Heat transfer technology company TKEnergizer’s patented thermal kinetic energiser (TKEnergizer) technology – which delivers heat in a uniform stream of high kinetic energy – took some time to gain momentum, but currently has an increasing presence in the steel-processing industry, says South African marketing partner Warren Diamond.

TKEnergizer changes the heat transfer properties of thermal processing from radiant heat to kinetic energy, which presents itself as a clear stream of heat-producing energy. The technology replaces conventional gas burners entirely, he explains.

The TKEnergizer system produces the equivalent heating effect of conventional systems, but with a far greater uniformity, rapid penetration at dramatically lower operating temperatures and without thermal stress, while reducing the harmful emissions associated with a conventional burner system.

The TKEnergizer system produces an average molecular jet speed of 220 m/s and significantly reduces processing times and heat loss, ensuring a gas saving of up to 80%, depending on the application.

TKEnergizer extends to all gas-fired industries using direct-fired, forced-draft heating apparatus – including ovens, boilers, kilns, incinerators and refractory heaters, as well as preheating, reheating or forging furnaces. It is also used successfully in preheating ladles and crucibles.

The TKEnergizer system is designed for operation in most metal-heating applications, from 100 °C to 1 350 °C, and a single TKEnergizer unit replaces as many as 15 conventional burners, as the system is not reliant on direction for its effects.

Diamond explains that, while traditional furnaces require the overheating of a furnace, in an application using TKEnergizer, the energy stream, furnace and product operate at the same temperature, which is the temperature of the molecule that hits the surface of the product. The molecules then release their latent heat directly into the load.

He explains that, for the TKEnergizer system to function optimally, four necessary conditions have to be met – gas firing, a positive draft, the creation of a heat trap and direct heating, as opposed to indirect heating.

The TKEnergizer system has been in continuous operation for eight years in Gauteng and, upon inspection, the system indicated no wear and tear, as the system runs cold and without moving parts. This dramatically reduces the ongoing maintenance costs associated with traditional burners.

The near-complete combustion of gas within the TKEnergizer system reduces nitrogen oxide and carbon dioxide emissions almost entirely, while using between 40% and 80% less gas.

TKEnergizer also reduces heat-processing times by 60% or more.

Diamond says the TKEenergizer systems are being installed worldwide for many metals-related applications. Gas-fired steam-generating boilers have also become an attractive market, which is gaining momen-tum globally in new industry sectors.