An indirect-heat thermal processor for processing bulk solids includes a housing including an inlet for receiving the bulk solids and an outlet for discharging the bulk solids and a plurality of heat transfer plate assemblies disposed between the inlet and the outlet and arranged in spaced relationship for the flow of the bulk solids that flow from the inlet, between the heat transfer plate assemblies, to the outlet. The heat transfer plate assemblies include a heat spreader, a heating element disposed adjacent the heat spreader, a temperature detection device spaced from the heating element and disposed adjacent the heat spreader, covers disposed on opposing sides of the heat spreader, the heating element, and the temperature detection device to provide a sandwiched assembly in which the heat spreader, the heating element, and the temperature detection device are sandwiched between the covers, heating element couplings coupled to the heating element and extending from the sandwiched assembly for controlling the heating element, and a connector coupled to the temperature detection device and extending from the sandwiched assembly for monitoring a temperature at the temperature detection device.

Method of combusting hydrocarbon fuel to form combustion products low in nitrogen dioxide (NO2) and carbon monoxide (CO) and mixing the combustion products with additional air to provide a heated air stream suitable for heating enclosed spaces includes the following steps: (a) delivering a fuel stream to a burner assembly; (b) delivering a combustion air stream to the burner assembly; (c) combining the fuel and air streams within a combustion chamber and heat exchanger wherein the mixture is ignited, completely combusted, and the temperature of the products of combustion are reduced; (d) providing tempering air to the external side of the combustion chamber and heat exchanger to transfer heat away from the combustion gases to tempering air; (e) combining the partially heated tempering air and cooled combustion products low in NO2 and CO; and (f) discharging the mixture into a space to be heated.

Method of combusting hydrocarbon fuel to form combustion products low in nitrogen dioxide (NO2) and carbon monoxide (CO) and mixing the combustion products with additional air to provide a heated air stream suitable for heating enclosed spaces includes the following steps: (a) delivering a fuel stream to a burner assembly; (b) delivering a combustion air stream to the burner assembly; (c) combining the fuel and air streams within a combustion chamber and heat exchanger wherein the mixture is ignited, completely combusted, and the temperature of the products of combustion are reduced; (d) providing tempering air to the external side of the combustion chamber and heat exchanger to transfer heat away from the combustion gases to tempering air; (e) combining the partially heated tempering air and cooled combustion products low in NO2 and CO; and (f) discharging the mixture into a space to be heated.

A blast furnace system is used wherein the coke rate is decreased by recycling upgraded top gas from the furnace back into its shaft section (which upgraded top gas is heated in a tubular heater prior to being recycled). The top gas, comprising CO, CO.sub.2 and H.sub.2, is withdrawn from the upper part of the blast furnace; cooled and cleaned of dust, water, and CO.sub.2 for increasing its reduction potential and is heated to a temperature above 850 C. before being recycled thus defining a first gas flow path used during normal operation of the blast furnace. Uniquely, a second gas flow path for continued circulation of top gas selectively through the heater and a cooler during operation interruptions of the blast furnace allows time for gradual controlled cool down of the heater in a manner to avoid heat-shock damage to the tubular heater.

A blast furnace system is used wherein the coke rate is decreased by recycling upgraded top gas from the furnace back into its shaft section (which upgraded top gas is heated in a tubular heater prior to being recycled). The top gas, comprising CO, CO.sub.2 and H.sub.2, is withdrawn from the upper part of the blast furnace; cooled and cleaned of dust, water, and CO.sub.2 for increasing its reduction potential and is heated to a temperature above 850 C. before being recycled thus defining a first gas flow path used during normal operation of the blast furnace. Uniquely, a second gas flow path for continued circulation of top gas selectively through the heater and a cooler during operation interruptions of the blast furnace allows time for gradual controlled cool down of the heater in a manner to avoid heat-shock damage to the tubular heater.

A sintering furnace can have a housing, one or more heating elements, and a conveying assembly. Each heating element can be disposed within the housing and can subject a heating zone to a thermal shock temperature profile. A substrate with one or more precursors thereon can be moved by the conveying assembly through an inlet of the housing to the heating zone, where it is subjected to a first temperature of at least 500 C. for a first time period. The conveying assembly can then move the substrate with one or more sintered materials thereon from the heating zone and through an outlet of the housing.

An indirect-heat thermal processor for processing bulk solids includes a housing including an inlet for receiving the bulk solids and an outlet for discharging the bulk solids and a plurality of heat transfer plate assemblies disposed between the inlet and the outlet and arranged in spaced relationship for the flow of the bulk solids that flow from the inlet, between the heat transfer plate assemblies, to the outlet. The heat transfer plate assemblies include a heat spreader, a heating element disposed adjacent the heat spreader, a temperature detection device spaced from the heating element and disposed adjacent the heat spreader, covers disposed on opposing sides of the heat spreader, the heating element, and the temperature detection device to provide a sandwiched assembly in which the heat spreader, the heating element, and the temperature detection device are sandwiched between the covers, heating element couplings coupled to the heating element and extending from the sandwiched assembly for controlling the heating element, and a connector coupled to the temperature detection device and extending from the sandwiched assembly for monitoring a temperature at the temperature detection device.

An indirect-heat thermal processor for processing bulk solids includes a housing including an inlet for receiving the bulk solids and an outlet for discharging the bulk solids and a plurality of heat transfer plate assemblies disposed between the inlet and the outlet and arranged in spaced relationship for the flow of the bulk solids that flow from the inlet, between the heat transfer plate assemblies, to the outlet. The heat transfer plate assemblies include a heat spreader, a heating element disposed adjacent the heat spreader, a temperature detection device spaced from the heating element and disposed adjacent the heat spreader, covers disposed on opposing sides of the heat spreader, the heating element, and the temperature detection device to provide a sandwiched assembly in which the heat spreader, the heating element, and the temperature detection device are sandwiched between the covers, heating element couplings coupled to the heating element and extending from the sandwiched assembly for controlling the heating element, and a connector coupled to the temperature detection device and extending from the sandwiched assembly for monitoring a temperature at the temperature detection device.

A graphitization furnace includes: a first electrode; a second electrode disposed so as to face the first electrode; a first energized heating element provided on a surface of the first electrode facing the second electrode; and a second energized heating element provided on a surface of the second electrode facing the first electrode. The first and second energized heating elements are configured to allow to be disposed therebetween, an object to be processed. The graphitization furnace is configured to heat and graphitize the object to be processed disposed between the first and second energized heating elements by energizing between the first and second electrodes.

A graphitization furnace includes: a first electrode; a second electrode disposed so as to face the first electrode; a first energized heating element provided on a surface of the first electrode facing the second electrode; and a second energized heating element provided on a surface of the second electrode facing the first electrode. The first and second energized heating elements are configured to allow to be disposed therebetween, an object to be processed. The graphitization furnace is configured to heat and graphitize the object to be processed disposed between the first and second energized heating elements by energizing between the first and second electrodes.