for inspection and cleaning. The design includes large access doors that provide easy entry and make it possible for single plates to be accessed, repaired or replaced.24 Learn more at www.solexthermal.com
  • 25. applicationsCOOLING & HEATING MINERALS AND SANDSCools and Heats Minerals andSands, Whether Highly Abrasive orExtra HotThe ultra-efficient Solex heat exchanger is a unique designcapable of cooling and heating a wide range of minerals and sands,including abrasive or high temperature products (up to 2000ºC). Cools Minerals and Sands Using up to 90% Less Zero Product Loss Energy Since air is not used to directly cool the product, the possibility Uses up to 90% less energy than of product loss and carry-over in the discharge air is eliminated. technologies requiring the use of air. Zero Emissions Emissions, dust, fines and odors are eliminated because air is not used to directly heat or cool the product.Suitable for High Temperature ProductsUnique design is capable of handling difficult high temperatureproducts of up to 2000ºC. Compact Design The vertical configuration gives this heatSuitable for Highly Abrasive Materials exchanger a small installation footprint,The mass flow design results in low product velocities and low bin-wall making it ideal for debottlenecking, revampspressures on the heat exchanger plates. This combination results or capacity increases.in extremely low abrasion of the heat exchanger plates and casing. Scan this QR code to view a video about Solex technology for 25 sands and minerals. Learn more at www.solexthermal.com
  • 26. applications DRYING & CONDITIONING OILSEEDS & GRAINS The Ideal Dryer/Pre-Heater for Grains and Oilseeds The Solex Dryer/Conditioner offers significant advantages for oilseed and grain applications. Pre-Heating Grains and Oilseeds The Solex pre-heater can operate on 100% recovered energy. The indirect method of heating with plates makes it possible to use waste heat as the source to indirectly heat the oilseeds or grains. Drying Grains and Oilseeds The Solex dryer technology operates with efficiencies of greater than 90%, and can also utilize waste heat as the heat source for drying, making it one of the most efficient drying technologies available on the market. Use Waste Heat for Added Efficiency Waste heat can be used as a heat source to indirectly heat the product, further enhancing the efficiency of this drying technology. Scan this QR code to view a video about26 Solex technology for oilseeds. Learn more at www.solexthermal.com
  • 27. applicationsDRYING & CONDITIONING OILSEEDS & GRAINSHot water or steam moves through the platebank to heat the material while a small amountof cross-flow air removes moisture from theproduct. Cross-Flow Air Typical Canola Conditioning Process 27 Learn more at www.solexthermal.com
  • 28. Design Advantages The off-set plate bank design achieves improved efficiency and uniform final product temperatures. LEVEL SENSOR Temperature Profile Between Plates 1 Product Entering First Plate Bank 100 90 1 80 70 2 2 Temperature (ºC) 60 Product Exiting 3 First Plate Bank 50 4 40 30 20 3 10 Product Exiting 0 Second Plate Bank 0% 25% 50% 75% 100% Position Between Plates 1 Product Inlet Temperature 2 Product Temperature Exiting First Plate Bank Temperature Equalization MASS 3 Product Temperature Exiting Second Plate Bank in Discharge Cone FLOW CONE 4 Product Discharge Temperature 4 Product Discharge28 Learn more at www.solexthermal.com
  • 29. Design AdvantagesThe Solex heat exchanger uses weldedheat transfer plates installed in areinforced, fabricated casing with Exchangerexternal fluid manifolds. This simple Platesbut advanced design offers manybenefits for reliable operation andeasy maintenance. Access Door Exchanger Plates » Plate technology provides high efficiency heat transfer surface. » Individual plates can easily be isolated or replaced. » Plate connections are at the top and bottom of the Full Height Access Door plates for true counter flow operation and the » Design allows full access for inspection ability to drain the plates. cleaning or plate removal. » Plates are fully welded and finished to meet ASME » Can be hinged or bolted depending on pressure vessel codes. the application. » Additional doors can be fitted on the manifold side. Materials of Construction » 304L/316L stainless steelFlexible Hose Connections between » Carbon steelPlate and Manifold » High grade alloys and duplex stainless steels» Flexible stainless steel hoses allow for thermal expansion.» Individual threaded connections allow for plate removal.» All connections are outside of the product stream. 29 Learn more at www.solexthermal.com
  • 30. Design Advantages The Solex indirect heat exchanger technology offers significant design advantages over traditional methods of heating and cooling bulk solids. Technology Comparison Solex Technology Fluid Bed Technology Rotary Drum Technology Energy Consumption Low High High Installed Capital Cost Low High High Maintenance Low Medium High Product Degradation None High High Modular Construction Yes No No (ease of expansion) Compact Design Yes No No (small installation footprint) Cooling Air Required No Yes Yes Air Emissions None Yes Yes Scan this QR code to30 view a video about Solex technology. Learn more at www.solexthermal.com
  • 31. Discharge OptionsThe right discharge feeder is a criticalcomponent in the successful operationof your bulk solids heat exchanger.Solex conducts a feeder assessmentand selects the best feeder for yourapplication. Solex ensures uniform product velocity over the heat exchange surface. Vibrating Feeder Gate Feeder The most universal feeder for a wide Best for high capacities. range of products. » Suitable for high duty applications » The flow rate is controlled by varying » Plane flow hopper incorporating frequency hinged gate to regulate flow » Low headroom requirement » High product capacity » No product degradation » Low headroom requirement » Good turndown capability » No product degradation Mass Flow Cone with Plane Flow Hopper to Mass Rotary Valve Flow Screw Feeder » Suitable for a wide range of applications » For special applications and products » The mass flow cone creates uniform » Variable pitch screw feeder creates product velocity. uniform product velocity mass flow. » Flow rate is controlled by a VFD on the » Flow rate is controlled by VFD rotary valve drive on motor » Provides air seal when feeding to » Collects products over large cross pneumatic conveying systems section and discharges at a single point » Typically lowest cost option » Low headroom requirement » Shear in valve may lead to product » Good turn-down capacity degradation or high abrasion rates » Requires more headroom for installation 31 Learn more at www.solexthermal.com
  • 32. Lab Testing The Solex lab testing facility provides its clients with extensive analysis of bulk solids materials to help evaluate physical and thermal properties of the bulk material, as well as determine material flow characteristics. Lab Testing Consists of the Following Procedures: 1 Material Property Analysis 3 Mass Flow Material characteristics of the product sample are tested to Mass flow testing (shear cell testing) is carried out to determine determine particle size distribution, bulk density, moisture material flow characteristics to ensure that mass flow (uniform content and angle of repose. velocity) is obtained in the equipment. 2 Flowability Testing 4 Thermal Property Analysis Flowability testing determines the optimum heat exchanger Thermal Conductivity testing is performed to provide the plate spacing. measure of how well a material conducts heat. Solex measures this in its lab using an advanced hot wire method.32 Learn more at www.solexthermal.com
  • 33. Pilot TestingSolex performs advanced theoretical modeling to predict the thermalperformance of the proposed equipment, and validates this modelingwith pilot testing under true process conditions. The result is guaranteedthermal performance.Theoretical ModelingThermaPro, the proprietary thermalmodeling sof t ware developed bySolex, enables precise theoreticalmodeling. ThermaPro accuratelypredicts product temperature profilesof the bulk solids materials at each pointthrough the heat exchanger providing100% accurate predictions of finalproduct temperatures. Pilot Testing Pilot testing is performed with test units that closely duplicate full size equipment. The on-site testing can help analyze and validate the following: » Equipment thermal performance. » Product flowability under true process conditions. » Heat exchanger performance over an extended time period. » Successful operation through typical plant cycles including possible upsets. » Successful operation with a specific product mix. 33 Learn more at www.solexthermal.com
  • 34. What Makes Solex Technology So Efficient? Traditional Cooling Technology Requires High Energy Consumption The most common method of cooling bulk solids is direct air-cooling – like fluid bed coolers or drum coolers. With this method, large horsepower fans take in and blow ambient air across the product. The air is then discharged through an air cleaning system to an exhaust stack. The inherent problem with using air to direc tly cool bulk solids is the signif icant quantit y of air required and the ex pense involved in chilling, proces sing and cleaning that air. Solex Cooling Technology Requires Minimal Energy The Solex technology cools bulk solids indirectly using water. With this technology, cooling water is pumped through a vertical bank of hollow stainless steel plates while the bulk solid passes between the plates at a rate sufficient to achieve the required cooling. No air is required in the cooling process and the energy requirements are minimized. The total energy consumption of the Solex heat exchanger can be 90% less than air-cooling methods.34 Learn more at www.solexthermal.com
  • 35. Energy Savings ExampleCompare the energy consumption of the Solex indirect cooling technology to a typical fluid bedcooler.Example: 50 tph FacilityEnergy Consumption: The energy consumption of the Solex cooler is 0.3 kWh/tonne vs 7 kWh/tonne for a typical fluid bed cooler.Energy Savings: The total electrical energy savings over five years is approximately USD $750,000.More Details: For more details on the energy saving feature of the Solex technology, visit www.solexthermal.com. 35 Learn more at www.solexthermal.com
  • 36. About Solex History Solex Thermal Science Inc. is a privately held company specializing in the science of heating, cooling and drying bulk solids. Founded under the name Bulkflow Technologies in 1999, Solex Thermal Science has installed over 400 heat exchangers in more than 43 countries world-wide. Experience Solex engineers of fer world-leading heat exchange exper tise. Even NASA has consulted with Solex on advanced heat exchange challenges. The heat–exchange specialists at Solex have the knowledge and experience to assist you in the implementation of advanced heat exchange solutions. World-Wide Technical Services Equipment Commissioning » A qualified Solex technical services representative is on-site with your team to ensure the Solex heat exchanger is installed and commissioned according to specifications. Training » On-site user training covers all aspects of equipment operation and maintenance. » Detailed maintenance procedures facilitate long and reliable equipment operation. Equipment Optimization » The Solex customer support team can verify and validate equipment and process performance in the field. » Solex helps clients identify and document opportunities for improvement in operational processes. Spare Parts » Solex provides both spare and replacement parts. Complete company and product details available at www.solexthermal.com36 Learn more at www.solexthermal.com
  • 37. World-Wide Customer SupportCORPORATE HEADQUARTERS Canada 100, 3595 114 Ave SE Calgary, Alberta, Canada T2Z 3X2 403-254-3500 info@solexthermal.com SALES & TECHNICAL SERVICES Asia Europe & Middle East +49 4109 25 04 85 +49 4109 25 04 85 info@solexthermal.com info@solexthermal.com Africa North America +49 4109 25 04 85 403-254-3500 info@solexthermal.com info@solexthermal.com Australia South America (Except Brazil) +49 4109 25 04 85 412-564-9003 info@solexthermal.com info@solexthermal.com Russia & FSU Brazil +7 495 350 4792 +55-11-4148-6700 ext 119 info@solexthermal.com info@solexthermal.com India +044 2445 2011/ 0611 info@solexthermal.com 37 Learn more at www.solexthermal.com
  • 38. Installation Photos38 Learn more at www.solexthermal.com
  • 39. Installation Photos Worldwide Customer Support 39 Learn more at www.solexthermal.com
  • 40. www.solexthermal.com