Industrial hot water heating can be a major energy and cost outlay for food processors and manufacturers. Reducing that energy usage is good for the company’s bottom line, the environment and the public. Smart processors are checking alternative technologies for heating water for CIP, hose stations, sanitation, cooking, etc., that not only saves money and energy, but also heats water to precise temperatures.
Calculator online: one such technology being explored is direct steam injection (DSI). The energy savings associated with replacing a heat exchanger with DSI heating can be estimated by using standard thermodynamic analysis and calculating the required energy from known process conditions (such as flow rate, incoming process fluid temperatures, required output temperature and steam pressure) and comparing the amount of energy needed for DSI heating with that needed for a heat exchanger.
Calculate energy usage: the calculator, developed by Hydro-Thermal’s certified steam system specialists, uses sound thermodynamic assumptions and formulas to estimate the energy used for specific process conditions and compares the required energy of a heat exchanger with that of a direct steam injection three way valve. Users can input their process flow rates, needed output temperature, fuel costs, and other data directly into the calculator. A comparison of the energy usage is shown side by side for each heating technology.
Calculator tested by experts: engineers and energy experts were given a back page look at the calculator and found it to be trustworthy. “Based on my knowledge and the assumptions you sent me, the calculations look very strong,” said a Sempra energy engineer (California). Other groups who have vetted the calculator include the Wisconsin Focus on Energy Group, the US Department of Energy and several engineering professors at the University of Wisconsin and the Milwaukee School of Engineering.
Anyone can use the online calculator: process and plant engineers and energy czars have logged on to use this tool. Because the calculator gives an estimate of their energy usage based on their exact process conditions, they find it very helpful in planning process improvements at their plant.