Category Archive: Retrofits

The Benefits of Retrofitting Process Heating Systems

sigma thermal replacement heater
At Sigma Thermal, we offer a wide range of industrial retrofit and upgrade services for process heating systems. Without proper planning and execution, the retrofitting process can be a frustrating one for many companies. Conducting a retrofit project without the proper knowledge and experience may result in poor functionality, damage to the system, or extended downtimes.

Sigma Thermal’s retrofit team utilizes expert skill and knowledge to ensure your retrofitting project is a success. We can assess your needs and make recommendations that will help improve your setup, resulting in optimal service for the life of your equipment.

During efficiency improvements, we provide our customers with an estimated return on investment (ROI) timeframe. Basically, we calculate the energy savings, compare that with the cost of the retrofit, and provide an estimate of how long it will be before they have “paid” for the retrofit with the saved fuel costs, and estimated annual savings thereafter.

Depend on our retrofit team to help you retrofit existing heaters for improved functionality, repair damaged systems, or upgrade older systems to more modern solutions.

Benefits of Retrofits

Benefits of Retrofits

Retrofitting industrial heating equipment presents a wide range of operational benefits. These benefits include:

  • Improved efficiency.
    Optimizing equipment to improve the process efficiency.
  • Reduced labor costs.
    Retrofitting identifies opportunities to automate a range of simple or complex processes, which will lower the overall labor requirements for production.
  • Compliance.
    Retrofitted systems will be updated to comply with all modern emissions standards and safety regulations, operate more reliably. This will lessen the likelihood of breakdowns and minimize downtime.
  • Lower operating costs.
    Increasing efficiency to reduce the amount of fuel needed to achieve the same amount of heat out of the furnace/heater.
  • Updated controls.
    Modern, updated controls facilitate more precise operations. In addition, outdated controls may be difficult to repair or replace. Retrofitted systems will be updated to comply with all modern emissions standards and safety regulations, creating a cleaner and safer work environment.
  • Improved system reliability.
    After being retrofitted, systems will operate more reliably. This will lessen the likelihood of breakdowns and minimize the downtime necessary for maintenance and repairs.

Types of Retrofits Sigma Thermal Offers

Our extensive retrofit services include emission upgrades and system modifications. Sigma Thermal also conducts retrofits on systems built by other suppliers. The type of retrofit that best suits your application is dependent on a handful of factors, the most important being the type of system that you have in place. As an example, systems running on wood call for different retrofit processes than those that run on natural gas or diesel fuel.

Our retrofit services include:

  • Replacement Parts

Replacing worn or damaged parts is key to a successful retrofit. We can replace ash conveyors, feeders, and lids on wood furnaces and heaters. We can also replace fuel trains and burners on natural gas and diesel process systems.

  • System Modifications

Our team can modify existing systems for more efficient operation or improved capabilities. For example, we can switch out a water-based cooling system for an air-cooled design.

  • Site Audits

The Sigma Thermal team will visit your site to identify areas for improvement in your heating system.

  • Repairs

Our repair teams identify problems and repair your process systems to restore functionality.

  • Custom Solutions

Our experienced technicians can offer custom retrofitting solutions for a wide variety of thermal fluid systems and alternative fuel types.

Sigma Thermal Retrofit Services

At Sigma Thermal, our suite of aftermarket services includes parts, maintenance and service plans, and retrofits. We offer long-term service plans designed to guarantee the performance and longevity of your system.

For more information about our retrofitting capabilities or other products and services, please contact us or request a quote.

Retrofitting with Sigma Thermal: Two Case Studies

Retrofitting equipment can be a frustrating process if not planned and executed properly. Sigma Thermal has worked on a variety of retrofitting projects, including heater coil replacements, heater modifications, custom thermal system solutions and much more. To learn how Sigma Thermal can help you with your equipment, read on.

Case Study 1: Replacement and Repair of Thermal Fluid Heating System at a Biomass Mill

Specifics: J14090 


This project consisted of replacing 3 convection style tube bundles for a wood-fired thermal fluid system. Parts of the system were destroyed in a fire at a biomass mill.
Sigma Thermal has done a lot of work for this client before, so they had confidence we could deliver within the timeframe needed.

What We Did

Sigma Thermal engineered a temporary blind while still giving them access to the damaged equipment so it could be replaced. This allowed the customer to run half of their process and maintain
production with the other half of their system. 

Case Study 2: Replacement of Two Natural Draft Burners

Specifics: J14099 

This project consisted of replacing 2 natural draft burners with 2 forced draft burners, along with all the required supporting parts required to make the change. Once the project was installed, the service group went on site to fine tune the new burners. This change greatly reduced the start-up time for the heaters – as the purge time for a natural draft burner is near 15 minutes – where the forced draft is closer to 2 minutes.

What We Did

Sigma Thermal made required modifications to the heater lid, fuel train, electrical system, and controls, all of which were included in this project.

Learn More about Sigma Retrofits

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