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John Butterfield
John Butterfield
KCI Publishing

Most recent articles

Using Continuous Helical Flow to Reduce Fouling
By John Butterfield | 02 June 2021
It would be an understatement to say that fouling is one of the most costly recurring problems in hydrocarbon processing, and that it hits process heaters and heat exchangers the hardest. Fouling can have a significant impact on heat transfer across the heat exchanger surface, and so likewise on both overall operational performance and total cost of maintenance.
Marc Simoens: a custodian
By John Butterfield | 26 May 2021
Marc Simoens is responsible for the quality assurance and quality control of the incoming refurbishment components for pressure containing equipment at Dow’s chemical plant in Terneuzen, The Netherlands. Heat Exchanger World recently caught up with him to talk about his work, the challenges he faces with heat exchanger pipes and tubing, and the advice that he would like to pass on to would-be suppliers, manufacturers, and endusers to Dow.
A failure report from the pulp and paper industry
By John Butterfield | 19 May 2021
A pulp and paper plant was facing a major problem when their digester preheaters started leaking, resulting in production loss. The shell-andtube heat exchangers were exposed to steam on the shell side and white liquor on the tube side. The tubes were made of Type 316L stainless steel. The preheaters had replaced the original ones which had performed satisfactorily for ten years. The new ones started leaking within seven months of operation. A detailed failure analysis was hence desirable.
Thermal processing of egg products
By John Butterfield | 12 May 2021
Corrugated heat exchangers in the food industry can help with processed egg pasteurisation. UK-based company HRS Heat Exchangers offers a solution to the issues presented by other heat exchanger designs used in the pasteurisation process with their new corrugated tube technology.
Isotherm Inc. – Innovating through enhanced heat transfer solutions
By John Butterfield | 05 May 2021
Isotherm, Inc. is a custom manufacturer specializing in the design and fabrication of heat exchangers, pressure vessels, and packaged systems for various industries such as industrial refrigeration, marine refrigeration, chemical & petrochemical, oil & gas, process and renewable energy. Heat Exchanger Worldhad the opportunity to speak with Adnan Ayub, President at Isotherm Inc. to discuss the company’s wide range of enhanced heat transfer technologies & innovative solutions.
Solutions to corrosive enviroments: casted bronze aluminium alloys
By John Butterfield | 28 April 2021
Corrosion causes problems in many different industrial applications. It can be due to different causes including chemical reactions, stress, and fatigue. Selecting the appropriate alloy for a given application is therefore an important step.
Natural refrigerants and heat exchanger applications
By John Butterfield | 21 April 2021
As the demand for green energy increases so does the need for natural refrigerants and heat exchangers to accommodate their operation. This article discusses examples of real applications for Pillow Plates and natural refrigerants. Using Pillow Plate heat exchangers with natural refrigerants for large-scale heating and cooling cuts down on the use of CFCs (Chlorofluorocarbons) and reduces environmental impact.
Bowman intercoolers save the day and thousands of dollars!
By John Butterfield | 13 April 2021
Two Cummins 4BTA Marine Diesel Engines were given a new lease of life and over US $8,000 saved by replacing the OE intercoolers with Bowman charge air coolers.
Life as a welding and materials engineer at Fluor Amsterdam
By John Butterfield | 07 April 2021
Jan-Willem Rensman works in the Energy & Chemicals Downstream business line at Fluor in Amsterdam, The Netherlands, where he is a Welding and Materials Engineer. There, he is responsible for reviewing the welding procedures and vendor fabrication practices related to welding, corrosion, and materials performance. Taking time out of his busy daily schedule, he talked to us about his passion and enthusiasm for what he does, particularly regarding his work with heat exchangers.
Designing a myriad of heat exchangers An interview with Mr. Bandaru Somasekhar of HGC Constructors Pvt. Ltd., Mumbai, India
By John Butterfield | 23 March 2021
When it comes to talking about designing static and rotary equipment for use in the light chemical, specialty chemical, and allied industries, Mr. Bandaru Somasekhar is no novice. Leading a medium-sized team of twenty engineers and designers he exudes enthusiasm and knowledge about his chosen profession.
Field report: cleaning of shell & tube heat exchangers
By John Butterfield | 17 March 2021
Looking at some ways to clean heavily soiled shell & tube heat exchangers, with an assessment of the advantages and disadvantages of these methods.
Ward Vessel & Exchanger Focusing on people first
By John Butterfield | 09 March 2021
As a manufacturer of industrial heat transfer equipment, Ward Vessel & Exchanger is committed to providing secondto-none service and exceptional value, while enhancing the success of their employees, customers, and suppliers. The company’s main mantra is, ‘It is not what we do, but how we do it’, and their focus is ‘People First’, whether it be employees, family, or communities served – which are at the heart of the company’s core values.
Industry trends the alloy you need for REACs
By John Butterfield | 03 March 2021
With an increased demand for cleaner fuels, refineries are taking a new approach to a variety of feedstock–from sweet to sour crude–that exposes their process equipment to harsher environments. This has been the case with REAC units in hydroprocessing systems, which have benefitted from design changes and metallurgical upgrades.
Heat-cured phenol coatings
By John Butterfield | 23 February 2021
This article looks at the use of heat-cured phenol coatings to provide safe corrosion protection for heat exchangers. Some case studies are examined and cost-saving advantages in both lifecycle costs and maintenance are pointed out.
Transformers, boilers and pressure vessels: megatons moved on air
By John Butterfield | 09 February 2021
Moving huge transformers, boilers, and pressure vessels, through production lines without causing slowdowns, or even shutdowns, can pose significant challenges. However, many companies do not realize that this type of equipment is easy to manoeuver around using air caster technology. In this article the technology is explained, and examples of how it works and eases the movement of heavy, complicated shapes are given and endorsed.
The Diverse World of Industrial Gases*
By John Butterfield | 03 February 2021
An interview with Fred Schweighardt, National Projects Leader – Advanced Fabrication Technologies for Airgas. Fred Schweighardt is a National Project Leader and International Expert for Airgas, an Air Liquide company, based out of Houston, Texas. In this capacity, he applies his extensive welding background to industrial gas applications in fabricating and manufacturing markets.
The use of titanium for heat transfer in the chemical processing industry
By John Butterfield | 27 January 2021
The transfer of heat from one fluid to another is an essential component of all chemical processes. Whether it is to cool down a chemical after it has been formed during an exothermic reaction, or to heat-up components before starting a reaction to make a final product, understanding the elements to design an effective, efficient heat transfer system is the key to cost-effective manufacturing of most chemicals today.
Milk fouling in heat exchangers
By John Butterfield | 19 January 2021
Some heat exchangers are used in very distinct industries with basically the same design. Take the Plate Heat Exchanger (PHE) for example. Companies in Oil & Gas and Food Processing employ this equipment, but the solutions developed in each field to cope with problems do not necessarily migrate between both industries. Even the manufacturers tend to segment their business lines and correspondent technical representatives, which may further prevent the flow of information.
Steam reformer tubes; lifecycle and integrity management
By John Butterfield | 12 January 2021
Steam reformers are used in ammonia, methanol and hydrogen plants and are one of the most critical items of equipment in terms of the potential impact on safety and production in case of failure. Reformer tubes operate within the creep range, and thus their useful life is finite and highly dependent on the operating conditions.
Working with steam turbines An interview with Jillian Toussaint of BP
By John Butterfield | 06 January 2021
In an informal interview, Principle Machinery Engineer at BP in the Netherlands Jillian Toussaint discusses her work with steam turbines, explains why digitalization will be increasingly important and – almost in passing– reveals exactly why engineering really should be every schoolleaver’s first choice of profession.
Corrosion resistance of heat exchangers in seawater desalination plants
By John Butterfield | 23 December 2020
This paper examines the corrosion of high-alloy stainless steels used in heat exchangers which are working in service in seawater desalination plants where chlorination of the seawater is used to limit microbial activity and can therefore provide a quite aggressive environment.
Best practices for welding duplex stainless steels
By John Butterfield | 15 December 2020
This article first explains why duplexes are increasingly the material of choice in process industries’ applications, before going on to explain the intricacies of welding duplex to dissimilar metals so that potential problems can be avoided. Aspects like the importance of the materials’ coefficients of thermal expansion, heat dissipation, thermal conductivity, and the fusion grain structure all need to be considered when joining duplex alloys to carbon steel and low-alloy steel.
Compact, high-efficiency heat exchangers: Understanding fouling
By John Butterfield | 08 December 2020
Within the class of compact heat exchanger, the sub-class of high efficiency CHEs is generally characterized by high film coefficients and low fouling factors that both contribute to higher overall U values. While these attributes alone tend to make the CHEs smaller in size than conventional shell-and-tube and other ‘longitudinal’ heat exchangers, the use of close channel spacings also allows this sub-class to get more heat transfer area into a given footprint and a given volume.
Heavy Metal & Tubes (India) Pvt. Ltd. A fully self-reliant company manufacturing stainless, carbon & alloy steel tubes from round bars to finished seamless tubes
By John Butterfield | 01 December 2020
Heavy Metal & Tubes (India) Pvt. Ltd. has a strikingly young and dynamic management, which is resolved to taking the company to new heights through its clear vision, state-of-the-art technology, highly talented and qualified staff, and its determination to produce the highest quality products to ensure customer satisfaction.
Orbital tube to tube-sheet welding
By John Butterfield | 25 November 2020
Each heat exchanger in which heat is exchanged in tubes, hence the designation tubular heat exchanger, comprises not only tubes but also a tubesheet or a tube header where the tubes end. Thousands of joints are required for just one heat exchanger and this underlines the importance of and the reason for an easily reproducible, reliable joint of high quality. When manufacturing heat exchangers no other work process is repeated as frequently as that used to fasten the tubes.
Ohmstede – Over a century of American heat exchanger expertise
By John Butterfield | 17 November 2020
Ohmstede has maintained its position as one of the most trusted names in American manufacturing for over a century. Since its foundation in 1905, Ohmstede has set the benchmark in the industry for all things shell and tube heat exchangers.
Coating: a viable way to prevent shell & tube heat exchanger fouling, reduce the carbon footprint of equipment and lower CAPEX
By John Butterfield | 10 November 2020
Each year, corrosion in process equipment causes substantial financial consequences in production plants, particularly in the chemical and petrochemical industry. Increasing investments for the replacement of equipment made of alloys lead to rising operating costs, which in turn endanger profitability and sustainability. One of the causes for equipment failure and loss of performance, particularly in heat exchangers, is fouling.
NESS Wärmetechnik GmbH: Convincing with competence and inspiring with ideas
By John Butterfield | 28 October 2020
NESS Wärmetechnik has been developing outstanding solutions for process heat systems for well over fifty-six year. Continually evolving its products and services in close collaboration with its customers to meet the latter’s unique requirement, the company is a well-known name throughout Germany and across the five continents with clients as far afield as California, Australia, China, and New Zealand. Heat Exchanger World recently caught up with Managing Director, Dipl.- Ing.
Kinam Engineering Industries: the heat exchanger specialist enters its 40th year of serving the process industries
By John Butterfield | 27 October 2020
Kinam Engineering Industries is a familyowned, heat-exchangermanufacturing specialist located in Mumbai, India. Entering its 40th year of serving the process industries, Heat Exchanger World recently caught up with one of its partners, Mr. Mehul Mehta to talk about the company’s success story, what makes it unique, and its strategy plans for the coming years.
Teadit: Leading R&D for critical process sealing solutions
By John Butterfield | 06 October 2020
As a worldwide development and manufacturing leader of critical process sealing solutions, Teadit continues to exceed customer expectations by providing high-quality service, impressive testing capabilities, and a full line of award winning products that are guaranteed to meet the demands of the most stringent environments.
Vermeer Eemhaven International: a heat exchanger maintenance knowledge center since 1955
By John Butterfield | 22 September 2020
Vermeer Eemhaven International is one of six healthy and experienced companies making up the VE Group. Established in 1955, it has been supplying innovative custom-made solutions to the process industries for almost sixty-five years. Working from seven modern production halls, it specializes in the design, manufacture, repair, and maintenance of shell & tube heat exchangers, airfins, and pressure vessels for the oil & gas, chemical, and petrochemical industries in a variety of materials.
Fouling and plate heat exchangers
By John Butterfield | 15 September 2020
The fouling factors, which are used in the design of heat exchangers are normally specified by the client based on his experience of running his plant, or on processes to simulate dirt accumulation on the heat transfer surfaces. If this fouling is not restricted to adequate levels then it can totally negate any benefits generated by skillful design.
Automated tube-to-tubesheet welding: Solutions for waste-heat boiler manufacturing
By John Butterfield | 01 September 2020
ACE Apparatebau Construction & Engineering GmbH provides an insight in to the different types of waste-heat boiler designs and their tube-to-tubesheet connection details in steam reforming plants.
Predicting defined and undefined problems in process plants
By John Butterfield | 25 August 2020
Enabling staff to accurately identify undefined problems ahead of time and the cause of defined problems allows plants to operate much more reliably and efficiently, says Precognize’s Chen Linchevski. OEM independent SAM GUARD can be easily applied to all process industry facilities, he stresses.
WORKING WITH A MYRIAD OF HEAT EXCHANGERS: An interview with Arjan Woerden of Shell Pernis, The Netherlands
By John Butterfield | 28 July 2020
Located at Rotterdam in The Netherlands, Shell’s Pernis facilities form part of the largest refinery in Europe and one of the biggest in the world. They cover an area of more than 1000 football pitches and employ over 1900+ staff spread over 60 plants. Working there is Arjan Woerden, a materials and corrosion engineer who is charged with looking after the crude distillation units (including hydrotreating units), the platforming unit, and the hydroconversion (hycon) unit.
Freedom! 3D printing will revolutionize heat exchanger design and manufacture
By John Butterfield | 23 June 2020
Until recently, heat exchanger design has been restricted broadly to two types, shell-and-tube and plate-and-frame. The manufacturing processes – welding, brazing or gasketing – are time-consuming and expensive. All this is changing, thanks to 3D-printing. This new technology has opened up heat exchangers to new designs, allowing them to be tailor-made for a given application.
Workshop report: heat exchangers connecting industry together
By John Butterfield | 02 June 2020
During the Stainless Steel World 2019 Conference & Exhibition, which was held in Maastricht, The Netherlands, November 26–28, a special workshop was dedicated to the huge variety of heat exchangers that perform critical duties in fundamental industries. Over sixty participants freely shared their experiences with an expert panel.
The bright future of heat pipe technologies
By John Butterfield | 26 May 2020
Brian Axcell, Professor at the Institute of Energy Futures at Brunel University and expert advisor on the EU-funded ETEKINA project, speaks with the ESCI about his career to date and the potential of heatpipes.
More efficient heat transfer through targeted turbulence generation
By John Butterfield | 19 May 2020
This article first briefly looks at the advantage and disadvantages of using thermal oils in heat transfer systems and the effect that their use can have on investment costs. It goes on to assess how turbulators (twisted tape inserts introduced into the heat exchanger) can not only significantly improve the heat transfer in the system itself, but can also help to ensure that the heat exchanger remains small.
Heat Exchangers at a manufacturer’s in India
By John Butterfield | 28 April 2020
Heat exchangers are to be found in a vast variety of industries nowadays, and certainly in the chemical specialty industry. We recently caught up with Mr. Mrinal Das, Chairman of the Flow Control Exchange Conference & Exhibition that was held in October in Mumbai, India, and who, in his everyday working life, is Executive Vice-President of Projects at Laxmi Organic Industries Ltd.
Electric heaters compared to heat exchangers: competitors or supplements
By John Butterfield | 21 April 2020
Whenever large electric heaters, flanged immersion or circulation heaters are shown at trade fairs, many visitors ask themselves whether this is a heat exchanger. Due to their external similarity, they can easily be confused with tube bundle or tube and shell heat exchangers. The purpose of this article is to provide a closer look at the differences of both systems, their limitations depending on specific applications and some advantages electric heaters may have.
Aluminium–bronze: a solution for tube and shell heat exchangers using brackish and/or sea water
By John Butterfield | 14 April 2020
Aluminium–bronze and nickel–aluminium–bronze (NAB) are not necessarily widely known but have been developed as solutions for seawater corrosion issues. At the same time, they also offer other interesting properties, such as resistance to biofouling.
Efficient use of waste heat in air conditioning and process air
By John Butterfield | 01 April 2020
Energy consultants and industrial energy managers will continuously have to find, implement and prove significant savings in the coming years. But what can be done when the ‘usual suspects‘ have already been implemented, from combined heat, power and cooling to LED lighting and compressed air leakage minimisation? The energy audits are ‘insatiable’, further suitable measures must be found.
Overseeing Refinery Processes at Par Hawaii
By John Butterfield | 24 March 2020
Bob McKaig is a process engineer who has worked at Par Hawaii in Kapolei, Oahu for the last twenty years. While he has been part of a number of departments, today his job revolves around ensuring that the company’s plants are kept running smoothly and meeting production needs while staying in safety and environmental compliance. His responsibilities cover unit optimization, the documentation of management of change, and training.
How to avoid the top 10 heat exchanger ‘mistakes’
By John Butterfield | 29 January 2020
With around 40 years’ experience of designing and installing heat exchangers – whether as part of a brand-new production line or as an upgrade or replacement to an existing unit – our engineers and sales staff have encountered a wide range of issues on sites. Here are ten of the most common mistakes that can occur as a result of poorly-specified or badly-installed heat exchanger systems – and, most importantly, how you can avoid them on your next project.
Overview of laser metal deposition for waste-to-energy pressurized boiler components *
By John Butterfield | 14 January 2020
This article gives a brief overview of recent Laser Metal Deposition (LMD) advances in the WTE boiler industry.
Substituting 316L by duplex in a heat exchanger combat erosion
By John Butterfield | 25 November 2019
In an organic chemical plant, a high-molecular weight organic acid vaporizer in a shell-and-tube heat exchanger, developed leakage within four months of going into service. The equipment was used to convert liquid acid to vapor under high pressure and above the boiling point of the acid. One of the nozzle pipes from the downstream reactor, which was processing the vapor in the same circuit, also developed a premature leakage.
Spiral or corrugated tube heat exchangers – which is best for wastewater treatment?
By John Butterfield | 05 November 2019
Since the first spiral heat exchanger was proposed back in the 19th century, they have become synonymous with the treatment of slurries and wastewater; materials which have a high fouling risk, are viscous, or which contain fibers and solid materials. However, in many situations the performance of a corrugated tube heat exchanger is equal to or better than that of a spiral design.
Cleaning industrial assets with Angara Industries
By John Butterfield | 22 October 2019
The team behind Angara Industries consists of dedicated professionals who have combined experience in chemical laboratory research and complex manufacturing of 25 years plus 26 years in industrial production and equipment service. In addition they have 42 years’ experience in sales and business development in oil & gas as well as other industrial and technical sectors. Managing Aging Plants had the pleasure of speaking with Ilya Rodin, CEO with Angara Industries.
Residual heat as green energy
By John Butterfield | 08 October 2019
In 2018, Shell began supplying the city of Rotterdam with enough residual heat from their Pernis refinery to meet the energy needs of 16,000 households. The project, known as the Pernis Residual Heat Initiative, depends on an interdisciplinary team of engineers to design and maintain the supply networks that make large-scale energy recycling possible.
Freedom! 3D printing will revolutionize heat exchanger design and manufacture
By John Butterfield | 12 September 2019
Until recently, heat exchanger design has been restricted broadly to two types, shell-and-tube and plate-and-frame. The manufacturing processes – welding, brazing or gasketing – are time-consuming and expensive. All this is changing, thanks to 3D-printing. This new technology has opened up heat exchangers to new designs, allowing them to be tailor-made for a given application.
Longitudinally welded stainless steel tubes and an appropriate logistics concept for heat exchangers
By John Butterfield | 28 August 2019
GEA has a reputation for fulfilling the high hygienic demands made by the food and beverages industry with its production machinery. The company’s Ahaus site produces not only milk and juice processing systems but also heat exchangers for heating and cooling in aseptic procedures. The fitted tubes inside the pressure vessels coming into contact with the products are supplied by Schoeller Werk in Hellenthal, Germany.
Heat recovery in steel plants to boost competitiveness
By John Butterfield | 14 August 2019
Kristijan Plesnik, energy manager at the steel production SIJ Metal Ravne in Slovenia, talks to ESCI about economic threats to steel production and how these may affect EU climate targets. Kristijan is also involved in the EU-funded ETEKINA project, which looks at new innovative ways to recover waste heat in energy-intensive industries using heat pipes.
Working together to find the best solution
By John Butterfield | 30 July 2019
To improve performance of heat exchanger tubing in challenging urea production environments, Sandvik Materials Technology worked with Stamicarbon BV to develop Safurex Star, an advanced alloy for use with high pressure (HP) strippers. Jane Eriksson, Sales & Marketing Manager for Tube EMEA for Sandvik Materials Technology discusses.
Longitudinally welded tubes: ideal for heat exchangers
By John Butterfield | 10 July 2019
GEA is one of the largest suppliers of process technology for the food industry and a wide range of other industries. The international technology group focuses on process technology and components for sophisticated production processes in various end-user markets. Heat exchangers are at the heart of much of its technology and longitudinally welded stainless steel tubes are proving the ideal material for these.
Cleaning industrial assets with Angara Industries
By Jolanda Heunen | 07 May 2019
The team behind Angara Industries consists of dedicated professionals who have combined experience in chemical laboratory research and complex manufacturing of 25 years plus 26 years in industrial production and equipment service. In addition they have 42 years’ experience in sales and business development in oil & gas as well as other industrial and technical sectors. Heat Exchanger World had the pleasure of speaking with Ilya Rodin, CEO with Angara Industries.
Optical Gas Imaging Vs. Method 21 for Detecting Hydrocarbon Emissions
By Stephanie Matas | 27 March 2019
Often with Leak Detection and Repair (LDAR) surveys, companies are stuck using traditional strategies that aren’t very efficient. In fact,despite recent technological advancements, many businesses seem reluctant to ‘take the plunge and embrace newer methods that would help them detect fugitive emissions in their operations. In this article, Terence Trefiak of Target Emissions Services discusses Optical Gas Imaging Camera (OGIC) technology for LDAR versus Method 21, and the AWP.

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