Heating Your Warehouse (How much does it really cost?)

Heating A Warehouse:  How Much Does It Really Cost?

Have you ever stopped to consider how much it costs to heat a warehouse? Well, we have, and the numbers are quite staggering.

Warehouse Wattage

When you have valuable materials to store through the winter months, keeping your warehouse at the proper temperature becomes an operational expense.

According to Madison Gas and Electric, “warehouses in the U.S. use an average of 7.6 kilowatt-hours (kWh) of electricity and 20,900 Btu of natural gas per square foot annually,” (Madison). Even if you’re only heating a 20X20 ft. warehouse, which would be incredibly small, that’s still an average of 3,040 kilowatt-hours and 8,360,000 Btu of natural gas annually. Over a year, that really adds up. The real issue, however, is that it is not the building that needs to be heated.  In most cases, the warehouse needs to be warm because you need to keep the materials and/or equipment inside at proper temperatures.industrial warehouse

Tips for Preventing Heat Loss

Large buildings with high ceilings and many doors and windows are not the easiest place to keep warm air in. Additionally, many industrial facilities accept deliveries or shipments several times a day, exposing the space to outdoor conditions. Consider these four areas of your warehouse and how you can conserve energy with simple improvements.

Check for Air Leaks Around Windows

Over time, the seal around most windows will begin to wear down. Leaks often go unnoticed because many warehouses have high windows that are hard to reach.

Keep the Heat: As part of your maintenance schedule, check the air temperature of the areas around your window at least a few times a year to see if the air is unusually hot or cold. If you recognize low temps, check the insulation around the window and possibly replace or add new weatherstrips.

Circulate Heat Collecting at the Ceiling

Heat rises above cold air in a building. This difference in air density can cause problems in a warehouse with high ceilings. This phenomenon is problematic because the heating system doesn’t properly heat the lower areas where employees are.

Keep the Heat: Destratify the air in your space by increasing airflow. Improved airflow in your warehouse helps maintain more consistent temperatures, or thermal equalized. Circulating the air keeps those working in the warehouse warmer without cranking up the heat.

Control Your Heating

Awareness is key.  You always want to have sufficient control over how much heat your building is using. You want to keep the building comfortable, but your energy bill should not destroy your bottom line.

Keep the Heat: Invest in a better method of monitoring the heating in your building. With today’s technology, there are numerous ways to monitor temperatures and energy use remotely.  Save money when you lower the heat when it is not necessary.

A Better Solution

An efficient building is an important part of optimizing operations.  Consider this, if you could heat only the materials you are storing in your warehouse, rather than the warehouse itself, how much could you be saving on energy cost in a year? The square footage you’d need to heat would be a small fraction of your warehouse’s dimensions. Is your warehouse primarily for storage?  Consider turning the heat off and still protecting your valuable materials.

There is an economical solution to such a scenario.  Powerblanket manufactures standard heating equipment and custom heating solutions for freeze protection and storage.  Whether you’re storing paint, coatings, spray foam, wax, chemicals of various kinds, DEF, propane, or anything else that may need to be stored at room temperature or above.  Powerblanket covers your assets.  Using radiant heating technology, Powerblanket products protect materials and equipment with even and direct heat distribution.warehouse

 

What Temperature is Too Cold to Pour Concrete?

What Temperature is Too Cold to Pour Concrete?
What Temperature is Too Cold to Pour Concrete?

Experts agree that the best temperature to pour concrete is between 50-60°F. The necessary chemical reactions that set and strengthen concrete slow significantly below 50°F and are almost non-existent below 40°F. Even when daytime temperatures are within the satisfactory range, winter concrete setting creates risks that could result in weak, inadequate concrete. If nighttime temperatures are below freezing, the water in the concrete will freeze and expand, causing cracks. Additionally, if temperatures reach below 40°F (but not freezing) during set time, concrete will take much longer to reach required strength. However, if the correct measures are taken, concrete can still be successfully placed during even the coldest months of the year.

Before embarking on a cold weather concrete project, it’s important to determine any special strength requirements or considerations. This will help as you schedule your pouring and determine which strategies you will use to keep your surroundings and materials warm. The predominant challenge you will face during a winter concrete project is ensuring that the concrete sets before it is exposed to freezing temperatures. You might take the following suggestions into consideration as you plan your upcoming project:

  • Use heaters to thaw frozen ground, snow or ice.
  • Use hot water to mix cement.
  • Keep dry materials in a dry, warm location.
  • Use products designed to set quickly. During cold weather, these products will not set as quickly as the instructions may indicate, but will set faster than conventional materials.
  • Use additives that accelerate set time. Use caution; if additives contain calcium chloride, any rebar or metal wire mesh in concrete will rust and cause concrete to crack.
  • Use extra cement (typically 100 lb/cubic yard) to make the reaction hotter and cause concrete to hydrate more rapidly.
  • Remember that you still need to wait for bleed water to evaporate. Incorporating the water into the surface during finishing will weaken the surface. Bleeding starts later and takes longer during cold weather; you can use squeegees or a vacuum to remove water quickly.
  • Wait until concrete has reached desired strength to remove any framework. If the framework is removed too early, the concrete will be damaged and the surface could collapse.

After implementing the above suggestions, It’s important to consider how you will keep concrete at the correct temperature during the curing process. Concrete must maintain a temperature above 50°F for approximately 48 hours for the correct chemical reactions to take place, allowing the concrete to eventually settle at 4000 psi. Two popular options used during cold weather concrete curing are heated enclosures and insulated blankets. If using an enclosure, ensure that the structure is both wind and waterproof. Additionally, ensure that there is proper ventilation for the space heater. Heaters cause an increase in carbon dioxide that could cause carbonation in the surface of the concrete, not to mention a work hazard for employees.

Powerblanket® concrete blankets are an extremely effective option for attaining and maintaining the correct temperatures for concrete pouring and setting. Powerblanket® concrete blankets can be used to thaw ground before pouring concrete and again after finishing to keep concrete from freezing. Utilizing Powerblanket concrete blankets will ensure that concrete is kept at the correct temperature for the necessary reactions to happen quickly and the desired strength to be reached. With Powerblanket, it’s almost never too cold to pour concrete!

Temperature makes all the difference when pouring concrete. Check out our article on how temperature affects concrete that is still curing inside the Hoover Dam!

Tank Cooling Solutions from Powerblanket

If you’re storing things in tanks, then you’re storing a lot of it. That being the case, you can’t afford to leave your valuable liquid or other material to the whims of Mother Nature. When it comes to Summer, heat can wreak havoc on your tank storage and operations. But rather than spending a boat load on refrigerated tanks, you can get much more economical tank cooling solutions with Powerblanket ICE.

 

Powerblanket ICE Tank Cooling Solutions

What are your options for tank cooling solutions when summer rolls around? Well, if you haven’t heard of Powerblanket cooling technologies, then your only option is likely to be a refrigerated tank. Refrigerated tanks certainly get the job done. But aside from being rather expensive, they don’t solve cooling problems for pre-existing tanks. In other words, if you don’t already have a refrigerated tank, then you’re going to be spending a lot of time and money replacing your present tank(s) with new refrigerated units.

Thankfully, there’s a much better option for you. Powerblanket tank cooling solutions allow you to apply an insulating exterior cooling system to any tank. From common sizes to custom application, Powerblanket cooling technologies will keep your tank storage at the ideal temperature during the hot summer months. With four cooling options to choose from, Powerblanket tank coolers offer cooling protection for small to large applications.

 

Benefits of Powerblanket Tank Cooling Solutions:

  • Prevent the extra costs and downtime associated with other tank cooling options
  • Maintain operational continuity with an easy-to-install solution
  • External application means there’s no need to empty or halt tank usage
  • Protect your valuable storage from being compromised by heat
  • Maintain profitability by eliminating ruined product and costly downtime

 

Features of Powerblanket ICE:

  • Powerblanket ICE Tank Cooling Systems use patented technology to draw heat away from the tank in order to cool the contents inside.
  • Our Tank Cooling Systems cover and insulate with a durable and easy-to-use system.
  • Powerblanket ICE systems are portable and easy to install and remove.
  • The Powerblanket ICE Tank Cooling System makes for easy temperature control of bulk materials.
  • Each tank cooling system can be left installed and running while tanks are in use.
  • Custom cooling systems can be designed for any size and shape of tank.

 

Learn More

Heating Solutions for Roofing Material

Are you looking for heating solutions for roofing material? Whether you’re roofing in the spring, summer, fall, or winter, you need to keep your roofing material hot and ready to roll. From adhesives to mineral surfaced roll roofing, the Powerblanket® Hot Box can help you keep your roofing materials warm and ready year round with portable, easy-to-use heating solutions.

Powerblanket hot boxesHeating Solutions for Roofing Material: The Powerblanket Hot Box

Research has shown that installing roofing materials in cold weather can negatively effect the integrity of the roof. Cold temperatures lead shingle glues to have a higher viscosity. This means the glue is too hard to set the shingles together properly. The ductile-to-brittle transition seems to happen in temperatures below 40 degrees Fahrenheit, and is usually when manufacturers void warranties for roofing products. With a recommended temperature of 70 to 80 degrees to roof, Powerblanket Hot Boxes and temperature controllers can solve the cold weather roofing dilemma.

Ideal temp for roofing materials graphicIn addition, the Powerblanket Hot Box (also known as the Bulk Material Warmer) is a great for countless applications. You can use the economical Hot Box for tar, adhesives, laminates, mineral surfaced roll roofing, and all other roofing materials. This will not only protect your supplies from freezing in cold weather, but will protect from inefficiency. By using the transportable and easy-to-assemble Hot Box and Beacon temperature controller, you can keep your materials at the ideal temperature regardless of what the weather is like.

Moreover, the Powerblanket Hot Box is designed with great structural integrity. Every unit comes with an internal, freestanding frame and can be easily assembled, disassembled, and reassembled. This makes the Hot Box ideal both for long-term storage of palletized product and on-site heating. Additionally, the option for an adjustable thermostatic controller gives you the ability to control the temperature range in order to prevent over or under-heating your product.

hot-box-one-cord, heating solutions for roofing materialPowerblanket® Hot Boxes:

  • Preserves temperature sensitive material
  • Installs quickly and effortlessly, and is compact and portable for storage
  • Heats palletized products: tar, resins, laminate, adhesives, mineral surfaced roll roofing, etc.
  • Features top and side access doors.
  • Is certified to UL and CSA safety standards

Learn More

Sources:

Anderson, David, Laurence Lapalu, Mihai Marasteanu, Yann Hir, Jean-Pascal Planche, and Didier Martin. “Low-Temperature Thermal Cracking of Asphalt Binders as Ranked by Strength and Fracture Properties.” Transportation Research Record: Journal of the Transportation Research Board 1766 (2001): 1-6. doi:10.3141/1766-01.

“How to Properly Stack Asphalt Shingles on a Pitched Roof – IKO.” IKO Global. Accessed October 04, 2018. https://www.iko.com/na/residential/building-professional/how-to-stack-shingles-on-a-roof/.

Cooling Solutions for Fermentation

Do you deal in the world of fermentation? If so, then you know how important it is to maintain the ideal temperature of your liquids. And with warmer weather already here, and with even hotter weather on horizon, you’ll need reliable cooling solutions for fermentation in place.

 

Powerblanket Ice Cooling ProductsPowerblanket® ICE: Cooling Solutions for Fermentation

With Powerblanket ICE, you can keep liquids cool, even under extremely hot conditions or during exothermic reactions, like fermentation. For years now, Powerblanket has provided numerous industries with innovative heating solutions through our line of ready-to-ship and custom applications (and if you need heating solutions for fermentation, we have those too).

Now, we offer innovative cooling systems alongside our revolutionary heat-transfer technology. And with the summer months approaching, cooling becomes a prime focus. With Powerblanket ICE cooling blankets, you can efficiently and economically regulate temperature-sensitive liquids, even when the temperatures are 100 °F or more.

Powerblanket ICE works by pulling heat away from the container in order to cool the contents inside. With three performance levels available, you can pick the solution that’s right for your budget and needs. Powerblanket ICE products are the perfect cooling solutions for fermentation.

 

Features of Powerblanket ICE:

  • Powerblanket ICE uses Powerblanket patented heat-spreading technology in reverse to draw heat away from the container and cool the contents.
  • Powerblanket ICE covers and insulates with the same robust system used in the Powerblanket heating products.
  • Ice box, ice pack and chiller-driven systems are portable (120VAC required for ice box and chiller systems).
  • Blankets can be left installed and running during routine procedures.

 

 

Methane Hydrates: A Dilemma for the Pipeline Industry

Sometimes the word methane carries with it a negative connotation, but if there’s a word or combination of words to trump it, it’s “methane hydrate,” at least if you’re in the piping industry that is. While methane hydrates can be found naturally occurring in the deep abys of the ocean bottom (and could serve as a good energy source) when it comes to gas lines, there’s nothing good to say about them.

 

 

What are Methane Hydrates?

In terms of simplicity, a methane hydrate is a combination of methane gas and water. When these two combine at freezing temperatures, they form a solid methane hydrate. Interestingly enough, these crystal-like rocks form naturally at the depths of the sea. And in cases of potential energy sources, well, methane hydrates could be a thing of the future. However, when it comes to the piping industry, these rocks just plain get in the way.

 

Methane Solids in Your Pipes

In the case of the piping industry, methane hydrates can put a stop on gas flow like plaque can put a halt on blood flow in our arteries. When natural gas passes through piping equipment at temperatures near or below freezing, the buildup of condensation and the contraction of gas molecules create these gnarly solids we’ve been talking about. When these hydrates buildup in pipelines, especially at transition points like valves, manifolds, and instrumentation, they can pose a substantial risk to continued operation. In fact, they can outright stop it in its tracks.

So what’s the solution? It’s a simple one. It’s heat. Adding heat to a pipeline can keep temperatures at the ideal level and will entirely prevent the formation of methane hydrates. When adding regulated and even heat distribution to your equipment in the form valve heaters, manifold heaters, and instrumentation heaters, hydrate formation is no longer a problem. Thankfully, this is one of the major areas Powerblanket assists the piping industry with. Our valve, manifold, and instrumentation heaters offer the easiest and most efficient solutions to heat maintenance on a natural gas or liquid pipeline. So if hydrate formation is a dilemma that keeps you up at night, reach out to Powerblanket today, so you can start sleeping better.

 

 

Ground Thawing – What a Concept

Frozen ground can put a damper on many a project. Whether you need to lay concrete or dig to repair a pipe, a stubborn layer of frozen ground can really make for a lot of extra work.

 

 

Thawing Frozen Ground before Summer

Here are a couple scenarios to play through, and there are many more to consider too:

Let’s say you or your construction crew need to dig to repair a pipe, or you need to prep to lay concrete on frozen topsoil. In either case, dealing with frozen ground is certainly not ideal. So what do you do? Well, waiting till the ground thaws in the late spring or early summer probably isn’t an option, and heating the ground with massive coils or large heating systems becomes expensive and cumbersome. Besides all this, this sort of approach takes rental fees, transporting the equipment, and a bit more money than you probably want to dish out.

But what if there was a solution that could prep the ground for you, with little to no effort or supervision on your part. And it’s a solution you can purchase and use every time you need it, since it’s so affordable. Well, Powerblanket has the answer in our patented heating technology.

 

Powerblanket’s Ground Thawing Blankets

With our ground-thawing technology, you can cover the area you need to thaw with a vinyl-encased blanket and leave the rest of it to the patented workings inside. Powerblankets disperse and deliver an even distribution of heat throughout the surface area. That’s why they can be used in applications such as ground thawing.

 

 

-Some Standout Features-

  • High watt density thaws frozen ground fast
  • Quickly remove frost prior to concrete pour
  • Melt snow and ice from roofs, walkways, and construction areas
  • Easily installed and removed
  • Can be used to cure epoxy and resins

See all the details of the Powerblanket® ground thawing blanket by downloading the free product spec sheet!

 

 

Protecting Your DEF Storage With DEF Heaters

Since the 2010 mandated regulations on diesel exhaust, the demand for DEF in the United States has only increased. If you’re in the DEF supply business, the important question now is how to keep your valuable product safe from the effects of cold weather. 

 

Powerblanket DEF storage heaterDEF Storage Essentials

Those familiar with Diesel Exhaust Fluid (DEF) are also familiar with the fact that it has to be stored within a reasonable temperature range. Unless you’re keeping it all in a well-insulated and well-heated warehouse, the winter months could pose some problems when it come to adequately maintaining your product.  (Even if you do have an insulated and heated warehouse, there’s still a much more energy-efficient way to store your DEF.)Here’s some helpful information from an additional source:

 

According to DiscoverDEF.com, “the shelf life of DEF is two years, if the fluid temperature remains between 15ºF and 65ºF (-9ºC and 18ºC). Where DEF is stored outside in bulk tanks or totes, then heating and cooling solutions are available to ensure it is kept within the correct temperature range, (http://www.discoverdef.com/def-equipment/handling-guide/).”So for all of you who have to store your DEF outdoors, the big question is what to do during cold weather, so as not to compromise the life of your DEF. Well, that’s where Powerblanket comes in.

 

Powerblanket’s® DEF Storage Heaters

ADVANTAGES AND BENEFITS:

  • Keep your DEF at optimal temperature for optimal shelf life and performance
  • Keep DEF stored outside and save costs on heating a warehouse
  • Heater provides uniform heat across entire heated blanket
  • Preset thermostatic control to prevent overheating
  • Keeps DEF and pump housing stored at optimal temperatures
  • Insulated top with flap for easy access
  • Two extended pump rack brackets

 

 

 

Winterizing Vehicles And Equipment That Use Hydraulic Oil

Powerblanket heated drum wrap with diagramWhat are the best solutions to prevent hydraulic oil from thickening or freezing?

There are a few ways of winterizing vehicles and preventing hydraulic oil from thickening or freezing, however some methods are more effective and safer than others. There are a few things to consider when determining the most effective method:

  1. How safe is the solution?
  2. How much time is required to monitor the heating source?
  3. How much power and energy is consumed with the heating solution?

wiHydraulic oil is an essential component to your equipment. Optimal functionality is dependent on the oil maintaining temperatures within a specific range depending on the type of oil your vehicle and equipment may use. Cold or freezing temperatures can alter the functionality of hydraulic oil and when this happens you run the risk of damaging your expensive equipment.

Heating hydraulic oil to maintain optimal temperatures is a great solution. A custom heating blanket by Powerblanket is the best way to maintain viscosity in your hydraulic fluid. Heating blankets can be designed to perfectly align the size and temperature with the needs or your equipment. Heating blankets maintain consistent temperatures, provide insulation and are removable and flexible for storage during warmer months.

The top five reasons to use a heating blanket vs. the alternative:

  1. Safe and effective heat
  2. Highly customizable
  3. Maintains optimal temperatures
  4. No need for monitoring
  5. Insulated blankets use less energy

Heating blankets by Powerblanket are powered by Greenheat patented Technology which has revolutionized effective and even heat spreading.

With several options available for heating hydraulic oil, finding the right solution for your equipment is essential. Blanket heaters by Powerblanket are a great solution for your hydraulic oil needs.

What DEF Storage Options Are Available To Protect DEF?

Keep DEF Tote From FreezingDiesel exhaust fluid (DEF) is an additive used in conjunction with a selective catalytic reduction (SCR) system. It helps reduce harmful pollutants omitted from diesel exhaust. When DEF is used with a SCR, it eliminates 94% of the pollutants identified as being the most hazardous. The two most offensive pollutants are particulate matter and nitrogen oxides.

 

  • Particulate Matter (PM) – PM is the term for a mixture of solid particles and liquid droplets found in the air. EPA  – Particulate Matter PM
  • Nitrogen Oxides (NOx) – NOx is a generic term for the various nitrogen oxides produced during combustion. ScienceDaily

 

“On May 11, 2004, EPA signed the final rule introducing Tier 4 emission standards, which are phased-in over the period of 2008-2015.” DieselNet

Staying compliant with the environmental protection agency (EPA) and the Tier 4 Standards are critical for many industry companies to remain operational. The Tier 4 Standards include all off road vehicles as well as the semi-trucks used on everyday highways. By 2015, all vehicles will be required to be compliant with Tier 4 Standards. This means diesel engines will need to find a solution to omit these pollutants.

A lot of questions still remain regarding the new systems developed and how to manage the little things that can cause operational interruptions.

One of the newly identified problems is that DEF needs to be stored in a controlled environment. Many storage options are available including large underground tanks, IBC totes, and one-gallon containers. The shelf life of DEF should be around a year if it is stored between 12°F and 86°F.

Many environmental zones can drop several degrees below 12°F, which requires a solution for keeping DEF from freezing. Fortunately, there are companies who have had the insight and engineering expertise to tackle this problem and have come up with viable solutions.

A few of these companies are:

 

All of these companies have designed storage aids to prevent DEF from freezing and to promote the longevity of DEF shelf life.

 

Bulk Material Storage and Heating Alternatives

Powerblanket Bulk Material Storage and Heating AlternativesColder weather causes all sorts of problems while working in outside, ambient conditions.  It can be particularly troublesome when working with temperature sensitive materials.  Operations are transitioning from smaller storage containers, to pallet containers and large, bulk storage tanks.  Finding the right heating solution for bulk material presents a challenge.

One option is to store product and containers in a warehouse or shed and heat the entire building.  While this is an option, it is not effective or energy efficient.  Heating a separate building to store product can cost hundreds of dollars per day in energy alone.  It’s also really difficult to bring product and material up to temperature in a timely manner by simply blowing in warm air.

 

Here are five factors to consider when looking for a bulk material heating solution:

 

  1. Portability –  Look for a solution that will allow you to transport the material to different locations heated and protected.  A portable solution  will also allow you to heat your material while at a job site.
  1. Energy Efficient –  Find a solution that will maximize efficiency and retain most of the heat being generated.  Heating solutions such as blanket-type heaters are extremely effective and energy efficient because they have direct contact to the thermal load.
  1. Effective  –  Bringing material up to temperature in a timely manner is critical to most operations.  Time is money.  Having a direct heat source with great heat retentive properties will achieve this.  A blanket-type heater, which is also insulated, will achieve this.
  1. Temperature Control –  Sometimes having temperature control capability is critical to a successful operation.  Overheating or under heating can ruin product, render it unusable and cause downtime.  Find a heating solution that allows you to control the temperature based on your job-site requirement and product blend.
  1. Custom Design Capability –  Partner with a heating company that has in-house engineering and is willing to custom design a heating solution for your unique needs.  Take the time to do some research and collaborate with heating experts to determine what heating solution will best achieve your desired end result.

Tote Heaters & DEF Tote Heaters

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Tote HeatersAre your plastic water tanks freezing? Do you store your DEF (Diesel Exhaust Fluid) in IBC Totes? During the cold season, these temperature-sensitive liquids can encounter frequent problems. Whether you work with sensitive chemical compounds, DEF to keep your equipment running, or just plain water, dropping temperatures can lead to dropping sales. So what are your options? We’ll discuss some pros and cons of different solutions and why Powerblanket Tote Heaters will do the best job.

Decisions, Decisions: Your Options for Tote Heating

Heat Trace

There are several ways to heat water and DEF totes. Heat trace systems, which generally involve some form of heat tape, are costly to repair, replace, and encounter several drawbacks. They’re inexpensive to purchase initially, since you can pick up the tape at basically any hardware store. For something large like a tote, you would need “a metric crap-ton” (as my coworker called it), to fully wrap it with heat trace. It doesn’t distribute heat evenly throughout the product either, since the heat is centralized on the tape and doesn’t really radiate. It’s better used for things like piping. Heated tape also has issues with wet weather conditions (like, er, snow?), leading to the expense of workers coming to scrape it off and reinstall new tape. 

thermal image showing uneven hot spots on band heater

Traditional Electric Blankets

Electric heat blankets are typically a better option, but can be expensive to run, and traditional models still leave hot and cold spots. By looking at thermal imaging of the majority of heated blankets, you can see your products run the risk of scalding or partially freezing. 

Tote Ovens

You’ll also likely come across electric or steam-heated drum and tote ovens. While this solution solves the question of temperature very well, there are still two issues. First, an oven is priiiiicy, and second, you are limited on space.

Then again, when it comes to protecting your precious material, perhaps price isn’t much of a factor. But who wouldn’t spend less for a product that does an even better job? Leave the oven for baking. There’s a better option.

Best Case Scenario: Powerblanket® Tote Heaters

Thermal Image of Powerblanket's Even Heat DistributionWe saw the flaws of all the other heating methods and wanted to find a better solution. This is why we created Powerblanket Tote Heaters. Powerblanket technology puts years of innovation into each blanket by spreading heat evenly, covering the entire surface area. They are cost-efficient to operate by increasing efficiency and reducing required labor. When it comes to tote heaters and DEF tote heaters, you’ll be able to keep chemicals to spec, equipment running, and your project on track for deadlines without spending a fortune. 

Learn More About Tote Heaters

 

DEF and Urea Temperature Control

DEF and Urea Temperature ControlDiesel Exhaust Fluid (DEF) is a mixture of 32.5% urea and 67.5% deionized water.  DEF freezes at 12o F (-11o C), but low temperatures will not cause the DEF solution to degrade.  Regardless, it is recommended that DEF be stored at temperatures above its freezing point so it’s always ready for use. Methods for heating and maintaining temperature in large totes, tanks, and containers can best be achieved with a Powerblanket DEF Heater.

High temperatures is where we run into problems with DEF degradation.  High Temperature will cause DEF to break down and can limit its shelf life.  DEF begins to decompose into isocyanic acid (ammonia) at temperatures above 122o F (50o C).  Diesel-powered vehicles that utilize urea SCR systems require fresh, uncompromised DEF in order to work correctly.  In order to limit DEF decomposition during storage, it is recommended that it be kept between 15º F and 65º F (-9º C and 18º C) and that it be placed away from direct sunlight.

Shelf Life

Shelf Life is a function of Ambient Storage Temperature. Listed below is a chart outlining the guide for shelf life based on ISO 22241-3 specifications.

..Temperature º F ..Temperature º C Minimum Shelf Life
< 50º F < 10º C 36 months
< 77º F < 25º C 18 months
< 86º F < 30º C 12 months
< 95º F < 35º C 6 months

Q & A

Q. How do I keep DEF from freezing and what happens if DEF freezes in the tank on my vehicle?
A. During vehicle operation, SCR systems are designed to provide heating for the DEF tank and supply lines. If DEF freezes when the vehicle is shut down, start up and normal operation of the vehicle will not be inhibited. The SCR heating system is designed to quickly return the DEF to liquid form and the operation of the vehicle will not be impacted. The freezing and unthawing of DEF will not cause degradation of the product.
———-
Q. Does DEF expand when frozen?
A. Yes, DEF expands by approximately 7% when frozen. DEF packaging and tanks are designed to allow for expansion.
———-
Q. How much DEF will a truck consume?
A. DEF consumption is expected to be approximately 2% of fuel consumption, depending on vehicle operation, duty cycle, geography, load ratings, etc.
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Q. What is the number of miles a truck can expect to travel on one gallon of DEF?
A. DEF consumption is directly related to fuel consumption. A truck averaging 6 MPG can expect to go approximately 300 miles on one gallon of DEF.
———-
Q. How can an operator determine how much DEF they will need/use?
A. DEF consumption will be approximately 2% of the diesel fuel consumed. Another way to consider it is that DEF will be consumed on a 50 to 1 ratio with diesel. (For every 50 gallons of diesel fuel burned, you will use 1 gallon of DEF).  If you know the average fuel consumption of a vehicle, you can easily calculate the amount of DEF that will be used.
Q. Is the DEF dose rate the same for all engine manufacturers?
A. The DEF dose rate will vary slightly amongst engine manufacturers. While most engines will have a dose rate of 2 percent of diesel fuel consumed, the dose rate will range from 1 percent to 3 percent.
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Q. What happens if the vehicle runs out of DEF?
A. Vehicles that use DEF will have indicators on the dash that will alert the driver of the quantity of DEF on board. A gauge similar to a fuel gauge will indicate the level of DEF. There will be a DEF low level warning lamp that will illuminate when DEF is low. If the vehicle is operated such that one would run completely out of DEF, vehicle power will be reduced enough to encourage the operator to refill the DEF tank. Once the tank has been refilled the engine will resume normal power levels
———-
Q. What is the recommend solution for temperature control of DEF at refilling stations and storage facilities?
A. Powerblanket DEF Temperature Control Shelters!
Get the DEF Guide

Powerblanket® Introduces Heated Pipe Wraps To Provide Freeze Protection and Rapid Thawing

SALT LAKE CITY — Featuring patented GreenHeat® Technology and able to fit nearly any size pipe, Powerblanket’s® new Pipe Wraps provide an environmentally friendly heating solution for freeze protection and rapid thawing of pipelines in oilfields, water treatment plants, paper mills, mining operations and other industrial applications. These lightweight wraps can be used to heat pipes, manifolds, pumps, hoses and other temperature-sensitive equipment.

Powerblanket’ s® innovative “ all-in-one” product design substantially reduces installation time, eliminates the need for multiple product procurement, and significantly reduces labor costs. The end result is an efficient, cost-effective heating solution with unlimited possibilities. Installing Pipe Wraps on long sections of pipe will maintain flowability and maximize production even in harsh winter conditions.

The new Pipe Wraps can be provided in sizes ranging from 2.5 centimeters to 2 meters (1 to 78 inches) in diameter to accommodate a variety of pipe sizes. The wraps are equipped with adjustable straps that ensure a secure fit to maximize heating performance. Powerblanket® wraps feature GreenHeat® Technology, a revolutionary heat spreading system that uses aerospace heating designs to deliver a highly efficient and uniform distribution of heat while only consuming low levels of energy.

Powerblanket® Pipe Wraps consist of heat trace, heat-spreading carbon fiber material, an insulation barrier and an outer vinyl shell — all in one package — allowing for fast and simple installation. By contrast, traditional heating processes involve labor-intensive installation of similar separately procured components, configurations that force heat into long sections of tents, or glycol — each of which are time-consuming, expensive and have potentially destructive environmental impacts.

Certified to all applicable UL and CSA safety standards, Powerblanket® Pipe Wraps are powered by regular 120V electricity and are safe to use on metal or plastic pipes and hoses. The wraps are also UV stabilized and are wind and water resistant, allowing flow within piping to continue even in temperatures as low as -50 degrees Celsius (-58 degrees Fahrenheit).

Powerblanket® provides superior heating solutions for a multitude of applications, including ground thawing, concrete curing, industrial and manufacturing temperature control, oil field services and many more. For more information, contact Powerblanket®, 1997 South 5070 West, Salt Lake City, UT 84104, call 877-642-5240 in the U.S. or 403-262-5770 in Canada, fax 801-601-2222, send an e-mail to[email protected], or visit the company’ s website at powerblanket.com.

Cold Patch Asphalt Material Warming

Are you in the asphalt business in need of asphalt material warming, or some other industry where you need potable, easy-to-use product heating? Do you need temperature maintenance for sensitive materials? Whatever the case may be, the Powerblanket® Hot Box can help you prep your materials for application or warm your product to the ideal temperature.

 

Storing asphalt materials in a heated boxThe Hot Box for Asphalt Material Warming

Powerblanket is proud to introduce the  Hot Box (aka: Bulk Material Warmer) to its innovative line of Eco-Friendly heating solutions.  With the Hot Box, you have a heating solution for remote-location use, job-site heating, transporting temperature-sensitive material, and many other heat-related requirements.

The Powerblanket® Hot Box can save you money and time by keeping your products from experiencing the detrimental side effects of cold weather. However, the Hot Box can also bring your product up to working conditions, when you require temperatures above the ambient degrees. One of our favorite examples to share in regards to this is that of Vern Fiehler, owner of Quick Road Repair in Alaska, and it has to do with asphalt material warming.

Vern had to bring his asphalt repair product up to working temperature before it could be applied. Unfortunately, his previous method of heating the product was very inefficient, and caused some real problems. When Vern met with the field maintenance crew of the Juneau Alaska International Airport in order to demonstrate the product he called Instant Road Repair (IRR), what happened was nothing short of disastrous. For the demonstration, Vern needed to heat IRR. He used a forced-air, ceramic heater to do this. However, the product didn’t perform well at all during the demonstration. Vern discovered that this was due to overheating. In fact, the product overheated 40°F / 22°C past its maximum workable temperature. This ultimately cost him a whole pallet of his product and the embarrassment he experienced in front of the airport staff.

Vern’s product is a great one. And his IRR wasn’t the thing to blame for this untimely setback. Instead, the culprit was merely an unreliable heating solution. Since then, Vern uses the Powerblanket® Hot Box for efficient and regulated heating of IRR.

Like all our products, the Hot Box is very user friendly. It can be easily assembled, disassembled, and reassembled, making it the ideal answer for cold weather storage, freeze protection, job-site heating, remote location use, and many other use cases. Our Hot Boxes come in three performance levels: Lite, Standard, and Premium. Each unit will maintain temperatures between 100°F and 120°F. And in the case of the Premium Hot Box, you have the option of adding an adjustable thermostatic controller, enabling more precise temperature control.

 

Hot Box Features:

  • Preserve temperature sensitive material.
  • Install quickly and effortlessly.
  • Heat bulk materials and palletized products: paint, caulk, resins and epoxies, etc.
  • Side access doors.
  • Certified to UL/CSA/CE standards.