Fire-rated heating chambers for special chemicals
One of the world's leading developers and manufacturers of special chemicals produces high-quality raw materials, auxiliary materials, additives and active substances which are used in almost all industrial sectors and consumer goods. For a particular treatment process, water-polluting and flammable chemical substances are heated in a heat chamber for further processing and fed into the production process with an increased viscosity. The process plant no longer met the current requirements and had to be replaced.
CHALLENGE AND TASK
WATER AND FIRE PROTECTION FOR THE HEAT CHAMBER
The heat chamber was to be used for the chemical production process in a fixed location, over a longer period of time (>6 months). Due to the flammability of the substances to be treated, increased fire protection requirements was needed.
HIGH-TECH FOR CONTINUOUS OPERATION
For the specific application, the heat chamber needed to offer space for eight IBCs or chemical pallets and be able to be loaded several times a day by forklift via two independently operable roller doors. Precisely adjustable holding temperatures in the range 40° C to 60° C were required, as well as digital interfaces for transmitting the process data to a control room. In addition, numerous environmental protection, safety, energy-saving and comfort features were required. DENIOS engineers specialising in thermotechnology, hazardous materials safety and fire protection, developed and built a custom-fit, turnkey solution.
THE SOLUTION
FIRE AND FLAME FOR FIRE PROTECTION
The DENIOS heat chamber for the hazardous substance treatment process meets the highest industry standards. The required fire protection is ensured by fire-rated walls on five sides, with REI 120 classification. They are designed to protect the interior of the chamber against fire in the production hall for 120 minutes. The floor-to ceiling design prevents potential fire flashover. The two roller shutter doors have a non-combustible insulating core. A fire-rated enclosure protects the externally-mounted air recirculation motor from any possible flames.
ROBUST, WELL THOUGHT-OUT AND SAFE
With grid shelves on two individually height-adjustable levels, the DENIOS heat chamber offers space for eight pallets. For static separation of loads, the shelves are positioned in the chamber but are not force-fitted to the supporting structure of the system. Shelf guards at each level ensure that the rear wall of the heat chamber cannot be damaged by setting pallets too far back. In the event of a leak, two removable spill pallets in 5 mm stainless steel with a volume of 2 x 1000 l each ensure environmental and hazard protection.
ADDITIONAL EQUIPMENT FOR SAFETY AND CONVENIENCE
DENIOS manufactured two robust, electrically-driven roller doors for efficient positioning and removal of the chemical containers. They can be opened and closed independently of each other by radio transmitter - for example, directly from the forklift. The electronic closing-edge safety device and the LED exterior lighting in front of the heat chamber reliably ensure that work can be carried out safely. This is activated automatically when the door is opened. For work safety and to save energy, the air recirculation fan switches off automatically as soon as a door is opened. The doors are painted inside and out in one colour with a 2-component PUR paint in RAL5010 (gentian blue).
CUSTOMISED CUTTING-EDGE ELECTRONICS
All the electrical equipment in the system meets the customer's specifications. DENIOS also integrated a premium control system in the switch cabinet on the outside of the heat chamber. This is designed according to IP54 - protected against water spray from all directions. Shunting terminals enable the transmission of process data to the control room of the production plant. In addition, all motors were protected against overheating by thermistors and designed according to IE3 and UCM. The customer received all wiring diagrams from DENIOS as digital files and in paper form.
RESULT AND CUSTOMER BENEFIT
IMPROVED ECONOMY, FUTURE-ORIENTED PRODUCTION
The new DENIOS heat chamber went into operation on time and has since been loaded and unloaded at least once per 8-hour shift. The integrated leak and fire protection, the robust, durable construction and the well thought-out functionality of the system offer the customer a high degree of safety and efficiency.
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