Choosing the right heating process for your operation can be difficult. Steam jacketing and steam tracing are options often considered. An advantage to both is that they involve steam to keep pipes or equipment warm. In turn, they are used to maintain temperatures for fluids such as oils, chemicals, or food products. However, they accomplish their goals through different methods. Are you confused between steam jacketing vs steam tracing? Let’s have a look at both of them. It will help you pick the one that suits you the best.
Steam-jacketed piping or vessels are surrounded by a layer of steam, whereas steam tracing utilizes small pipes that carry steam along the outside of the primary pipe. Each option has its advantages and disadvantages.
Steam Jacketing Vs Steam Tracing: Which One To Pick
Here, we will explain both of them. We will detail costing, efficiency, etc. By the end, you will have an idea of which best suits your needs. So, let’s go!
1. What is Steam Jacketing?
Steam Jacketing uses an external jacket that encircles the pipe and tank. Steam flows into this jacket to heat the contents. It’s like a warm blanket for your equipment. The jacket covers the whole surface. This allows for steady, uniform heating. It is conventional in the chemical processing industry. Jacketed pipes can sustain temperatures up to 350°C (662°F). That’s hot enough for almost all heavy fluids. This is quite popular among companies, especially for thick and sticky liquids like molasses or asphalt. The heating prevents the fluids from settling and getting clogged.
The layout is quite simple but effective. Steam enters through an inlet and exits after the heat exchange. The temperature can readily be controlled by the use of valves. About 60% of large-scale refineries use steam jacketing on critical operations because it is integrated into the very design of the equipment. This makes it reliable in handling heavy-duty work. However, it does not come cheap. You will need specialized piping or vessels. Maintenance can take up time as well. However, continuous heating is still a viable option.
2. What is Steam Tracing?
What is steam tracing in piping? Small tubes are placed alongside the pipe. These tubes carry steam to warm the pipe’s surface. Nip into business parlance: the steam system might be considered a hot wire next to your process line. Tubes are usually made of copper, stainless steel, or even some other alloy in some cases. They are strapped or welded. The system’s advantage is flexibility: you can trace pipes for any length. Studies report that steam tracing does some 70% of pipeline heating in oil refineries. It is useful for long runs or irregular shapes.
The heat is realized from steam inside the tubes. Heat is transferred through contact into the pipe. More tubes give more heat, whereas fewer tubes give less heat. In a typical setup, there are 1-3 tubes per pipe. Each tube can supply anywhere from 0 to 200 W of heat per meter. That is sufficient for most fluids. It is a lot easier to install than jacketing. You would not really need custom tools to do the installation. But it may not give even heating. It is a bit more suited for smaller systems or perhaps an emergency fix.
3. What is the function of steam jacketing?
Where a double-wall system exists, with the inner pipe holding your product and the outer layer being a steam jacket, it is that steam jacket. Steam enters at high pressure, probably between 50-150 psi. It is made to flow around the pipe and, in doing so, to heat it. Heat transfers through the pipe wall to the fluid, keeping all at a constant temperature. Compared with unheated ones, jackets decrease heat loss by up to 30%. It’s a closed system, therefore, very efficient.
Once put into service, the design is pretty much fixed. There’s no chance of making any significant changes. Valves and pumps control steam flow. With the right execution, a jacket could last for more than 20 years. Around 45% of food processing plants use it for tacky products, like chocolate. It prevents buildup inside of pipes. But, if jacket steam leaks, it can be very costly to repair. You may have to shut down the entire operation. It is most suitable for stable, long-term processes.
4. How Does Steam Tracing Work?
Steam tracing uses external tubes to deliver heat. The tubes run parallel to the pipe. Steam flows through them at 10-50 psi. The heat radiates to the pipe’s surface. Insulation is added to trap the heat. This keeps the pipe warm without a full jacket. It’s less invasive than jacketing. Around 80% of gas plants use tracing for freeze protection. It works well in cold climates.
You can add more tubes if you need extra heat. A single tube heats a pipe up to 150°C (302°F). The system is modular. You can trace only the parts that need it. Installation takes less time than jacketing. However, heat distribution can be uneven. Gaps between tubes might leave cold spots. Maintenance is simpler, though. Replace a tube, and you’re back in business. It’s ideal for flexible setups.
5. Cost of Steam Jacketing
Steam jacketing requires a larger upfront investment cost. Custom piping or vessels are expensive in their own right. Jacketed pipe costs from $500 to $1,000 per meter. Add about $200 to $300 more for installation, and this is quite an investment. That would be the operational costs depending upon the use of steam. A typical such system uses 10-20 kg of steam over an hour. So, based on that, costing $10 per ton of steam would make it $0.10-$0.20 an hour. Larger plants can easily afford this.
The payback here occurs over time. Jacketing generally has a longer lifespan than tracing. Because of constant temperature, one might be able to save 15% on energy costs. While repairs are rare, they can be expensive: jacket replacement could cost thousands of dollars. About 30% of chemical plants choose jacketing even with the price. For critical processes, it’s worth it. This may not be exactly your cup of tea if you are money-tight, though. Plan for the long haul with this one.
6. Cost of Steam Tracing
Steam tracing is cheaper by installation. You can buy a tracing tube for $20-$50 and install it for about $50-$100 per meter; you spend half as much as for jacketing. Operating costs are rolled up the same. You would use 5-15 kg of steam every hour. That is $0.05-$0.15 hourly at $10 per ton. Affordable for the smaller units. This is what about 65% of mid-sized plants consider when applying tracing.
They also maintain lower costs for repair. Pipes that are broken are also easy to substitute. Replacement costs are $100-$200 per section. You don’t have to take much from your pocket on repair. But you might end up needing more tubes as time goes by. Heat losses are 20% more than jacketing. And this adds to the energy bill. It’s a trade-off. Tracing saves money at the front end but likely costs more to run.
7. Steam Jacket Efficiency
Steam jacketing is considered highly efficient. The jacket fully surrounds the pipe. This closes down heat losses to a minimum. Tests show that it retains around 90% of steam heat. This is magnificent for energy savings. The even heat prevents fluids from freezing or thickening. Thus, 50% of the heavy oil processors use it. You get reliable output every time.
But, including design makes all efficiencies possible. It’s steam waste for poorly made jackets. Some efficiency drops by up to 25% due to leakage. Regular checks are a must. Steam pressure needs to remain steady, too. It would be most effective for high-pressure systems such as 100 psi. Jacketing shines among large and stable operations. Short runs or small-size pipes are inefficiencies. Pick it for the large, steady jobs.
8. Efficiency of Steam Tracing
Steam tracing calculation shows that it is less efficient overall. Heat only comes from the tubes. This leaves some areas cooler than others. Efficiency sits around 70%-80%. Insulation helps, but you still lose heat. Tracing can use 10% more steam than jacketing for the same job. It’s better for targeted heating, though. You heat only what you need.
The system works well with good planning. More tubes mean better coverage. A triple-tube setup boosts efficiency to 85%. But cold spots can form between tubes. This might slow your process. Tracing is great for long pipelines. It’s less ideal for wide tanks or vessels. Use it where flexibility matters more than perfection.
Conclusion
Steam jacketing and steam tracing both heats well, but they’re different tools. Do you know which to pick between steam jacketing vs steam tracing? Jacketing gives even, efficient heat for big, stable jobs. It’s costly and slow to install but lasts long. Tracing is quick, cheap, and flexible. It’s best for pipelines or small fixes, though less efficient. Your choice depends on your process. Need steady heat for a tank? Go jacketing. Want a fast setup for a pipe? Pick tracing. Costs, scale, and urgency matter too. Weigh your needs. Both can work—you just need the right fit. Make your call based on facts, not guesses!
Leave A Comment