Using the Hydroheater for direct steam injection heating
Hard water issues, loss of production, plant shutdowns, and damage to your reputation are a few of the many consequences of not having water at critical temperatures exactly when you need it.
If you depend on unlimited hot water at precise temperatures and required flow rates, we have your solution. Not only will you have all the hot water you need, but our heaters are self-cleaning and need far less maintenance and upkeep than any heat exchanger. Our solutions will replace large tanks, spargers or heat exchangers with a much smaller footprint and far greater energy efficiency.
Hydro-Thermal’s patented heating system works by mixing steam and process liquids completely while delivering consistent temperature and instantaneous heating. For more information on our advanced direct steam injection technology, click here.
Hydro-Thermal’s history of Hydroheater innovation
Hydro-Thermal takes great pride in its history of product innovation and industry expertise.
The EZ Heater was invented in 2005 specifically for processing water. Five years later, the EZ Skid was developed, giving customers the convenience of a complete, easily integrated system. Since 2005, we have installed approximately 650 EZ Heaters and EZ Skids in more than 20 countries around the world. In addition, Hydro-Thermal offers the Industrial and Sanitary Hydroheater for customers that have unique water processing needs.
Our staff has presented extensively on water heating issues and solutions, at private institutions and universities, as well as conferences including: California League of Food Processors (CLFP), Technical Association of the Pulp and Paper Industry (TAPPI), Fuel Ethanol Workshop, PetFood Forum, and many more.
Our engineering staff consists of 15 brilliant minds that span a variety of specialties including fluid, electrical, mechanical and design engineers. They have formed strategic research partnerships with our customers, leading Midwestern universities, research associations and independent R&D engineering firms, to constantly evolve our products and inspire new product development.
Direct steam injection heating utilizing the Hydroheater
No matter what your industry or application Hydro-Thermal’s heating solutions will assure you savings energy costs, maintenance down-time, and more.
With instantaneous hot water where you need it, our products are ideal for anywhere maintaining a minimum temperature is critical or that you need reliable, immediate hot water.
Our most popular hot water heating applications include:
CENTRAL HOT WATER SYSTEMS Ensure hot water for your entire plant with a header and recirculation type system. Click here to learn more:
During cleaning and wash down at a facility, it is common to run out of hot water. The spargers or heat exchangers are not flexible enough to account for the varying conditions of wash down versus normal production. Hydro-Thermal’s solution with turn down capabilities is flexible enough to provide hot water instantaneously at your desired temperature during production or plant wash down.
LOCALIZED HOT WATER SYSTEMS FOR CRITICAL TEMPERATURE WATER Take central hot water to whatever temperature necessary at required flow rates via a small slip stream system. Click here to learn more:
For temperature specific operations, Hydro-Thermal has you covered. We understand the importance of meeting proper wash down or sanitation temperatures to avoid fines or recalls. If getting hot water to a specific location is an issue, then we have your solution. Our technology can utilize a small slip steam off of your central hot water system and bring water up to the exact temperature that is required.
HOSE STATIONS, SPRAY BARS, AND TANK SPRAY BALLS Header supplies hot water to applications off a single recirculated line. Click here to learn more:
Replace multiple stations and mixing T’s with just one central EZ Hose Station system. The EZ Heater’s self-cleaning design eliminates scaling or fouling due to hard water. The EZ Hose Station also eliminates the need for steam piping to each individual hose drop while providing accurate and safe temperature control from a single location with steam-safety features integrated directly into the system. Whether it’s one or multiple stations, the EZ Heater hose station system will meet your needs in a safe, effective way.
INGREDIENT WATER OR TANK HEATING Easily and efficiently heats tanks on in-feed or in recirc mode, trim heat. Click here to learn more:
We can heat the fluid going into the tank; re-circulate the tank to maintain a specific temperature, or leave the tank cold and heat the liquid exiting the tank, producing hot water on demand. Hydro-Thermal’s solution can be used for utility or 3A sanitary ingredient water. Many customers see a return on investment (ROI) in less than three months.
WATER SIDE OF HEAT EXCHANGER OR JACKETED TANK HEATING Precise temperature control in a closed loop system eliminates burn-on concerns. Click here to learn more:
Some reactions may change from heating to cooling and back to heating several times. Hydro-Thermal’s solution can maintain the recycled water temperature within close limits. It modulates the steam flow while it is heating the water. The faster speed of response with our instantaneous heating results in the jacket water temperature following the set point as rapidly as changes are called for. The precise temperature control obtained has enabled users to operate at optimum temperature conditions to obtain the greatest yield from the batch, eliminating burn-on, over cook, or under cook.
CLEAN IN PLACE (CIP) Easily heats a one to three CIP tank system on demand. Click here to learn more:
Proper cleaning and sanitation is an important safety concern for you and your customers. Hydro-Thermal’s solution allows you to clean equipment at the optimal temperature in one pass. If caustic or aseptic solutions are being heated, then the Hydroheater can be manufactured using 316L material components. Whether you need to heat a tank or heat on the discharge to the exact temperature, the Hydroheater can meet your needs.
CAN TOPPING Cans or jars are automatically filled with product and then topped off with a brine or water solution at very specific temperatures (typically (185-190ºF). Click here to learn more:
By heating the brine to exact temperatures, Hydro-Thermal’s solutions can kill bacteria and increase shelf life. With health concerns, FDA recalls over E-coli and other bacterial contamination, meeting exact temperature requirements for sanitization and pasteurization is critical in the canning process.
JACKETED VESSELS OR REACTORS Our solution provides all the benefits of efficient direct steam contact jacket water heating along with accurate temperature control that eliminates burn on and overcook. Click here to learn more:
The initial temperature rise can be as fast as the available heat transfer surface, product heat sensitivity and water circulation rate will allow. No floor space is required because our heater is installed in the vessel piping where convenient. In addition, by being able to achieve +/- ½ degree F, the reaction or cook is optimized.
PASTEURIZATION From tunnel pasteurizers, retorts, to HTST and UHT pasteurization standards, Hydro-Thermal has the right solution.Click here to learn more:
Our heaters and systems will kill microorganisms ensuring product safety and reducing the risk of a recall. Whether heating dairy products, soups, and everything in between, we have the experience and knowledge to pasteurize your product safely and effectively.
ANNEALING A water/acidic solution can be heated and treated in order to make the material more workable so that it can be used in further processing.Click here to learn more:
Hydro-Thermal has helped metal processors achieve thousands of dollars in energy savings by switching from spargers or heat exchangers to our heating solution. These manufacturers no longer need to store and reheat water because they will achieve instantaneous hot water every time. In addition, our industrial heaters can handle corrosive or abrasive slurries/solutions. For instance, one annealing customer was impressed that our solution could handle super heated steam and river water without any clogging or fouling.
BOILER FEED WATER Achieving optimal production levels can often be tied to the productivity of the manufacturer’s boiler. Ensure that you have consistent steam levels while reducing corrosion, scaling, and fouling by using a Hydro-Thermal heating system.Click here to learn more:
In addition, our customers see significant energy savings from recycling their waste steam and do not have to worry about disposing of their condensate discharge, because the Hydroheater utilizes 100% latent and sensible energy in the steam and does not require a condensate return system. Optimize your steam production by utilizing a Hydroheater to preheat your feed water.
Want to see how our water heating solutions can benefit you? Click here to get a free analysis.
Additional information on Hydro-Thermal’s direct steam injection technology
Here are some additional resources for water heating applications
Central Hot Water - A case study about a meat processing company that utilizes Hydro-Thermal's direct steam injection technology for their central hot water.
Tank Heating - Additional information about using Hydro-Thermal's direct steam injection technology for tank heating.
What's in a degree? - A document describing the importance of precise temperature control when heating water.