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Baker Furnace Blog-Cleaning the Air You Breathe Part 2

The Use of Thermal Oxidizers for Air Pollution Abatement

As a continuation of our blog last month we would like to discuss the use of Thermal Oxidizers for air pollution abatement in this month’s blog. Although most people have never heard of them, thermal oxidizers help clean harmful pollutants from the air we breathe.

Factories, refineries and power plants can emit a wide variety of air pollutants, and these emissions can contain carbon monoxide, sulfur dioxide, nitrogen dioxide, and even lead and ground level ozone. Tiny particles, known as particulate matter, can combine with these pollutants in the air to form hazardous air pollutants and volatile organic compounds.

To protect the earth and the air we breathe, governments now regulate industrial emissions. To meet the regulations many chemical plants use thermal oxidizers to remove pollutants before they enter the atmosphere. Recuperative thermal oxidizers help manufacturers clean the air you breathe in a more efficient and cost-effective way.

How Thermal Oxidizers Clean the Air

Basic thermal oxidizers contain a blower system, inlet tube, combustion chamber and several smaller components. They work by heating the air to very high temperatures, which destroys the polluting compounds. Blowers direct process air into the combustion chamber where natural gas, heated to high temperatures, break hazardous compounds into their smaller, harmless components. Clean air then enters the atmosphere. Unfortunately, much of the natural gas heat used to destroy the pollutants is lost into the atmosphere as well, at significant financial cost to the manufacturer.

Recuperative thermal oxidizers are the next generation of thermal oxidizers in that they can recover some of the heat lost in the operation of basic thermal oxidizers. Instead of moving directly into the atmosphere after treatment, the hot air passes through the heat exchanger a second time to preheat the incoming process air stream. This additional step can provide tremendous costs savings because recovering the heat helps minimize the use of natural gas in the heating process.

Baker Furnace has been an industry leader in custom industrial pollution control system engineering and manufacturing for more than 25 years. Our skilled team specializes in making recuperative thermal oxidizers and other pollution abatement systems for industrial air pollution control. Baker Furnace thermal oxidizer systems destroy 99.9 percent of volatile organic compounds from air. Follow us on social media for up-to-the-minute news on recuperative thermal oxidizers, industrial furnaces and more.

Baker Furnace Blog-Cleaning the Air You Breathe Part 1

 

Take a deep breath. If you filled your lungs with clean, fresh air, you may have thermal oxidizers to thank. Thermal oxidizers help you breathe easier, reduce disease, and even live longer by cleaning pollutants from the air.

Air pollution is one of the most serious problems in the world. The air you breathe may contain dangerous particulates and biological molecules that can cause allergies, disease, and even death to humans, plants, and animals. Diseases relating to air pollution were responsible for 1 in 13 deaths – six times higher than deaths associated with malaria.

Short- and long-term exposure to air pollution is associated with a number of health problems, according to the Environmental Protection Agency (EPA), including increased respiratory symptoms and hospitalization for heart or lung diseases. Some toxic or hazardous pollutants in the air may cause cancer or other health problems, such as reproductive issues or birth defects. Exposure to air pollution can even lead to premature death.

Sources of Air Pollution

Air pollution can come from natural and manmade sources. Dust from the ground, smoke from wildfires, methane emitted by farm animals, and even volcanic activity are natural causes of air pollution. Motor vehicles, aircraft and marine vessels are manmade sources of air pollution, as are fumes from hairsprays and aerosols.

Industry has the potential to create a significant amount of air pollution. Combustion from stationary sources, such as factories, refineries and power plants, pumps a wide variety of dangerous pollutants into the air. Examples of hazardous air pollutants and sources include the benzene in gasoline, methylene chloride used as a paint stripper and solvent, and perchloroethylene emitted from some types of dry cleaning facilities.

Organic compounds contain carbon; volatile organic compounds are organic compounds that easily become gas. Volatile organic compounds may contain hydrogen, oxygen, chlorine, fluorine, sulfur bromine, or nitrogen. Volatile organic compounds combine with nitrogen oxides to form ground-level ozone, or smog. Burning fuel, such as gasoline, coal, wood, or natural gas can emit volatile organic compounds, as do oil and gas fields, diesel exhaust, solvents, paints, glues, and other products.

The Use of Catalytic Thermal Oxidizers for Air Pollution Abatement (Cleaning the Air you Breathe)

Thermal oxidizers destroy hazardous air pollutants (HAPs) and volatile organic compounds (VOCs) from industrial airstreams. A thermal oxidizer breaks down pollutants by exposing hazardous gases to high temperatures, and then releases the treated gases into the air.

There are two main types of thermal oxidizers: catalytic and direct-fired. A catalytic oxidizer is a piece of equipment that features a blower system, inlet tube, head exchanger, combustion chamber, oxidation catalyst bed and several smaller components. Blowers direct air through the heat exchanger into the combustion chamber where the process stream is heated further using a burner or electric heat.  As the heated process stream passes through the catalyst bed, converting hazardous compounds into their smaller, less harmful components. Clean air, CO2, water vapor, and heat then enter the atmosphere. Direct-fired thermal oxidizers use a blower system to introduce the process stream directly in contact with the burner flame.  Recuperative direct-fired oxidizers reclaim some of the heat before it is lost to the atmosphere.

Thermal oxidizers can destroy more than 99 percent of VOCs in air to reduce unhealthy substances in the air you breathe every day. Three main factors influence the effectiveness of thermal oxidation: temperature, residence time and turbulence. Most organic compounds ignite at temperatures between 590 °C (1,094 °F) and 650 °C (1,202 °F) so many thermal oxidizers operate at much higher temperatures. Residence time is the amount of time gases remain in the oxidation chamber. Turbulence is the mixture of combustion air with the hazardous gases.

Baker Furnace has been an industry leader in custom industrial pollution control system engineering and manufacturing for more than 25 years. Our skilled team specializes in a variety of pollution abatement systems, including thermal oxidizers, for industrial air pollution control. Baker Furnace thermal oxidizer systems destroy 99.9 percent of volatile organic compounds from air. Follow us on social media for up-to-the-minute news on industrial furnaces and more.

Expansion Leads to Employment Opportunities in 2018 at Baker Furnace

In the beginning of 2017, Bakers Furnace expanded their operations with a new, larger facility located in Brea, California. Due to this expansion, Baker Furnace is now hiring a variety of positions in skilled trades and engineering. Baker Furnace Inc. has been designing and manufacturing industrial ovens, heat treat furnaces, and pollution control equipment since 1980. Baker Furnace is a division of Thermal Product Solutions (TPS), a leader in the design and manufacture of industrial and laboratory ovens and furnaces, and environmental temperature cycling and stability test chambers.

Baker Furnace offers career opportunities with competitive salaries, healthy lifestyle benefits, and retirement options. Employees are also offered onsite training and leadership development. Bakers Furnace employees describe their careers as challenging work with opportunities to advance paired with a family-oriented work place. Bakers Furnace is looking for innovative and motivated people to join the team. If this sounds like you, contact Bakers Furnace to learn more about their competitive wages and benefits package that includes a generous time off plan and 401K with a company match. Check out the current job openings or submit an application at https://www.bakerfurnace.com/career-opportunities. The TPS group is always looking for strong performers for their locations across the nation so even if the job of your dreams is not listed you should still apply!

Current Job Openings:

  • Field Service Technician
  • Electrical Engineer
  • Mechanical Engineer
  • Welder/Fabricator/Mechanical Assembly Technician
  • Production Manager

“Baker Furnace is known for high quality heat processing and pollution control equipment. Their pollution control line of thermal oxidizers and industrial afterburners are used by companies to prevent pollutants from entering the air we breathe. We are excited about the growth of the Baker Furnace location and opportunity the location gives us to better serve our west coast customers. I’d like to invite you to join our team so make sure to visit our website to apply.” David Strand, President/CEO, TPS, LLC

Looking Forward to 2018 at Baker Furnace

2017 was a great year for Baker Furnace – we moved to a new, larger location in Brea, California, and equipped it with a 10-ton overhead crane, welding machines, and plasma cutter. The new location is already helping us fill more orders than ever before. In fact, we think 2018 may end up being one of our best years yet.

Many exciting opportunities are coming our way in the upcoming year, and we look forward to detailing each opportunity in our blogs. We will also discuss a number of topics that are important to you, your business, and the community in which you live.

In our 2018 blog series, for example, we will focus on pollution control. We will begin 2018 with a 2-part series on cleaning the air you breathe. Because it damages crops, animals, forests, bodies of water, and human health, air pollution is one of the most serious problems facing our planet today. We will review some of the causes of industrial air pollution, and talk about ways Baker Furnace is helping industries reduce the emissions that lead to air pollution.

Baker Furnace Talks about Applications in 2018

The pollution control industry uses numerous applications to keep earth’s environment a healthy and clean place in which to live. Each application removes toxins from the earth and air in a slightly different way. We will cover some of these applications in 2018, providing you with essential information on such applications as:

Air Pollution Abatement – cleans harmful particulates from indoor and outdoor air

Soil Remediation – removes petroleum and fuel residues or other hydrocarbons, heavy metals, cyanides, pesticides, creosote, volatiles, and semi-volatiles from soil

VOC Abatement – removes volatile organic compounds (VOCs) industrial chemicals, solvents, alcohols, and gasoline and other petroleum products

Fume Incineration – destroys VOCs, hazardous air pollutants (HAP’s), odors, and other toxins before factory emissions enter the environment

Organic Liquid Incineration – removes toxins from oil refinery waste, liquid ink waste, petrochemical waste, liquid chemical waste, High COD (chemical oxygen demand), dyes waste, Low CV (Calorific Value), and many more.

Hydrocarbon Destruction – hydrocarbons are a type of volatile organic compound that come from fuel that does not burn completely in an engine.

For more information about the processes that battle pollution control check back frequently with the Baker Furnace blog. Be sure to follow us on Facebook and Twitter, and to connect with us on LinkedIn for updates about Baker Furnace!

Baker Furnace –2017 Year in Review

The holiday season is a time to reflect back on the events throughout the year that have made an impact on our lives. Our Baker Furnace team would like to take a moment to share some of the events in 2017 that had a lasting impact on both our business and the world around us.

 

Baker Furnace – On the Move in 2017

Baker Furnace moved to a new location in Brea, California earlier this year. The new 40,000 square-foot location gave Baker Furnace the space needed to grow while continuing their commitment to quality, excellence, and craftsmanship in the manufacturing of industrial ovens, pollution control equipment, and furnaces. The new facility features state-of-the-art equipment, including a 10-ton overhead crane, welding machines, and plasma cutter. This equipment ensures accurate, high quality, and timely production of equipment that our customers use for heat treating, drying, curing, finishing, and pollution control.

Record Shipments in 2017

The new location helped us streamline workflow for better efficiency and reach record shipments of custom and standard units in a variety of configurations. Some of these units such as thermal oxidizers and afterburners will be used in the pollution control industry along with waste incineration units used to create waste-to-energy solutions for municipal, commercial and industrial clientele.  Drop bottom furnaces, crucible furnaces, car bottom furnaces, and batch ovens will be used for a variety of applications in the heat treating, foundry, composites, and automotive industries.

Pollution Control Equipment Making the Earth a Cleaner Place

Industrial air pollution is a serious environmental and human health problem. Air pollution is the presence of very small particles, biological molecules, and other harmful gases in Earth’s atmosphere. The Journal of Industrial Pollution Control says that air pollution can cause disease and damage to living organisms. Baker Furnace thermal oxidizers and industrial afterburners remove many of these harmful pollutants before they get into the atmosphere.

Thermal oxidizers serve as air pollution control in chemical plants by decomposing hazardous gases at a high temperature then releasing the decomposed gases into the atmosphere. Industrial afterburners destroy industrial pollutants, such as hazardous air pollutants, volatile organic compounds, and industrial odors and fumes.

Our team here at Baker Furnaces takes great pride in providing equipment that made the world a cleaner place this year and we look forward to continuing this in the years to come.

 

 

A New Location Leads to Record Shipments for Baker Furnace in 2017

Baker Furnace began 2017 poised for growth in a new location with 40,000 sf of manufacturing space.  This past year the facility has seen record shipments of custom and standard units in a variety of configurations. Some of these units such as thermal oxidizers and afterburners will be used in the pollution control industry along with waste incineration units used to create waste-to-energy solutions for municipal, commercial and industrial clientele.  Drop bottom furnaces, crucible furnaces, car bottom furnaces, and batch ovens will be used for a variety of applications in the heat treating, foundry, composites, and automotive industries.

As the west coast division of the Thermal Product Solutions (TPS), the Baker Furnace facility creates opportunities to manufacture and deliver equipment to west coast customers for the other TPS brands at a more competitive price due to reduced freight costs. The TPS family shares engineering and production resources to deliver the highest quality products in the industries they serve.

“The move to a larger location for Baker Furnace allowed them to improve their work flow efficiencies and streamline their production floor. With record shipments in 2017, these improvements were essential to Baker Furnace’s ability to fulfill the orders received throughout the year.”  Dave Strand, President & CEO

About Baker Furnace

Baker Furnace, Inc. has been designing, engineering, and manufacturing industrial ovens, pollution control equipment and other heating equipment since 1980. Their custom and standard equipment are used for a multitude of applications including heat treating, finishing, drying, and curing. Many of the industries they serve require specific temperature uniformity and equipment performance documentation. Their experienced engineering team can meet even the most stringent standards for their customers’ equipment.

Baker Furnace is owned by Thermal Product Solutions (“TPS”), a leading American manufacturer of industrial ovens, furnaces, pharmaceutical sterilizers, laboratory ovens, environmental temperature chambers, and stability test chambers. TPS provides thermal processing and test solutions for a range of industries. Other TPS brands include Blue M, Gruenberg, Tenney, Lindberg, Lunaire, MPH, and Wisconsin Oven.

Soil Remediation is Making the World a Cleaner Place

According to a study conducted by the Environmental Protection Agency, there are currently thousands of sites across the United States that are contaminated by the releases of chemicals, toxins and other disruptive sources. They are often created by some type of industry activity or the improper disposal of waste. These sites don’t just pose a threat to the larger environment – they also detract from human health and well-being, disrupt the local ecosystem and limit the ways in which these areas can be used.

Thankfully, soil remediation has proven to be an effective method for addressing these challenges head on. Sometimes referred to as soil washing, this is a process that is intended to remove things like petroleum and fuel residues, heavy metals, pesticides and other contaminants from affected areas. There are four main types of soil remediation that may be used to remove contaminants from the ground.

Bioremediation

One of the most prominent types of soil remediation is called bioremediation, which involves the treatment of affected soil by biological means. Experts use aerobic and anaerobic bacterium to consume and break down the pollutants in the soil, essentially cleaning up the area through the most natural means possible. Once all of the contaminants in the area have been consumed, the bacterium die off – another one of the distinct advantages of this technique.

Thermal Soil Remediation

Another popular type of soil remediation is called thermal soil remediation. This involves the process of heating the contaminated material to the point where it evaporates, effectively eliminating impurities in both soil and water. If you’ve ever heated tap water in a pan on your stove before cooking with it, you’ve essentially gone through a simplified version of this same concept.

With thermal soil remediation, polluted materials are typically treated at temperatures that range from 650 degrees all the way up to 900 degrees. They are then discharged into a cooling unit and recycled back into the affected area.

Air Sparging

Air sparging is a type of soil remediation where large volumes of air are injected into contaminated soil to “force out” the problem materials in the form of organic vapors, which are then more thoroughly treated via carbon filtering. While this is an effective method, the actual amount of time it will require will vary depending on a number of factors like how concentrated the contaminated area really is, the pH factor of the soil, the permeability of the soil and more.

Encapsulation

Encapsulation is a unique form of soil remediation because unlike the others, it doesn’t actually “filter” contaminants from soil. Instead, it separates them. Mixing polluted soil with materials like lime, cement and concrete, for example, can prevent those contaminants from further spreading to clean soil. This is a great way to take an existing problem and prevent it from getting worse, but it does admittedly impede the process of using that soil for cultivation at any point in the future.

The actual type of soil remediation used will typically vary depending on the specifics of the situation. For some contaminated sites, bioremediation or thermal remediation may be a perfect option. For others, only encapsulation will do. Regardless, these are just a few of the techniques that companies all over the country are using to keep our environments safe and protect our delicate ecosystems.

At Baker Furnace, we design and manufacture a variety of pollution control equipment including thermal soil remediation systems. Our soil remediation systems are proven to treat contaminated soil and remove pollutants. In addition to pollution control equipment, we also manufacture industrial ovens, heat treat furnaces and other heat-treating equipment.

 

View Pollution Control Equipment →

Burn Out/Burn Off Ovens Play an Important Role in Finishing Applications

The finishing industry continually needs to remove paint or powder coatings from metal hardware or equipment used during the process. Powder coating lines use hooks and racks to transfer products through the application and curing process. These items become coated in the paint and periodically need to be cleaned. Burn out/burn off ovens make easy work of removing and stripping paint and powder coatings from the fixtures used for finishing processes.

How Burn Out/Burn Off Ovens Work

These heavy-duty ovens use a form of incineration called pyrolysis to chemically decompose organic materials. This is accomplished by heating the material in an oxygen-controlled environment to a temperature that will destroy the organic material but will not cause flare ups or damage the part.

To reduce the chance of igniting the material, the oven is operated in a slightly negative pressure or vacuum condition. A water suppression system detects if the temperature gets too high. If it does a fine mist of water is injected into the oven which will turn to steam immediately and displace the oxygen and smother any flare ups or fire.

Why Use this Type of Process?

Cleaning metal parts is a difficult and time-consuming process. For example, finishing operators must routinely clean and maintain components of paint lines. Overspray contamination and safety are the main reasons to be concerned with paint buildup on system components.

Manufacturers of electric motors and tools, companies working with plastics and rubber, and custom manufacturing industries also employ burn out/burn off ovens to safely clean parts and components.

Benefits of Using Burn Out/Burn Off Systems

Because these ovens contain a built-in afterburner, any smoke or fumes produced in the cleaning process are contained and treated. No contaminants are released into the environment. They are also energy efficient and require minimal labor. This system enables a quick turnaround time for parts making them very time- and cost-efficient.

View Baker Furnace Industrial Ovens and Furnaces →

 

To learn more, please contact us today. You can also follow us on our blog, Twitter, and LinkedIn to stay up to date on all the Baker Furnace news!

Aluminum’s Role in the Auto Industry

It wasn’t too long ago that steel was the king of the automotive industry, but that is quickly changing. With stricter efficiency standards, aluminum has become the go-to material for numerous parts and components used throughout vehicle manufacturing.

The role of aluminum in the auto industry is expected to grow 7.4% in the next five years. Aluminum is being used in all types of vehicles, from small compact cars to heavy-duty pickup trucks, and in all types of components, from chassis and structural components to mechanical systems.

To ensure the strength and durability needed to meet the requirements of the auto industry, aluminum must first undergo certain heat treating processes. Aluminum aging and solution heat treating are common processes used to prepare the material for use.  Aluminum solution treatment is a two-part process (heat and quench) that takes the alloying elements into solution and retains them by quenching. Aluminum Aging is a second process that hardens the aluminum by applying heat in a time-temperature dependent process. By changing the properties of aluminum, it becomes more resistant to stress, a characteristic that is vital for withstanding modern driving conditions.

Aluminum aging ovens are designed to create the precise conditions that harden aluminum. Drop Bottom Furnaces are used for solution treating aluminum. During the process the load is first heated in the batch oven and then dropped into a quench tank to cool.

Aluminum in the auto industry has consistently grown over the years and will continue in the years to come. At Baker Furnace we manufacture industrial ovens and furnaces for aluminum treatment. Visit our website for more information!

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Baker Furnace Ships Heavy Duty Industrial Oven for Heat Treating Aluminum Parts

Baker Furnace announced the shipment of a gas fired batch oven to an aluminum forging company. The industrial oven will be used to pre-heat large aluminum ingots used to manufacture parts for the Aerospace industry.

The maximum temperature rating of this industrial oven is 1000°F with work chamber dimensions of 14’ W x 11’ L X 6’ H. The batch oven pre-heats large aluminum ingots to 1000°F. The ingots are then removed from the oven and placed in a forging press that forms the aluminum into a shape. The batch oven chamber is designed to withstand the impact of aluminum ingots weighing over 3,000 pounds as a forklift operator drops the aluminum ingots into the oven chamber.

“For this project, we needed to pay special attention to the chamber and floor design to ensure that no damage would occur from the impact of the aluminum ingots being loaded. A 10” thick hard castable refractory floor was one of the design features to make sure the oven could withstand the loading process.” – Tim Bacon, VP Business Development

Unique features of this industrial oven include:

  • 10” thick hard castable refractory floor
  • Vertical lift door with pneumatic locking mechanisms
  • Interior bumper guards to withstand impact
  • UL 508A listed control panel
View Baker Furnace Industrial Ovens →