The heating of fluids and slurries can be a significant energy and operating cost for manufacturers and food processors. Reducing that energy usage helps optimize the bottom line and its impacts on the environment and the public. Hydro-Thermal's Energy-Saving Tool helps engineers and production operators compare the energy savings involved when installing a heating system.
Hydro-Thermal Energy-Saving Tool: Calculate the Heat Process Savings Easily
Hydro-Thermal has developed an energy-saving tool that calculates standard thermodynamic assumptions and formulas to estimate the operating cost for specific process conditions. By calculating these variables, the savings can be shown side-by-side, comparing the results of an internally modulated DSI heater versus a heat exchanger.
Because the calculator tool estimates yearly savings based on a company's exact process conditions, it can be used to plan process improvements. An example of this comes from a large pet food processor in the Midwestern United States. They were updating their heating systems from a large shell and tube heat exchanger that supplied hot water to a tank for an extensive recirculation system used for their hose stations, spray bars, and general washdown needs. The Hydro-Thermal energy-saving tool found that installing the Hydro-Thermal EZ Heater would not only deliver hot water instantaneously — but would also save an estimate of almost $12,000 a year in operating costs.
- 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 direct steam injection (DSI) heaters are internally modulated systems. But they take direct heating a step further by precisely metering the steam flow. This results in instantaneous condensation of the steam and provides temperature control within 1° by operating at higher steam velocities.
This higher velocity produces improved, often rapid-mixing, and nearly instantaneous condensation of the steam into the process fluid. As a result, more than 20% of steam's energy in DSI can be present as sensible heat because it utilizes both the latent and sensible heat of the steam. Unlike indirect heating methods, like heat exchangers, they require less steam flow for a given process. In addition, condensate return is not needed because all the steam's energy is transferred to the process— in effect, 100% of the condensate energy is recovered. This instant transfer of heat offers two main advantages of Hydro-Thermal's direct steam injection: precise temperature control and operating savings from energy efficiency.
No matter your industry or application, there is a need for a fluid heating process somewhere in the facility. Therefore, it's essential to know the costs upfront to save money. Many have discovered that installing Hydro-Thermal DSI heaters to replace heat exchangers saves money and improves product quality, whether heating water or viscous slurries.