engineering fundamentals ProSonix Direct Steam Injection Heaters

ProSonix Direct Steam Injection Heaters
Company
Profile

ProSonix is a technology company that assists customers in optimizing their fluid processing heat transfer applications. We  specialize in the application of Direct Steam Injection heating for liquids, slurries, along with municipal and industrial waste stream sludge heating. We offer solutions in the form of consulting, products solutions, and technical services.

Internally Modulated Steam Control - The key to proper steam mixing, which assures smooth operation and stable temperature control, is driven by achieving a choked flow condition at the point of injection. The design of the PSX heater steam diffuser is engineered to achieve a pressure drop to achieve a choked flow condition. This choked flow condition assures near sonic velocity delivery of the steam and controls the mass flow of the steam, not the steam pressure. The PSX heater has an integral actuator that controls a variable position stem plug, allowing for maintaining high velocity steam injection throughout the range of the heaters operation.

 

 

Pro-Sonix is a company that delivers value added fluid heating solutions, both technical services and product based, for industrial process companies in the Biofuels, Chemical, Pulp & Paper, Mining, Food, and Wastewater markets.

 

 

Products
  • Direct Steam Injection heaters for industrial and utility water heating applications
  • Steam Injection heaters for slurries
  • Jet Cooker style Steam Injection heaters for wet milling starch processing, industrial starch cooking, and ethanol
  • Inline Direct Steam Injection heating for high viscosity sludges or fibrous slurries
Contact Tom Podwell
Address P.O. Box 26676
Milwaukee, WI 53226-0676
Country United States
Telephone 800-849-1130
Email info@pro-sonix.com
Website www.pro-sonix.com
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PSX Direct Steam Injection Heater

Liquid & Steam Pressure Relationship: 

We are often asked about the importance of the relationship between the liquid pressure and the steam pressure. The Steam and liquid pressure are related to one another in several ways.
First and most important is the need for a differential between the steam pressure and the liquid pressure.
All Direct steam injection heaters rely on high steam velocity to drive the condensation of the steam and transfer energy in a stable and rapid manner.  This differential will determine the velocity of the steam. The ideal case is where the liquid pressure is less than 60% of the absolute steam pressure.  Many direct steam heaters will not operate if that condition is not met, particularly those that utilize an external steam control valve to adjust the amount of steam injected.  In externally controlled heaters, the steam pressure is substantially reduced through the steam control valve, so the available steam pressure is much lower than the design pressure.
Second, minimizing the differential between the steam pressure and the liquid pressure presents fewer process upsets, leading to more stable DSI heater operation (no hammer & vibration), better pump integration, and improved temperature control. All these can be optimized by maintaining high velocity steam injection to promote rapid and complete condensation of the steam.
The ProSonix Diffuser heater design utilizes a unique internal steam control design whereby the steam and liquid pressures can be much closer and still provide high velocity steam injection.  In our design, we can operate with liquid pressures up to 80% of the absolute steam pressures.
In general, the pressures should meet the following condition:

Equation 1:

   
 

Pliquid  ≤ [(Psteam + 101 kPa)x0.8]-101kPa


There are a variety of ways to meet this condition in real world applications.
1.                   Choose a steam supply high enough to meet the requirements
2.                   Reduce the liquid pressure
a.       Move the heater to a higher elevation
b.      Trim pump impellers
c.       Change pressure settings in control loops
Standard ProSonix heaters are designed to operate on steam pressures as high as 300 psig (2000 kPa).  Although it is possible to operate at steam pressures above 300 psig, external factors such as leakage and seal ratings, generally make it impractical.  In addition, there is no operational advantage to operate at higher steam pressures since in most cases, the steam velocity will not increase significantly, once the conditions in Equation 1 are met.

 

 

ProSonixTM Direct Steam Injection Heater, some features worth noting:

 

  • Precise Temperature Control - The temperature control is typically +/- 1 °F which improves process heating reliability.
  • Smooth Operation - The PSX Heater utilizes an internally modulated steam control design which controls the steam mass flow and not the steam pressure thus eliminating steam hammer and vibration issues. Direct mechanical control of the steam injector allows for linear process heating control and repeatable performance.
  • Low Pressure Drop – Typically around 2-3 psig or less.
  • Reduced Maintenance – The Sonic Velocity steam injection produces a self cleaning design eliminating problems with mineral and scale build-up.
  • Compact Design – The PSX heater can be installed in the piping requiring no floor space.
  • Process Fluid Flexibility – The PSX Heater has several designs which makes it suitable for water heating, viscous slurries, and wastewater sludge’s.
  • Positional Steam Inlet – Allows the steam inlet to rotate 360° to meet the incoming steam piping regardless of the slurry inlet and discharge positions for ease of installation. 

http://www.pro-sonix.com/Products.html

-Manufacturing , Processing and Tooling > Heaters and Heating Elements
-Manufacturing , Processing and Tooling > Heating and Cooling
-Manufacturing , Processing and Tooling > Tanks and Vessels
 

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ProSonix Jet Cooker - Direct Steam Injection Heater

ProSonix Jet Cooker for Starch  Wet Milling, Dry Milling, Starch Conversion and Grain Ethanol! We have been assisting customers to improve their Jet Cooker performance ... stop by and let's discuss your application...

  • Radial Slurry Flow - The ProSonixTM Jet Cooker is designed for automatic operation and precise positioning of the PSX Heater condensing tube relative to the steam injector. Multiple internal bearing surfaces assure uniform alignment between the Condensing Tube and Steam Injector for more uniform flow.
  • Improved Jet Cooking Performance - The PSX Heater is designed for Ethanol and Starch process applications, where optimization of the pressure drop results in improved starch cook-out performance and a reduction in enzyme costs. The uniform alignment between the Condensing Tube and Steam Injector for more uniform flow and eliminates the need for over driving the combining tube to compensate for mis-alignment.
  • Reduced Maintenance - Multiple internal bearing surfaces assure uniform alignment between the Condensing Tube and Steam Injector for more uniform flow and improved reliability over traditional DSI heating devices. We have eliminated the single point bolt stud connection which is a common failure point in other Jet Cookers.
  • No Black Box Controls - Control and operation of the OptiShearTM  is done directly by the plant DCS/PLC with no proprietary control panels or software.
  • Reduced Plant Air Consumption - OptiShearTM uses an AC motor to operate the drive.
  • Positional Steam Inlet – Allows the steam inlet to rotate 360° to meet the incoming steam piping regardless of the slurry inlet and discharge positions for ease of installation.

http://www.pro-sonix.com/biofuel.html

-Manufacturing , Processing and Tooling > Heaters and Heating Elements
-Manufacturing , Processing and Tooling > Heating and Cooling
-Manufacturing , Processing and Tooling > Tanks and Vessels
 

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ProSonix Inline Direct Steam Injection Heater
ProSonixTM PSX Inline Direct Steam Injection Heater

For Pretreatment heating of fibrous Cellulosic Biomass

  • High viscosity sludge’s and slurries
  • Anaerobic digestion and Biogas production
  • Suitable for corrosive and abrasive applications
 FEATURES & BENEFITS: (PATENT PENDING)

 

  • 3-Dimensional Steam Injector delivers up, down, and side to side steam injection pattern to optimize steam mixing and rapid condensation.

     

  • Angled Diffuser (Steam Injector) reduces flow disruptions and is well suited for fibrous slurry flow. 

     

  • Single Point Steam Injector diffuser connection allows for complete fluid pass through clearance with no build-up points for fibrous materials.

     

  • Low Pressure Drop across the PSX Heater reduces energy consumption and improved process pumping performance.

     

  • Internally Modulated Steam Injection controls mass flow of steam allowing for smooth and stable operation.

     

  • Positional Steam Inlet allows steam inlet flange to be rotated in 360° for ease of steam piping connection.

     

  • Single & Multi-Stage Heating for processing flexibility and high temp (above 300 deg F) heating applications 

 http://www.pro-sonix.com/files/Direct_Steam_Injection_Heating_of_Fibrous_Slurries.pdf

-Manufacturing , Processing and Tooling > Heaters and Heating Elements
-Manufacturing , Processing and Tooling > Heating and Cooling
-Manufacturing , Processing and Tooling > Tanks and Vessels
 

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ProSonix Pilot Lad Direct Steam Injection Jet Cooker

The ProSonixTM PSX-38 Lab Jet Cooker Direct Steam Injection heater is designed for Pilot Lab starch cooking applications. The ProSonixTM unique method of direct steam injection utilizes internal steam modulation via an integral Pneumatic Actuator to accurately deliver the appropriate mass flow of steam for the required heating. This modulating 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 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 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.

 

·         Sonic velocity steam injection via internal steam modulation provides stable and vibration free operation.

·         Flowrate: 0.25 – 1.0 gpm
·         Precise temperature control to +/- 1°F for reliable heating performance.
·         Compact design suitable for minimal installation space requirements.
·         Well suited for High Solids Concentration starch slurries.
·         Can be installed in any orientation.
·         High temperature rise (up 250°F) in a single pass.
·         Standard materials of construction are carbon steel and 316SS.
·         Wear Coatings are available for erosive slurries applications.
·         Standard NPT fittings for 150 psig steam.
·         Designed to ASME B31.1

http://www.pro-sonix.com/OptiShear.html

 

-Manufacturing , Processing and Tooling > Heating and Cooling
-Manufacturing , Processing and Tooling > Tanks and Vessels
-Scientific Instruments > Thermal Processing
 
 

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