Direct Steam Injection Applications — Industries and Process Applications
Direct steam injection (DSI) systems manufactured by Primetech are used across a wide range of process industries for efficient, controllable liquid heating. The key advantage of DSI over indirect heating methods is near-100% thermal efficiency — all steam energy is transferred directly to the process fluid without heat exchanger losses or fouling. The following industries and applications use Primetech DSI systems.
Pulp and Paper Industry DSI Applications
In the pulp and paper industry, direct steam injection is used for starch jet cooking — gelatinising cationic and native starch slurries at capacities from 500 kg/hr to 65,000 kg/hr. DSI is also used for white water heating on paper machines, broke pulp slurry heating, and process water temperature control. Jet cookers eliminate fouling of heat exchanger surfaces by cooked starch and provide uniform gelatinisation for consistent retention and strength properties.
Pharmaceutical Industry DSI Applications
In pharmaceutical manufacturing, DSI heaters in 316L stainless steel with electropolished internals are used to heat Water for Injection (WFI) and purified water to hot storage loop temperatures of 80-85 degrees Celsius for microbial control. DSI is also used for batch reactor temperature control, syrup and liquid formulation heating, and CIP water pre-heating. cGMP compliant design with no dead legs and self-draining construction.
Chemical and Petrochemical DSI Applications
Chemical plants use direct steam injection for reactor feed preheating, brine and caustic solution heating, pipeline heating and tank farm temperature maintenance. DSI eliminates tube fouling in heat exchangers handling reactive or viscous feedstocks. High-capacity systems up to 35,000 kg/hr steam throughput have been supplied for molasses slurry heating and chemical conditioning applications.
Food and Beverage DSI Applications
Food and beverage applications include UHT pasteurisation of milk at 135-150 degrees Celsius, juice pasteurisation, gelatin liquid heating, sauce heating and beverage temperature control. DSI provides instantaneous heat transfer, minimal thermal damage to food products, and easy CIP cleaning. Pioneer Jellice India uses Primetech DSI for gelatin liquid heating from 50-55 degrees Celsius to 145 degrees Celsius.
Sugar and Distillery DSI Applications
Sugar mills use DSI for cane juice heating before clarification, eliminating scale build-up in conventional multi-pass juice heaters. Distilleries use DSI for molasses slurry heating, fermentation temperature control and yeast cultivation. High-capacity molasses heating up to 65,000 kg/hr steam throughput demonstrated at Kothari Fermentation and Vijay Anand Kraft Papers.
Water and Wastewater Treatment DSI Applications
Water treatment and wastewater plants use DSI for anaerobic digester sludge heating at mesophilic (35-37 degrees Celsius) and thermophilic (52-55 degrees Celsius) temperatures, industrial effluent pre-treatment, and process water heating. DSI handles fibrous sludge without heat exchanger blockage and provides in-situ pasteurisation during thermophilic AD operation.