Heating fluids and slurries can consume substantial energy and contribute to high operating costs for manufacturers and food processors. Reducing energy usage optimizes the bottom line and minimizes the environmental impact. Hydro-Thermal, a leading provider of innovative heating solutions, offers an Energy-Saving Tool that allows engineers and production operators to calculate the potential savings achieved by installing a direct steam injection (DSI) heating system.
Hydro-Thermal Energy-Saving Tool: Calculate the Heat Process Savings Easily
Hydro-Thermal has developed an advanced energy-saving tool that utilizes standard thermodynamic assumptions and formulas to estimate the operating cost of specific process conditions. The tool provides a side-by-side energy savings comparison between an internally modulated DSI heater and a heat exchanger by inputting various variables.
This powerful calculator tool considers a company's exact process conditions to estimate yearly savings accurately, enabling effective planning for process improvements. Take a real-life example from a large pet food processor in the Midwestern United States. As part of their heating system upgrade, they used a large shell and tube heat exchanger to supply hot water to a tank for an extensive recirculation system, catering to their hose stations, spray bars, and general washdown needs. Utilizing the Hydro-Thermal energy-saving tool, they discovered that installing the Hydro-Thermal EZ Heater would provide instantaneous hot water and result in estimated annual operating cost savings of nearly $12,000.
Conditions:
- Flow Rate: 150-200 GPM [34-45 m³/hr]
- Inlet Temperature: 120˚F [49˚C]
- Discharge Temperature: 180˚F [82˚C]
- Water Supply Pressure: 70 psig [4.8 barg]
- Steam Supply Pressure: 100 psig [6.9 barg]
Why Hydro-Thermal Has the Advantage
Hydro-Thermal's DSI heaters stand out due to their internally modulated systems, which take direct heating to the next level by precisely metering the steam flow. This precise control ensures instantaneous condensation of the steam and temperature control within 1°, achieved by operating at higher steam velocities.
The higher steam velocity promotes improved and often rapid mixing, resulting in nearly instantaneous steam condensation into the process fluid. As a result, more than 20% of the steam's energy in DSI heaters can be present as sensible heat, utilizing both the latent and sensible heat of the steam. In contrast to indirect heating methods like heat exchangers, DSI heaters require less steam flow for a given process. Furthermore, they eliminate the need for condensate return since all the steam's energy is transferred to the process, allowing 100% recovery of the condensate energy. This instant heat transfer offers two key advantages of Hydro-Thermal's direct steam injection technology: precise temperature control and significant operating savings through enhanced energy efficiency.
No matter the industry or application, fluid heating processes are vital in numerous facilities. Therefore, understanding the costs upfront is crucial for saving money and optimizing operations. Many companies across various industries have discovered the benefits of installing Hydro-Thermal DSI heaters to replace traditional heat exchangers. This switch results in cost savings and improves product quality, whether you're heating water or viscous slurries.
To explore your specific application's potential savings and benefits, we encourage you to contact our application experts. They can provide you with a free evaluation tailored to your requirements. Contact us today at 800-952-0121 or send an email to
