Application Overview
A mineral processing facility required on-demand hot water to fill process tanks as part of a regular intermittent operation. The system needed to start automatically, run for 5 to 10 minutes, shut down, and repeat this cycle multiple times per day.
Because the application involved harsh operating conditions and frequent cycling, the customer needed industrial-grade equipment that could:
- Reach required 176°F (80°C) temperature quickly
- Operate quietly and smoothly across a wide range of flow (6-30 gpm [1.4-6.8 M³/h])
- Withstand repeated start and stop operation 10-20 times per day
- Remain reliable with minimal maintenance
The Challenge
The facility’s existing direct steam injection heater from another manufacturer struggled in this intermittent duty. The system had significant problems, including:
- Steam hammer and vibration, particularly on startup and shutdown
- Fouling inside the heater, reducing performance and requiring maintenance
- Difficulty maintaining desired temperature
These issues made the system unreliable and unsuitable for the demands of mineral processing.
The Solution
The customer replaced the existing heater with a ProSonix ProJet® Steam Injection Heater, paired with a ProSonix AccuTemp™ temperature controller.
The ProJet® was selected specifically for its simple, reliable, and proven design, making it well suited for intermittent on-demand hot water applications.
Key ProJet® technologies that addressed the problem included:
- A unique 2-stage self-modulating steam flow control design that maintains high steam flow velocity across a wide operating range
- Complete condensation and mixing of steam in the water, eliminating steam hammer, vibration, and noise
- Self-cleaning design
- Precise and stable temperature control, even during rapid startups
- Simple, durable construction, reducing maintenance needs
- Interchangeable steam injectors, allowing flexibility if heating requirements change
The AccuTemp™ controller was integrated so the system automatically activates as soon as the required flow rate is achieved, delivering hot water instantly without operator intervention.
The Results
After installation, the ProJet® system immediately resolved the issues caused by the previous heater.
- Smooth, instantaneous hot water on demand
- Zero vibration or steam hammer
- No fouling, even with frequent on-and-off cycling
- Reliable operation multiple times per day, every day
- Consistent, fast heat-up to target temperature
The ProJet® now runs quietly and reliably in an application where the previous heater consistently failed.
Why ProJet® Was the Right Fit
Mineral processing environments demand rugged, dependable equipment that performs consistently under tough conditions. The ProJet® Steam Injection Heater delivered exactly that.
- A compact, economical, and easy-to-install design
- Proven performance in intermittent, high-demand applications
- Long-term reliability with minimal maintenance
By combining 100% energy transfer using both the latent and sensible heat of steam with a robust, vibration-free design, the ProJet® provides a dependable solution for industrial hot water generation.
Conclusion
For industrial applications requiring on-demand hot water, frequent cycling, and rugged reliability, the ProSonix ProJet® Steam Injection Heater is a proven solution. In this mineral processing facility, ProJet® eliminated fouling, vibration, and steam hammer, delivering quiet, instant, and reliable hot water exactly when needed.