As plants look to improve energy efficiency and reduce waste, capturing low pressure steam for process heating can offer major savings.
The Challenge
A large chemical manufacturer was venting low-pressure (10 psig, 0.7 Barg) waste steam to the atmosphere, losing valuable energy that could have been recovered for process use. Although low-pressure steam has nearly the same energy content as higher-pressure steam, it has far fewer practical uses in most processes.
The plant needed to heat two large water tanks from 80°F to 200°F but struggled to find an efficient, practical solution. Traditional spargers caused steam hammer, vibration, and uneven heating, while indirect systems such as heat exchangers were costly to install and maintain.
The plant turned to ProSonix Direct Steam Injection (DSI) heaters, which offered a reliable way to convert waste steam into consistent, efficient tank heating, eliminating hammer and improving energy utilization at the same time.
Key Plant Requirements
- Recover and utilize waste steam for tank heating.
- Heat two 15,000 gal (57 m3) tanks from 80°F to 200°F (27°C to 93°C)
- Provide smooth, hammer-free steam injection to protect tanks and piping.
- Improve energy efficiency and reduce operating costs.
The Solution
The plant installed ProSonix J-Series Jet Steam Spargers in each tank, engineered specifically to use the available low-pressure 10 psig waste steam as a heating source.
The J-Series spargers provided:
- Free heating of the tank by using steam that had previously been vented to atmosphere
- Direct, controlled steam injection that heated both tanks to 200°F in 150 minutes.
- Smooth, stable operation without steam hammer, vibration, or thermal stress.
- Energy recovery, converting vented steam into useful process heat instead of atmospheric loss.
Results & Benefits
- Recovered waste steam, reducing energy consumption and costs.
- Achieved consistent heating, raising tank temperatures from 80°F to 200°F in 150 minutes.
- Protected equipment by eliminating steam hammer and vibration issues.
- Improved efficiency and reliability, and reduced maintenance.
Summary
By installing ProSonix J-Series Jet Spargers, the chemical company successfully turned vented steam into a reliable, cost-saving heating solution. The project delivered consistent tank heating, energy recovery, and safer operation, demonstrating how Prosonix DSI technology helps plants increase the value of their steam.
To learn more about waste steam recovery, view our Waste & Vent Steam Recovery Application Profile here.