This large Midwest beef processing plant needed to maintain precise temperature control at a point-of-use hot water station for beef feet cleaning (a CCP – critical control point). As the final product is for human consumption, beef feet cleaning must reach and maintain proper temperature per USDA requirements. If 160°F [71°C] is not met, this will result in a loss of product, time, and energy.
Flow Rate: 0-75 GPM [0-17 m³/hr]
Inlet Temperature: 140°F [60°C]
Discharge Temperature: 160°F [71°C]
Water Pressure: 50 PSIG [3.4 barg]
Steam Supply Pressure: 120 PSIG [8.3 barg]
SOLUTION
Hydro-Thermal® replaced (3) Emech mixing valves with an H2015 EZ Skid™ system dedicated to the beef feet point-of-use station. By adding this system, the plant was able to lower its central hot water system set-point from 160°F [71°C] to 140°F [60°C].
By replacing their valves with the EZ Skid™, the processing plant saved on energy, time, maintenance and ensured product quality with an estimated $42,000/yr in energy savings.
GOAL
• Maintain precise temperature control • Decrease batch time • Enhance product quality
ACCOMPLISHMENTS
• Lowered set-point temperature • 6 month ROI • Simplified the point-of-use process • Reduced maintenance to a once a year check
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A large pork processing plant needed to supply 180°F water to critical applications throughout the plant with fluctuating flow rates. The main challenge was to find the true flow rates in order to size the system properly for different variables. The viscera process (removal of internals and wash-out of cavity) stays at a constant 75 gpm but has a variety of hoses, saws and sanitizers which makes the flow range from 75 gpm up to 200 gpm at different times during the day. The primary concern is always maintaining 180°F+ at the point of use to avoid shutdowns and downtime, and secondly, reducing energy and maintenance costs.
Flow Rate: 75-200 GPM
Inlet Temperature: 130°F from Rendering
Discharge Temperature: 200°F
Water Pressure: 60-70 PSIG
Steam Supply Pressure: 100 PSIG
SOLUTION
Hydro-Thermal® designed and installed a 3” EZ Heater Skid system to replace a shell and tube heat exchanger and utilized the tank as a buffer to smooth out the fast flow fluctuations (turndown). The EZ Heater Skid system pulls hot water from rendering operations at approximately 130°F and heats it to a consistent 190°F on the floor (under 180°F causes plant shutdowns that cost $300/min of downtime, over 200°F burns on tallow to pans, knives and conveyors).
Exact details of pipe sizings, applications and flow rates enables the system to keep a constant temperature on the floor and meet the stringent demands of the USDA.
GOAL
• Maintain precise temperature control for fluctuating flow rates • Avoid unscheduled shutdowns and downtime • Reduce energy costs • Reduce maintenance time and costs
ACCOMPLISHMENTS
• Consistant temperature control at all flow rates • Constant up-time due to reliability • Dramatic maintenance savings • 15-20% in energy savings
Are you wondering what applications are ideal for direct steam injection? Visit our industries page to learn more about industries and applications.
A certain poultry slaughter plant needed supplemental heating to their current Ludel heater during high demand production requirements in the sanitation and cleaning process. They needed: instantaneous hot water at up to 400 gpm [109 m³/hr], improved production with reduced cycle times and better temperature control.
Flow Rate: 400 GPM [109 m³/hr]
Inlet Temperature: 45°F [7°C]
Outlet Temperature: 150-200°F [66-93°C]
Water Pressure: 100 PSIG [6.9 barg]
Steam Pressure: 100 PSIG [6.9 barg]
SOLUTION
Hydro-Thermal® installed EZ Heater® model H2040 with a Medium (M) diffuser to meet the side-arm system requirements. The end user has realized the inherent advantages of the new unit’s design through instantaneous hot water, improved production with reduced cycle time, and eliminating scaling and fouling.
GOAL
• Supplemental heating during high demand • Instantaneous hot water • Reduced cycle times • Accurate temperature control
ACCOMPLISHMENTS
• Instantaneous hot water • Reduced cycle time • Eliminated scaling & fouling
Are you wondering what applications are ideal for direct steam injection? Visit our industries page to learn more about industries and applications.
A power plant was looking to improve their lime slaking process for flue gas desulphurization and cleaning. They needed to: instantly meet and maintain precise temperature control for proper mixing of slurry, increase production with reduced cycle times, and reduce energy costs.
Flow Rate: 80-110 GPM [22-30 m³/hr]
Inlet Temperature: 33-75°F [1-24°C]
Discharge Temperature: 80-95°F [27-35°C]
Target Mix Temperature: 60°F [16°C]
Water Inlet Pressure: 135 PSIG [9.3 barg]
SOLUTION
Hydro-Thermal’s EZ Heater model H2020 EHS System was installed in this facility for the slaker water heating process.
Installation of the unit has proven the inherent advantages of its design with:
• Better product quality with precise temperature control • Instantaneous hot water on demand with adjustable flow rates • Increased production time due to faster product heating • 28% time and energy savings compared to previous heating technologies
GOAL
• Precise temperature control • Reduce cycle times • Reduce energy costs
ACCOMPLISHMENTS
• Precise temperature control • Hot water on demand • Increased production • 28% more time and energy savings
Are you wondering what applications are ideal for direct steam injection? Visit our industries page to learn more about industries and applications.
A container board manufacturer and paper mill needed a heater to precisely control the temperature of the Kraft stock prior to bleaching to maximize chemical efficiency and minimize bleaching costs. Hydro- Thermal® was contacted to design a Hydroheater® to replace a current direct contact steam heating system, an adaptation of a static mixer. Stress cracking in the mixer was caused due to inadequate condensing capabilities, rough operation and vibration. Steam hammering on startup was severe enough to compromise the mixer and associated piping supports.
Hydro-Thermal engineers determined that in order to meet the stock flow requirements, a larger Hydroheater would be requiredthan had been previously designed. With winter fast approaching, and with it the complications caused by lower temperatures, Hydro-Thermal was faced with designing and manufacturing a custom Hydroheater in only four months. The decision was made to fabricate the new Hydroheater rather than use stainless castings. Delivery and installation were accomplished three weeks ahead of schedule. The Kraft stock temperature is precisely controlled within 1°F [.5°C]. All hammering and vibration problems have been eliminated completely, and after six months of operation, no downtime has
A major pulp and paper company needed to unload rail cars filled with sodium chlorate using tempered water to dissolve the NaClO3 and create the proper solution strength. They use an elemental chlorine-free process for bleaching in their pulp mills. Traditional ECF replaces elemental chlorine with chlorine dioxide in the bleaching process.
10-20% of the product can remain undissolved in railcars and then returned to the chemical manufacturer if the water is not at the proper temperature. This company wanted to improve their railcar unloading process by eliminating loss of product due to inconsistent temperature control. They also had to maintain safety restrictions derived from the highly corrosive and hazardous material.
Flow Rate: Up to 1200 GPM [273 m³/hr]
Inlet Temperature: 30°F [-1°C]
Discharge Temperature: 190°F [88°C]
Steam Supply Pressure: 60 PSIG [4 barg]
SOLUTION
The solution was to use a K414AS series Hydroheater® with a 316 body, 2205 duplex head (high nickel alloy) and a titanium stem plug. It now dissolves the NaClO3 with precise and consistent 190°F hot water. The Hydroheater replaced competitive direct steam injection heaters that cost significantly more to maintain due to the entire unit being unnecessarily cast in titanium.
A railcar carries $50,000-$60,000 of NaClO3. This pulp mill goes through 1 railcar/day and they have been saving an estimated 10% of $50,000 ($5,000) a day, or $30,000 a week. With the cost of the K414AS, they averaged a two-week Return on Investment (ROI).
Improve Your ROI During Sodium Chlorate Car Unloading
Hydro-Thermal’s direct steam injection products can help you get a larger ROI. Our Jetcookers can help achieve precise temp controls & eliminate your sodium chlorate loss. Request a quote to improve your railcar unloading ROI today.
GOAL
• Precise temperature control • Eliminate product loss • Improve workplace safety
ACCOMPLISHMENTS
• Precise temperature control • Reduced maintenance time and costs • Eliminated product loss • Improved safety • Two week ROI
Are you wondering what applications are ideal for direct steam injection? Visit our industries page to learn more about industries and applications.
A bleached paper and board mill in North Carolina, USA, needed to provide consistent green liquor temperature to two causticizing lines in the recovery process. The mill operates two causticizing and lime kiln lines and heats green liquor to each line. Precise temperature control of the green liquor to the slaker is crucial to a smooth operation.
HEATER 1
Fluid: Green Liquor
Flow Rates: 600-1000 GPM [136-227 m³/hr]
Inlet Temperature: 165°F [74°C]
Discharge Temperature: 180-185°F [82-85°C]
Steam Supply Pressure: 150 PSIG [10.3 barg]
HEATER2
Fluid: Green Liquor
Flow Rates: 1200-2400 GPM [273-545 m³/hr]
Inlet Temperature: 160°F [71°C]
Discharge Temperature: 185°F [85°C]
Steam Supply Pressure: 150 PSIG [10.3 barg]
SOLUTION
Hydro-Thermal has supplied a K414AN and K415AN Hydroheaters for the two differing production rates of the causticizing lines. The first orders were 23 years ago and have been operating a Hydroheater for green liquor since. The mill is pleased with the consistent performance of the heaters and has developed a preventative maintenance plan to rebuild the heaters annually to ensure uninterrupted operation – per the mill “we probably over do it (with preventative maintenance) but it’s a critical operation so we can’t take a chance”. The mill purchased an upgraded model in the K515AN in 2009 to replace the K415AN and is continuing with the same performance.
GOAL
• Precise temperature control • Smooth operation
ACCOMPLISHMENTS
• Precise temperature control • Uninterrupted operation • Eliminated downtime due to maintenance
“We probably over do it (with preventative maintenance) but it’s a critical operation so we can’t take a chance.”– Mill Maintenance Mgr.
Are you wondering what applications are ideal for direct steam injection? Visit our industries page to learn more about industries and applications.
A former Nekoosa Packaging Corporation in Valdosta, Georgia, USA, needed to eliminate hammering and scaling problems exhibited by existing green liquor heater. Nekoosa has been using an externally modulated direct contact steam heater, mass steam flow rate was controlled by varying the pressure of the steam with an external control valve. The resulting pressure variations of the steam resulted in a reduced range of stable operation. When the heater was operating outside the limited range of stability, the heater exhibited severe hammering and vibration with consequent damage to internal components.
Fluid: Green Liquor
Flow Rates: 300-800 GPM [82-218 m³/hr]
Inlet Temperature: 140°F [60°C]
Discharge Temperature: 190°F [88°C]
Fluid Supply Pressure: 40 PSIG [3 barg]
Steam Supply Pressure: 150 PSIG [10 barg]
SOLUTION
Hydro-Thermal engineers installed the K414AN Hydroheater prior to the slaker in order to precisely control temperature and maximize the conversion efficiency of slaked lime. Installed in 1989, the mill reported that all hammering and vibration had been eliminated. The temperature of the green liquor had been precisely maintained at 190˚F [87.8˚C], and the Hydroheater has operated without scaling or fouling.
Update: Regular maintenance can provide years of service even in a corrosive environment. The mill carries a spare heater for easy swapout and uses a 2-3 year rebuild schedule to replace internal wear components. The current heater is on the fourth rebuild and has been in operation for 12 years.
This major tire and rubber company needed to heat 26% PVC slurry without hammering and plugging. The slurry required heat added prior to dewatering in a centrifuge. Indirect methods of heating were not considered because of the high potential for the slurry to foul the barrier heat transfer surface. For this reason, a competitive direct-contact steam heater was being used; however, the heater hammered violently, compromising pipe fittings and supports. Periodically, the PVC slurry would back-flow into the steam supply line and harden, requiring disassembly for acid bathing.
Fluid: 26% PVC Slurry
Flow Rate: 45 GPM [10 m³/hr]
Inlet Temperature: Variable; 35-120°F [2-49°C]
Discharge Temperature: 167°F [75°C]
Steam Supply Pressure: 60 PSIG [4 barg]
SOLUTION
The Hydroheater was evaluated for this application because of its ability to handle viscous slurries with high solids. Internal modulation of steam in the Hydroheater would eliminate the hammering problems and the potential for the PVC slurry to backflow into the steam lines.
Hydroheaters were installed and have been operating since 1987. The hammering problems associated with the competitive heater have been eliminated. Internal modulation of steam in the Hydroheater prevents the slurry from back-flowing into the steam supply lines. The need for routine cleaning has been eliminated due to its self-cleaning design.
GOAL
• Eliminate hammer and plugging • Eliminate back-flow into steam supply line • Eliminate acid bathing
Factory with pharmaceutical equipment mixing tank on production line in pharmacy industry manufacture factory
A seafood company that has been a major supplier of clams for over 25 years needed a heating solution with the flexibility to handle several different recipes while eliminating product waste and preventing tank burn-on. The end user was adding several recipes to their product line and needed a solution that could handle different operating conditions for food starch concentrations ranging from 0-22% (potato, corn, clear jell, and more). They have been using a Hydro-Thermal competitor’s direct steam injection heater but found it difficult to clean and maintain. This disrupted their production cycle and increased batch time.
Fluid: Up to 22% Starch Slurry
Flow Rate: 30 GPM [6.8 m³/hr]
Inlet Temperature: 50°F [10°C]
Discharge Temperature: 195°F [91°C]
Steam Supply Pressure: 100 PSIG [6.9 barg]
SOLUTION
Hydro-Thermal installed an A307 Sanitary Hydroheater® turn-key skid system to address plant expansion and new product lines. A culinary steam filter was also provided to ensure product quality and consumer safety by USDA regulations. The Sanitary Hydroheater is 3A certified and uses patented technology that produces sonic velocity steam through the nozzle, preventing product burn on and fouling of the heater.
The sea food producer is now able to process several different recipes using the same equipment and has reduced waste while improving quality of the end product.
Update: Plans to install additional Hydroheaters throughout their plant for continuous improvement and sustainability efforts.
GOAL
• Eliminate product waste • Prevent tank burn-on • Ability to heat different operating conditions • Decrease batch time
ACCOMPLISHMENTS
• Improved product quality and reduced waste • Reduced cycle time • Reduced maintenance costs and time
Are you wondering what applications are ideal for direct steam injection? Visit our industries page to learn more about industries and applications.
A carpet manufacturing facility wanted to replace the current heat exchanger with a better water heating solution for their wash box station. They were looking for: energy efficiency, better temperature control, and better turndown control and capabilities.
Flow Rate: 200 GPM [55 m³/hr]
Inlet Temperature: 50˚F [10˚C]
Discharge Temperature: 110˚F [43˚C]
Water Supply Pressure: 85 psig [5.9 barg]
Steam Supply Pressure: 100 psig [6.9 barg]
SOLUTION
Hydro-Thermal’s EZ Heater® model H2030 with a Large (L) diffuser was installed to successfully adhere to each of the specifications desired. The customer has realized the inherent advantages of its design with:
• Easy installation and replacement of technologies • 28% more efficient than the heat exchanger • Instantaneous hot water on demand at exact temperature • Excellent turndown control and capabilities • Patented self-cleaning design to prevent scaling and fouling
GOAL
• Increase efficiency • Precise temperature control • Improve turndown control and capabilities
ACCOMPLISHMENTS
• 28% more efficient • Instantaneous exact temperature control • Lower maintenance • Excellent turndown
Are you wondering what applications are ideal for direct steam injection? Visit our industries page to learn more about industries and applications.
This tomato sauce producer was using a competitor’s 3-way steam valve heater with poor results. The unit had difficulty maintaining target temperatures, caused a loss of product due to burn-on, and consistently had issues with severe hammer and vibration. These issues caused concern over the piping’s integrity and added extra maintenance time and costs.
Fluid: Tomato Sauce
Flow Rate: 25-75 GPM [6-17 m³/hr]
Inlet Temperature: 45°F [7°C]
Discharge Temperature: 195°F [91°C]
Steam Supply Pressure: 120-130 PSIG [8-9 barg]
Viscosity: 75,000 cP
SOLUTION
A Solaris® Hydroheater, designed for highly viscous fluids was installed and successfully replaced our competitor’s 3-way valve heater. The straight-through flow design of the process steam heater minimizes flow disturbances and enables instantaneous condensation of steam without vibration or noise.
