Is tank heating with a Sparger a good choice? YES, if you install a ProSonix J Series Sparger
Heating tank water is an essential step in many industrial processing applications and there are many options to choose from to heat the water or fluid. A common, simple, and inexpensive option is to install a sparger into the tank. A typical sparger is designed with a pipe that extends into the tank with a simple nozzle that delivers steam to the tank. The design is basic but is prone to many problems including:
- Loss of energy
- Reliable temperature control
- Inconsistent steam mixing and heat transfer
- Rough operation & steam hammer
- Nozzle clogging and fouling
While there can be issues with tank spargers if not designed correctly to meet the application requirements, many facilities utilize them because they are so easy to install and operate. ProSonix has developed a better option for tank sparging. Our tank spargers deliver higher efficiencies, a more reliable performance, and various jet sparger designs to address both performance and budget requirements. ProSonix has combined the technology of high velocity, direct steam injection heating with the simple design of a tank sparger. High velocity steam assures complete mixing of steam, reduced vibration, and saves energy losses from uncondensed steam bubbles.
How the ProSonix Tank Spargers solve the performance issues of common tank spargers:
Loss of Energy – Typical Tank spargers are not able to fully condense the steam, so bubbles remain. The bubbles rise to the top of the tank and the energy is released to the atmosphere. ProSonix tank spargers utilize 100% of available energy by completely mixing the steam and water. There are no uncondensed steam bubbles in the tank. ProSonix tank spargers heat up faster and there is less heat loss to the atmosphere, which also helps save energy.
Reliable Temperature control – Typical tank spargers deliver steam into one area of the tank, so it is difficult to monitor the temperature throughout the entire tank. Hot and cold spots can form when the steam is not entirely mixed which leads to inaccurate temperature readings. By modulating the steam, the ProSonix jet sparger can maintain high steam flow velocity to insure complete and rapid condensation of the steam Proper temperature control ensures processing optimization at the desired set point.
Limited Operating Range – A ProSonix tank jet sparger is unique because of its self-modulating design over conventional spargers as the self-modulating design allows for a wider operating range. High velocity steam eliminates rough operation and improves mixing of the steam and water. Reaching sonic velocity eliminates uncondensed steam which cause steam hammer and vibration.
Steam Hammer – When uncondensed steam bubbles collide with tank walls, steam hammering can occur which can damage the tank and result in energy loss. The controlled modulating section of the ProSonix spargers eliminates steam hammering and provides reliable, repeatable heated water day after day.
Nozzle Clogging and Fouling – Tank spargers are known for nozzle clogging and fouling. ProSonix spargers are engineered with a self-cleaning design driven by the high velocity steam flow so no downtime or additional maintenance required.
No floor space required – A tank sparger is a great option when floor space is at a premium. ProSonix spargers do not require an additional floor space like heat exchangers do.
ProSonix has developed a tank sparger that eliminates the issues commonly associated with tank spargers and delivers a design that has an increased operating range, a controlled self- modulating design and flexible sizing options for each application.
Additional benefits of a ProSonix tank sparger:
- Flexibility – ProSonix spargers are inserted into the tank and can be designed in varying lengths to ensure thorough heating of the water or fluid.
- A wider range of operation with multiple steam trim selections for each jet sparger and a self-modulating design.
Key Direct Steam Injection Benefits:
- Energy savings resulting from more efficient steam condensation, faster tank heat-up, and reduced heat loss to atmosphere.
- Lower maintenance due to the PSX Jet Spargers self-cleaning design
- Reliable process heating reduces process upsets and elimination of steam hammer
- Improved temperature control allows for a more reliable heating process
ProSonix Jet Sparger Solution
Install the PSX Jet Diffuser Tank Mount Sparger on the tank wall to the heat the tank until the tank reaches a steady state temperature. Various size tanks can be accommodated with single or multiple Jet Sparger arrangements.
The PSX JSeries jet sparger can operation in a mass steam flow mode for tank heat-up and trim temperature mode for tank heating maintenance times. When conventional spargers attempt to operate in this high turndown mode, rough operation & vibration can occur. Once the desired tank temperature is achieved, a single PSX steam injector can be operated to maintain the required temperature in the tank. Injection of high velocity steam minimizes improves condensation and mixing thus structural damage to the tank from the sparger can be eliminated. As the PSX heater utilizes sonic velocity steam injection, scale and mineral build issues in the steam injector cab be
The tank temperature can be controlled via a tank sensor, a discharge sensor, a cascade control loop, or in a variety of configurations allowing consistent precise temperature control. The internal steam control design of the PSX heater controls the steam mass flow and not the steam pressure thus eliminating steam hammer and vibration issues.
ProSonix has combined the technology of high velocity, direct steam injection heating with the simple design of a tank sparger.
Custom engineered solution, built specifically for your application.
- Designs for steam pressures from 15-300 psig and flowrates from 1 – 15,000 gpm
- Steam turndown 100% and liquid turndown up to 10:1.
- Modulating steam flow design (how it works) with 100% steam turndown no external steam flow control valve required
- Temperature control accuracy of +/- 1 deg F
- Self-cleaning design – no mineral or scale build-up
- Materials of construction is stainless, carbon steel and special alloys upon request.
- Common Applications: Instant hot water, CIP cleaning, whitewater heating, boiler feedwater heating