Direct Steam Injection System Manufacturer — Primetech, Chennai
Skid Mounted Direct Steam Injection (DSI) System
Primetech manufactures skid-mounted direct steam injection systems for industrial process heating. The DSI system injects steam directly into the process fluid, achieving near-100% thermal efficiency through direct contact heat transfer — eliminating heat exchanger fouling and inefficiency. Each skid includes a DSI heater, PLC control panel, RTD temperature sensors upstream and downstream, pneumatic control valve on steam line, pressure switch, air filter regulator and all interconnecting pipework. Applications include milk pasteurisation, juice heating, brine heating, process water heating, starch cooking, sludge heating and chemical reactor feed preheating. Industries served: food and beverage, dairy, pharmaceutical, chemical, petrochemical, fertiliser, textile, pulp and paper, water treatment and power utilities.
Tank Mounted Direct Steam Injection System
Tank-mounted direct steam injection systems use steam spargers or injectors installed on or into tank walls to heat stored liquids. Steam condenses directly in the liquid, releasing latent heat rapidly and promoting uniform mixing. Eliminates the limitations of internal coil or jacket heating. Used for heating heavy fuel oil, bitumen, molasses, brine, caustic, chemical solutions and process fluids in storage tanks. Primetech tank-mounted DSI systems have been supplied to sugar mills, paper mills, refineries, chemical plants and utilities across India and internationally.
Jet Cooker for Starch Processing
Primetech jet cookers use direct steam injection to cook and gelatinise starch slurries in the pulp and paper industry, food processing, and pharmaceutical starch manufacture. High-pressure steam is injected directly into the starch slurry stream, raising temperature from 25-40 degrees Celsius to 95-140 degrees Celsius in milliseconds for complete gelatinisation. The turbulent mixing ensures uniform cooking without hot surface contact, eliminating fouling. Available with PLC temperature control, RTD feedback and modulating steam valves. Capacity range from 500 kg/hr to 65,000 kg/hr steam throughput. Proven references include Kothari Fermentation, Vijay Anand Kraft Papers and Kuantum Papers.
What is DSI?
Direct Steam Injection Heating
⬥ Near 100% Thermal Efficiency
Direct Steam Injection (DSI) is a highly efficient industrial heating method in which steam is injected directly into a liquid or process fluid. Unlike indirect heating, direct contact between steam and product allows instantaneous heat transfer, resulting in precise temperature control and uniform heating with minimal energy loss.
DSI systems are favoured over traditional shell-and-tube or plate heat exchangers in applications requiring rapid temperature rise, compact footprint, and precise control.
- Near 100% thermal efficiency — all steam energy transferred to fluid
- Instantaneous temperature rise — no slow warm-up
- No fouling surfaces — steam contacts fluid directly
- Precise PLC-based temperature control
- Suitable for viscous, shear-sensitive, and particulate fluids
Skid Mounted System
Product
Skid Mounted DSI System
A compact, pre-assembled package designed to heat liquids efficiently by injecting steam directly into the process flow. The skid integrates all instrumentation and control into a single deliverable unit.
DSI Heater
Primary component that injects steam directly into the fluid stream for precise, rapid heating and efficient energy transfer.
PLC Control
Programmable logic controller automates operation with real-time monitoring of temperature, steam flow, and safety interlocks.
RTDs (Before & After)
Resistance temperature detectors upstream and downstream of the injector for accurate temperature feedback and control.
Pressure Switch
Senses steam supply pressure and triggers alarms or shutdowns if steam moves outside safe operating limits.
Air Filter Regulator
Ensures clean, regulated instrument air to pneumatic devices, enhancing reliability of actuators and control valves.
Pneumatic On/Off Valve
Pneumatically actuated steam control valve enabling precise steam delivery based on PLC signals.
Tank Mounted System
Tank Mounted DSI System
Steam injectors or steam spargers are installed on or into the tank wall, distributing steam directly into the liquid volume. As steam condenses upon contact with the cooler liquid, it releases latent heat — providing very fast, uniform heating with high thermal efficiency and minimal energy loss.
The condensation of steam promotes effective mixing and reduces temperature gradients within the tank, making it superior to coil or jacket heating for large storage or process tanks.
Common Applications
- Food & Beverage — milk, juice, and beverage heating
- Dairy — milk pasteurization
- Pharmaceutical — process water, batch reactor heating
- Chemical — process fluid heating
- Oil & Gas — tank and pipeline heating
- Textile — dye bath heating
- Water & Wastewater Treatment
Jet Cooker
Jet Cooker
A jet cooker using a DSI system is an advanced process unit designed to convert raw starch slurry (including cationic starch) into fully cooked, ready-to-use starch. High-pressure steam injected directly into the slurry ensures rapid heating and gelatinization with minimal energy consumption.
~100% Thermal Transfer
Direct injection maximises steam economy vs indirect methods.
Uniform Product Quality
High turbulence guarantees homogeneous cooking — consistent viscosity and solubility.
Reduced Fouling
High-velocity mixing prevents starch deposition on heat surfaces.
PLC Controlled
Steam pressure, slurry flow, and retention time finely tuned for desired cooking degree.
Applications
- Food & Beverage — gelatinization
- Pulp & Paper — starch and pulp cooking
- Water & Wastewater — sludge heating
- Pharmaceutical — thermal treatment of bio-based materials
- Starch & Sweetener Industry — corn, wheat, and tapioca starch processing