The research center, or CAER for short, consists of professional scientists and engineers engaged in improving the efficiency and environmental impact of Kentucky's indigenous fuel, i.e., coal. "We are specifically using the FC reactors to study and develop cheaper and more efficient catalysts for the Fischer-Tropsch process, which uses hydrogen and carbon monoxide to produce a wide range of hydrocarbons," explained Rob Spicer, an ASME member and mechanical engineer working at the Lexington research center. "These products include oils, and paraffin and olefin waxes that can be used as chemical feedstocks."

A floor stand holds each of the stainless steel reactor heads steady, while operators use a hand crank to lower the reactor body. They load coal into the reactor and crank the body back up toward the head. A metallic seal ring or a self-energizing O-ring seal the reactor body and head.

The operator sets the pressure of the reactor, typically within a range of 175 to 350 psig, and temperatures from 230 to 270°C. A 0.5-horsepower electric motor automatically activates an exterior drive magnetically coupled to an agitator that spins to mix the contents and promote the reaction.

Basically, the Instantrol comprises a self-actuated regulator, a shell-and-tube heat exchanger, and a steam trap. The heater package is connected to municipal water and steam lines. The water flows through the copper tube bundle of the heat exchanger, while the regulator controls the steam flow heating the water to the desired temperature, most commonly between 90°F and 160°F.

A thermal sensor actuates the regulating valve on the Instantrol heater package to prevent overheating and increase energy efficiency.

The Instantrol is equipped with a temperature-regulating valve that improves energy efficiency and prevents overheating. The regulator uses a bulb-and-capillary system, containing a thermally responsive chemical that actuates a bellows atop the steam valve.

The bulb is mounted in a housing in contact with the water inside the heater. When the bulb senses that the water temperature has reached its set limit, the chemical in the capillary vaporizes, activating the bellows and closing the steam valve to prevent overheating.

Welch's, headquartered in Concord, Mass., uses Instantrol to provide the hot water for its jam and jelly processing. Iowa State University in Ames and the University of Tennessee in Knoxville use the heaters to provide the hot water for dormitories and laundry rooms, as does the U.S. Marine Corps in its barracks at Camp Lejeune, N.C. Other users include Coca-Cola, NASA, Norfolk Naval Shipyard, Goodyear Tire, General Electric, and USX.

USFilter engineers in Colorado Springs, Colo., worked around the clock to refurbish two retired CMF systems, which were the only ones that could be provided promptly for the emergency installation. Engineers from Mequipco, USFilter's representative in Winnipeg, Manitoba, and MR2 McDonald and Associates, in Regina, Saskatchewan, connected the two trailer-mounted water purifiers to the municipal water system at North Battleford's civic center, and the town's fire hall.

The microscopic pores in the USFilter CMF systems' membranes capture Cryptosporidium bacteria to make North Battleford's water drinkable.

Up to 72,000 gallons per day pass through each system's polymeric membranes, which contain microscopic pores that trap Cryptosporidium, Giardia cysts, and other pathogens. The filtered water is distributed to residents who present themselves with jugs. The alternative had been to boil tap water.

The Saskatchewan installation is one of the most recent battles USFilter has waged against water-borne bacteria. The water authority in Kenosha, Wis., fearing an outbreak of Cryptosporidium from nearby Milwaukee, installed a series of Memcor microfiltration units at one of its plants that treats more than 14 million gallons of drinking water daily.

Parts are brought into the Rotoclean on a 63-inch-wide, segmented, stainless steel conveyor. They pass under the machine's carousel, which can be equipped with two, four, or eight arms to coat from 13 to 39 linear feet per minute.

Rotoclean applies the optimum amount of varnish, minimizing solvent use and waste.

The spray nozzles on the end of each arm are controlled by a proprietary angular correction system designed to evenly cover flat and contoured parts, regardless of their position on the conveyor. This capability reduces varnish consumption and overspraying, translating into less solvent to clean the con-veyor and the reinforced rubber feeder tubes.

A ventilation system draws air through vents in the conveyor, reducing downtime for cleaning the spray booth. In addition, process air is sent through a cardboard prefilter that removes 95 percent of its impurities, reducing sludge, wastewater, and disposal costs. Any excess spray product is cleaned off the conveyor with a bronze blade for recycling.

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