Is anything there to replace the Heat Exchangers in Process Industry ?

Replacing of Heat Exchangers are possible in Process Industry. Any Process Industry greatly depends on heat exchangers for the recovery of energy through process fluid or utility fluid.

Why replace a heat exchanger?
Documented energy savings of up to 30% have been reported when replacing a shell-in-tube or plate and frame heat exchanger with a direct steam injection heater from Hydro-Thermal. Heat exchangers heat through a metal barrier which absorbs much of the steam's energy. Direct steam injection heaters, on the other hand, are your smart energy investment because they are more energy efficient by using all the industrial steam's energy to heat process fluids or utility water.

What is Direct Contact Steam Injection?

Direct steam injection transfers heat by precisely injecting metered amounts of steam into the process fluid, liquid or slurry. Injecting steam more rapidly and more efficiently transfers heat energy than indirect heat exchangers. Direct contact steam heating uses all of the sensible and latent energy in the steam, providing 100% thermal efficiency. Energy savings can be considerable reductions in the 20% - 30% are common.

Controlling Steam Flow

A Hydro-Thermal steam injection heater is an internally modulated mixing valve that controls both steam flow and mixing. Steam mixing is controlled by an internal stem plug that meters the amount of steam allowed to pass through the nozzle. Internal modulation eliminates the need for an external steam control valve.

Nozzle design ensures constant steam pressure and velocity at the point where steam contacts the liquid or slurry, eliminating the potential for pressure upsets and ensuring smooth heater operation. This feature provides tight temperature control to the process and extraordinary energy efficiency.

Low Maintenance Because of Self-Cleaning Design

The Hydroheater is cleaned by its own turbulent mixing action, so it does not foul or scale. Chemical clean-out is never needed for our heaters, so they save money and lower the environmental impact of harsh cleaning chemicals.  Maintenance time is also greatly reduced.
Thanks to the self-cleaning action these steam heaters have the flexibility to heat slurries containing a high concentration of solids or non-Newtonian liquids.

Compact Design

Hydroheaters and all accessories are compact and installed as part of the piping, requiring less space than heat exchangers or spargers.

Specifying a Direct Contact Steam Heater

To specify a Hydroheater, general information about the process and the fluid properties such as specific gravity, density, solids content, viscosity and whether any abrasive or corrosive products are present must be taken into consideration. Other information needed are flow rates and steam pressures.

More reasons to replace heat exchangers or spargers with a steam injection heater from Hydro-Thermal

• Less maintenance and more up time
  
• Exacting control of required process conditions and temperature
  
• Smaller foot-print
  
• Hydro-Thermal expertise, training, support services and warranty
  

Unlike heat exchangers or spargers, the Hydroheater is engineered specifically for your process conditions and unique application.

*** Application constraints are there.