1. Introduction The TJF device is a highly advanced heat exchanger that uses the energy of steam to both heat and pump liquids with no additional external power supply. Its operation is based on the phenomenon of increased compressibility of a homogenous two-phase supersonic jetflow compared to the compressibility of the separate phases. The specific internal parameters of the device are engineered in accordance with a unique proprietary model of two-phase jetflow physics, researched and perfected by the ENSAT Science and Engineering Team. The TJF device is a three-way (liquid inlet, steam inlet, hot liquid outlet) metal T-fitting, implemented for flange, thread or welded installations. 2. Transsonic Jet-Flow Device (TJFD) Schematics and Operation
Water and steam are supplied to the device separately. When mixed they form a homogeneous two-phase steam and water mixture. The local speed of sound within such a mixture is rather small (5-10 m/s). Therefore the speed of steam and water mixture at the device mixing chamber inlet is equal or greater than that of local sound. When the supersonic mixture is decelerated at the outlet of the mixing chamber there is a rapid pressure increase, and then the steam phase is condensed. As a result, the outlet mixture pressure is much higher than the inlet water and steam pressures. Because of developed surface of heat exchange in the mixing chamber due to foggy or foamy structure of the steam-water mixture, dimensions of the device are smaller compared to all heat exchangers of surface type, plate heat exchangers included. Though externally similar to widely-used conventional jet-flow devices (ejectors and injectors), TJF devices are engineered according to know-how theoretical methods, distinctly different in their internal flow profiles, and, therefore, classified as devices using “pressure jump”. This controlled pressure jump effect allows a much wider range of stable operation than conventional steam ejectors, and provides opportunities for using TJF devices in applications where injectors or ejectors can not be implemented or are not effective. TJF equipment is engineered to provide stable operation within a wide range of inlet parameters.Conventional heat exchanger size compared with TJF device size 3. TJFD Technology Advantages Depending on the specific TJFD installation environment, the consumer will benefit from the following technology advantages: - Fuel consumption will be reduced by 2-5% due to heightened efficiency of the heat exchange process.
- Electrical power conservation of 50-70% resulting from reduction of electric power consumption by circulation pumps.
- Operational and upkeep costs reduced by at least 2 times due to stable operation, absence of regular upkeep services, and easy maintenance.
| Basic Parameters | Fitting Diameter, mm | | DN 25 | DN 40 | DN 50 | DN 65 | DN 80 | DN 100 | | Nominal heating capacity, MW (GCal / hour) | 0,47 (0,4) | 1,4 (1,2) | 2,33 (2,0) | 3,72 (3,2) | 5,6 (4,8) | 9,3 (8,0) | | Performance, m3/hour | up to 5 | up to 15 | up to 25 | up to 40 | up to 60 | up to 100 | Nominal Steam Consumption
ton / hour | 0,66 | 2,2 | 3,06 | 4,8 | 7,3 | 12,3 | | Device weight, kilograms | 9 | 15 | 22 | 30 | 34 | 45 | | Device Dimensions (L x H), mm | 183x95 | 243x125 | 263x130 | 282x145 | 302x160 | 332x175 |
Mass production of standard TJF device models, certified as TUV and ISO 9001 compliant has been established in cooperation with the Povolzhskaya Electro-Technical Company at Cheboksary, Russia. The devices are certified by the Russian national standards board – RosStandart. 4. TJF Device Applications and Engineering Solutions Heating System Basic Schematics and Components: System components: - TJF Devices, engineered according to consumer’s technical specification.
- Mounting framework compatible with industry standards
- Control and measurement devices according to system specifications.
- Component interconnection piping of required diameters
Illustration 1. This first heating system implementation layout is recommended for use with steam inlet pressures of 4-10 bar for outlet hot water at temperatures of more than 95°C.
Illustration 2. The second implementation layout is recommended for use with steam inlet pressures lower than 4 bar for outlet hot water at temperatures below 95ºC. Illustrations 1 and 2 show typical installations of TJF devices – before and after the network pumps. The TJF heating components practically completely replace the heat exchanger setup. The installation of TJF components also allows lowering the pressure drop in pipeline significantly, improving pump operation and lowering pump energy consumption. Illustration 3. Installation of TJF devices in parallel with existing heat exchangers. Illustration 3 gives an example layout for installing a TJF device in parallel with existing heat exchanger capacities. Parallel installation allows using the TJF device both as a regular heating provider and to compensate during low temperature periods or to provide instant-on backup capacity in case of regular boiler failure. Unlike conventional heat exchangers, TJF device heat energy transfer efficiency is near 100%.
Illustration 4. Heating of Chemical Treated Water and Pumping It for Deaeration. The TJF device has a very wide range of applications in various heating networks. Illustration 4, for example, shows an implementation layout for heating Chemical treated feedwater and pumping it into deaeration modules. TJF device operating characteristics are guaranteed to conform to engineering specifications, so heating network operations can be analyzed with a high degree of precision before the actual implementation, so the customer can “see firsthand” how the heating network will behave in different environmental conditions after the TJF equipment is installed. A sample performance map for a typical DN-80 device is shown in Illustration 5.
Illustration 5. Adjustment Characteristics for TJF DN-80 Device
1 – Water throughput, m3 / hour
2 – Steam consumption, tons / hour (show at [value x 10])
3 – Heating capacity, GCal / hour
4 – Outlet water temperature, °C
5 – Inlet water temperature, °C
6 – Inlet / Outlet temperature delta, °C
X axis values show steam inlet pressure in bar.
The area marked by gray diagonals provides a stable pumping effect. 5. Each TJF Device Package Includes: - The TJF Device in protective packaging
- Technical specifications for the device
- Schematics of device / device complex.
- List of required mounting materials
- Implementation schematics detailing installation, and all required connectors and their dimensions for integration with existing systems.
- Operating instructions.
- Requirements for inlet parameters and connected systems.
- Manufacturer’s technical manual.
6. Outlet Capacity Adjustment is based on changing inlet steam pressure and the number of devices installed. Inlet consumption adjustment is controlled by a bypass line. TJF equipment can be adapted to work with any inertia-less valves and centrifugal pumps. 7. Areas of Application: - General heating systems
- Heating and hot water supply systems
- Heating chemical treated feedwater and pumping it into the deaeration module
- Preheating fresh feedwater and pumping it into the water treatment cycle.
8. Operational and Maintenance Issues The basic difference is that in a TJF system, conventional plate and surface heat exchangers are replaced with highly effective TJF mixing devices. This means that there will be no condensate runoff. The implications of this change are thoroughly explained in the technical materials included with each device. The resulting increases in feedwater treatment costs are well below the savings gained from lowering fuel, electric energy and maintenance costs for conventional heat exchangers and network pumps. TJF technology, based on the controlled rapid pressure increase phenomenon, can be applied almost universally, in most situations where a liquid is to be heated, pumped or homogenized (or saturated), be it water, some other chemical mix, or a foodstuff (mayonnaise, carbonated drinks). TJF equipment was installed and has shown faultless operation at more than 250 widely varied industrial and residential sites across Russia and abroad, including : “Admiralteyskie” Shipyards (St.Petersburg), “SeverStal” steelworks, “UralCable” cabling plant, “KazanOrgSintez” organic compound synthesis plant, “SerpukhovKhleb” bakery, a number of different size residential heating and hot water supply systems (city-wide level to small villages and military outposts), several major Russian hydroelectric plants, and many others. The outstanding characteristics of ENSAT technologies have been officially certified by the Russian Ministry of Economic Development and the Ministry of Energy and were included as an integral part of the “Energy-Efficient Economy for 2002-2005” Federal Development Program, and various high-profile regional and industry sector energy conservation programs. |
