Alpha Thermal Process, LLC

Alpha Thermal Process is a concept-oriented small business that provides engineering advice and consulting services on the development, design, and selection of process equipment for, and the operation of, high-temperature mineral and materials processing.

Core Competencies

Our core competencies include, but are not limited to, industrial furnaces such as rotary kilns, the ubiquitous industrial workhorse widely used in the related industry, fluidized- and static-bed furnaces. With several new rotary kilns sized in all capacity ranges and several others in operation redesigned and retrofitted for optimized operation, we pride ourselves in being the most knowledgeable in the field with a wide spectrum of process knowhow:

Industries Served

The industries we serve include Minerals, Metals & Materials Processing; Fuels & Combustion; Cement & Lime Operations; Thermal Destruction of Waste; Lightweight Aggregate; Power Generation; Nanoparticles; Food Processing, etc.

Pyro-Technical Applications

The pyro-technical applications we cover include: Calcination; Roasting; Induration/Sintering; Simple heating/cooling; Melting; Drying; Ore reduction, extraction, beneficiation, etc.; Combustion for confined flame applications including internal combustion engines and industrial furnaces.

We offer the following:

Novel Process Applications

  • While we are experts on rotary kilns, we recognize that they may not be the best match for your process or site conditions. We help our clients identify and select, based on their process data combined with our vast process experience, the thermal system that best matches their process. If you need help developing your process data, and establishing conditions for scale up AlphaThermal can assist you to meet your process dreams with the help of our partners.
  • With the right lab data (TRL = 2-3) or pilot plant data (TRL = 3-5), we can provide process design calculations leading to the sizing of demonstration/commercial scale (TRL = 5-8) furnace of choice and related appurtenances upstream and downstream of the main furnace. (TRL is US-DOE defined Technology Readiness Level).
  • We provide design layout using the latest design tools available such as AUTOCAD, Inventor, etc., and complete the design with flowsheets, engineering drawing as blueprints for fabrication and P&ID to match.
  • We offer our own industrial supervisory controls and data acquisition systems programming, control systems integration using a combination of PLCs and control software packages such as but not limited to Allen Bradley/Rockwell Automation and Automation Direct, and embedded microcontrollers such as Atmel AVR for data acquisition and supervisory control of the process and related emissions.
  • Alternatively we can oversee, manage, and/or provide advice and due diligence on your vendors that supply process equipment, unit operations, controls, instrumentation, and any other process-related work.
  • We provide supervision of the fabrication of the select thermal system (our own design or vendor supplied), installation and commissioning of the installed system for your technology.

Optimization of Existing Systems

  • If you have existing furnace in operation and are looking for productivity increases AlphaThermal can evaluate your operation to identify areas for improvement that support reductions in energy use, capacity increases and/or product quality improvement and emissions abatement. In most cases AlphaThermal has helped customers achieve 10% improvements across the board.
  • Our approach is strictly scientific and based on accurate data collection via kiln audits, data analysis and operational diagnosis via our multivariate scientific tools such as comprehensive thermodynamic modeling, computational fluid dynamics (CFD) and simply collective knowhow based on collective experience.
  • For energy, product quality and emissions issues we focus on source flame shaping via our extensive knowledge of kiln aerodynamics. Typically our computational tools and in-depth interpretation of the model results will inform changes to burner and/or kiln internal design.