Advanced Technology For Continuous Flow Indirect Heating and Cooling
Any applications where you need to put heat into or take heat out of a solid, sludge or slurry is a great application for the BCR thermal processor. Screw type heat exchanger technology has been used around the world for the agricultural, chemical, construction and food industries for over 90 years. This versatile system is capable of heating or cooling everything from Apples to Zinc.
Minerals Filter Cake
Coal Fines and Bottom Ash
Woody Biomass & Bagasse
Mining & Minerals
Sludge and Wastewater
BCR thermal processors are continuous, indirectly heated, or cooled processors, meaning the material flows into the equipment and out of the equipment in a continuous stream and the heating medium, such as water, steam, thermal oil or hot gasses are never in direct contact with the feedstock. The result is accurate thermal processing™ without material degradation or contamination. The screw-type thermal processor has a greater density of heat transfer surface area per cu.ft. of equipment volume than most other thermal processor technology. As a result, the size and footprint of a BCR processor is typically smaller than other thermal processing™ technology.
Thermal units can be constructed from a variety of materials, from carbon steel to specialized high temperature and corrosion-resistant alloys. Abrasive products are not a problem. Rotors and housings can be fabricated utilizing wear-resistant hard surfacing and incorporate innovative flight designs such as replaceable flight sections and double-lead flighting for reduced RPM. BCR’s screw-type processors are available with single, twin, or quadrotors up to 48 inches in diameter. Equipment can be supplied bare bones or as a complete system incorporating: PLC Controls, Touch Screen HMI interface, Bulk Feed, and Bulk Cooling systems, condenser, and thermal fluid heaters. Equipment can be pre-piped, skid-mounted, and prewired for easy installation.
The BCR ELECTRIC-SCRUTM is an electrically heated screw-type heat exchanger for continuous thermal processing™ of a wide range of materials. The ELECTRIC-SCRUTM incorporates multiple heating zones with the unique advantage of being able to provide controlled heating at different process stages within the same unit. Feedstocks can be heated to over 1200F while under a sub-ambient vacuum or pressure. The largest quad screw units utilize four augers with the capacity of over 6 MMBtu/hr of available heat output. Depending on the application, the Electric-ScruTM can incorporate single, double, or quadruple rotors. The Electric-ScruTM processor can be fabricated from carbon steel for low-temperature applications or specialized high temperature, corrosion-resistant alloys for higher temperature applications.
Capable of heating feedstocks to over 1200F
Multi-zone time/temp process control
Sealed and inserted process chamber
Self-Cleaning rotor design for sticky materials
Uniform or zoned heating of the shell and rotors
Electrical heating elements contained around the parameter and within the hollow core of the screws are operated to heat the screws evenly at a controlled rate. Thermocouples are installed at the discharge end of the processor, which measures the material temperatures at the specified location. The equipment is designed airtight with nozzles for possible injection of an inert gas such as nitrogen to limit the oxygen content. The housing is insulated for minimal heat loss. An adequate number of vapor ports are installed in order to collect the off-gas emissions generated during system operation.
An electric or hydraulic motor is installed at the feed end, which drives the screws at a controlled rate. The motor is designed to have an adequate torque capacity capable of starting the screws even when it is loaded with material. The material of construction exposed to heat and product is generally 310 stainless steel. The screw flights can be coated in a hard surfacing overlay to minimize wear on the flights.
Holo-ScruTM: Highest Efficiency, Greatest Versatility, Most Widely Used Technology
Heat Transfer Mediums Include: Thermal Oil, Steam, Liquid Salts, & Water
With over two thousand installations worldwide, hollow screw processors are the most widely used and versatile thermal processors for bulk materials on the market. The BCR Holo-ScruTM is a continuous, indirectly heated screw-type heat exchanger that can be used for heating, cooling, drying, and a variety of other processes where there is a need to put heat into or take heat out of flowable materials. The Holo-ScruTM consists of hollow flighted rotors and a jacketed housing through which a medium such as water, steam, or thermal heat transfer fluids are circulated. Holo-ScruTM processors are available with single, twin, or quadruple rotors up to 60 inches in diameter. Holo-ScruTM processors used for heating have the highest thermal efficiency due to the continual closed-loop recycling of heat transfer medium. The result is almost all the heat put into the system is imparted into the bulk material with very little being lost to the environment.
Max Operating Temperature: 720˚F
Max Operating Pressure 350 psi
Max Operating Vacuum 50 millitorr
Pre-heating ahead of processing or drying operations
Sterilization of food products
Drying and Calcining:
Water removed from slurries, sludges, and filter cakes
Molybdenum drying and roasting
Industrial sludge drying
Solvent Recovery: Solvent removal from polyethylene, polypropylene, rice bean, soybean meal, and chemicals
BCR’s Cooling-ScruTM technology, with indirect cooling, can deliver the product exit temperature you need while maintaining a continuous (in/out) process flow. Indirect cooling technology delivers accurate temperature control without directly contacting the product with liquids or gasses. The rotor and housing of the screw conveyor are jacketed allowing the cooling medium, water or water glycol mixture, to indirectly cool the feed as it is conveyed down the length of the Cooling-ScruTM. The cooling can occur at ambient pressure under pressure, or vacuum. Cooling-ScruTM technology can be used to cool anything from Apples to Zinc.