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Heating Vats and Tanks by Steam Injection: Home Capabilities Industries Services Products Training
Heating Vats and Tanks by Steam Injection: Home Capabilities Industries Services Products Training
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Steam Engineering Tutorials > Steam Engineering Principles & Heat Transfer
Direct steam injection involves the discharge of steam bubbles into a liquid at a lower temperature to transfer heat. This tutorial explains the
process and the methods used, including the relevant heat transfer calculations.
Heat is transferred by direct contact between the steam and the liquid, consequently this method is only used when dilution and an increase in liquid mass is
acceptable. Therefore, the liquid being heated is usually water. Direct steam injection is seldom used to heat solutions in which a chemical reaction takes place,
as the dilution of the solution would reduce the reaction rate and lower the productivity.
Direct steam injection is the most widely used method for boiler feedtank heating throughout industry. This method is often chosen because of its simplicity. No
heat transfer surface or steam trap set is required, and there is no need to consider the condensate return system.
One major difference between indirect heating and direct steam injection, is that the volume (and mass) of the process fluid is increased as steam is added, by
the amount of steam injected.
Another difference is that, when calculating the steam flowrate to a steam coil, the pressure in the coil is considered, but for steam injection, the pressure before
the control valve is considered.
In some cases (where the liquid surface is not at the overflow pipe level), this will increase the head of liquid over the injector as time progresses. However, this
increase is likely to be small and is rarely taken into account in calculations.
A greater head of liquid over the point of injection will give the steam bubbles maximum opportunity to condense before they reach the surface.
• Velocity of the bubble - The velocity of the bubble at the point of injection will also depend on the difference between the steam pressure and the liquid head.
It is desirable to keep this differential pressure as low as possible, so that bubble velocities are also as low as possible and the bubbles are given the maximum
time to condense before they reach the surface.
• Temperature of the liquid - The rate at which the steam will condense is directly proportional to the temperature difference between the steam and the liquid
being heated. As with all heat transfer processes, the rate of heat exchange is directly proportional to the temperature differential.
It is always advisable to ensure that the temperature of the liquid is correctly controlled and is kept to the minimum required for the application, so that the
maximum heat transfer rate is maintained and there is no wastage of energy.
Sparge pipes
This is simply a pipe mounted inside the tank, with the holes drilled at regular positions (typically 4 o’clock and 8 o’clock) when viewed from the end, equally
spaced along the length of the pipe, and with the end blanked off. The steam exits the pipe through the holes as small bubbles, which will either condense as
intended or reach the surface of the liquid (see Figure 2.11.1).
Sparge pipes are inexpensive to make and easy to install, but are prone to cause high levels of vibration and noise. A much more effective method is to use a
properly designed steam injector.
These calculations (steps 1 to 5) are based on Examples 2.9.1 and 2.10.1 as far as heat losses are concerned, but with the tank containing water (c p = 4.19
kJ/kg °C), instead of weak acid solution and the water being heated by steam injection rather than a steam coil.
Step 1 -
find the energy required to heat up 12 000 kg of water from 8°C to 60°C in 2 hours by using Equation 2.6.1:
Step 2 - find the mean steam flowrate to heat the water by using Equation 2.11.1:
The mean steam flowrate to heat the tank material is calculated by again using Equation 2.11.1:
Step 4 - find the mean steam flowrate to make up for the heat losses from the tank during warm-up. From Example
2.9.1:
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2.9.1:
Whilst it is reasonable to accept that the steam’s liquid enthalpy will contribute to the rise in temperature of the water and the tank material, it is more difficult to
accept how the steam’s liquid enthalpy would add to the heat lost from the tank due to radiation. Therefore, the equation to calculate the steam used for heat
losses (Equation 2.11.2) considers only the enthalpy of evaporation in the steam at atmospheric pressure.
Step 5 - Determine the steam load to heat a tank of water by steam injection. The total mean steam flowrate can be
calculated as follows:
Clearly, the process tank needs to have sufficient space above the starting water level to allow for this increase. For safety, an overflow should always be included
in the tank construction where steam injection is involved.
Alternatively, if the process requirement had been to finish with a mass of 12 000 kg, the mass of water at the beginning of the process would be:
Steam injectors
A more effective alternative to the sparge pipe is the steam injector as shown in Figure 2.11.3. The injector draws in cold liquid and mixes it with steam inside the
injector, distributing heated liquid to the tank.
Example 2.11.2
Based on data from Example 2.11.1, propose a steam injection system.
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Required steam injection rate = 569 kg/h
The steam injection pressure = 1.0 bar
Ideally, because of the low pressures involved, the injectors would be installed at opposite ends of the tank to give good mixing.
An alternative would be to use higher pressure steam. This would allow the use of just one, smaller injector, reducing costs and still providing good mixing.
If the mean heat transfer rate is not known, another method can be used to determine the mean steam flowrate. This requires the use of a heat balance as
described below.
It should be noted that both methods return exactly the same result, so whichever is used depends upon the user’s choice.
Example 2.11.3