We are replacing thermic fluid heater used for pre-treatment degreasing & phosphating and changing them to rad heat gas heating elements.
Thermic fluid heater is a highly inefficient way of heating the tanks as we have to increase and maintain the temperature of thermic fluid to 200 C to get a temperature of 80 C in the phosphating tanks to overcome transmission losses and then pumps are required to transfer the thermic fluid from thermopack to the utility and as there are lot of moving parts it requires a lot of real-estate and maintenance.
As we insert our tubes directly in the tanks we are able to eliminate almost all the transmission losses and give a system which is approximately 90% efficient.
The payback for this system is less than 1 year. [Publication Link]