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How Direct Steam Injection works - Hydroheater - JetCooker

Hydro-Thermal Jetcookers - The Industrial Inline Steam Heater

Industrial Jet Cooker Applications & Benefits

The Industrial Jetcooker is ideal for heating liquids and slurries over a wide range of viscosities and solid contents to precise temperatures. With the unique manual or automatic combining tube adjustor, you can easily control the process shear which makes this heater the perfect choice for achieving optimum starch conversion.

 

What is a Jetcooker?

The Hydroheater® is the original and most advanced Jetcooker™ because it fully adjusts shear mechanically and utilizes the eductive energy of steam creating a shockwave in the condensation (heat transfer) process.

Trust the Real Jetcooker™. Although others try to use the name, trust the Hydro-Thermal starch Jetcooker that has been the predominant direct steam injection (DSI) device for over five decades, and has become the standard heating technology in the starch conversion industry.


How Do Jetcookers Work?

The industrial Jetcooker works by internal parts precisely mixing measured amounts of steam directly into a liquid or slurry. This instantaneous transfers heat from steam to liquid. Through the process of the steam condensing, this completely eliminates steam hammer and vibrations which causes a turbulent mixing action that self-cleans the unit. The two things that make our Jetcookers better than other heaters is the distinct use of internal modulation and choked flow. These and our patendented direct contact inline steam injection heater heater utilizing a 3-way value are what separate us from others.

 

How is Internal Modulation Utilized in Jetcookers?

Internal Modulation assures precise steam control and produces predictable results based on the position of the stem plug. A variable-area steam nozzle meters steam flow at the point where steam and liquid first contact and mix. This technique eliminates the need for an external steam control valve. Only the cross sectional area of the steam nozzle changes which provides process stability through a much wider variation of your process conditions.

 

What is Choked Flow in Jetcookers?

CHOKED FLOW (propels, accelerates, launches) your process heating to the speed of sound. Precisely engineered nozzles generate a steam pressure differential that “chokes” the mass flow rate of steam and accelerates it to sonic velocity unique to Hydro-Thermal Hydroheaters. When the steam heater's flow is choked, the Jetcooker can internally modulate the steam flow by adjusting the flow area between the steam and process fluid giving you precise and rapid temperature control. Steam traveling over 1500 ft/sec creates a forceful jet preventing hard water scale and burn on from building up. The self cleaning feature frees you from frequent process interruptions and chemical baths resulting in total uptime!

 

Key Benefits for Industrial Jetcookers

Hydro-Thermal’s Jetcooker is the starch industry standard because it provides benefits that other technologies cannot to optimize the starch conversion process.

1. Maximum Yields With Jetcookers

Achieve the highest possible ethanol yield in either dry or wet milling operations. Heating the corn mash in the Jetcooker is the first step to opening the starch molecules so the enzymes can break it down into sugar. The slurry starts out and has a targeted temperature of 185°F (85°C). Once it reaches the Jetcooker, the temperature set point has a range between 210°F and 225°F (99°C and 107°C). It is equally important to maintain a constant pressure drop across the Jetcooker optimizing shear, mixing characteristics, and overall performance efficiency.

2. Shear Effects

The primary goal of cooking starch is to break the polymer chains to maximize conversion to dextrose in the saccharification process. This breakdown is achieved through thermal and chemical action on the starch molecule during the hydration and hydroxylation processes. In a Jetcooker, a large amount of energy is applied through two mechanisms: mechanical shear and turbulence. These forces break up any clumps in the starch slurry. In addition, exposing steam to the starch molecules causes a high degree of depolymerization. The heat transfer rate between the fluids is extremely high, and the cooked starch leaving the Jetcooker is thoroughly mixed and at a uniform temperature.

Read more about the mechanical shear and turbulence in Ethanol Production

 

3. Precision Temperature Control Utilizing Jetcookers

Temperature Control Temperature is critical in the starch conversion process. There needs to be a fine balance enzyme activity, ideal cook temperature, and consistent temperature distribution in the cooked starch. The Jetcooker is capable of extremely precise temperature control which is ideal to maintain this equilibrium. It allows for consistent, and depending on conditions, a reduction in enzyme dosing. In addition, the Jetcooker allows for the high cook temperature needed to optimal starch conversion and primary liquefaction, all while achieving a homogeneous temperature distribution in the cooked starch.

Click here for more information on the importance of temperature in starch conversion


4. Solids Control

Solids control is largely a function of the mixing performed ahead of the Jetcooker. Proper mixing technology and screening of larger clumps of starch will greatly affect the maximum conversion rate possible in a cooking environment. The Jetcooker can help disperse clumps, increasing the homogeneity of the starch as it is exposed to the steam. This is accomplished by manipulating the velocity of the starch internally inside a Jetcooker. The mechanical energy added to the slurry serves as a final mixer/disperser and can reduce the variance in slurry density at the point of contact between the starch slurry and the steam. It does so by mechanically shearing any relatively small clumps of starch that may have made it through the initial screening and reducing their size further. The remaining clumps are typically then dispersed by the steam jet.

 

Benefits of Direct Steam Injection Jetcookers

  • Hydroheaters reduce energy/steam consumption
  • 100% Thermal Efficiency; uses both latent and sensible heat of the steam
  • Eliminates energy losses through condensate return
  • Eliminates the heat transfer barrier of heat exchangers for improved efficiency
  • Reduces process heating time
  • Jetcookers have quicker startups (tankless water system)
  • Single pass in-line process heating
  • Faster tank heating (self-pumping recirculation loop)
  • Sonic velocity steam injection allows for instantaneous heating
  • No need to use an external steam valve
  • Precise temperature control to +/1ºF [0.50°C] over large liquid turndown ratio
  • Fast response to changes in temperature setpoint

 

 

Jetcooker Industries & Applications

The Industrial Hydroheater is used in a variety of applications including pulp and paper processing, starch cooking, biofuelsethanol and starch conversion, large volume water, anaerobic digestion, cooking, and more. In fact, the Industrial Hydroheater is Hydro-Thermal’s most commonly used heater. To learn more about applications for our inline steam heater categorized by industry, head over to our industries page.

Jetcookers in Ethanol & Starch Conversion

  • Liquefaction - achieving highest yields with both dry or wet milling operations
  • Grain mashing
  • Starch Blooming
  • Steep Water Heating
  • Clean in Place (CIP)

Discover more ways that Jetcookers can save time & money in the ethanol & starch conversion industries.

Pulp & Paper Jetcooker Applications

  • Whitewater Chest or Silo Heating
  • Non-Venturi Pumping
  • Repuper Fiber Heating
  • Pulp Stock Washing
  • Green Liquor Heating
  • Black Liquor Heating
  • Sodium Chlorate Railcar Unloading

Learn more about Jetcookers being used in the pulp & paper industry here.

Utizling Jetcookers in Chemical Processing

  • Jacketed Vessels & Reactor hot spot elimination
  • Tank heating & washing
  • Reverse Osmosis / Ultrafiltration
  • Deaerator/Boiler Feed Water

Learn more about Jetcooker applications in chemical processing!

Jetcooker Cooking Applications

  • Hot Fill / Aseptic
  • On Demand Cooking
  • Pasteurization
  • Can Topping
  • Immersion Cooking (Cook in a Bag)

More Industries

Discover the full list of industries that our hydroheaters & Jetcookers work for. Find out if you can save time & money with one of Hydro-Thermal’s Jetcookers or Industrial Hydroheaters.

 

Jetcooker Product Designs/Descriptions/Capabilities

  • Available in eleven sizes
  • Flow rates up to 6,700 gpm
  • Sizes from 1/4" to 12" outlet piping
  • Large temperature rise possible
  • Rugged ASME design/construction
  • Available in a variety of alloy materials
  • High solids capability
  • Can be designed for low shear (water heating) to high shear (starch conversion)

 

Custom Jetcooker Systems

There are many ways that you can customize your Jetcooker to your specific processing needs.

Custom Skids - ATTEC® skids are available utilizing the Jetcooker. ATTEC systems are designed, built, and installed to your individual process specs.

High Vibration Applications - Hydro-Thermal's heaters utilize a Fisher reverse-acting diaphragm actuator (“fail close”). Generally coupled with a filter/regulator and a Fisher DVC 2000 or a DVC 6200 positioner that converts a 4-20 mA DC input signal to pneumatic output signal to the actuator. For high vibration applications remote mount positioners are available. Alternative positioners are available depending on unique processing conditions or upon request. Please contact Hydro-Thermal for more details.

Abrasive Fluids - The Jetcooker is very robust and reliable, and can be further enhanced as needed for heating abrasive fluids. For many applications, a weld overlay and enriched material in key areas is sufficient. Some applications such as slurries with sand content require additional overlays outside the basic weld overlay. This technique has greatly increased the heater’s internal component lifespan. Other fluids have required more extensive modifications. In oil sands froth heating applications, for example, a combination of a weld overlay as well as the use of hard, abrasive resistant materials is recommended. For specific requirements for your application, please contact Hydro-Thermal directly.

High Temperature Rise - All Jetcookers include a combining tube. An extended combining tube may be recommended for a large ΔT (high temperature rise). Please contact Hydro-Thermal for more details.

 

3A Certified Jetcookers

For companies that require a 3A certified Jetcooker, the Sanitary Hydroheater is the perfect option to effectively cook food & beverages, starch & sweeteners, and more.

 

Custom Jetcookers Made For Your Specific Operating Needs

The Industrial Hydroheater/Jetcooker is made for your specific operating conditions.  We need to know a little bit about your process and plant set-up in order to design the heater or skid that will work best for your conditions.  Please fill out this form or contact us here.

Looking for more information on our products? Head over to our products page. 

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Hydro-Thermal is the global leader in the development and manufacturing of Hydroheaters. Through our vast global channel partners, we support hydro heating in six continents and all industrialized areas. We create heating systems for a variety of industries including: pulp, paper, chemical, ethanol, food & beverage, metal, & more!

Hydro-Thermal Corporate 

400 Pilot Court
Waukesha, WI 53188 USA
Phone: (262) 548-8900
Fax: (262) 548- 8908