ProSonix heaters behave differently because the steam flow is controlled inside the heater, not by reducing steam pressure with a valve upstream like used with a homemade sparger or other heating styles.
In many DSI setups, a pressure control valve “turns down” the steam by lowering its pressure. That makes the steam move slower as it contacts the fluid, so it doesn’t fully condense right away. Pockets of live steam form and then implode in the pipe or tank — that’s the roughness and hammer you’ve seen.
A ProSonix Heater keeps the steam at high velocity through internal modulation. The steam stays in a choked-flow state, so it condenses immediately as it enters the liquid. With proper steam-to-liquid pressure differential, there are no wandering steam bubbles — meaning stable heating and no steam hammer.
ProSonix steam injection heaters provide up to a 50:1 turndown ratio on steam flow.
No. The ProSonix steam injection heater features a self-cleaning design. The high-velocity steam flow continuously eliminates scale build-up within the Jet Diffuser.
The steam supply pipe must be sized to ensure the required steam flow (as shown on the heater sizing worksheet) can be delivered to the heater at the design pressure. Generally, the steam pipe should be at least as large as the heater’s steam inlet.
On the liquid side, the PSX Heater can be configured to match your existing process piping. Unlike many heaters with fixed liquid connections, we can modify the liquid pipe size to suit your installation and help keep it a simple “pipe-spool” fit. If matching your current liquid line size is important, just let us know during sizing.
Keep in mind that forcing both the process liquid and steam inlet sizes to match existing piping can limit flow rate, temperature rise, or control range. ProSonix independently sizes the steam and liquid inlets for optimal temperature control and the heating performance your process requires.
The PSX Heater can handle up to 75°F (42°C) of steam superheat without modification.
For applications exceeding this, please contact ProSonix or your local representative to review your design.Yes. The PSX Heater can be installed either upstream or downstream of a pump. There are some considerations if installing the heater upstream of the pump.
Consult your ProSonix representative to confirm the appropriate installation configuration for your system.
ProSonix does not specify a single steam pressure, but the steam pressure must always be higher than the liquid pressure to ensure proper operation.
Identify the available steam pressure at the point of heating, and we will design the Jet Diffuser to maintain sonic velocity operation.
Standard designs are available for up to 150 psig (10 Barg), with optional designs for 300 psig (20 Barg) and higher.
Keep in mind that steam pressure affects both diffuser sizing and piping costs—using higher-pressure steam may often be the most economical choice.
No. Some heating devices can cause a 15–20 psid drop, but the PSX Heater’s true inline, flow-through design keeps losses low. In most applications, the liquid pressure drop is only about 1–2 psi.
No. The PSX Heater’s internally modulated design includes an integral actuator that controls steam flow through an engineered variable-area diffuser.
This eliminates the need for an external steam pressure or globe valve on the incoming steam line.
Thanks to the PSX Heater’s internal modulation, most applications are unaffected as long as the liquid pressure is below approximately 70% of the steam pressure (in absolute terms). Operation remains stable if the liquid pressure varies below that threshold.
Generally, no. However, “water” can mean several different fluids in industrial contexts.
Please inform your ProSonix representative if you are heating demineralized water, condensate, or similar fluids, as these can cause corrosion on injector components and may require special design considerations.
Many process fluid heating devices have limited operating ranges.
ProSonix inline heaters, however, typically offer a much wider operating range and seldom limit process flexibility.
A sudden loss of liquid flow can cause steam hammer and must be avoided.
Installing a flow switch on the liquid line or monitoring the liquid pump allows for safe shutdown of the heater.
A high-temperature alarm in the control system is also recommended to detect excessive temperature rise.
Any steam from a well-maintained industrial boiler system is generally suitable for the PSX Heater.
Properly placed steam traps should remove condensate before it reaches the heater, as condensate can cause rough operation and premature wear.
A steam strainer should also be used to remove foreign material.
Both industrial and culinary grades of steam are acceptable for use.
No. ProSonix uses a patented radial multi-port steam injector that introduces steam at high velocity using choked-flow principles. This design ensures rapid condensation without creating eductor or “steam pumping” effects, resulting in negligible impact on fluid flow or pressure.
While your boiler or steam header has a rated pressure, it’s important to know the actual steam pressure at the heater location.
Account for pressure losses due to line friction, fittings (elbows, tees, etc.), and components like valves and strainers to determine the design steam pressure available at the heater.
You don’t need to oversize a PSX Heater to “cover” future capacity. What matters most is how the heater performs at your current operating demand, because that’s where control quality and reliability live.
When a steam trim is oversized for what you run today, the system spends most of its time at the very bottom of its control range. That typically means sluggish or unstable temperature control, rough operation, and faster wear on internal components.
PSX Heaters are built to avoid that tradeoff. Each unit accepts multiple replaceable steam diffuser (trim) sizes, covering roughly 10% to 100% of maximum capacity. For best performance, you want the selected trim to operate in the 20–90% range of injector capacity during normal conditions.
If your process grows later, you’re not stuck. You can increase capacity by swapping in a larger diffuser/trim at that time—without compromising today’s control or paying the performance penalty of oversizing up front. In short: size for what you need now, and adjust easily if demand changes.