Power Plants & Refineries

Reverse Osmosis

Reverse-OsmosisProSonix DSI Heating Solutions

  • Angled Steam Injector is designed for hi viscosity, hi solids and difficult to pump slurries and sludges
  • Low pressure drop of typically 1-2 psig
  • Precise temperature control to +/- 1°F (-17°C)
  • Expanded body allows for insertion of steam diffuser to maintain proper flow velocities thru heater
  • Single or multi-stage heating for flow rates from 1 – 10,000 gpm
  • High temperature rise up 250°F (121°C) in a single pass
  • Standard carbon steel or 316SS. Optional alloys and wear coatings available for erosive or corrosive applications
  • Designed to ASME B31.1; optional ASME, CRN or CE/PED certification

Well Suited For

  • High solids, high viscosity and difficult to pump slurries
  • Slurries with large particulate
  • Fibrous slurries such as pulp stock and biomass
  • Anaerobic digestion of municipal wastewater biosolids, animal by-products and biogas production
  • Mining and mineral processing applications

The ProSonixTM I-Series Direct Steam Injection heater’s unique method of direct steam injection utilises internal steam modulation via an integral pneumatic actuator to accurately deliver the appropriate mass flow of steam for the required heating. This modulating design offers a precise method of steam control through a choked flow control delivery of the steam. Choked flow is the phenomenon of accelerating a vapor to maximum velocity by creating a pressure differential through an engineered opening. By establishing choked flow, the steam mass flow is metered to precisely control the heating of the liquid. This produces predictable results based on position of the stem plug. Through a variable-area steam diffuser, steam flow is metered at the point where steam and liquid first contact and mix.

Features & Benefits

  • 3-Dimensional steam injector delivers up, down and side to side steam injection pattern to optimise steam mixing and rapid condensation
  • Angled diffuser reduces flow disruptions and suitable for fibrous slurries
  • Single point steam injector diffuser connection allows for complete fluid pass through clearance with no build-up points for fibrous materials
  • Eliminates plugging and fouling from burn and scorch sensitive slurries and sludge’s
  • Internally modulated steam injection controls mass flow of steam allowing for smooth and stable operation
  • Energy savings as a result of low pressure drop across the PSX DSI heater
  • Positional steam inlet allows steam inlet flange to be rotated in 360° for ease of steam piping connection
  • Secondary internal steam shut-off (optional) for integral steam shut-off

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Boiler Feedwater Heating

Typical Boiler Feedwater Heater Process DiagramBoiler Feedwater Heaters via Direct Steam Injection

Power generating plants utilise steam boilers to produce electricity energy for their operation. These boilers often have feedwater heaters which are an integral part of the plant’s thermodynamic cycle. The presence of the heaters in the cycle improves the thermal efficiency of the power plant by lowering the amount of thermal energy required to generate a given amount of electrical by re-using produced steam in a heat exchanger to heat feedwater prior to the Deaerator.

Issues Associated with Boiler Feedwater Heating

  • Heat exchangers are prone to mineral and scale build-up on the internal components. This scale build-up reduces their thermal efficiency and requires costly cleaning and replacement of damaged components
  • Mineral and scale build-up can lead to a plugging/fouling issue which increases energy consumption from the condensate pumps
  • Replacement of the heat exchangers requires considerable floor space and foundation improvement because of their size, weight and cleaning access requirements

ProSonix Direct Steam Injection Heater Solution

The PSX heater can be installed to heat up the returned condensate with low pressure steam from the turbine.  Often times steam temperatures of 600°F (316°C) and feedwater temps of 400°F (204°C) are not uncommon. The key to efficient, safe and predictable steam injection is the use of internally modulated steam control and to inject steam at sonic velocity to achieve choked flow. By achieving choked flow, sonic velocity conditions can be achieved for steam injection. The use of an integral pneumatic actuator allows for sonic velocity steam injection for the PSX Heater to operate in a choked flow manner for good, non-violent mixing. The PSX heater is an internally modulated heater, with a variable position stem plug, that varies the mass flow rate of steam by changing the area in which the steam may pass. This type of modulation allows the full steam pressure to always be present at the point of injection, regardless of plug position.

Key PSX Heater Direct Steam Injection Benefits

Eliminate Steam Hammer
  • Stable operation the internally modulated steam control design of the PSX heater controls the steam mass flow and not the steam pressure, thus eliminating steam hammer and vibration issues
  • Lower maintenance due to the PSX heater’s self cleaning design (no scaling or plugging/fouling)
  • Low pressure drop across the PSX Heater (typically 1-2 psig) reduce pump integration issues and flow disruptions
  • Economical installation as the PSX heater can be installed in the piping with no floor space requirements
  • Precise temperature control, typically +/- 1°F (-17°C), allows for a more reliable heating process
  • High turndown on both steam and liquid allow for process flexibility and process condition variations