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Process Heating – Temperature Stability Under Dynamic Flow Rates Direct Steam Injection for Sustainability David Degelau Hydro-Thermal Corp Certified Steam.

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Presentation on theme: "Process Heating – Temperature Stability Under Dynamic Flow Rates Direct Steam Injection for Sustainability David Degelau Hydro-Thermal Corp Certified Steam."— Presentation transcript:

1 Process Heating – Temperature Stability Under Dynamic Flow Rates Direct Steam Injection for Sustainability David Degelau Hydro-Thermal Corp Certified Steam System Specialist

2 Presentation Summary Industrial heating methods Direct steam injection (DSI) basics Inherent properties for sustainability Case Studies -

3 Industrial Heating Methods Direct and Indirect Steam Heating

4 Indirect or Direct Heating Hot condensate out Cold liquid in Steam in Cold Liquid In Warm out Steam in Warm out

5 Direct Fluid Heating - Sparging Sparging – Oldest method of direct steam injection – Very inefficient – Prone to tank failure – Limited temperature control – High maintenance costs

6 Common Sparging Problems Steam Hammer – Steam bubbles present in pipe – Bubbles combine and grow – Bubbles contact cool pipe wall and collapse – Water rushes into void at high velocity Overheated zone around sparge nozzle Steam bubbles in pipe may damage tank Steam bubbles may escape into atmosphere

7 Direct Fluid Heating – Mixing Tees Mixing Tees – Very high maintenance – Prone to scaling and fouling – Steam hammer common – Potentially very dangerous – Limited temperature control

8 Direct Fluid Heating – Sparge Tube Perforated tube sparger – Requires external steam control valve – Very high maintenance – Prone to scaling and fouling – Steam hammer common – Limited temperature control due to external control – Internal spring prone to breakage TM

9 Direct Steam Injection vs. Heat Exchangers

10 Contrast: Heat Exchanger vs. DSI Indirect vs. Direct – Indirect = heat transfer only; no fluid mixing Steam in (Hot) Warm out Cold Liquid in Hot Condensate out

11 DSI Advantages Rapid and uniform heatingimportant in starches and food products Can heat highly viscous fluids Handles fluids that are difficult to heatavoids bake-on; abrasive slurries Compact footprint Minimizes plugging and fouling Rapid response time

12 Energy Losses in the Heating Process Water Treatment Makeup water Process Fluid HX Trap system Boiler Blow Down losses Condensate losses Stack losses Flash losses Heat loss Steam Pump power

13 Maintenance – Steam Systems Water Treatment Slurry HX Trap system Boiler Condensate return Blow Down Makeup water * Steam Survey, 2002 Greg Harrell, Ph.D., P.E. US Dept. of Energy

14 Internal Modulation Steam Velocity ~1500 ft/sec Full Steam Pressure (Psteam) High Velocity Steam Jet Steam Nozzle Combining tube Stem / Plug Hot Liquid Discharge Steam Inlet Liquid Inlet Patented internal modulation DSI unit

15 Contrast: Sparging vs. DSI Paper mill – actual data Reduced steam usage by 33% – 932 lbs (422 Kg) with spargers – 624 lbs (283 Kg) with DSI Time Savings Daily production increased by 32%

16 Maximum Boiler Energy Efficiency 100% efficient use of steam heat energy Reduced steam consumption Less energy required at boiler 25% - 30% reduction is common Lower energy costs rev 3.09

17 Energy Comparison Report Process fluid to be heated Process flow rate Incoming temperature Desired temperature at output Available steam pressure % of condensate returned to the boiler Boiler makeup water temperature Hours per day in use Boiler fuel cost per million Btu

18 Energy.gov ENERGY Calculator Process fluid type In/out temperature Process flow rate Hours per day in use Steam pressure % condensate returned Boiler makeup water temperature Boiler fuel cost per million BTU

19 Precise Temperature Control = Efficiency Poor Temp Control Tight Temp Control Tight temperature control results in Lower set-point

20 Direct Steam Advantages Reduced steam consumption Significantly lower energy costs Low maintenance Handles fluids that are difficult to heatavoids burn-on; highly viscous or abrasive slurries are no problem Small size Consistent, precise discharge temperature No condensate return required

21 Sustainability & the Triple Bottom Line Economic – Sales, profits, ROI – Jobs created – Taxes paid Environmental – Air, water quality – Energy usage – Waste produced Social – Community impacts – Product responsibility Sustainability Triangle Firms that maximize the sweet spot thrive in changing environments

22 Direct Steam Injection Technology Real-World Results Case Studies

23 Typical Food Processing Applications Utility Heating CIP and COP water heating CIP and COP water heating Washdown hose stations Washdown hose stations Jacketed kettles Jacketed kettles Sterilization pots Sterilization pots Can topping Can topping Bottle and can rinsing Bottle and can rinsing Thermal inactivation Thermal inactivation Process Heating Pet food processing Pet food processing Thick stock/paste heating Thick stock/paste heating Baby food/formula cooking/pasteurizing Baby food/formula cooking/pasteurizing Sauce heating/thickening Sauce heating/thickening Soup base cooking Soup base cooking Condiments heating Condiments heating UHT pasteurization UHT pasteurization Starch cooking Starch cooking

24 Success #1 Processor Reduces Cycle Time (Slurry Heating) Meat slurry cooking Customer needs to give permission to use name, or use a not to be named company format

25 Success #2 Plant Improves Throughput (Water Heating) Jacketed vessel tanks Replaced inefficient tank sparger – Scaling clogged heater – Steam hammer damaged tanks DSI benefit impact – Self-cleaning design increased uptime by 20% – $2000/month saved by eliminating tank welding repairs – Consistent temperature set-point maintained 60°F incoming water raised to 200°F 400 gallons per minute (widely fluctuating)

26 Success #3 Firm Improves Product – Slurry Viscosity Product in extruder - viscosity kept at acceptable levels to run smoothly and faster Save time Save energy

27 Summary: DSI = Sustained Benefits DSI effectively transforms heat energy – Near-instantaneous energy (heat) transfer – Effectively 100% efficient Significant measurable sustainable benefits – Energy savings – Sanitation effectiveness – Lower production costs – Reduced maintenance costs – Productivity improvement More work gets done = more bottom line profits!

28 Thank You! David Degelau 400 Pilot Court Waukesha, WI Hydro-Thermal Corp Engineer, Certified Steam System Specialist


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