A long-time customer was looking for a solution to their struggles packaging tomato paste into aseptic containers. During the long 14-week season, the Solaris heating system ran well, optimizing performance to provide a quality product and a stable operation. The Solaris was customized to meet the unique demands of heating both hot- and cold-paste of 28-35% NTSS. This successful solution incorporated a custom Solaris heater built into a supply manifold and steam conditioning system for a 4 inch [DN100] aseptic paste line.
Fluid: Hot and Cold-Break Paste
Circulation Rate: 60-300 GPM [14-68 m³/hr] (turndown in configured system is 2:1)
Inlet Temperature: 180-195°F [82-91°C]
Discharge Temperature: 212-218°F [100-103°C]
Temperature Rise for a Single Heater: 17-38°F [9-21°C]
Steam Supply Pressure: 175-300 PSIG [12-21 barg]
SOLUTION
A season of trials resulted in a system package designed for either 4 or 6 inch [DN100 or DN150] aseptic paste lines. Solution includes custom Solaris heaters in either single or dual pass with a frame constructed of welded square tubing with feet to anchor into concrete plus schedule 40 piping and flanged connections at the inlet and outlet. The steam line includes a drip leg and steam trapping to ensure dry steam supply. Isolation and check valves prevent paste from backing up into the steam line. An additional steam conditioning system will be provided with a pressure control loop and culinary filter if necessary. In addition, the system is supplied with wiring to allow flexibility in control systems, unless existing temperature and pressure transmitters can be used.
GOAL
• Decrease vibration & hammering • Decrease burn-on to extend or eliminate cleaning cycles • Achieve more precise temperature control
ACCOMPLISHMENTS
• Eliminated burn-on (up to 4 weeks with no deposits or burn-on) • Eliminated steam hammer in heating system and downstream piping • Minimized high frequency vibration • Consistent temperature control during feed-forward production • Flow turndown exceeded 2:1 without a change in stable operation • Pressure swings up to 100 psi during divert mode to feed-forward transition had no effect on heater stability
The producer of a starch base for mayonnaise needed a 3A approved product for cooking starch slurries used in-line. They were currently using a non-sanitary competitive direct steam injection heater to heat the starch slurry used in processing various starch based products. It was difficult to control temperatures and had to be taken out of line to adequately be cleaned.
Fluid: 34% Starch Slurry
Flow Rate: 7 GPM [2 m³/hr]
Inlet Temperature: 140°F [60°C]
Discharge Temperature: 198°F [92°C]
Steam Supply Pressure: 100 PSIG [6.9 barg]
Viscosity: 75,000 cP
SOLUTION
The solution was to install a 3A Sanitary Hydroheater®. It has no moving parts in the product contact area, is self draining and sealed for external washdown. It provides precise temperature control to ±1°F [0.5°C], produces instant heating of the product, and is 100% thermal efficient. The Hydroheater injects a precise amount of steam through the nozzle at a constant velocity, which results in a more homogeneous blending of the starch base, while also eliminating the risk for plugging and fouling. The instant heat transfer causes the steam to disperse into the product quickly, eliminating hammer and vibration associated with other similar type devices.
The Hydroheater in this application resulted in reduced maintenance, cut CIP cleaning time by a third, and produced a better cook out of the starch; this contributed to better cost control by utilizing less raw starch in the process. Also, the Hydroheater eliminated the need to shut down the production line to remove the heater for cleaning.
GOAL
• Acquire 3A heater for slurry heating • Maintain accurate temperature control • Reduce cleaning time
ACCOMPLISHMENTS
• Installed Sanitary (3A) Hydroheater • Precise temperature control • 100% thermal efficiency • Cut cleaning time by 1/3 • Increased cost control with less starch usage • Eliminated need to remove heater for maintenance
A major US Brewer needed an efficient and reliable method to precisely heat circulated water/solutions for a CIP application of beer filler lines. The application presented a variable heating load of 0-35° temperature rise requirement. To simplify system design and accomplish the degree of control necessary under the variable conditions, the decision was made to use direct steam heaters. The original installation utilized a competitive heater which proved incapable of operating smoothly over the entire range of temperature requirements. Excessive hammering during operation required frequent disassembly to repair internal components.
Fluid: Recirculated Water
Flow Rate: 175 GPM [40 m³/hr]
Inlet Temperature: Variable; 60-185°F [16-85°C]
Discharge Temperature: 185°F [85°C]
Temperature Rise per Pass: 0-35°
Steam Supply Pressure: 70 PSIG [7 barg]
SOLUTION
The K411AS Hydroheater® was evaluated by the engineering team as a replacement heater for the CIP application. Final decision to purchase the Hydroheater was based on simple geometry and the unique feature of internal steam modulation. This enables the Hydroheater to operate smoothly over the entire range of steam flow (temperature) requirements without hammer or instability. To simplify installation, the Hydroheater was supplied as a complete package with temperature controller.
The Hydroheater was installed in early 1989 and has met performance expectations by providing smooth, hammer-free operation with precise control of loop temperature. The successful performance of the Hydroheater has resulted in the installation of Hydroheaters on two additional CIP systems.
GOAL
• Precise temperature control with varying conditions • Simplify CIP design • Smooth operation
ACCOMPLISHMENTS
• Installed K411AS Hydroheater • Smooth operation over varying conditions • Simplified design with temperature controller • Eliminated hammering • Installed Hydroheater on two additional CIP lines
Ice cream producer Blue Bell Creameries in Broken Arrow, Oklahoma was looking to optimize their clean in place (CIP) and clean out of place (COP) operations. They were using a hot water tank with a steam heat tube bundle. This system had a fixed volume of water capacity with a long recovery time. The system’s limitations were especially frustrating during transition periods of full production to cleaning.
“The standard for reliability is how long can equipment be used with scheduled maintenance with no unplanned downtime. This equipment will operate for months and months with no downtime with a variety of skill level operators.”– Mike Tate, Maintenance Manager at Blue Bell Creameries
SOLUTION
After researching alternative options, Blue Bell Creameries selected a Hydro-Thermal 2-inch EZ Heater skid with a 3-inch steam line. The system has been in production since August 2015, and it can fill multiple tanks quickly at proper temperatures.
Operators can also quickly and easily adjust temperatures, which fixed problems during transition periods that occurred with their previous equipment.
• Able to fill multiple tanks quickly at proper temperatures (reliable hot water on demand) • Quick, easy temperature adjustments • Efficient transition periods between full production and cleaning
A major U.S. high fructose corn syrup producer was experiencing difficulties cooking corn starch in the liquefaction stage with a competitive jet cooker. The competitive jet cooker was unable to provide completely cooked starch and required a static mixer downstream. In addition, the competitive unit was unable to operate under the varying production rates dictated by seasonal demands without hammer and instability.
Fluid: 38% Corn Starch Slurry
Flow Rate: 1,050 GPM [238 m³/hr]
Inlet Temperature: 125°F [52°C]
Discharge Temperature: 225°F [107°C]
Steam Supply Pressure: 150 PSIG [10.3 barg]
SOLUTION
Hydro-Thermal® installed an Automatic Hydroheater®. The Hydroheater is the only jet cooking device which provides a fully adjustable mechanical shear force to insure a complete, uniform cook-out of starch. Internal modulation of steam in the Hydroheater provides for unlimited steam flow turndown for smooth operation over varying slurry flow rates and temperature requirements. The simple geometry of the Hydroheater allows it to operate day in, day out without plugging or fouling. Hammer-free operation, internal modulation of steam assures precise temperature control of the cooked starch.
The producer’s cook is complete and uniform with a homogeneous solution provided for saccharification. The static mixer has been eliminated from the system. The plant is now able to operate under variable production demands while maintaining a consistently high quality cook from the Hydroheater. Downtime has not been required for cleaning the Hydroheater due to its self-cleaning design.
A contract specialty chemical manufacturer required a heater that would precisely control the temperature of the jacket water for a 2000 gallon glass-lined reactor. This particular vessel is used to produce a variety of products the company manufactures. For this reason, the tempered water loop is required to provide complete control flexibility while maintaining precise temperature limits. Due to a previous circumstance, the company was very sensitive to eliminating the potential for thermal shock to the glass lining.
Fluid: Water
Circulation Rate: 125 GPM [28 m³/hr]
Initial Batch Temperature: 50-80°F [10-27°C]
Max. Batch Temperature: to 190°F [88°C]
Jacket Water Temperature: to 310°F [154°C]
Temperature Rise per Pass: 0-30°
Steam Supply Pressure: 100 PSIG [6.9 barg] at 338°F [170°C]
SOLUTION
The internal modulation of steam of the K410AD Hydroheater® provides precise control of temperature and complete range ability while eliminating steam hammer and instability. It operates smoothly over a wide range of heating requirements encountered with batch reactors and is installed as the final control element in the tempered water loop, instantly responding to temperature needs for heating or cooling. The precise control the Hydroheater affords over jacket temperature eliminates the potential for damage to the glass lining from thermal shock. Maintaining a liquid phase in the vessel jacket throughout the entire batch cycle ensures a quick response to batch requirements as well as simplifies the design, installation and tuning of the system.
The tempered water loop was installed with a Hydroheater in accordance with Hydro-Thermal’s recommendations. Precise control of batch temperature within 1°F has been accomplished without the problems of overshoot. Exothermic reactions are precisely controlled and damage to temperature sensitive batches has been eliminated.
If you are looking for a new precise method to provide precision jacketed reactor heating, fill out our Hydroheater quote form today.
GOAL
• Meet temperature rise requirements • Complete control flexibility • Eliminate potential of thermal shock to glass lining
ACCOMPLISHMENTS
• Installed K410AD Hydroheater • Precise temperature control • Eliminated hammer and instability • Eliminated chance of damage to glass lining
This plant is located in the southern USA where it is warm for the majority of the year. During the short winter, heaters are needed to heat water and maintain a constant temperature in three outdoor holding tanks. Two of the holding tanks contain acrylic acids and the other contains acrylamide acid. If these chemicals are not kept at a constant temperature they can freeze and the thawing process could be hazardous or ruin the product. In order to ensure the safety of their employees and maintain a quality product, the M108 Hydroheaters company needed a dependable heater that would keep constant temperature. Since 1993, the company has been using three Hydroheaters (one for each holding tank), but after several years of worry-free operation, the heaters needed maintenance due to wear.
Fluid: Water
Flow Rates: 50 GPM [11 m³/hr]
Initial Temperature: 33°F [1°C]
Outlet Temperature: 75°F [24°C]
Steam Pressure: 324 PSIG [22 barg]
SOLUTION
The company decided to purchase three M108 Hydroheaters instead of rebuilding their old units. The application was critical so the company decided it was better to replace the heaters instead of risking their employee’s safety and ruining the product. The chemical company is happy with the precise temperature control and minimal maintenance, which is why they decided to repurchase heaters from Hydro-Thermal. The chemical company is also now aware that yearly maintenance is recommended on all heaters so that they continue working effectively and efficiently. The install went smoothly and the company is anticipating the winter months when they get to turn on the new heaters.
Looking for Chemical Holding Tank Heating Systems?
Get in touch with us today to help you keep potentially dangerous chemical tanks at a precise temperature with our direct steam injection jet cookers. Contact us or fill out a jet cooker quote form to begin the process for a safer chemical tank heating solution.
GOAL
• Maintain constant temperature in outdoor climate • Maintain product quality
ACCOMPLISHMENTS
• Installed (3) M108 Hydroheaters • Precise temperature control • New installs eliminated safety risk to employees • Maintained product quality • Minimal maintenance
Are you curious about our patented direct steam injection technology? Click here to learn more.
Are you wondering what applications are ideal for direct steam injection? Visit our Industries page.
Do you want to learn more about our products? Click here for more information.
The Hydro-Thermal K6 Autopilot® is an optional feature of the K600 Hydroheater® that will optimize performance and reduce manual operation. It is a highly engineered device that is designed specifically to improve your plant’s operation. Heat completely, uniformly, optimally and without local operator intervention. The K6 Autopilot automatically adjusts the Hydroheater’s product flow path as process conditions change to maintain a constant pressure drop across the unit. This results in optimized shear, mixing characteristics and more effective starch conversion, leading to lower enzyme usage and higher yields.
From a digital control system (DCS) or other control package, the K6 Autopilot receives analog 4-20mA signals representing actual differential pressure and the different pressure setpoint. The K6 Autopilot automatically adjusts the position of the combining tube as needed, to maintain a constant product pressure drop. The outputs to the DCS are the measured pressure drop, and the combining tube position. The alarm outputs are analog range alarms, combining the tube-over-travel alarm and the no-movement/reverse-movement alarms. These are available locally at the control panel via indicator lights, and also provides output to a DCS as discrete signals.
To change the flow path, the air motor and gear assembly, adjust the CTA driveshaft position; this moves the combining tube linearly, thereby adjusting the combining tube to nozzle gap. As the combining tube/nozzle gap is widened, the pressure drop is lowered. As the gap is narrowed or closed, the pressure drop is increased. The pressure drop is measured between the inlet and the discharge of the slurry connections on the Hydroheater.
Autopilot Lite
The Autopilot Lite system uses the same mechanical components as the standard Autopilot systemco pilot with the exception of the control panel with the PLC. This requires the control logic carrying out the control functions, alarms as well as safety measures having to reside in the plant DCS.
Co-Pilot
The Co-Pilot is a calibration tool that allows convenient electrical position zeroing of the Combining Tube in the maintenance shop environment rather than at the Heater installation site. It simulates the position display of the Autopilot panel which shows 0% at a sensor output current of 4.5 mA. With the Combining Tube at the mechanical zero, the location of the position sensor on the bracket can now be adjusted to show 0% on the Co-Pilot display.
*K500 Hydroheater can be updated with the K600 Autopilot/Autopilot Lite/Co-Pilot technology. Contact Hydro-Thermal to request an upgrade.
Key Autopilot Aspects
Local control panel with inputs for differential pressure transmitter signal, pressure drop set point and system enable (Auto/Manual)
Panel is adaptable to new and existing applications
Stand-alone capabilities for heating and Autopilot/Slave to DCS
DCS control options
Digital and Analog signals
Modbus TCP
Ethernet/IP
Local panel displays for measured pressure drop and combining tube position
Compatible with K611-K616 Hydroheaters
100% performance warranty
Start-up assistance available
Standard Construction and Compliances
Major components are treated for corrosion resistance
Receives and sends signals to DCS or other control package
Control panel
Remote mounting
NEMA 4X
Compliance standards with UL, CSA and NEC
High vibration solution for applications exceeding 5g’s available
Autopilot Case Study
One of our current installations is in Badger State Ethanol, a dry mill ethanol production facility that produces almost 60 million gallons of ethanol each year. Check out how the plant, which now has a differential pressure (DP) of 0.1 after the Autopilot install, has increased operating consistency here.
Relating to the ethanol installation, the Autopilot system performs differential pressure changes automatically by monitoring the slurry pressure before and after the heater. Changes are made to the position of the combining tube based on measured DP and compared to the set-point DP. The result is a constant and more accurate DP across the heater. In essence, by controlling DP, the Autopilot allows ethanol plants to remove a variable from their process and gives them the flexibility to increase or decrease production levels while still creating a consistent product with the Hydroheater.
Model
AInches (cm)
BInches (cm)
K610
7.63 (19.38)
15.65 (39.75)
K611
7.63 (19.38)
16.18 (41.10)
K612
7.63 (19.38)
16.18 (41.10)
K613
7.63 (19.38)
16.96 (43.08)
K614
7.63 (19.38)
17.83 (45.29)
K615
7.63 (19.38)
19.15 (48.64)
K616
7.63 (19.38)
19.60 (49.78)
K617
7.63 (19.38)
20.90 (53.09)
Designed for specific operating conditions
We need to know a little bit about your process and plant set-up in order to design the solution that will work best for your conditions. Please fill out this form or contact us here.
For an overview of all of Hydro-Thermal’s products click here.
A large pet food processor with headquarters in St. Louis, MO, USA, needed to replace a legacy sparge system used to cook meat slurry for its high level brand dog food. The old sparger cooking system did not hit proper temperature and, at times, could not hold the temperature for the needed time. This was a major issue as reaching proper temperature is important for a consistent and uniform cook. It was also plagued with burn on and plugging of the system, requiring constant shutdown to fix the problem.
Flow Rate: 100 GPM [23 m³/hr]
Inlet Temperature: 32°F [0°C]
Discharge Temperature: 187°F [86°C]
Steam Supply Pressure: 60 PSIG [4.1 barg]
SOLUTION
Preceding 1995, this company purchased its first direct steam injection Hydroheaters for flavoring applications. Because they were pleased with the temperature control and low maintenance of the other units in the plant, they chose dual A210 Sanitary Hydroheater® systems for this mission critical meat slurry cooking application.
The dual Sanitary Hydroheater systems provided significant improvements for the plant by:
• Passing meat slurry through to be thawed, mixed and then uniformly cooked to a tight temperature control of ±1°F • Constant up-time due to reliability and temperature control • Meat slurry consistency is maintained and no plugging occurs
GOAL
• Hit and hold proper temperature • Achieve a consistent and uniform cook • Eliminate burn-on and plugging
ACCOMPLISHMENTS
• Achieved uniform cook • Tight temperature control • No plugging or burn-on • Low maintenance
Are you wondering what applications are ideal for direct steam injection? Visit our industries page to learn more about industries and applications.
Tests have shown that when the shower water is about 122°F [50°C] the detergents and microbicides dispersants are most effective. This is true whether the washing system is continuous, intermittent or whether felts are washed during shutdown periods. It’s essential that felts be kept as clean as possible to not only prolong their life, but more importantly, to maintain paper machine production speeds and minimize downtime.
Engineered for Maximum Efficiency
There are no frills in this felt washing water heating system. It was designed to give dependable service, quicker response and assure delivery of heated water at the temperature desired. Felt cleaning schedules never need to be worked around any warm-up periods or shutdown delays. Heating starts instantly and stops instantly. At the same time, it is completely safe because raw steam never contacts the felt. Water must be flowing through the flow switch before the steam supply is turned ‘on.’ The steam supply valve is closed immediately should therebe an interruption in water flow.
Low Cost
An automatic Hydroheater is the heart of the system. It quietly heats the water while it modulates the steam flow. High velocity steam produces the turbulence for instantaneous heating and prevents scaling of internal surfaces. The two-response temperature controller senses the heated water temperature just downstream of the automatic Hydroheater and provides the output pressure for precise control. The other two items in this system, one flow switch and one solenoid operated steam valve, work together to prevent any steam from coming in contact with the felt. As soon as water flows through the flow switch, its circuit is closed, energizing the steam solenoid. Only then does steam flow to the automatic Hydroheater.
Dependable System has Wide Acceptance
Many paper mills are using this low cost controlled felt washing water heater system with automatic Hydroheaters. Some of them have been in operation for 10 or 15 years without any major maintenance or parts replacement. When this system is used, felt washing water heating problems will be solved.
Are you wondering what applications are ideal for direct steam injection? Visit our industries page to learn more about industries and applications.
An upper Midwest, USA, specialty paper mill, that has been in business for over 125 years, needed to heat whitewater and fresh water tanks for paper machines that make multiple grade changes each day. They needed to heat a 25,000 gallon [95,000 Liters] fresh water tank from 40°F [4°C] to 130°F [55°C] for use as whitewater make-up at grade change. The time to temperature it took for the water to reach temperature often exceeded 2 hours. The in-tank sparging system was very slow to heat the tank and running the paper machine cold at startup. This often caused an outage of spec paper and lost production. It also required extensive maintenance.
1 – Heat fresh water during tank fill
Fluid: Fresh Water (mill water)
Flow Rate: 900 GPM [204 m³/hr]
Inlet Temperature: 40-60°F [4-16°C]
ΔT: 22°F [-6°C]
2 – Recirculate side stream until 25,000 gallon tank reaches target temperature. Tank must reach temperature in 2 hours
Several options were presented to this mill. The solution they chose was a Solaris® S206 in-line heater for fresh water or tank recirculation. The Solaris, with its straight-through design is appropriate for several types of applications, and it fit well here because of the easy in-line installation with the existing fresh water line and high-turndown capability.
The tank currently fills 20°F [-7°C] hotter than the old sparge system and total time to temperature of 135°F [57°C] is less than 2 hours. The improved paper machine start-up time on grade changes has resulted in reduced broke generation and less time to change over grades.
GOAL
• Precise temperature control • Instantaneous hot water on demand for grade changes • Eliminate lost production • Eliminate extensive maintenance
ACCOMPLISHMENTS
• Precise temperature control • 20% hotter water on startup • Increased production • Eliminated extensive maintenance
Are you wondering what applications are ideal for direct steam injection? Visit our industries page to learn more about industries and applications.
A large Midwest, USA, pet food processor needed to replace their large shell and tube heat exchanger that supplied hot water to a tank and then out to a large recirculation system. Scaling was a major issue on the heat exchanger as well as high energy usage. The plant also needed to make sure it had enough hot water at the right temperature for peak usage hours.
A 4-inch EZ Heater® three-way valve was installed which now supplies hot water on demand for their processing floor. This system supplies hot water instantaneously for hose stations, spray bars, spray balls in tanks and general wash-down needs. The EZ Heater never clogs or fouls and only requires a once-a-year maintenance schedule. The company now saves energy and maintenance time. Their uptime has greatly increased and, as a result, so has their production.
GOAL
• Eliminate scaling • Reduce energy usage • Precise hot water on demand at peak usage hours
ACCOMPLISHMENTS
• Instantaneous hot water on demand • No clogging or fouling • Low maintenance • Increased uptime and production
Are you wondering what applications are ideal for direct steam injection? Visit our industries page to learn more about industries and applications.
