Thaw Shed Equipment
For reduced operating expense and higher throughput
New Thaw Shed Technology
A breakthrough utilizing our proven infrared technology has led to the development of a vastly improved method for thawing frozen coal cars prior to dumping. An internal study by the innovative research department at Norfolk Southern has indicated that this new application improves the efficiency 30 - 50% over previous thaw shed designs, saving energy and increasing production potential. This savings is achieved by the use of a state-of -the-art computer controlled Quartz infrared heating system that has been successfully used in heating applications throughout numerous industries.
Energy Expense Reduction
Energy savings will be optimized by enhancing the control system to include programmable logic controls and proper zoning. This allows the cars to be "tracked" through the sheds. Tracking involves the following of each frozen car with a traveling pattern of infrared radiation. Power consumption is reduced to zero before and after the radiation pattern.
Increased production
The high tech system uses GOLDENROD® infrared emitters that have instantaneous reaction time. No pre-heating of the thawing equipment is necessary. The speedy reaction time of the GOLDENRODā high-intensity IR emitter permits rapid processing times, whether there is one car or hundreds of cars to be thawed.
Increased Efficiency
Thaw shed equipment of the past has required reflectors for proper operation. The dusty, dirty environment causes these external reflectors to become immediately dirty and ineffective, robbing radiant efficiency form the equipment. The GOLDENRODā IR equipment from TDM has its own integral gold reflectors that cannot become soiled. This permits high efficiency even after long periods of use because there are no external reflectors to get dirty and lose efficiency.
Formal Test Results
A 21 page report on the thaw shed testing, dated August 4, 1995, is available from Norfolk Southern. The following is an excerpt from the report:
summary
Quartz infrared lamps were tested and compared to the resistive heaters currently installed in the thaw sheds in Norfolk. Quartz heaters were more efficient than the resistive heaters. They began heating the car wall immediately while the resistive heaters required a warm-up time of 1 - 2 minutes.
Using the same amount of power, quartz lamps transferred heat through the car wall two times faster than the current heaters. We calculate coal will be thawed 30% faster using quartz lamps.
Since 1977, 4,229 cars per year per shed have been thawed in Norfolk. Using quartz lamps, 5,498 cars per year per shed could have been thawed in the same amount of time. We estimate revenues would increase $1.77 million per shed. Increased throughput would also increase car utilization.
Using quartz’s instant-on, instant-off capabilities, sensors, and computer controls, thaw shed operation can be optimized to maximize power savings and eliminate equipment damage.
We estimate power savings will range from $25,431 - $83,507 per year per shed depending on operating parameters and electricity costs. Additional savings from reduced maintenance / installation requirements and equipment protection requirements will average $35,000 per year. Also, the thaw shed will not need to be insulated, saving $67,652. Equipment damaged, including failed air brake hoses, failed AEI tags, bearing degradation, elastomeric seals on brake valves and slack adjusters, and paint damage, will be drastically reduced due to precise and accurate temperature control. We estimate $200,000 per year savings.
Total Annual Savings / Benefits Are Projected To Be
| Additional Revenues | $ 1,770,000.00 |
| Average Power Savings | $ 55,000.00 |
| Maintenance Savings | $ 35,000.00 |
| Equipment Damage | $ 200,000.00 |
| Total Savings / Benefits | $ 2,060,000.00 |
| One Time Savings | $ 67,652.00 |
One impediment to using aluminum cars, composite cars, and cars with composite parts is heat damage from the thaw shed. Quartz lamps will provide the temperature control necessary to use lightweight cars in the thaw shed. Equipment Marketing previously estimated that rebuilding Little Big Reds in aluminum instead of steel could save as much as $ 1.2 billion dollars over 25 years. Their analysis includes an estimated $ 1.9 million dollar loss from thaw shed damage, including $ 1 million in the first 5 years. Those losses would be avoided with a computer - controlled quartz lamp thaw shed.
About Thermal Designs & Manufacturing, Incorporated.
The staff of Thermal Designs & Manufacturing, Inc. has been handling infrared applications for over twenty years. TDM’s beginnings date back to the first automotive infrared oven installed at General Motors in 1954.
Equipment Availability
Improved efficiency and increased production can be obtained whether you upgrade an existing thaw shed or build a new one. Single car thaw sheds as well as larger, multi car sheds can be purchased.