U.S. patent application number 16/392917 was filed with the patent office on 2019-08-15 for steam generator and reactor.
The applicant listed for this patent is Qolibri, Inc.. Invention is credited to Imad Mahawili.
Application Number | 20190249863 16/392917 |
Document ID | / |
Family ID | 62025398 |
Filed Date | 2019-08-15 |
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United States Patent
Application |
20190249863 |
Kind Code |
A1 |
Mahawili; Imad |
August 15, 2019 |
STEAM GENERATOR AND REACTOR
Abstract
A method of producing an active chemical species, steam or
superheated steam includes flowing one or more fluids through a
conduit, locating one or more incandescent lights in close
proximity to the conduit, and using at least a portion of the heat
emitted from the one or more incandescent lights to heat the one or
more fluids flowing through the conduit so that the fluid or fluids
are disassociated into chemical components, associated into a new
compound, or converted into steam.
Inventors: |
Mahawili; Imad; (Roseville,
CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Qolibri, Inc. |
Roseville |
CA |
US |
|
|
Family ID: |
62025398 |
Appl. No.: |
16/392917 |
Filed: |
April 24, 2019 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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PCT/US2017/057356 |
Oct 19, 2017 |
|
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16392917 |
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62412526 |
Oct 25, 2016 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F24H 1/10 20130101; H05B
3/0052 20130101; F22B 1/28 20130101; F24H 1/142 20130101; F24H 1/12
20130101; F22B 1/281 20130101; F22B 1/282 20130101; F22B 1/30
20130101; F24H 2250/14 20130101; F24H 1/162 20130101; F24H 1/43
20130101 |
International
Class: |
F22B 1/28 20060101
F22B001/28 |
Claims
1. A method of producing an active chemical species, steam or
superheated steam comprises: flowing one or more fluids through a
conduit; locating one or more incandescent lights in close
proximity to the conduit; and using at least a portion of the heat
emitted from the one or more incandescent lights to heat the one or
more fluids flowing through the conduit so that the fluid or fluids
are disassociated into chemical components, associated into a new
compound, or converted into steam.
2. The method according to claim 1, wherein the locating one or
more incandescent lights includes locating one or more tungsten
halogen lamps in close proximity to the conduit.
3. The method according to claim 2, wherein the locating one or
more tungsten halogen lamps in close proximity to the conduit
includes locating at least two tungsten halogen lamps in close
proximity to the conduit, optionally locating at least four
tungsten halogen lamps in close proximity to the conduit, or
optionally locating six or more tungsten halogen lamps in close
proximity to the conduit.
4. The method according to claim 1, wherein the locating the lamps
includes locating the lamps around the conduit.
5. The method according to claim 1, or further comprising
surrounding the lamps with the conduit.
6. The method according to claim 2, wherein the locating the lamps
may include surrounding the lamps with a first portion of the
conduit, and locating the lamps around a second portion of the
conduit.
7. The method according to claim 2, wherein the locating the lamps
includes surrounding the lamps with a first portion of the conduit,
and surrounding the first portion of the conduit with a second
portion of the conduit.
8. The method according to claim 7, wherein the flowing one or more
fluids through the conduit includes flowing the one or more fluids
into the second portion of the conduit wherein the second portion
of the conduit forms the inlet to the conduit.
9. The method according to claim 1, wherein the flowing the water
includes flowing one or more fluids through two conduits, and
locating the light in close proximity to at least one of the
conduits, and optionally both conduits.
10. The method according to claim 1, further comprising locating
radiation shields between the end of the lamps and the conduit to
shield the ends of the lamps from at least some of the radiation
emitted by the lamps and heat emitted from the conduit.
11. A generator comprising: a conduit having an inlet and an
outlet, with the inlet being in fluid communication with a source
of one or more fluids; and one or more incandescent lights located
in close proximity to the conduit wherein at least some of the heat
emitted from the one or more incandescent lights is used to heat
the one or more fluids flowing through the conduit.
12. The generator according to claim 11, wherein the one or more
incandescent lights includes one or more tungsten halogen lamps
located in close proximity to the conduit.
13. The generator according to claim 12, wherein the one or more
tungsten halogen lamps includes at least two tungsten halogen lamps
in close proximity to the conduit, optionally at least four
tungsten halogen lamps are in close proximity to the conduit, or
optionally six or more tungsten halogen lamps are in close
proximity to the conduit.
14. The generator according to claim 11, wherein the lamps are
arranged the around the conduit.
15. The generator according to claims 12, wherein the generator
further includes first and second mounting bases for holding the
opposed ends of the lamps.
16. The generator according to claim 15, wherein the bases are
formed from a ceramic material, such as a machineable glass
ceramic.
17. The generator according to claim 12, wherein the conduit
includes first and second portions, the first portion extending
between the lamps with the lamps surrounding the first portion of
the conduit, and the second portion surrounding the lamps.
Description
TECHNICAL FIELD AND BACKGROUND OF THE INVENTION
[0001] Steam generators are devices that use heat to boil liquid
water and convert it into steam. The heat is typically from fossil
fuels, electricity, nuclear energy, or renewal energy. There are
number of different types of steam generators that operate under a
wide range of operating pressures to achieve a wide range of steam
quality production. Most steam generators are high pressure vessels
constructed out of a variety of steels. Steam generators take a
long time typically in the range of several minutes to hours to
achieve steam at a predetermined stable operating pressure and
temperature.
[0002] For example, small steam generators, which typically use
electricity, take several minutes to produce saturated steam at
approximately one atmosphere and nearly 100 degrees centigrade.
Small superheated steam generators, which typically output steam at
steam at about 500 degrees centigrade or greater, take a much
longer time to achieve the desired boiler pressure that produces
the desired superheated steam temperatures.
[0003] One of superheated steam's value lies in its ability to
release tremendous quantities of internal energy that can be used
to drive mechanical systems, such as turbines and reciprocating
piston engines. By remaining above the condensation temperature of
water vapor at the pressures at which these systems operate,
superheated steam avoids the formation of water droplets, which
droplets would otherwise damage these systems due to their
incompressible nature (at those operating pressures). Therefore, of
prime importance is the compressible nature of superheated steam,
especially when driving a reciprocating engine or turbine.
[0004] Therefore, this delay can limit the application of
superheated steam in processes that demand rapid superheated steam
injection, such as in typical semiconductor manufacturing.
[0005] Accordingly, there is a need for a faster way to produce
steam, especially superheated steam.
SUMMARY
[0006] In one embodiment, a method of producing an active chemical
species, steam or superheated steam, includes flowing one or more
fluids through a conduit, locating one or more incandescent lights
in close proximity to the conduit, and using at least a portion of
the heat emitted from the one or more incandescent lights to heat
the fluid or fluids flowing through the conduit so that the fluid
or fluids are disassociated into chemical components, associated
into a new compound, or converted into steam.
[0007] In one aspect, locating one or more incandescent lights
includes locating one or more tungsten halogen lamps in close
proximity to the conduit.
[0008] In a further aspect, locating one or more tungsten halogen
lamps in close proximity to the conduit includes locating at least
two tungsten halogen lamps in close proximity to the conduit,
optionally locating at least four tungsten halogen lamps in close
proximity to the conduit, or optionally locating six or more
tungsten halogen lamps in close proximity to the conduit.
[0009] In another aspect, locating the lamps includes locating the
lamps around the conduit.
[0010] In yet another aspect, the method includes surrounding the
lamps with the conduit.
[0011] According to yet another aspect, locating the lamps may
include surrounding the lamps with a first portion of the conduit,
and locating the lamps around a second portion of the conduit.
[0012] In yet another embodiment, locating the lamps may include
surrounding the lamps with a first portion of the conduit, and
surrounding the first portion of the conduit with a second portion
of the conduit.
[0013] In a further aspect, flowing the fluid or fluids through the
conduit includes flowing the fluid or fluids into the second
portion of the conduit wherein the second portion of the conduit
forms the inlet to the conduit. In this manner, the second portion
of the conduit forms an insulation layer around the first portion
of the conduit.
[0014] In yet another embodiment, flowing the fluid or fluids
includes flowing fluid or fluids through two conduits, and locating
the light in close proximity to at least one of the conduits, and
optionally both conduits.
[0015] In any of the above, the method may include locating
radiation shields between the end of the lamps and the conduit to
shield the ends of the lamps from at least some of the radiation
emitted by the lamps and heat emitted from the conduit.
[0016] In another embodiment, a generator includes a conduit having
an inlet and an outlet and one or more incandescent lights located
in close proximity to the conduit. The inlet is in fluid
communication with a source of fluid or fluids wherein at least
some of the heat emitted from the one or more incandescent lights
is used to heat the fluid or fluids flowing through the
conduit.
[0017] In one aspect, the one or more incandescent lights include
one or more tungsten halogen lamps located in close proximity to
the conduit.
[0018] In a further aspect, the one or more tungsten halogen lamps
includes at least two tungsten halogen lamps in close proximity to
the conduit, optionally at least four tungsten halogen lamps are in
close proximity to the conduit, or optionally six or more tungsten
halogen lamps are in close proximity to the conduit.
[0019] In another aspect, the lamps are arranged around the
conduit. For example, the generator further includes first and
second mounting bases for holding the opposed ends of the lamps. In
one aspect, the bases are formed from a ceramic material, such as a
machineable glass ceramic.
[0020] In yet another aspect, the conduit includes two portions--a
first portion that extends between the lamps with the lamps
surrounding the first portion of the conduit, and a second portion
that surrounds the lamps.
[0021] Accordingly, the generator can quickly heat and convert
gases and/or liquids, such water into steam, namely superheated
steam.
DETAILED DESCRIPTION OF THE DRAWINGS
[0022] FIG. 1 is a schematic drawing of a typical commercial
tungsten halogen high temperature lamp;
[0023] FIG. 2 is an enlarged plan view of an end base for a
plurality of lamps;
[0024] FIG. 2A is a cross-section view taken through line IIA-IIA
of FIG. 2;
[0025] FIG. 3 is a schematic drawing of the lamp array system
mounted between two end bases;
[0026] FIG. 4 is a schematic drawing of a lamp array system with a
process conduit extending there through;
[0027] FIG. 5 is a schematic drawing of the lamp array system and
process conduit of FIG. 4 shown housed in enclosure;
[0028] FIG. 6 is a schematic drawing of the lamp array system with
another embodiment of a process conduit;
[0029] FIG. 7 is a schematic drawing of the lamp array system with
a third embodiment of a process conduit; and
[0030] FIG. 8 is a schematic drawing of the lamp array system with
a fourth embodiment of the process conduit.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0031] Referring to FIG. 4, the numeral 10 generally designates a
generator or reactor that heats a fluid or fluids, such as liquids
or gases. The illustrated embodiment is described herein in the
context of a steam generator that heats water to generate steam,
specifically superheated steam, but it should be understood that a
gas or gases or a gas and liquid may be heated using the same
technology to disassociate or associate the gas, gases and/or
liquids into other desired compounds. Further, the present steam
generator can heat water to generate steam, specifically
superheated steam, at a rapid rate. For example, steam generator 10
can generate superheated steam in seconds versus minutes, which is
associated with conventional steam generators. As will be more
fully described below, generator 10 is configured to produce nearly
instantaneous steam and, more specifically, nearly instantaneous
superheated steam at about one atmosphere and at a temperature in a
range of 100 C to several hundred degrees centigrade. Several
examples of the amount of steam, the temperature of the steam, and
the rate of steam production are provided below.
[0032] As best seen in FIG. 4, generator 10 includes one or more
incandescent lights 12 (see FIG. 1) that are located in close
proximity to a process conduit 14 for directing heat to the process
conduit. Process conduit 14 includes an inlet or input 14a for
coupling to a source of gas and/or liquid, such as water, and an
outlet 14b from which the heated product, such as steam, is output
from the generator. For example, suitable gases for association or
disassociation may include gases associated with, for example,
semiconductor processing.
[0033] Referring to FIGS. 3 and 4, power is delivered to the one or
more incandescent lights 12 by a computer-based control system 16,
which is coupled to a power supply (not shown) and to the
electrodes of the lamps to regulate the power delivered to the
light or lights, for example based on the water flow rate and the
desired superheated steam outlet temperature. Computer-based
control system 16 includes a microprocessor based controller and
may include one or more a sensors in communication with the
controller to detect one or more process parameters. For example,
computer-based control system 16 may include one or more sensors to
detect the flow rate of the water at or near the input and one or
more temperature sensors to detect the steam's temperature at or
near the outlet, and optionally to detect the temperature of the
conduit and/or the lamps. Computer-based control system 16 may also
include other electronic components that are programmed to carry
out the functions described herein, or that support the
microprocessor and/or other electronics. The other electronic
components include, but are not limited to, one or more discrete
circuitry, integrated circuits, application specific integrated
circuits (ASICs) and/or other hardware, software, or firmware, as
would be known to one of ordinary skill in the art. Such components
can be physically configured in any suitable manner, such as by
mounting them to one or more circuit boards, or arranging them in
other manners, whether combined into a single unit at the generator
in a control unit or distributed across multiple control units.
Such components may be located at the generator or they may reside
separately from the generator, for example, in remote location from
the generator. When located separately, the components may
communicate using any suitable serial or parallel communication
protocol.
[0034] In the illustrated embodiment, lights 12 comprise a
plurality of tungsten halogen lamps 18 (e.g. see FIGS. 1, 3, and
4), including for example tungsten halogen high temperature lamps.
A halogen lamp is incandescent tungsten lamp that has tungsten
filament and a small amount of halogen gas, such as iodine or
bromine added. The addition of the halogen gases to the tungsten
filament produces a halogen cycle chemical reaction that increases
the operating life of the lamp. High temperature lamps are
commercially available from a variety of companies, for example
Fannon in the US or Ushio of Japan.
[0035] Optionally, referring to FIG.1, lamps 18 may be manufactured
with a totally clear quartz cylindrical bulb or housing 18a or may
have portion of the inside of the housing coated with a film 20,
such as partial gold thin-film, to focus the energy emitted from
the filament inside the housing in a desired direction. Alternately
or in addition, an external reflective coating, such as a thin gold
film, may be applied to the exterior of the housing. Lamps 18,
which as noted are conventional, may include a ceramic cap 18b on
each end into which the ends of the filament extend and couple to
electrodes 18c, 18d for coupling the respective lamp to a power
supply as controlled by control system 16.
[0036] To support the lamps in a spaced relationship around the
process conduit 14, generator 10 includes first and second end
bases 22, such as shown in FIG. 2. Each end base 22 may be formed
from a ceramic material, including mica or a machineable ceramic
material, such as a machineable glass ceramic, which is available
under the trademark Macor. As best seen in FIGS. 2 and 2A, end
bases 22 include a plurality of openings 24 through which the lamp
electrodes extend for coupling the power supply. In the illustrated
embodiment, end bases 22 are formed from a disk shaped member with
an optional central opening 26 for receiving the process conduit
and an annular recess 28 that extends around opening 26 for
receiving the respective end caps of lamps 18. As would be
understood the shape, size, number of openings and location of the
openings in the end bases may vary depending on the size and number
of lamps that are used, and the type of process conduit, as will be
more fully described below.
[0037] Openings 24 are located in an annular recess 28 of end base
22 and arranged around radially spaced from opening 26 so that when
the lamps are mounted to the respective end bases 22, lamps 18 will
be arranged around opening 26 to form a central passage 30 (FIGS. 3
and 4) there between to receive process conduit 14. Thus, in this
embodiment, the lamps 18 surround the process conduit 14. Hence,
the reflective coating 20 may be applied to the outer side of the
respective lamps so that the heat emitted by the lamps is directed
inwardly toward the process conduit. The number of lamps may be
varied, including at least two lamps, at least four lamp, and
optionally six or more lamps, as shown in the illustrated
embodiment.
[0038] To increase the heat transfer, lamp 18 are located in close
proximity to process conduit 14 in FIG. 4. For example, the term
close proximity means in a range of 5 to 10 mm, in a range of 2 to
30 mm, or optionally in a range of 1 to 7 mm. In this manner when
combined with the use of the reflective coatings, most if not all,
the heat emitted from the lamps is directed toward the process
conduit.
[0039] Referring again to FIG. 4, in the illustrated embodiment,
process conduit 14 comprises a straight tube, such as a tube formed
from a variety of materials, such as steel, stainless steel alloys,
aluminum, copper, glass, quartz, alumina, silicon carbine, zirconia
or the like, that extends through passage 30 (FIGS. 3 and 4) and
through the enclosure described below. The diameter and wall
thickness of the tube may vary, and depend on the specific process
requirements and the desired chemical reaction result to be
achieved, but should be no less than about 6.35 mm (0.25 inches) in
diameter. For example, the diameter of the tube may typically fall
in a range of 150 to 300 mm, in a range of 100 to 1500 mm, or
optionally in a range of 300 to 600 mm with a wall thickness
falling in a range of 0.12 to 0.75 mm, in a range of 0.02 to 2.54
mm, or optionally in a range of 0.25 to 0.5 mm.
[0040] To reduce heat loss and further prevent the risk of injury
to a person in close proximity to the generator, generator 10
optionally includes an enclosure 32 (FIG. 5). Enclosure 32 includes
opposed ends walls 34a and 34b and perimeter wall 36 that extends
between the two end walls 34a, 34b to house and enclose lamps 18,
process conduit 14, and end bases 22. End walls 34a, 34b include
openings for the inlet end of process conduit 14 and for the outlet
end of process conduit 14 so that the generator, with the exception
of the inlet and outlet ends, is fully contained within the
enclosure. Optionally, the enclosure may be formed from thermally
insulated material, such as various ceramics. Additionally,
enclosure 30 may include internal insulation material, such as
quartz wools or the like. Alternately, or in addition, enclosure 30
may include an outer water-cooled jacket formed in perimeter wall
36, or that extends around perimeter wall 36, to provide insulation
or additional insulation.
[0041] In a test of a generator constructed in accordance with the
first embodiment, namely with six 1000 W tungsten halogen lamps
operated at 40% power and a water input flow of 120 cm.sup.3 per
minute, superheated steam was produced at nearly 500.degree. C. in
less than 15 seconds, which is equivalent approximately to 200
liters per minute of superheated steam.
[0042] According to a second embodiment of a generator, the process
conduit may be configured to surround the lamps. Referring to FIG.
6, generator 110 includes a process conduit 114 is configured as a
coil with a first linear portion that forms the input 114a and a
second linear portion 14b that forms output 114b, which extend
through the end walls of enclosure 130 similar to the previous
embodiment. In this manner, process conduit 114 surrounds lamps 18.
With this configuration, the surface area of the process conduit is
greatly increased and, therefore, more heat emitted from the lamps
may be absorbed by the fluid flowing through the process conduit.
Further, with this configuration, the reflective coatings may be
eliminated or their location may be varied. For example, the
reflective coatings may be provided on the inwardly facing side of
each respective lamp so that all the heat emitted by the lamps is
directed outwardly through the outwardly facing sides of the
lamps.
[0043] To maximize the heat absorbed by the process conduit, the
coiled portion of the process conduit is sized such that it covers
the majority, if not all, of the heated lengths of the respective
lamps (see FIG. 1).
[0044] According to yet another embodiment of a generator 210, the
process conduit may be configured with two portions--a first
portion that surrounds the lamps, and a second portion which is
surrounded by the lamps. Referring to FIG. 7, process conduit 214
of generator 210 includes a first, coiled portion 216 that is
coiled and surrounds the lamps 18, and a second straight portion
218 that extends between the lamps 18 and is surrounded by the
lamps, similar to the first embodiment. The coiled portion of the
process conduit is joined with the straight portion of the process
conduit by a third portion 220, which has an inverted L-shaped
configuration. As would be understood, the shape of the third
portion may vary. In this manner, the coiled portion 216 is in
series the straight portion 218 of process conduit 214.
[0045] In the illustrated embodiment, the coiled portion 216
includes the inlet 216a for fluid communication with the water
supply through the perimeter wall 236 of enclosure 230, and the
straight portion 218 of process conduit 214 extends downwardly
through the end wall 234b of enclosure 232 to output the steam.
Enclosure 232 is of similar construction to enclosure 32 and
provides an insulated enclosure for the lamps 18 and for most of
the process conduit, with the exception of the inlet and outlets.
Therefore, reference is made to enclosure 32 for any additional
details.
[0046] With this increase in surface area in the process conduit,
generator 210 may produce a very high temperature superheated steam
at a very high volumetric flow rate. In one test, a generator of
the type described herein (with the six 1000 W tungsten halogen
lamps) can generate 400 L per minute of superheated steam at 60%
lamp power at temperature of nearly 500.degree. C.
[0047] In yet another embodiment of a generator, the process
conduit may include a first portion that surrounds the lamps and a
second portion that surrounds the first portion of the process
conduit. Referring to FIG. 8, the numeral 310 generally designates
another embodiment of a generator. Generator 310 includes a first
coiled portion 316 that surrounds the lamps 18 and a second coiled
portion 318 that surrounds the first coiled portion 316 of the
process conduit 314. In the illustrated embodiment, first coiled
portion 316 is sized to extend over the heated length of each of
the respective lamps, similar to the second and third embodiment.
Second coiled portion 318 is sized to extend over first coiled
portion 316 and substantially the full length of the lamps 18.
Consequently, the outer coiled portion is longer in coil length
than the inner coiled portion. Additionally, the diameter of the
second coiled portion may be greater than the diameter of the first
coiled portion so that it completely surrounds the inner coiled
portion as described and shown. Further, insulation may be added to
the outer coiled portion prior to installing it within the
enclosure (not shown, but reference is made to the enclosures of
the previous embodiments for examples of insulation). In the
illustrated embodiment, both the inlet and outlet ends of the
process conduit extend through one of the end walls of the
enclosure and, therefore, exit the generator from the same
side.
[0048] By directing the water about the inner coiled portion 316 by
way of outer coiled portion 318, the outer coiled portion 318 of
the process conduit 314 may act as an insulator to reduce heat from
reaching the enclosure for safe handling during operation and,
further, to increase the thermal efficiency of heat transfer from
lamps to the process conduit.
[0049] Optionally, generator 310 may include one or more radiation
shields 340. Shields 340 may comprise plates, such as circular
plates, and be constructed of high temperature ceramic materials,
including mica or other machineable ceramic material, including
machineable glass ceramic similar to the material that may from the
end bases. Shields 340 are located between the end of the lamps and
the process conduit to shield the ends of the lamps from at least
some of the radiation emitted by the lamps and heat emitted from
the process conduit. These radiation shields, therefore, minimize
the amount direct radiation heat loss that can reach the outer coil
and the generator's enclosure. Accordingly, with the addition of
the outer coil, the high temperature insulation between the coils,
and the radiation shields the lamps' ends can be cooler than they
would otherwise and, therefore, can extend the life of the
lamps.
[0050] In any of the above generators, a ventilation fan may be
incorporated into the enclosures, which draws outside ambient air
into the space inside the enclosure between the insulated process
conduit and the enclosure to cool the end of the lamps, which may
extend the life of the lamps.
[0051] In any of the above generators, as shown in reference to
generator 310, thermocouple tubes 350 may be added and coupled to
the process conduit, such as the inner coiled portion in the
illustrated embodiment, and to the computer based control system
(e.g. the control system 16 referenced above, which may be used in
this and any of the above generators). The thermocouple tubes 350
may allow for greater control over the operation of the respective
lamps and steam production by providing feedback on the temperature
of the process conduit to the control system, which as noted above
may use the temperature of the process conduit to control the
generator.
[0052] Accordingly, the generators described herein can produce
superheated steam in a matter of seconds, for example in as little
as 10 seconds, depending on the percent of lamp power employed and
water input flow rate. The generators also can be turned off nearly
instantaneously by turning off the water flow and the lamp power.
It can be used in production cycles with variable cycle times or it
can be used to produce continuous flow rate of superheated steam at
constant temperature. This can be achieved readily by the use of
the computer control system described above, that controls the
percent power delivered to the lamps based on the water flow rate
and desired superheated steam outlet temperature. These generators
can produce superheated steam at one atmosphere and therefore do
not require any of the costly certifications of the high pressure
superheated generators. However, it should be understood that the
generators may use back pressure at the outlet or downstream from
the outlet to vary the pressure in the process conduit. It is also
highly competitive in costs and ease of installation in a variety
of commercial applications from steam health spas to chemical,
biological and semiconductor processing to name a select few.
* * * * *