Direct steam heating is more energy-efficient than indirect heat exchangers. Direct injection incorporates the introduction of steam directly into the target process fluid for heat transfer quickly over short distances. They allow for control over the flow rates of both steam and the target fluid. The mix turbulence gives the direct steam heaters an edge over other heat exchange mediums. The operators only need to modulate the diffuser nozzle and the steam plug for easy working. The heat transfer to slurry or liquid takes place almost instantly over a short distance. It provides for approx. 25% energy savings with a typical thermal efficiency of 100%.

The Komax Advantage of Direct Steam Heating

Komax Direct Injection Steam Heaters are custom made in different sizes ranging between 2” to 24”. The Komax patented Equalizer Mixing module can directly inject saturated steam into the target liquid for the desired temperature. The short time and distance of heat exchange facilitate energy efficiencies. The patented equalizer comprises six mixing chambers that are similar in diameter. Therefore, enabling the division and recombination in the process flow. It leads to high turbulence that creates homogeneously dispersed small steam bubble sizes leading to uniform heat transfer. The process does not involve any vibration, water hammering, or excessive noise outputs.

Komax’s patented internal module ensures total control of steam flow rates, temperature management, and rapid mixing.

Modus operandi

The heat exchange module for the direct injection steam heater is engineered with precision. It can inject steam through the nozzle (diffuser) at variable flow rates to match the operating requirements. There is a massive drop of steam pressure as it achieves the same pressure as the target fluid. Such action ensures instantaneous mixing of the two streams.

These heaters can be calibrated for precise steam injection amount and area (cross[1]section) to achieve and maintain desired heat loads. Such ability makes the direct steam injection heaters a preferred choice for heating different liquids and slurries with varying viscosities. Komax heaters have a custom internal trim designed per the needs of the client.

Industry use case

The direct injection steam heaters find their applications in industries like Chemicals, Power generation, biofuels, food & beverages, plastics, etc.