Typical Applications of Superheated Steam (Drying to Reacting)
to Improve Productivity

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The basis for the steam applications is discussed below:

Heating:  Steam offers heat transfer coefficients that are very high. The heat content is also very high. Steam dries faster than air above the inversion point.

Antimicrobial: Dry high quality low-oxygen steam is a known antimicrobial agent without any organic residue.

Chemical:  Many steam reactions are beneficial for energy production and biomass. Superheated steam offers high kinetics.

Penetration: Steam as it condenses, continues to wick.

Additive:  Add to Gas Or Plasma Streams

Low Pressure Steam: Check out the options.

Industrial Sector
Products
Biomass (for electricity generation) Sawdust, wood fiber, pulverized coal, wood chips, wood pulp, spruce and birch bark, milled peat, peat for briquettes
Chemical industry Washing powder, pigment, potassium salt, powdery chemicals, catalysts, coloring agents, regeneration (chemical), carbon activation.
Food industry (sugar) Sugar beet pulp, dietary fiber from sugar beat
Food industry (base materials) Hog fuel, corn fibres, protein containing base materials (soy beans, rape seed, sunflower seed, soy meal, okra, etc.). Peel vegetables like potato or tomato or dry vegetables, essential oils, organic compounds
Food industry Shrimp, pork, bamboo shoot, paddy / rice, herbs, cacao beans, corn gluten, tobacco (drying, expansion). From cooking to cleaning. Videos and Media Gallery.
Food industry (starch) Starch, potato, vegetable, wheat flour, distillers grain and other staples. From cooking to cleaning. reported to much better than vacuum drying.
Food industry (meat) Pork, bone meal. Clean meat tables and study tables. Food laboratory. Review a study.
Epoxy. Mold Curing and drying. Polymer curing, reactions, coagulation. Drying of sand molds and investment molds.
Chemical processing Reaction kinetics manipulation, water-shift and WGSR, reverse water gas-shift reaction, flavor reactions, photosynthesis
Paper & pulp applications Paper, fibre/fiber sludge from waste water treatment, drying
Textile applications (Coated) textile, drying, cotton fibers, improve water uptake, improve quality of fiber yarn for cotton
Waste materials Industrial wastes, filter cakes, sludges from water purification, municipal sludge
Vegetables & fruit Vegetables, Tea, Coffe, herbs
Dairy industry Milk powder, flash drying
Potato Potato products, fries (pre-drying)
Metal finishing For antimicrobial and other types of cleaning/finishing metals, semiconductors, silicone/plastics, rubber, composites and ceramics.
Building materials Wood, lime mud (before calcination), paint, adhesive, mineral wool, fibres, lumber, cement curing, Shrink wrap packaging, quick energy efficient use.
Laundry industry/ General to special cleaning Laundry, dry cleaning, cleaning (several levels including microbial). Clean bio-mplants and textiles.
Textile fiber enhancement Improved torsion strength of the fiber
HVAC cleaning please click to cleaning

Videos and Media Gallery

Superheated Steam Generators – 1kW | High Efficiency Steam Recirculating Ovens

One Atmosphere Boiler OAB® Other Suggested Applications

Why use an autoclave if your need is high temperature steam?

Calculate the energy used in pressurization/vacuum and compare foot-print with the OAB.

Foot print of steam generators. Boilers are not for continuous steam, Save wasted energy from vacuuum or pressure

Commonly Asked Question: Does one need high pressures or vacuum for steam to penetrate textiles or cloth packs?

Answer: Most often no provided the steam is superheated properly. Steam self-propels as a gas. Use the unlimited capacity for continuous steam generators.

For a more detailed answer……please inquire here for pack penetration.

Calculations of Savings from Smart Lower Power Consumption Technologies

Efficient steam tunnels for packaging, shrink wrap, antimicrobial and textile

The examples below are provided only for ideation. Please contact MHI for specific details. No result is guaranteed.

Use the OAB® for Oil Softening of Heavy Oil in Wells and Tanks. Transition towards smart capital expenditure (CAPEX) and innovative operational expenditure (OPEX) are imminent in the oil and gas industry, especially with highly unstable barrel prices. Reduce foot print. Easy to carry. Reduced use of electric and water. Use for Oil Mud. Most Compact.

OAB® Oil Softening Test.

Pilot Plant Steam Generator for Possible Pharmaceutical Applications.

Safer because no pressure leaks, high temperature kinetics and energy efficiency.

Simple SaniZAP Clean dirt and grime in difficult to reach places. First soften and clean with handheld superheated steam then power-blow with hot air. Need more steam – the OAB models are ideal. Steam-soften with the proper superheated MightySteam. Then VTA hot air blow with the powerful VTA-1GC hot air powerblower unit. Simple. No water mess and use of the highest temperature steam. Use for restorative cleaning and degreasing

Pilot Plant Steam Generator for possible steam reforming, with carbon, bioproducts or methane and nitrogen for ammonia applications. The steam generators from MHI namely the OAB and HGA devices are very efficient, controllable and clean.

For example the reaction 2N2(g) + 2CH4(g) + 2H2O(g) + O2(g) = 4NH3(g) + carbon oxide by products  is a negative free energy feasible reaction at 400C.  Or use for bio diesel,or with carbon to produce hydrogen or other clean fuels.

Electric Steam Generator. Foam cutting high speed, low power, no mess with thermal steam cutter. Use best steam that evaporates on cutting. Ultra High Purity Steam. Also called UHP or UHT steam. Textile, continuous heat setting and laundry steam chamber use.

Superheated Steam Generator for use in steam oxidation studies. Use HGA-S or HGA-M.

Continuous steam. Unlimited capacity.

Save big on easy paint removal techniques with MHI steam from enamels to hard paints (view powerpointinquire or rapid buy). Can you find a better paint remover? Foam cutting. Thick foam cutting speeds ~1″/s.

Save 90% energy for cleaning (example for bird droppings). Consumer packaging labels. Improved energy, less water use, improved speed and quality.

Energy Saved for Laundry or Garment pressing. Car seat Pressing. Laundry Use.  The energy requirement is approximately 0.15 – 0.30 kWh / kg of linen (source http://www.rabc-wfk.com/module3/Module3_EN.pdf). This is a good number for dry-cleaning but for full steam drying it may be best to use a number like ~1kWh per /kg. If you are using and paying operationally for a 300kW boiler (1,024,327 BTU/hr) (or 30BP); are you dry-cleaning 900 kg (close to a ton of linen) of laundry in an hour? If this is not so please consider OAB instead to save energy. The cost of energy is similar whether gas or electric. Click here for savings from energy efficiency.  Garment dewrinkle, heatsetting and textile conditioning in a raoid energy efficient manner.

Energy saver for heat set of textiles (dye drying). Choose OAB-4-300 Model.

Drying of silicates, sand, porcelain and investment molds during casting.

Drying with steam- ceramics to textiles. Choose steam higher than 250C. Non condensing. Note OAB steam generators may be turned off and on quickly unlike most pressure vessel type boilers. Continuous steam without pressure drop again best for quality control. Most often neither pressure or vacuum is required in an applications. Pressure is often just a way for traditional boilers to achieve high temperature- not required for the specific application. See also Steam Energy Calculator and steam kinetics.

Seats pressing in rapid demand operations like automobile seats manufacture. At 10 cents per kWh a 300 kW boiler operational cost could be as high as $30 an hour. A 10 kW OAB machine reduces this payment to ~ $1 per hour. Many electric companies offer grants to make capital changes with energy efficient new machinery. Whether a 12 kW OAB may substitute for a 300 kW boiler depends on the application. Most applications where a high velocity jet is required can be met by the OAB® . Please see video in Videos and Media Gallery section.

In many applications a deSuperheater is required.  This is a complex mixing of steam and water and very nozzle dependent.  The OAB, HGA-S and HGA-M orovide modern solutions for mixing at reliably low cost conditions

Improving starterter oxidation for copper tubes.

Steam Copper-tubes for water delivery to start protective oxide (Malakite) barrier in them. Reduces copper contamination and other contaminants from pipes that do not have this starter oxide. Do internal pipes. Please contact MHI for known technical results and referal to the proper EPA laboratories for your carification.. User may need to call government agency for proof of results. Please contact MHI for details.

High Pressure Steam Boiler can be avoided. Laundry boilers, tunnels and other energy improvement uses are possible in the garment and laundry industry. Several levels of efficient cleaning and de-wrinkling Higher temperatures de-wrinkle leather more easily. E.g. Clean fifty pound loads with an OAB® and canopy. The canopy does not need to be a heat dissipating rigid surface!
Choose your own steam bluing/blackening for attractive surfacing. Use steam generator for steam oxidation studies. Use Process Steam for oil (normal and heavy oil) and natural gas to reduce viscosity.
Commercial Steam Boiler and OAB. Cheese Making.

Heat Processing to make cheese is varied the type of technologies used in practice. The time and temperature programme for heating is determined by the method of heating and the type of cheese. Some cheeses require heating to temperatures above 40°C-56°C (133°F) Normally at 37 – 38°C the activity of the mesophilic lactic acid bacteria is retarded. Time is taken check the acidity, Above 44°C or more the mesophilic bacteria are deactivated, and they are killed if held at 52°C between 10 and 20 minutes. Heating beyond 44°C is typically called scalding. Some types of cheese, such as Emmenthal, Gruyère, Parmesan and Grana, are scalded at temperatures as high as 56°C (133°F) . Some of the most heat-resistant lactic-acid-producing bacteria survive this treatment e.g. Propionibacterium freudenreichii ssp. shermanii“. Credit to http://www.food-info.net/uk/dairy/cheese-production.htm is acknowledged for the above information.

Pure Steam Generator. Milk and Cottage Cheese. Augmentaion of process. Significant reduction of energy from unwieldy and high Btu/hr (kW) boilers currentlysee use.

A frequently asked question is: I do understand that milk products have increased considerable resistance to deterioation when UHT steam is used. However will this denature protein in any way that is bad for me? The answer can be found on many web sites like http://www.bodybuilding.com/fun/muscle-mystery-does-denatured-protein-still-make-you-grow.html. Bakery Operation with on demand (on-off) steam. Food processing humidification.Benefits that may also follow from SW-OAB® Steam in addition to saving considerable energy for shrink labeling activities. — OAB® and MightySteam®’s patented heating system
and service allows for an industrial strength steam output.

Continuous Superheated Process Steam for Odor Removal and Other Uses.  Carbon Activation. Superheated steam can be used for physical/chemical activation of carbon resulting in enhanced nanoporous and porous structures of carbon ( about 10-(50-80) nm). The resultant carbon is called activated. It is higly porous and activated. This nanoporous/mesoporous microporous structure is expected to enhance the removal of toxic hydro-carbons and other dangers from waste water/water works and from gas. Continuous steam temperature that is required is greater than ~800°C and dry. Please consult MHI for known techniques for start-up of carbon containing canopies or drums. One important requirement for this is the availability of instantaneous steam, within minutes because moisture if present tends to clog pores. The OAB-4 system or the OAB-12 system makes instantaneous steam. Please see video on Videos and Media Gallery. Electric Superheated Steam. What is the difference between Disinfection and Sterilization? See box below. Steam temperatures greater up to 1300C.
http://health.yahoo.net/news/s/nm/nightmare-bacteria-shrugging-off-antibiotics-on-rise-in-u-s
Steam Sanitation: Studies have shown that even 1 second of residency time of 248°F (120°C) steam is roughly 97% effective against common strains of bacteria1. In controlled experiments, higher temperature steam requires lower residency times to achieve effectiveness. This result most likely follows the common law of chemical kinetics where speed increases exponentially with temperature.
What is the difference between Disinfection, Sanitizing and Sterilization? Sterilization vs. Disinfection vs. Sanitation
There are 3 fairly commonly accepted levels of “clean” in many industries. Sterilization refers to the statistical destruction and removal of all living organisms. Disinfection generally refers to inanimate objects and all vegetative cells, but not spores. Sanitation refers to the reduction of microorganisms to levels considered safe from a public health viewpoint. The official definition of sanitation, according to the Association of Official Analytical Chemists, for food product contact surfaces is a 99.999% (5-log) reduction of contaminants in a 30 second period. For non-product contact surfaces, a 99.9% (3-log) reduction in contamination is necessary. What is anti-microbial cleaning?

Sterilization requires 6 to 12 log or more cleaning potency mostly done in steam sterilizers that are approved for this purpose. the antimicrobial market has been largely comprised of chlorine (bleach), ozone, quaternary ammonium compounds (quats), per-acetic acid (PAA), formaldehyde and glutaraldehyde (aldehydes), and hydrogen peroxide. All of these technologies have limitations in addressing sanitization and disinfection needs.

Steam is powerful. Se Patents Other published patents have shown superheated steam can clean upto sterilization levels. Patent numbers 8,940,245, 8,945,468, 8,652,403, 8,435,459 and many others that are available. See also http://www.diffen.com/difference/Disinfect_vs_Sterilize

Steam Boiler for Steam Kettles, Processing Mash with Steam, Saving Energy and Materials. Save considerable energy and time. Generally from cold start cut up to 1/3 the time. Will preservatives be reduced by steaming – most likely not? Commercial Steam Generator for packaging

View efficient steam tunnels for packaging, shrink wrap, antimicrobial and textile

Industrial Steam Generator and Tunnel for cotton fiber moisture doubling. Moisture in cotton yarn fiber is able to make the fibre more abrasion resistant as well as more fatigue resistant. Use for heat-set and save considerable energy. No need to use vacuum or pressure chambers. Review amazing ROI.

SaniZap® technology is employed in the MightySteam™ line of steam cleaning products and also by the MightySteam™ service which represents a service that provides for the cleaning of interior and exterior surfaces utilizing concentrated superheated steam for residential, commercial and industrial purposes.

Tankless Instant Steam Generator

Steam and continuous steam chamber for curing rubber or plastic and improving fibers for textiles (cotton)

Type of Cotton (Treatment) Moisture Meter Reading on a low humidity day (Base 35 %RH in Cincinnati) Moisture Meter Reading on a very high humidity day. (Base 70 %RH in Cincinnati) Torsion abrasion comparative test.

Relative Scale

Untreated 3 – 5.2 4.9 – 5.8 2-4 Low
Vacuum Steam Treated by Conventional Process 5.9 6 – 8.5 9-12 Medium
MHI steam (tested after about 4-6 days post treatment) 8 – 9.5 10 10-20 High
Endotoxin Free Steam Industrial Steam Boiler
Laboratory Superheated Steam Low Pressure Steam Boilers
Electric Superheated Steam Generator High Pressure Steam Boilers
High Temperature Steam Low Pressure Steam
Low Pressure Steam Boiler Steam Generator Boiler
Steam Roasting. Activated carbon by steam both Stage 1 and Stage 2 (Steam of 700C and 1100C) Electric Steam Boiler
Electric Steam Superheater Steam Boilers
Steam Reforming Hydrogen Wine barrel conditioning and reconditioning. See also hybrid.
Heavy Oil recovery with low energy and water input. Use in Oil storage and Oil tanker applications.
Wood Conditioning for utility, packaging and hobby use. Safe kettle-heating for Breweries, Flavors and other such use Industries.
Energy efficient kettle heating for Breweries, Flavors and other such uses. Superheated Steam Drying
Instant Steam Generator Superheated Steam Boiler

Touch-up steam – 1Kg/hr of steam up to 400°C. Use for steam spray purposes only.
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How much money savings from energy savings with smart steam power technology

Lower power consumption by : 1 kW 10 kW 100 kW
Approximate savings per year of : $876 $8760 $87600

Assumptions include 1kWhr-10 US cents. Continuous use for the year.

Compare the OAB to:
Fire Tube Boilers Water Tube Boiler
Industrial Boiler Gas Steam Boiler

Traditional boilers yield saturated steam (Tsat and Psat are linked). Boiler efficiencies increase with lower pressures. At 10 Bar the saturation temperature is only 180°C. This temperature can almost instantly be achieved with the OAB and other MHI steam generators at a safer 1 bar pressure. If the steam is for heating purposes, please compare the enthalpy. If the steam is for work purposes please use the work potential row below, the work potential increases with both temperature and pressure. Work potential is measured from 25°C base temperature. The cost of boilers increases for very high pressure ratings. However even at 100 Bars the saturation temperature is only 311°C. Again a fairly easy and routine temperature from the OAB.

1 Bar =100000 Pa = 14.5 psi, 10 Bar =1000000 Pa =145 psi, 100 Bar = 107 Pa = 1450.3 psi

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