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Bruest Catalytic Heaters, Division of Catalytic Industrial Group, Inc.
713 N. 20th Street, P.O. Box 827
Independence, KS 67301
800.835.0557
Ph: 620.331.0750 - Fax: 620.331.3402

 

 

 

 

HotCat is the Ultimate in Efficient Pipeline Heating and a Superior Alternative to Water Bath Heaters

Advanced Pipeline Heating Systems Have No Moving Parts, are Easy to Maintain

HotCat pipeline heating systems consist of multiple catalytic infrared gas heaters that apply a precise level of heat directly to the heat exchanger. Bruest systems employ greater surface area by optimizing the pipe diameter in the heat exchanger. This maximizes heat transfer while slowing the flow of gas. This results in highest-possible retention time - and best-possible transfer of heat energy to gas.

The Bruest pipeline heating system is a stand-alone system that's custom-engineered and self-contained: the pre-plumbed fuel gas manifold that feeds the Bruest Catalytic gas heaters is built into the unit, as are the heat exchanger tubes. Both are ASME stamped.

Quiet Operation: No Firetube Noise

The dull roar of a firetube from water bath heaters is commonly described by operators - and neighbors - as resembling a freight train.

Bruest catalytic pipeline heating systems are quiet; regardless of operational mode, they are noiseless, and highly preferable to water bath heaters for sites such as town border stations.

 

HotCat Pipeline Heating Systems Deliver Maximum Efficiency

To understand the differences between the HotCat pipeline heating system and water bath heaters, start with how they are sized.

With a water bath heater, you need 3 datapoints: the temperature of gas entering the compressor
or regulator station, the outlet temperature, and the flow rate - the cu. ft. per hour flowing. Next, determine how much heat will be needed to achieve the desired outlet temperature, keeping in mind that pressure cut reduces temperatures, and you'll need to compensate for this "refrigeration effect."

For instance, you have 45-degree incoming gas, and the pressure cut lowers that to 5 degrees. You need it at 60 degrees, so, the task is to calculate how much heat must be applied to the gas, prior to the pressure cut, to achieve 50 degree gas on the outlet.

If 700,000 BTU is needed to raise a given quantity of gas to a certain temperature - that's the duty factor. So, you engineer a heat exchanger to deliver that. The Bruest pipeline heating system has very high transfer efficiency.

With water baths you will need a significantly larger unit to achieve the same heating result.

 

Why Are Water Baths Lower in Efficiency?

The answer is indirect heating, as opposed to the direct heating of HotCat pipeline heating systems. Water baths have 4 stages of heat transfer, and with every stage, heat energy is lost.

The four transfers are: (1) heat source (flame) to fire tube, (2) fire tube to water-glycol mix, (3) glycol mix to steel tube bundles, and (4) tube bundles to natural gas.

The HotCat pipeline heating system uses catalytic infrared as the source, rather than a flame. It produces clean, flameless infrared energy, and it heats the heat exchanger with just two transfers: (1) infrared to heat exchanger and (2) heat exchanger to the gas.

 

Pay Only for the Energy You Need

A second difference between the Bruest pipeline heating system and water bath devices is when they have to be on - and not. A water bath heater has two settings - high and low. Turndown ratio is 2:1, and when demand is not high, they still have to maintain a substantial volume of glycol-water mix at 120 degrees. And the system cycles on and off to maintain that temperature level, even when there is little or no flow. (When demand rises, you can't start-up with cold solution.)

The Bruest pipeline heating system is zoned, and has turndown ratios of 8:1 at the lowest, and 16:1 at the highest, (for automated systems). So in summer, or when demand is otherwise low, our system can be turned completely off. Operational costs plummet, because there is no vessel full of solution sitting around, keeping warm.

The Bruest system is automated, with sensors for inlet and outlet and set point controls that call for more heat when needed. And then, it's only for the quantity of heat actually needed, based on the specified outlet temperature. When the desired outlet temperature is achieved, the system enters shut-down mode.

The energy savings of the Bruest pipeline heating technology are immediate and substantial. Operating a HotCat, rather than a water bath heater, immediately produces energy cost savings that are significant, and recurrent.

Installation Flexibility in Pipeline Heating Systems

A water bath heater / firetube device requires 15' of clearance outside the perimeter. Bruest HotCat gas heaters can be installed in Class 1, Division 2, Group D areas without restriction.

 

Remote Control Saves Time, Labor

HotCat's design allows real-time start-up and control from your command center. Systems are engineered with zones that allow turn-down ratios of up to 16:1 for greatest efficiency.

Facing a "Nor' easter?" With Bruest pipeline heating systems, as demand increases, operators can respond immediately, directing the precise amount of heat, precisely where it's needed. And because heat is direct, pipeline heating is fast and efficient. When the demand changes, downward adjustments are also made quickly, reducing energy consumption, saving time, labor and dollars, and improving overall safety.

Bruest HotCat monitors gas inlet temperature to provide positive, immediate control of gas outlet temperatures, without costly instrument configurations.

 

HotCat Pipeline Heating Systems are the Best Freeze Protection for Natural Gas Lines & More

The technology is also applicable for heating:

  • high pressure gas from wellheads and distribution stations
  • natural gas at gate stations
  • high pressure gas from oilfields
  • fuel gas for turbines and compressors
  • light hydrocarbons

HotCat Application Questionnaire

Read summaries of the benefits of Bruest heating systems vs. water bath systems.

Click Here

  HotCat pipeline heating systems are made in numerous pre-engineered models, for town border stations, fuel gas for compressors, distribution & transmission stations.

Large Capacity Models

The HC575 HotCat
and the HC2000 HotCat

 

Large-capacity line heaters for our
utility customers

Bruest re-engineered the panel doors with hinges, so access to the panel was simpler and faster and didn't require operators to "lift-and-remove" the doors. We also added heavy-service insulation to the door panels for maximum heat retention.

Our line heater data sheet describes the operational, maintenance and environmental benefits of HotCat Line Heaters.