Bio Fuels
Biomass & Cellulosic Pretreatment
Biomass pretreatment is the initial stage of preparing hemicellulosic materials such as corn stover, grass, straw and wood fiber for ethanol conversion.
- Hemicellulose is the part of the carbohydrate portion of plants such as grass, corn stover, straw and trees, to mention a few. Like conventional starch conversion to ethanol, hemicellulosic materials can be converted to sugars and fermented to create ethanol, bio-diesel or other useful products
- All structural plant matter is a combination of cellulose, hemicellulose and lignin. Only the direct cellulose is readily convertible to fermentable products. Hemicellulose must be converted to a fermentable form of sugar and lignin is generally not convertible and must be removed
In all cases, the main technological hurdle is to free the cellulose material in the plant to allow it to be converted without significantly reducing the yield of the existing cellulose material. This process is generally referred to as ‘pretreatment’ of the biomass.
Biomass Slurry Heating Challenges
- Traditional heating approaches with heat exchangers present significant processing challenges such as achieving the required processing temperatures which are typically 300°F (149°C) or higher
- High solids (20-25%), high viscosity and pumping issues present unique challenges to achieve reliable process heating performance
- The use of steam injection in a vessel or tank has been utilised in a lab scenario; however, batch processing is not practical when scaling up to production plant level
- Simple steam injection devices like spargers have limited efficiency in condensing the steam which leads to temperature control problems and severe steam vibration
- Corrosion and erosion issues require unique product design and metallurgy solutions
Keys to Successful Direct Steam Injection (DSI) Integration
Direct Steam Injection (DSI) is a very good approach; however, steam has a tremendous amount of energy and needs to be applied properly for successful results. One of the key factors to successful DSI, is to inject steam at sonic velocity to achieve choked flow.
Spargers, Fixed Eductors & Venturi Style DSI
These units use a fixed nozzle to inject steam. Steam control is attempted via an externally modulated steam control valve. With an externally modulated steam injector, the steam pressure is adjusted to control the flow rate of steam with a control valve.
The problems arise when the steam pressure has been dropped to a point where the steam flow is no longer choked. This can be seen most often at start up and shutdown of externally modulated steam injectors in the form of noise, vibration and hammering. With an external steam valve, there is always a pressure drop before the steam reaches the injector. Some sparger devices use passive springs and tube assemblies that tend to stick, resulting from scale build-up, causing temperature control problems.
The use of external steam control devices to control the steam flow by modulating the steam pressure can lead to excessive steam hammering and vibration. Steam hammering and vibration often result from poor mixing and condensing of the steam. As temperature demand drops, steam pressure drops, lowering the steam velocity and potentially causing instability. Uncondensed steam bubbles will typically collapse when it comes in contact with a cold pipe wall in the liquid piping. When these bubbles collapse, the slurry rushes in to fill the void and impacts the pipe wall. In some cases this will result in some pinging noise and in severe cases, steam hammer and vibration.
PSX Heater Solution
The PSX heater uses a unique method of steam injection via an integral steam control device. The key to efficient, safe and predictable steam injection is to inject steam at sonic velocity to achieve choked flow. All steam injectors need to operate in a choked flow manner for good, non-violent mixing. The PSX heater is an internally modulated heater that varies the mass flow rate of steam by changing the area in which the steam may pass. This type of modulation allows the full steam pressure to always be present at the point of injection regardless of plug position. The PSX heater has an integrated Pneumatic Actuator that allows for the engineered steam diffuser opening to vary according to the temperature demand.
Flow rates can range from 1 – 5,000 gpm and a temperature rise of up to 250°F (121°C) in a single pass through the heater.
Key PSX Heater Direct Steam Injection Benefits
- The Internal Steam Modulation design of the PSX heater controls the steam mass flow and not the steam pressure thus providing reliable temperature control
- Sonic velocity injection leads to stable operation eliminating steam hammering and vibration
- The Low Pressure Drop across the PSX heater reduces energy consumption and allows for more reliable heating process (typically +/- 1%)
- Direct mechanical control of the steam injector allows for linear process heating control
- The PSX heater is controlled by the plant PLC/DCS or local controller with no proprietary software required
- The PSX heater can be installed in the piping requiring no floor space
- Single and multi-stage heating arrangements allow for processing flexibility
Biogas Production
More and more agricultural and dairy farms as well as beef, hog and poultry operations are considering the use of anaerobic digestion for biogas production. These operations typically produce a significant amount of organic matter in the form of manure. Anaerobic digestion is a biological process that breaks down organic solids. Manure can be processed in anaerobic digesters and the byproduct is methane gas. The methane gas can be captured, stored and used to run electrical generators and boilers for use in the farm operations. Heat exchangers can face the following challenges when heating sludge:
- Live steam used to provide heat for heat exchangers creates hot spots where sludge can burn and build-up plugging the heat exchanger tubes. This increases maintenance costs and an increased pressure drop across the heat exchanger
- Upgrading from mesophillic to thermophilic often require multiple heat exchangers in series to achieve the necessary temperature rise
- Increased pressure drop adds demand to the sludge pumps thus increasing energy usage
- Temperature control problems can be present as there is a lag time from slurry entering and then being discharged
To overcome these challenges, Direct Steam Injection (DSI) is a very good approach. There are correct ways to apply DSI and approaches that may not produce desirable results. One of the key factors to successful DSI is to inject steam at sonic velocity to achieve choked flow.
Spargers, Fixed Eductors &Venturi Style DSI
These units use a fixed nozzle to inject steam. Steam control is attempted via an externally modulated steam control valve. With an externally modulated steam injecton the steam pressure is adjusted to control the flow rate of steam with a control valve.
Problems arise when the steam pressure has dropped to a point where the steam flow is no longer choked. This can be seen most often at start up and shutdown of externally modulated steam injectors in the form of noise, vibration and hammering. With an external steam valve, there is always a pressure drop before the steam reaches the injector.
The use of external steam control devices to control the steam flow by modulating the steam pressure can lead to excessive steam hammering and vibration. Steam hammering and vibration often result from poor mixing and condensing of the steam. As temperature demand drops, steam pressure drops, lowering the steam velocity and potentially causing instability. Uncondensed steam bubbles will typically collapse when it comes in contact with a cold pipe wall in the liquid piping. When these bubbles collapse, the slurry rushes in to fill the void and impacts the pipe wall. In some cases this will result in some pinging noise and in severe cases, steam hammering and vibration.
PSX DSI Heater Solution
The PSX heater uses a unique method of steam injection via an integral steam control device. The key to efficient, safe and predictable steam injection is to inject steam at sonic velocity to achieve choked flow. All steam injectors need to operate in a choked flow manner for good, non-violent mixing. The PSX heater is an internally modulated injection heater that varies the mass flow rate of steam by changing the area through which the steam may pass. This type of modulation allows the full steam pressure to always be present at the point of injection regardless of the plug position. The PSX heater has an integrated Pneumatic Actuator that allows the engineered steam diffuser opening to vary according to the temperature demand.
Flow rates can range from 1 – 5,000 gpm. The PSX heater has a high heating capacity and can achieve a temperature rise of up to 250°F (121°C) in a single pass through the heater.
Key PSX Heater Direct Steam Injection Benefits
- Stable operation due to the internal steam modulation design which controls the steam mass flow and not the steam pressure thus eliminating steam hammering and vibration issues
- Low maintenance due to the PSX heater’s self cleaning design
- Low pressure drop reduces demand on the sludge pumps lowering energy costs
- Better temperature control allows for a more reliable heating process (typically +/- 1%)
- Reduced installation and operational costs with the elimination of the condensate return system
- Direct mechanical control of the steam injector allows for linear process heating control
- Control is maintained by the plant PLC/DCS or local controller with no proprietary software required
- PSX heater can be installed in the piping requiring no floor space
Grain Ethanol Processing
The OptiShear jet cooker is designed for starch cooking, wet mill processing of starch, ethanol production and fructose and alcohol production. ProSonix’s unique method of direct steam injection utilises internal steam modulation via an integral Pneumatic Actuator and variable position steam plug, to accurately meter the mass flow of steam, through choked flow conditions. ‘Choked flow’ is the phenomenon of accelerating a vapor to maximum velocity by creating a pressure differential through an engineered opening. By establishing choked flow, the steam mass flow can be metered to precisely control the heating of the liquid. This produces predictable results based on the position of the steam plug. Through a variable-area steam diffuser, steam flow is metered at the point where steam and liquid first contact and mix.
- Starch slurry processing is designed for starch slurries with solids concentration of up to 40%
- The OptiShear is well suited for all types of starch such as corn, potato, wheat, rice and cassava or tapioca
- High velocity steam and turbulent mixing injection via internally modulated steam control and variable position steam plug for vibration free operation
- Precise temperature control of +/- 1°F (-17.2°C) for reliable heating performance
- The OptiShear can be installed in any orientation and requires no floor space for installation
- Automatic or manual operation simplifies process integration
- Can be installed in any orientation. High temperature rise 250°F (121°C) in a single pass
- Materials of construction. Standard carbon steel or 316SS with optional wear coatings available for erosive slurry conditions
- Standard ANSI class connections (NPT threaded or RFF flanged) for 150 psig steam, with optional 300 psig available. Design standards- designed to ASME
Adjustable Slurry Gap Optimises Starch and Steam Mixing, Reducing Enzyme Use
In starch cooking, proper agitation or ‘shear’ is required to optimise the thermal effect of the steam on the starch particles. The OptiShear Jet Cooker is equipped with an adjustable Condensing Tube (CT). The adjustable CT can be positioned to vary the gap relative to the steam nozzle, creating a narrow slurry gap. This narrow gap between the CT and steam nozzle optimises the steam exposure to the thin ribbon of starch slurry as it enters the CT. By changing the position of the CT relative to the face of the steam nozzle, back pressure inside of the OptiShear can be optimised to reduce uncooked starch and enzyme usage.
Radial Slurry Flow
In the OptiShear design, the condensing tube and steam nozzle interface is truly coaxial, ensuring the starch slurry gap is uniform throughout the full 360° flow path. The tube rests on multiple bearing surfaces so there is no movement of the tube relative to the injector except to adjust the gap.
Advanced Drive System
The tube movement in the ProSonix heater to adjust the starch gap is accomplished using a threaded engagement. The tube is rotated and an external thread moves the tube towards or away from the injector (nozzle). Moving the tube in this way changes the orientation of the tube inside the heater, causing any wear spots of the tube to move as well. This has the beneficial effect of evening out the wear of the internal parts, extending their operating life.