Key Direct Steam Injection Benefits

Tank Heating

Jet Sparger Optimisation

Jet Sparger Optimisation Heating of water tanks or vessels in many applications is done to stage hot water for use in production, cleaning, line and filter flushing and a number of other uses. Common methods of tank heating are through the use of heat exchangers, eductors or spargers. The incoming water is usually around 45°F – 60°F (7°C – 16°C) and is typically heated anywhere from 100°F – 150°F (38°C – 66°C) for applications involving sanitizing or cleaning.

Tanks and vessel systems typically heated by the use of heat exchangers, eductors, and steam spargers can experience the following issues:

Spargers and eductors may damage the tank because of the sometimes violent nature of the condensation process
Using an external steam control valve to control steam pressure produces low velocity steam which leads to inefficient steam mixing and condensation. Uncondensed steam will either produce steam hammering or escape to atmosphere leading to energy losses
Heat exchangers require a condensate return system. Plug and ineffective steam traps along with flash releases can lead to energy losses and maintenance issues
Heating of water can leave mineral and scale build-up that causes maintenance and performance problems for heat exchangers and spargers
Some sparger devices use passive springs and tube assemblies that tend to stick, resulting from scale build-up, causing temperature control problems

Jet Diffuser Efficiency

High velocity steam delivery assures complete mixing of steam, reducing occurrences of vibration and saves energy losses from uncondensed steam escaping. Integral stem plug eliminates need for steam pressure control valve.

Single or Multiple Jet Sparger Configurations

A single Jet Sparger can be used for small tanks. When heating larger tanks, or if a higher temperature rise is required, multiple PSX Spargers (2-4) can be placed around the tank. Multiple Jet Sparger configurations also allow for rapid heat-up, and when desired temperature is achieved, (1) PSX Jet Sparger can be operated for trim temperature control.

PSX Heater Solution

Install the PSX Jet Diffuser Tank Mount Sparger on the tank wall to the heat the tank until the tank reaches a steady state temperature. Various size tanks can be accommodated with single or multiple Jet Sparger arrangements.

The PSX heater has a high heating capacity which accelerates tank heat-up time over the time it takes conventional steam sparging. Once the desired tank temperature is achieved, a single the PSX heater steam injector can be operated to allow for trim temperature control of the tank until the desired tank temperature achieved. Injection of high velocity steam minimises improves condensation and mixing, thus structural damage to the tank from the sparger can be eliminated. As the PSX heater utilises sonic velocity steam injection, scale and mineral build issues in the steam injector is eliminated.

The tank temperature can be controlled via a tank sensor, a discharge sensor, a cascade control loop or in a variety of configurations allowing consistent precise temperature control. The internal steam control design of the PSX heater controls the steam mass flow and not the steam pressure, thus eliminating steam hammering and vibration.

Note: Use of tank sparging for applications above 150°F (66°C) may be inefficient and lead to extended heating times. For tank heating applications above 150°F (66°C), the PSX Inline heater is recommended.

Key Direct Steam Injection Benefits

Energy savings resulting from more efficient steam condensation, faster tank heat-up and reduced heat loss to atmosphere
Lower maintenance due to the PSX Jet Spargers self cleaning design
Improved safety due to better steam injection heating methods (elimination of steam hammering)
Better temperature control allows for a more reliable heating process
Reduced maintenance costs from the elimination of condensate return system

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Whitewater Heating

Whitewater-Heating White water is a fine particle slurry used throughout the paper making process. Its name derives from fine fiber particles in the water that give it a milky white appearance. White water drains from the paper stock into a pit below the paper machine and is used for a variety of uses in the paper making process.

White water systems must periodically be cleaned to remove bacterial build up that occurs over time. This process is known as boil-out, in which the white water is raised to near boiling temperatures of around 180°F – 190°F (82°C – 88°C) to kill any bacteria in the system. A caustic solution is sometimes added to shorten the process and increase the effectiveness. The water is held at temperature until all bacteria is killed.

White water systems are typically heated by heating tank contents with steam spargers in the white water chest. Steam Injection Heaters that use a steam pressure reducing valve (PRV) experience a pressure drop in the steam pressure which leads to low velocity steam flow. Low steam velocity leads to poor steam mixing. Externally controlled steam injection heaters may lead to:

Ineffective condensation of the steam from the spargers, damaging the chest walls leading to expensive repairs
Steam escaping from the tanks and venting to atmosphere
Hot and cold zones to be present in the whitewater chest, leading to variable stock temperatures at the paper machine head box

PSX Heater Solution

A PSX Jet diffuser heater is installed in the white water system to quickly raise the white water temperature to near boiling and then throttle back to maintain the desired temperature.

ProSonix unique method of steam injection utilises an internal steam control to precisely deliver the appropriate mass flow of steam for the required heating. This is achieved via and integral Pneumatic Actuator, and a variable position stem plug in the steam jet diffuser. We do not throttle or regulate steam pressure. This design offers a precise method of steam control through a choked flow control delivery of the steam. Choked flow is the phenomenon of accelerating a vapor to maximum velocity by creating a pressure differential through an engineered nozzle. By establishing choked flow, the steam mass flow can be metered to precisely control the heating of the liquid.

Key Direct Steam Injection Benefits

Energy savings resulting from faster tank time and reduced heat loss to atmosphere
Lower maintenance due to the PSX heater’s self cleaning design
Improved safety due to better steam injection heating methods (elimination of steam hammer)
Reduced operating costs by reducing costly machine down time
Faster tank heat up time (~ 6-8 times that of traditional sparging) equals less machine downtime

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Hot Water Supply Systems

Hot-Water-Supply-Systems-2 In the Food industry, blanching of vegetables and potatoes is a common practice. Enzymes in vegetables are inactivated by the blanching process. Blanching is the exposure of the vegetables to boiling water or steam for a brief period of time. The vegetable must then be rapidly cooled in ice water to prevent it from cooking. There are a number of applications where containers need to be cleaned and pauperised prior to being filled in the packaging process. Processes such as fruit and vegetable juice processors, potato processors, vegetable and fruit canning and so forth are all processes that require hot water supply for cleaning and washing of packages and containers prior to filling.

Blanching processes will operate at temperatures of 190-205°F (43-96°C). Water is delivered to the blancher which in turn needs to be heated prior to processing the vegetables or potatoes in the blancher. Proper temperature control ensures processing optimisation. A low pressure drop across the water heater allows for more efficient operation of the pumps and better control for the spray nozzles. There are a number of challenges associated with conventional water heating methods:

Heat exchangers require floor space for installation space and room to remove tubes for cleaning. Other issues are lag response time, mineral and scale build-up and high pressure drop
Traditional mechanical spargers are prone to plugging and fouling
Conventional steam injection heaters with external stream control via a steam PRV are prone to process upsets such as hammer and vibration

PSX Heater Solution – Inline Heating

ProSonix’s unique method of steam injection utilises an integral pneumatic actuator and a variable opening steam diffuser to deliver high velocity steam injection heating. We do not throttle or regulate steam pressure. This design offers a precise method of steam control through a choked flow delivery of the steam. Choked flow is the phenomenon of accelerating a vapor to maximum velocity by creating a pressure differential through an engineered nozzle. 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 position of the stem plug. Through a variable-area steam diffuser, steam flow is metered at the point where steam and liquid first contact and mix. This method eliminates the need for an external steam control valve or downstream mechanical mixing devices. High velocity steam flow optimises the steam mixing and condensation with the liquid and eliminates problems with vibration/steam hammer.

Key Direct Steam Injection Benefits

Precise temperature control +/- 1 °F (-17°C) assures optimal processing conditions
Self cleaning design eliminates costly maintenance issues from scale and mineral build-up
Energy savings as the low pressure drop (typically 1-2 psig) reduces energy pump demand
High turndown of both steam and water flowrate allow for flexible operating conditions
Ease of installation as the PSX heater can be installed on the pasteuriser or in the water piping above

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Meat & Poultry Processing

Hot-Water-Supply-Systems In the Food industry, processing of meats and poultry requires heat and significant amounts of hot water for many of the process and cleaning applications throughout the plant.

Meat producers use a combination of scalding and de-hairing to prepare for evisceration. Carcasses are immersed in the tank that is filled with water at 136 to 140°F (58 to 60°C). The carcasses will be turned to ensure even scalding during the 4-4½ minute cycle. The water temperature is critical, because high temperatures degrade the meat and can excessively soften the skin, which can lead to tissue damage from subsequent handling. Low temperatures lead to excessive immersion times or difficult hair removal
Slaughtered carcasses are sprayed with hot water after de-hiding and after evisceration to clean the surface of the carcass. The carcass is hung from the overhead conveyor and an operator uses a high pressure sprayer to wash the surface of the carcass.Water must be at least 170°F (77°C) and may contain acetic or lactic acid to help kill all micro organisms. Too high of temperatures will damage the meat
Cutting tools, knives and evisceration equipment requires regular cleaning and sanitising. FDA approved temperatures must be maintained
Chicken processor will scald chicken paws. Accurate temperature control is required to avoid ‘graying’ the paw
Most facilities pre-treat the wastewater before discharging the water to the public sewer system. Sludge processing in digesters is common to break down organic solids and to produce methane for boiler energy supply

There are a number of challenges associated with conventional water heating methods:

Heat exchangers often plug and foul which reduces reliability and processing times
Water flow constantly varies based on processing conditions and clean-up periods
Processing plants must be able to demonstrate proper sanitising temperatures and are maintained to meet FDA approval

PSX Heater Solution – Inline Heating

‘Choked flow’ is the phenomenon of accelerating a vapor to maximum velocity by creating a pressure differential through an engineered nozzle. 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 stem plug.

Through a variable-area steam diffuser, steam flow is metered at the point where steam and liquid first contact and mix. This method eliminates the need for an external steam control valve or downstream mechanical mixing devices. High velocity steam flow optimises the steam mixing and condensation with the liquid and eliminates problems with vibration/steam hammering.

Key Direct Steam Injection Benefits

Precise temperature control +/- 1 °F (-17°C) assures optimal processing conditions
Self cleaning design eliminates costly maintenance issues from plugging and fouling
Energy savings as the low pressure drop (typically 1-2 psig) reduces energy pump demand
High turndown of both steam and water flow rate allow for flexible operating conditions
Ease of installation as the PSX heater can be installed in the water piping saving valuable floor space

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