Heating Air with Steam: Efficiency and Options

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SUMMARY

The discussion focuses on the most efficient methods to heat pressurized air from 60°F to 200°F using available resources, specifically saturated steam at 50-80 psig and electricity at 480V. Participants highlight the advantages of using an air-steam heat exchanger over an electric coil heater, emphasizing lower ownership costs and reduced control complexity. The discussion also notes the importance of insulating steam pipes to maintain efficiency and suggests that a small thermodynamic steam trap can be utilized effectively. Overall, the consensus favors steam heating due to its operational benefits.

PREREQUISITES
  • Understanding of steam heating systems, specifically air-steam heat exchangers.
  • Knowledge of thermodynamics related to heating pressurized air.
  • Familiarity with electrical heating systems, particularly electric coil heaters.
  • Basic principles of insulation for steam pipes to prevent heat loss.
NEXT STEPS
  • Research the design and efficiency of air-steam heat exchangers.
  • Learn about thermodynamic steam traps and their applications.
  • Investigate insulation materials and techniques for steam pipes.
  • Explore control systems for maintaining outlet temperatures in heating applications.
USEFUL FOR

Engineers, HVAC professionals, and process designers involved in heating systems, particularly those utilizing steam for industrial applications.

dyollnave
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Hey everyone, I have a questions. I am trying to determine the most efficient way to heat pressurized air (35-40 psig, and a flow of 20-30 scfm) at an inlet temperature of 60F, to an exit temperature of 200F with minimal pressure lose. On site I have the availability of saturated steam at (50-80 psig, with a flow rate of 50lb/hr avg, 287 lb/hr max.), as well as electricity(up to 3-phase, 480v). What are the best options given the above information.

What are the advantages/disadvantages of a air-steam heat exchanger vs. an electric coil type heater.

Condensate trapping and drain are not an issue, as waste water disposal is already in place.

Thanks a bunch, I look forward to joining everyone on PF!
 
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The air will be used to dry items further down the process line, not vented into a room.
 
Maybe you checked this, but looking at your numbers, I back of envelope calculated that you have plenty of steam flow available. A small thermodynamic steam trap would also be fine.

Main advantage of steam heater is:

* cost of ownership (less than 10 lb/hr steam vs about a 1.5 kW heater),
* no need for high voltage (240/480 volt, 3 phase, 60 Hz),
* less controls (power must be cut if heater element surface temperature reaches HIGH alarm setpoint).

Of course, you will need to insulate your steam pipes leading to the air heater.

Are you going to control heater outlet temperature?
 

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