MHF Services
"Industrial Furnaces and Incinerators
for any application"
MHF Services
"Industrial Furnaces and
Incinerators
for any application"
1-800-253-1454
Having built furnaces for all of the major furnace manufacturers as well as having worked on over 60% of the American furnaces in existence, our experience has kept us aware of the issues and concerns of multiple hearth furnace owners and operators. We have constructed and rehabilitated furnaces in 47 American states (including Alaska), Puerto Rico, Canada, Europe, Asia, Africa, and South America. As a result, we have seen numerous failure mechanisms and have brought long term solutions to these problems.
After working for all of the major Furnace and Incinerator manufacturers, MHF Services was established to streamline the industry by creating standardized parts and patterns. Shortly after its formation, the MHF Services division answered the requests of our customers by producing "drop-in" replacement parts for all MHF's. One specific example of this on Multiple Hearth Furnaces, is the IFCO out-hearth that is constructed from standard shaped firebrick (9" x 4 1/2" x 2 1/2"). The IFCO out-hearth contains tailor made drop holes to efficiently control gas flows as well as maximized refractory zoning for increased hearth life. Because of the flexibility in the drop hole design, the out-hearth can be constructed from virtually any skew-brick ring design. The IFCO out-hearth is just one of the many examples of how our team of MHF specialists improved upon an existing design, part, or pattern. Furthermore, we have created new parts and patterns such as the MHF BURNER, IFCO skew brick, and the IFCO Door/arch system. MHF Services prides itself as being the only MHF Supplier and Installer in the world who is capable of supplying and installing any part needed for virtually all Multiple Hearth Furnaces.
Consulting & Inspection Service
Provide a complete interior and exterior inspection service. The written report discusses current problems, forecasts possible future concerns, and provides long term solutions.
We offer a full range of engineering services related to furnaces and combustion systems. Our core capabilities center around complete mechanical and process engineering for full furnace systems from concept analysis, through laboratory testing, equipment design, field installation, to start up and training. This full system expertise also translates into qualifications in specific areas where existing or potential problems may develop. These would include such areas as emissions controls, combustion systems, rabbling patterns, or materials of construction. Some examples of recent studies are:
Carry-over of Fines to Exhaust from a Carbon Furnace
Rabbling Alterations due to Feed Quality Changes in a Municipal Sludge Incinerator
Refractory Lining Costs versus Energy Efficiency in an Industrial Furnace
Combustion System Modernization for an Oil Refinery Furnace
Hazardous Scrubber Water Disposal from a Pharmaceutical Waste Incinerator
Refractory Material Optimization for a Dryer in a Mining Application
In addition, we work with a number of engineers across the country whose specialized abilities we can bring to bear on a project as the need may arise. Our knowledge of the industry, furnaces, and the individual skills and strengths of people in the industry allow us to provide the highest level of knowledge that can be applied to your project.
Our on going technical support team helps keep your new furnace installation in top shape, and can rejuvenate an older furnace to top efficiency. We offer full inspections, (top-to-bottom, inside and out) with a complete written report. Our technicians not only adjust burners, but continually check and recalculate the burner settings. We have made a lot of innovations in furnace design and operation over the years, and we constantly search for ways to apply these ideas, or to develop new solutions.
Finally, we stress that all of our technical work has one common ingredient--common sense. Our company began as a construction concern many years ago. As we have evolved and grown, manufacturing and engineering have become a significant part of our business, but we try never to lose sight of what we learned in the field--that engineered solutions have to work in practice as well as on paper.
Click
here to download a line sheet on our Engineering and Technical Services
Multiple Hearth Sludge Furnace Combustion Engineering Services
Improved
Sludge Furnace operating modes and equipment modifications to:
Engineering
analyses and on-site operational testing to identify and demonstrate corrective
operating modes to solve airflow and temperature control problems, increase
capacity, or to achieve emission compliance.
Engineering design requirements and assessments for:
Equipment and operating mode modifications,
Upgrades
to reduce emissions and fuel use, and furnace
rehabilitation and major upgrade projects
Clean
Air Act Title V CO and NOx
Major / Minor Source assessments and emission compliance analyses.
Industrial Furnace has built Fluidized Bed Sludge Incinerators for all the major manufacturers. In addition, when repairs to existing Fluidized Bed Incinerators are needed, Industrial Furnace often gets the call. Over the years, we have made repairs to many different designs of Fluid Beds. As a result of this experience, nobody can offer the level of expertise that we can. Industrial Furnace offers “One-Stop Shopping” for the design and building, or repair, to suit your Fluidized Bed Incineration needs. We have extensive contacts throughout the industry enabling us to handle the project from beginning to happy ending, including the engineering and design, building, and permitting. We believe we are the ONLY company capable of handling all the different aspects of building a furnace completely in house.
IFCO maintains two pilot furnaces at our Rochester, New York, facility. The first is a 36" O.D.x (4) hearths multiple hearth furnace, with continuous feed capabilities. It has recently been relined with new refractory, refitted with the latest in automatic controls, and provisions have made for indirect firing if required. The other unit is a small muffle furnace which can be used for batch testing.
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The multiple hearth furnace is available for use in our lab, or it can be moved to the customers location for on-site testing. Modifications can be made to match specific needs of the process to be tested. The furnace can be operated either by the customer's personnel or ours. Some examples of tests that have been run in the furnace include de-lacquering of aluminum chips and processing of mineral powder in a pure nitrogen atmosphere.
Our Integration Services division was formed in November 1992 to serve the automation market in the justification, specification, design and integration of process control, computer integrated manufacturing and monitoring systems.
We provide design engineering, equipment, installation, and programming for a full range of automation systems. Our projects can be as small as converting a single device from manual to automatic, or PLC control, or as large as providing full-scale turn-key distributed control packages for entire thermal processing systems.
MHF
Enhancement Technology
We incorporate the latest technology to rehabilitate
older Multiple Hearth Furnaces to perform equally, or better than newer furnaces
with modern equipment. One success story is our recently completed project at the RM
Clayton Plant in Atlanta, Georgia.
Before and After
Click here to view a graph showing the dramatic improvements.
For a complete story on this project, please click
here!!
(Please be patient while the document
loads, Thanks!!)
Flue
Gas Recirculation (FGR) Systems
We
are the exclusive installers of Chavond Barry Engineering Corporation’s
patented
FGR technology. FGR Systems move
flue gas from the feed hearth of a multiple hearth incinerator to a hearth below
the volatile burning hearth. The following are some of the benefits of this
state of the art technology.
Reduction in NOx Emissions
Reduction
in Fuel Usage
Reduced Slag Formation and Associated Lost Time.
Increased Incineration Capacity
Reduced THC Emissions
Increased
Stability of Operation
Added
Stability
-Operators report that the incinerator is more stable. They need to pay less
attention to the incinerator each hour and still maintain control.
Extended
Life
-Another benefit is anticipated extended refractory and casting life.
Maintaining steady temperatures is the best way to preserve the incinerator's
refractory and castings.
Higher
Incineration Rates
-Through the benefit of added stability, it is now possible to operate closer to
the limits of the auxiliary equipment. The operators are able to operate closer
to the upper limits of the ID fan and scrubber since there is less need to save
room for upsets.
Complete
Ash Burnout –Reduction
in Slagging and/or “Clinkers”
By
recirculating the hot gas to the lower hearths we maintain a high enough
temperature to complete the burnout. Since the introduction of FGR, there have
been no "sludge balls" found in the ash from either installations in
Woonsocket, RI or New Haven, CT. It has been noted that the ash is finer and
free from lumps and clinkers. Difficulties with the pneumatic ash transfer
system at Woonsocket have been eliminated. The fine ash passes easily through
the conveying system without clogging.
With special shaped refractory brick deliveries approaching 52 weeks and the costs of these specialty shapes rising exponentially, we developed our own standard-shaped out-hearth constructed of all 9"x4 1/2"x2 1/2" series firebrick. Naturally, it’s called the IFCO Out-Hearth. We are the only supplier to offer standard shape refractory brick hearths for all multiple hearth furnaces.
We also offer prescription drop holes, altered to the customer's specifications, for better gas flows throughout the multiple hearth furnace process loop. Our Skew backs are a contiguous ring of interlocking shapes fastened to the furnace shell. maximum strength is assured while the longest life is expected. Highest resistance to slippage is accomplished.
Owner/Operators enjoy more online time and reduced costs of stockpiling at their warehouses. Standard shapes are made under the most controlled manufacturing processes for sizing, materials composition, and firing which assures uniformity in the hearth and the best bang for the buck.
When properly installed, within the strict company standards that our craftsman provide, our hearth system is the dome structure that the Herreshoff model first sought and all have pursued since the multiple hearth furnace concept was born.
Our 100,000 square foot warehouse stocks a full line of refractory products as well as furnace parts and castings. Our facility enables us to keep our customer's furnace downtime at a minimum and maintain an operation where "saved time is saved money.
Parts, Castings, & Patterns
After years of being a supplier of parts and castings, MHF Services incorporated a division that has complete parts available for all of the manufactured multiple hearth furnaces in existence.
We have our own patterns for all of the major castings that multiple hearth furnace operators require in their day to day operations such as rabble arms, teeth, lute caps, bearing assembly sets/parts. Our pattern services team can reproduce and/or improve patterns. Our foundry and machine shop pour grey iron and ductile steel as well as stainless castings in any quantity. For our customers who are currently using cast iron or ductile parts, MHF Services will work with you to develop better alloys for your operation that will result in longer life and lower overall operating costs.
In summary, because of the direct purchasing ability and our large customer base, MHF Services can buy in quantity. As a result we offer low prices that are equal to or better than OEM parts, as well as providing prompt service.
We supply and install combustion systems for all types of industrial furnaces.
Please note that we are a distributing
installer for North American Manufacturing Company; and as a result, we
are able to pass on discounted pricing to our customers.
The following is an example of our ability to meet the specialized needs of
our
customers.
In response to the desires of our customers, we are
constantly trying to improve current
products and
inventing new ones. A real success story is
our MHF
Burner that was developed in conjunction
with North American Mfg. Company. MHF Burner is a non-slag burner that offers
better turn down ratios, better mixing in the combustion zone, and easier
disassembly when necessary.
To download a bulletin on the MHF Burner, click here.
We supply and install gas scrubbing systems for furnace applications that exceed current and future air quality control standards for biosolid incinerators and dryers.
Solutions to other MHF concerns and issues
Our field refractory experiences have given us the tools necessary to develop a better system for door jambs and arch replacement. The door area refractories facilitate maximum protection, best access, and stability.
Another innovation is our improved burner tile for the older burners. Our burner tile is manufactured from a very dense and high purity/high alumina, non-wetting refractory material. The burner block is extremely resistant to chemical attack and thermal spalling. Our burner cone configuration produces a flame pattern that limits slagging and provides the best heat distribution throughout the combustion zone. When our service professionals install these materials around one of our prescription-cut mandrills or into a door system, the advancements are remarkable.
Contact your local service representative to learn more about these and other upgrades available for your furnace.
Employees complete the OSHA HAZWOPER Training Course as well as an IFCO training course to maintain knowledge in all areas of their fields.
Applications and Installations
The following are some of the manifold operations and applications for a Multiple Hearth Furnace (MHF).
SEWAGE SLUDGE INCINERATION: In this process, dewatered sludge (usually 22-25% solids) is incinerated and reduced by 97% resulting in less sludge, or ash, being shipped to a landfill. With the improved technology in areas such as gas scrubbers, flue gas recirculation, and combustion systems, among others, MHF’s are clearly the most economical, efficient, and environmentally friendly means to dispose of sludge.
CARBON ACTIVATION AND CARBON REGENERATION: Activated carbon MHF’s remain the accepted technology for the production of activated carbon from coal, petroleum coke, and various wood products. Specific industries for activated carbon are granulated sugar refining, high fructose corn syrup manufacturing, tertiary wastewater treatment, and ground water remediation. MHF technology for carbon regeneration is most commonly used to regenerate spent activated carbon with minimum losses of carbon while producing adsorption properties equivalent to virgin carbon. Bone char regeneration would be in this category of MHF’s and is used primarily in cane sugar production.
CALCINERS: In the mineral industry, magnesium oxide is created by burning off the carbon dioxide from magnesium carbonate. Kaolin clays are calcined for use in the paper, refractory, and paint base industry, among others. In some water treatment processes, MHF’s re-calcine lime.
CHARCOAL MANUFACTURING: MHF’s are used in the process of producing briquettes.
ALUMINUM INDUSTRY: MHF’s de-lacquer recycled aluminum chips. Cryolite is recovered in aluminum smelting operations.
MISCELLANEOUS: MHF’s are used as oil refinery catalyst recovery, various roasting of mineral ores, nickel ore roasting, uranium yellow cake dryers to
remove the uranium, regeneration of bauxite and diatomaceous earth filter media, and molybdenum production and moly concentrate drying.
For a complete list of Furnace installations, click here....
To
download a line sheet on our the Engineering Services provided by our MHF
Services Division,
please click here
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