Sustainability through simplicity
The connection between fewer moving parts and more reliable bulk solids processing
Author: Jamie Zachary
Industrial processes don’t slow down. Neither can the equipment that powers them.
And yet, many processors still rely on heat exchange systems that are inherently complex and loaded with moving parts that are prone to wear. Bearings fail. Flights wear out. Motors overheat. Every failure brings downtime, extra cost and frustration.
Now, contrast this with cutting-edge equipment that has been engineered for simplicity. No fans, no fluidization, no friction. Only slow, controlled movement of free-flowing solids through a bank of stationary heat transfer plates.
Plate-based moving bed heat exchangers (MBHEs) offer a distinct approach to thermal processing, with an emphasis on simplicity, reliability and energy efficiency. With fewer mechanical components and a design centered on a gravity-flow indirect heat exchange, these systems offer a low-maintenance alternative that delivers consistent, high-quality results.
The problem with moving parts
Traditional rotary drums and fluid beds are widely used across many industries, but they come with trade-offs.
Rotary drums, for instance, rely on mechanical rotation and lifting flights to tumble material in a rotating shell. While effective at distributing heat, the operation can impose wear and tear on internal components, especially when processing abrasive materials such as fertilizers or minerals. Bearings, seals, and drive systems are common points of failure that can lead to costly downtime.
Fluid bed systems typically use large quantities of low-pressure air to suspend and mix particles. While this type of equipment allows for effective heat transfer, high amounts of energy are required to power fans, collect and convey fines streams and filter air prior to discharge to the environment. Furthermore, the constant motion of particles can cause product attrition, increase dust formation and further complicate operational and maintenance practices.
With both types of equipment, high operational complexity can strain personnel resources and introduce risks of unplanned downtime.
“Complexity can lead to vulnerability and often also to increased costs,” says Warren Chung, Regional Director, Asia Pacific at Solex Thermal Science. “The more moving parts you have, the more things there are to monitor, service or replace. That’s especially problematic in 24/7 operations, where downtime directly impacts profitability.”
The value of fewer moving parts
By comparison, Solex’s plate-based MBHE technology uses passive gravity flow of material through vertically stacked, hollow plates. The heating or cooling fluid — typically water, steam or thermal oil — circulates inside the plates, never coming into contact with the product.
Because the product doesn’t tumble or mix, mechanical wear of components is minimized. There’s no need for motors, fans, or internal agitators in the heat transfer zone, which drastically simplifies operation and lowers the risk of breakdowns.
“Sustainability isn’t just about emissions or energy use,” says Stan Pala, Global Sales Director at Solex. “It’s also about designing equipment that lasts longer, works more effectively and requires less resources to operate and maintain it. That’s where simpler systems like MBHEs really shine.”
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From fertilizer to sugar, biosolids to minerals, and everything in between, Solex’s plate-based moving bed heat exchangers are helping companies around the world and across a wide range of industries streamline their operations, reduce maintenance demands and meet long-term sustainability goals.
Explore our Applications to learn more, or contact our team to speak with a heat exchange expert today.
This entry was tagged Heating, Cooling, and last updated on 2025-6-16