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Infra-Red to Convection Ovens
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Kemac, Infra-Red Technologies

"Many companies RESELL catalytic,
few can MAKE it”

The Gas-Cat™ Infra-Red catalytic emitter (heater) was pioneered within the Infra-Red Technologies product line. Over the Gas-Cat™'s almost 20 years history, over 10,000 emitters have been produced, most of which are still in operation today.

Trimac designs all forms of radiant technology as well as convection. For the majority of difficult curing or finishing applications, catalytic infrared however provides the safest, most energy efficient and accurately controllable heat source producing the optimum finish on your product.

Trimac Industries is one of only a handful of companies worldwide with the capability of actually manufacturing catalytic emitters. Benefiting from our years of experience solving difficult finishing challenges, Trimac best understands how to apply and control the radiant heat to ensure our customers produce the best finished product. In addition, since we are the only manufacturer worldwide of catalytic emitters who also manufactures aqueous washers, Trimac's breadth of knowledge and range of capabilities are unique to the industry.

 

The Gas-Cat™ uses a safe, flameless, proprietary technology to produce infrared energy through a catalytic reaction. This means NO FLAME is used to generate heat. Convection ovens, by contrast, use a flame to heat the surrounding air to raise the surface temperature of the product. Because of the flameless construction, the Gas-Cat™ can be ordered certified to be explosion-proof, meeting Factory Mutual and Canadian Standards Association insurance standards for use in Class 1, Division 2 environments.

Infrared uses light energy (much like solar energy) to heat products and penetrate and cure the coatings throughout. The infrared waves excite molecules within a product (thus generating heat) but pass, generally undisturbed thorough the surrounding air. Infrared energy is generated one of three ways, catalytic, electric or gas-
fired. Catalytic infrared is a medium to long wave energy and is typically considered the best all-around fit because of its controllability, speed, safety, economical energy usage and superior curing capabilities. Electric generally produces short to medium wave energy which is best suited for products needing a high, intense heat or extremely high volume, fast production environments. Electric infrared however operates at a considerably higher cost because of the greater utility consumption. Gas-fired infrared can also produce a similar medium to long wave energy like catalytic, but uses a flame to produce heat and so has some of the same limitations as gas convection.

Beyond the safety and energy savings of using catalytic infrared, the Gas-Cat™ typically requires 1/3 of the floor space needed to cure with convection heat.
Because infrared heat is directly absorbed by the part and energy is not wasted by heating the surrounding air, parts therefore get to temperature quicker. This means that lines can run faster or cure times can be shorter. The result is you pay for less energy which reduces overall operating costs.

Gas-Cat™ usage can also result in a higher gloss and brighter finish for finished products. In liquid paint applications, the infrared energy allows solvents and water to be driven out of paint before a skin can form. In powder applications, gelling and cross-linking of the powder occurs at a faster rate and prevents powder blow-off from air movement.


Catalytic heat is created by a chemical reaction using our proprietary Gas-Cat™ catalyst. This catalyst (a substance that alters the rate of a chemical reaction) coats the pad within the emitter and during operation it chemically reacts with the fuel, creating controllable face temperatures from 250°F to 1000°F, depending on configuration.

•  To begin the process, an electric heating element or calrod is turned on to preheat the catalyst coated pad

•  Once the catalyst pad reaches 250°F (the temperature that will self-sustain the chemical reaction with the fuel gas to convert it to energy) measured by the thermoswitch, a signal is sent to the control panel
•  Once a heater is at temperature, the safety shut-off valve allows the gas to flow to the heater

•  The combination of oxygen and the fuel gas in the presence of the catalyst impregnated pad creates the chemical reaction which generates the heat

•  Once this process has stabilized, the electric heating element is turned off

•  The main byproducts of this chemical reaction are H²O and CO².

•  Due to the flameless construction of a Gas-Cat™ emitter, they can safely be specified and have been certified for use in hazardous locations by FM and CSA


• Stainless steel housing, framing & rivets
      Lengthens life and improves performance of heater

• Welded construction
      Redundant structural integrity & gas tight seal

• 4” heater height
      Significantly less heat loss out back of heater

• 1' center structural ribs on heaters
      Prevents width warping affecting gas seal & cure control

• Lateral stiffening ribs
      Prevents length warping affecting gas seal & cure control

• ½” thick catalytic pad
      Improves uniform heat transfer

• Contoured gas dispersion tube
      Uniform gas flow for even heat distribution

• Low watt density electrical rods
      Reduces heater burnout & increases life

• Recompact heating elements after contouring
      Improves heat transfer & eliminates potential for arcing

• Higher operating pressures
      Improved controllability of temperature


• No flame

      Safe for Class 1, Div. 2, Group D Hazardous locations

• Heats objects faster
      Reduces time and space required

• Rapid cure temperature
      Minimal powder blow-off

• Can cure in 1/3 the space
      Significant gas and space savings

• Oven zoning capability

      Control over energy usage for individual part cure times

• Produces virtually no NOx or CO
      Reduces toxic emissions and environmental expense

• Only by-products are water vapor & CO²
      Simplifies regulatory compliance

• Lower flue emissions
      Less conditioned plant air lost from ventilation

• Fuel utilized more efficiently
      Less make-up air required (less dirt & energy usage)

• Accurate temperature control
      Fewer incidences of skinning and popping

• Redundancy
      Multiple heaters permit maintenance during operation



SIZE

BTUH

WATTAGE

B 6-12

3,000

85

B 6-24

6,000

180

B12-12

6,000

200

B12-18

9,000

200

B12-24

12,000

400

B12-30

15,000

400

B12-36

18,000

600

B12-42

21,000

600

B12-48

24,000

800

B12-60

30,000

1000

B12-72

36,000

1000

B18-18

13,500

400

B18-24

18,000

400

B18-30

22,500

400

B18-36

28,000

900

B18-42

31,500

900

B18-48

37,000

1200

B18-54

40,500

1200

B18-60

45,000

1500

B18-66

50,000

1500

B18-72

54,000

1500

B24-24

24,000

1200

B24-36

36,000

1200

B24-42

42,000

1200

B24-48

50,000

1600

B24-54

54,000

1600

B24-60

60,000

2000

B24-72

72,000

2000







GAS-CAT™ EMITTERS CAN BE ORDERED:
  •  Standard
  •  Standard with Explosion Proof
  •  With MR4 (Manual Start Device)
  •  Explosion Proof with MR 4
Trimac Industries Repairs & Remanufactures all emitter brands



 Curing
Powder coatings
Water-borne paints
Solvent-based paints
Plastic and latex surfaces
Lacquered metal components
Silkscreen prints
Boat and shoe adhesives
Plastisol coated parts
 
 Drying
Water evaporation
Fiberglass gelcoats and resins
Washed, dyed or finished textiles
Skins and color-sprayed leathers
Ores
Ink drying
Adhesives and surface sealing
Metallic inks
 
Shaping
Thermo-forming
Vacuum forming
Pressure forming
Setting twist in synthetic fibers
Setting nylon and perlon threads
Preheating rubber sheeting for extrusion
Heating papermache for molding or pressing
Shrink wrapping
 
Heating
Industrial molds pre-heating
Hazardous location heating
Metal embossing rolls
Paint kitchens
Pipeline gases
Instrumentation in cold locations
Comfort heating
Grave plots
Infrared heat works like the sun does heating the earth or evaporating the water in a lake. Flameless Gas-Cat™ catalytic Infra-Red is a directed, controllable source of medium to long wavelengths. At these wavelengths, as much as 96% of the energy is absorbed by the paint or other medium when the heat waves contact it.

Natural gas or LP fuels are introduced to the heated surface of the catalyst pads in the oven. The gas contacts the platinum catalyst and is oxidized at the surface of the heater by chemically reacting with the air at the surface of the pad to generate a temperature from 250° to 1000° Fahrenheit, without generating a flame. The infrared waves penetrate the coating surface and heat the coating throughout its thickness, leaving the outside surface porous enough to allow solvent and/or water to escape before the surface is cured.

Infrared heat drives the solvents and water out of the paint before the surface cures, and results in a higher gloss, brighter finish.
   
Infrared heat is inexpensive to operate compared to a convection oven when performing the same function. Unlike a convection oven, infrared passes through air without heating it, only solid materials are heated. Since the ambient air in an infrared oven is not heated, thinner, less expensive insulation can be used for oven enclosures. Although some energy is conducted to the base material when heated by infrared, all of the base is not raised to the surface temperature, thereby saving energy costs.
   
Infrared is an excellent heat source for gelling and curing powder. Since circulating air is not the source of heat, the powder is not blown off parts nor is there cross contamination from other colors. As a result, a better finish is achieved.
   
The products of chemical reaction are CO2 and water vapor. Therefore, exhaust is minimal, reducing the amount of makeup air that must be heated.
   
 

12601 Kaw Dr, Building C, Bonner Springs, KS 66012 || 913-441-0043 • 800-830-5112, Fax: 913-422-2004 || E-Mail Us
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