What is Direct Steam Injection Heating?
In a direct steam injection heating application, steam is mixed directly with the fluid being processed. The mixing is instantaneous, quiet and 100% of the steam energy is transferred to the fluid. Because steam is part of the process there is no need for a condensate return. The high velocity steam injection design of the steam injection heater eliminates scaling, fouling and steam hammering. Direct steam injection heaters are inline heaters so are installed in existing piping and do not require additional floor space.
ProSonix manufactures a complete line of direct steam injection heaters for industrial applications. The steam to water heat exchanger is utilized for applications for water heating, slurry heating, hi viscosity fluids, and hot water storage tank heating. From simple applications to tough to process slurries, ProSonix has an equipment solution.
ProSonix Equipment Solutions
I-Series
- Water or Viscous slurries
- Pipe In-Line as a Spool Piece for Easy Installation
- Steam and Process pipe are sized separately
- No Floor Space Required
- 1-10,000 GPM
Typical Applications:
Hot water for plant sanitation, CIP Cleaning hot water, boiler feedwater heating, paper mill whitewater heating, jacketed vessel heating, central hot water system, wastewater heating, anerobic digester sludge heating, tank rail car cleaning system, poultry processing hot water scalder, vegetable blancher hot water and can toppingC-Series Jet Cooker
- Optimized Starch Conversion
- Condensing Tube Adjustment to perfect Pressure Drop
- Sweetener, Grain Ethanol, and Alcohol Production
- Simple Installation
Typical Applications:
Starch jet cooker for grain sweetener production, wet mill grain processing, grain dry mill ethanol jet cooker processing, starch cooking with a jet cookerJ-Series
- Tank/Vessel Heating
- Water or Slurry Heating
- Pipe Mount or Direct to Tank
- Simple Installation with Specialized Diffuser
Typical Applications:
Hot water storage tank heating, tank mount jet sparger, tank rail car cleaning system, steam sparging hot water tanks, CIP hot water tank heatingProJet™
- Simple and Cost-Effective Water Heating
- Easy Installation
- Sanitary or Industrial design with specialized diffuser
- No Floor Space Required
Typical Applications:
Hot water for plant sanitation, CIP Cleaning hot water, boiler feedwater heating, jacketed vessel heating, meat harvest floor hot water sanitation; reverse osmosis water heating, central hot water system, tank rail car cleaning system, poultry processing hot water scalder, vegetable blancher hot water and can toppingDirect Steam Injection Heating Applications
Utility Heating
Hot water needs for sanitation, cleaning, sterilization, wash-down, CIP, COP.
Process Heating
Steam directly mixes with product to cook, heat, pasteurize, etc., or used in batch cooking with kettles or pots.
Direct Steam Injection Heating For Your Process
Utility Hot Water
Applications: Cleaning stations, CIP, COP, Cutting tools, Sanitizers, Tank HeatingReplace: Spargers, heat exchangers, mixing tees and other DSI units
Benefits:
- ENERGY efficiency
- Precise temperature
- On-demand hot water
- No scaling or fouling
- Reliability
- Turn-down capabilities
CIP/Central Hot Water
Applications: Tank and vessel spray balls, conveyors, sterilization and hose stationsBenefits:
- ENERGY efficiency
- Precise temperature
- On-demand hot water – when and where you need it
- No scaling or fouling
- Small footprint
- Faster heating
- Large turn-down capabilities
- Reliability!
Tunnel Pasteurization
Applications: Evisceration stations, sanitizing, plucking stations, cook pots, retort and can toppingReplace: Spargers, heat exchangers, other DSI units
Benefits:
- ENERGY efficiency
- Precise temperature
- On-demand hot water
- No scaling or fouling
- Small footprint
- Faster heating
- Reliability
Meat & Poultry
Applications: Evisceration stations, Sanitizers, Carcass Wash, Plucking stations, Cook pots, Tripe WashReplace: Spargers, heat exchangers, other DSI units
Benefits:
- ENERGY efficiency
- Precise temperature control
- On-demand hot water
- Product Integrity
- Reliability
Jacketed Kettle Heating
A batch process “indirect” heating method usually used while adding and mixing ingredients.Tank inside of a Tank with heated water in-between.
Hot water eliminates hot spots and burn-on with uniform heating and exact temp control = Product Quality.
Immersion Cooking with DSI
Heat cook tanks of water from 120°F - 195°FWater is re-circulated at and brought up to temp quickly and efficiently (very little steam loss vs. sparging)
Product is prepped and sealed in polypropylene bags then loaded on racks and set in cook tanks to cook in the bag
Accurate temp control throughout the process to ensure proper cook and eliminates bag bursts! No product loss or degradation
Optimizes quality of food effectively and efficiently
Solution: I-Series Heaters for Tank Heating/Recirculation
Basic Hot Water Applications for Direct Steam Injection Heating
- Central Hot water Loop with hose drops
- Replace multiple steam/water mixing stations
- Eliminates maintenance and downtime due to scaling and fouling
- Eliminates risk of direct contact with dangerous, high temperature steam
- Meets USDA regulations with accurate temp control
- Less water needed with accurate temperature control
- Sanitization
- Instantaneous, unlimited hot water at accurate temperatures for CIP, COP
- Wash down and proper sanitizing of product with accurate temp control
- Processing stations and equipment – unlimited hot water when and where you need it
- Tanks Jacketed Kettles and Cooking Pots
- Maintains batch consistency with instant hot water at precisely controlled temperatures
- Eliminates Burn-On and Product Degradation
Improve Your Process with Direct Steam Injection Heating!
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WHY ProSonix™ Direct Steam Injection Heating?
- Precise Temperature Control – no product degradation
- Fast and Uniform Heating
- Eliminate Burn on and Optimize Product Quality
- Nearly 100% Energy Efficient Solution = Energy Savings!
- Can heat from water to highly viscous and chunky slurries with our swath of heating solutions and technology
- Easy In-Line Installation – no floor space required
- Reduce or eliminate downtime
- No Scaling and fouling from hard water
- Reliability = Total Up Time!