It's Not The Heat It's The Humidity

1/15/2019 It’s not the heat; it’s the humidity - Plant Engineering
It’s not the heat; it’s the humidity

Most industrial processes can handle high heat conditions, but many require some
control over the amount of moisture in the air. Whether manufacturing musical
instruments, semiconductors, processed foods, or simply heating a warehouse, the
amount of moisture in the air impacts product quality and worker comfort.
BY DANIEL M. CICERO, ONDEO NALCO CO., NAPERVILLE, IL AUGUST 8, 2002
Key concepts
Indoor air quality must be
considered when
selecting a humidi cation
system.
Systems that make their
own steam for
humidi cation avoid
problems with volatile
amines.
Corrosion inhibitors in
humidifying steam must
be chosen carefully.
Sections:
Humidi er design and
operation
Corrosion inhibitors
Systems
Sidebars:
A health problem solved
Most industrial processes can handle high heat conditions, but many require some control over the amount
of moisture in the air. Whether manufacturing musical instruments, semiconductors, processed foods, or
simply heating a warehouse, the amount of moisture in the air impacts product quality and worker comfort.
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A number of mechanisms exist for maintaining proper humidity. Picking the right method depends on
speci c needs. There are also some environmental factors that need to be taken into consideration.
Corrosion inhibitors, commonly used in steam boiler distribution systems, need to be considered when
thinking about humidi cation.
Humidi er design and operation

Direct steam injection humidi ers , the most common humidi cation system, control the introduction of
steam into heating ducts in response to a signal from a humidistat. Steam enters the body of these
humidi ers, passes a number of ba es, which force any moisture or particulate out of the vapor, and is
introduced into the duct through a manifold (Fig. 1). Direct steam humidi ers require very little upkeep.
Fig. 1. Direct steam humidi cation provides immediate response.
This system provides excellent response to demand and pinpoint control of output. Because it uses steam
directly, no bacteria are produced. However, any volatile amines used as boiler corrosion inhibitors are
introduced into the steam, which could be a problem.
Steam-to-steam humidi ers use a steam coil immersed in a water bath to heat the water to boiling (Fig. 2).
The boiling water produces humidi cation steam at atmospheric pressure. This system avoids the problems
presented by volatile amines in boiler steam since there is no contact between boiler steam and
humidi cation steam, barring failure of the heat exchanger.
Fig. 2. Steam-to-steam humidi ers avoid problems with volatile amines in boiler water.
Steam system operators make a tradeoff, eliminating the risk of odors and exposure but reducing the energy
e ciency of the humidi cation system.
Because of common concerns about exposure to neutralizing amines or odor complaints caused by them,
many consulting engineers specify these systems for new construction.
Steam-to-steam humidi ers are susceptible to problems caused by water impurities such as calcium,
magnesium, and iron. These impurities can deposit as scale, necessitating cleaning. Scale also insulates the
heating coil, reducing the thermal e ciency of the humidi er. Because time is required to boil the water,
response to control input is generally slower than with direct steam injection systems.
Electronic (or electrode) steam humidi ers are used to generate humidi cation steam when a source of
steam is not available. Electrode-type units pass an electric current through water to provide steam (Fig. 3).
The water used in these units must conduct electricity. Use of pure demineralized, deionized, or distilled
water alone will generally not provide su cient conductivity for electrode units.
Fig. 3. Electronic steam humidi ers are used when steam is not available.
As with steam-to-steam humidi ers, water impurities can adversely impact the operation of the humidi er.
Water with a high mineral concentration necessitates routine cleanings; water with a low mineral
concentration is corrosive to the electrodes. These systems do provide a viable humidi cation option when a
source of steam is not available and the advantages of a steam-to-steam humidi cation system are desired.
Electronic (ionic bed) steam humidi ers use immersed resistance heating elements to boil water and
generate humidi cation steam much like electrode and steam-to-steam humidi ers. Since current does not
pass through the water, high-purity water can be used. Ionic bed humidi ers allow the use of almost any
water source.
Ionic bed cartridges, containing a brous media to attract solids from water as the temperature rises,
minimize the buildup of solids inside the humidi er. Maintenance of these units generally involves little more
than periodic replacement of the cartridges.
As with other indirect humidi cation methods, control is sometimes adversely impacted by the time needed
to boil the water.
Water spray humidi ers inject water directly into the air duct. This method generally results in poor
humidi cation and temperature control because water spray contains virtually none of the heat of
vaporization required to increase the relative humidity of the air. Water spray humidi cation is a virtually
constant enthalpy process, making it different from all other humidi cation systems that increase the relative
humidity with almost imperceptible increases in dry bulb temperature.
Water spray humidi ers respond to control input slowly because evaporation must take place before
humidi ed air can be recirculated. Unvaporized water can cause deposits to build up on surfaces, creating
sanitation hazards. These systems also tend to suffer from corrosion and bacterial contamination.
Corrosion inhibitors
The choices for chemical corrosion inhibition in steam systems have changed little in the past 50 yr. They
are:
Neutralizing amines
Filming amines
Oxygen corrosion inhibitors
Blends of emulsi ers.
Of the four choices available, the rst three have been in common industrial use since the 1940’s.
Neutralizing amines are the most common of the chemical inhibitors. They are volatile, nitrogen-
bearing compounds that condense with the steam, neutralize any acids present, and raise the
condensate pH su ciently to reduce corrosion.
Neutralizing amines have a number of drawbacks. For one, they cannot inhibit oxygen corrosion,
the most common corrosion mechanism found in heating systems. Often, these systems
operate intermittently and oxygen is introduced during any o ine periods. The combination of
oxygen, moisture, and elevated temperature has serious corrosion implications.
These compounds are volatile, and sometimes contribute odors, which many users nd
troublesome. Because they are volatile, they pass readily through direct steam humidi ers.
Noncondensed amines pass the ba es to the outlet manifold. Condensed amines exit the
humidi er through the steam trap at the bottom.
Although neutralizing amines have a long history of good technical performance, they can offer
some environmental, health, and safety concerns. (See sidebar on “A health problem solved”).
Filming amines are long-chain amines that adsorb onto piping surfaces, effectively inhibiting
oxygen and carbonic acid corrosion, but they create feeding and control challenges that make
them unattractive to many potential users.
Because of their strong cationic charges, they act as detergents, “scrubbing” old deposits and
loose material out of the condensate system. These corrosion products are commonly
deposited in low points in the condensate system and routinely clog strainers and other steam
equipment.
Oxygen corrosion inhibitors , most commonly erythorbic acid and diethyhydroxylamine (DEHA),
offer
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concentrations are high or carbonic acid is present, their use can become uneconomical.
Blends of emulsi ers commonly used in the food industry have been shown, over the past
several years, to effectively inhibit oxygen and carbonic acid corrosion. They form a non-
wettable, substantive barrier on metal surfaces. The blends perform much like lming amines,
but because they are essentially non-ionic, they do not ush out corrosion products or form
sticky deposits in the condensate system.
These inhibitors are also non-volatile and contribute no odors, an important property in HVAC
installations. Experiments have shown that nonvolatile corrosion inhibition chemicals will not
pass through direct steam humidi cation systems, eliminating the problems associated with
neutralizing amines while maintaining the high e ciencies of the direct steam humidi ers. This
approach shows promise as a method for returning high e ciencies without exposure to
neutralizing amines.
Systems
The type of humidi cation system installed depends on the availability of plant steam, the need
to avoid amine exposures, requirements for pinpoint control of humidity, cost, and other factors
speci c to any particular facility.
New treatment options, coupled with highly e cient humidi cation systems, can meet many
needs for safety and e ciency. Direct steam humidi cation offers greater e ciency than other
options, but operational concerns often make other humidi cation choices more attractive.
— Edited by Joseph L. Foszcz, Senior Editor, 630-288-8776, jfoszcz@reedbusiness.com PLANT

ENGINEERING magazine and the author extend their appreciation to Armstrong International, Inc.
for supplying the illustrations and table.
Comparison of humidi cation methods
Steam- Ionic bed

Direct Electronic
to- electronic Water spray
steam steam
steam steam
Effect on Virtually no Substantial
temperature change temperature drop
Unit capacity per Small-very Small to Small to
Small Small
unit size large medium medium
Vapor quality Excellent Good Good Good Poor
Response to control Immediate Slow Fair Fair Slow
Good to Below
Control of output Average Average Average
excellent average
Sterile Programmed Programmed
Bacteria Subject to severe
medium to not to not
Sanitation/corrosion can be corrosion and
corrosion- promote promote
present bacteria problems
free bacteria bacteria
Maintenance Monthly to Quarterly to Weekly to
Annual Monthly
frequency
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Maintenance Low High Medium Low High

di culty
Cost per unit of
Low High Medium Medium Medium to high
capacity
A health problem solved

NIOSH completed a Health Hazard Evaluation at a manufacturer of electrical circuit boards and
electrical equipment. In this case, the company had been using neutralizing amines for boiler lay-
up. When the boilers were brought online, high concentrations of amines were introduced into
the work areas.
Symptoms consistent with acute toxic effects of diethylaminoethanol and cyclohexylamine were
noted in many of the employees. These included nausea, dizziness, vomiting, and eye, nose, and
throat irritation. A signi cantly higher risk of having several symptoms was noted among the
employees in the areas humidi ed with boiler steam than among employees in nonboiler steam
humidi ed areas.
The exposure to the two corrosion-inhibiting chemicals was responsible for the workers’
symptoms. Subsequently, the company suspended the practice of using steam from the boilers
to humidify the building.
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It's Not The Heat It's The Humidity

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1/15/2019 It’s not the heat; it’s the humidity - Plant Engineering

It’s not the heat; it’s the humidity

Humidi er design and operation

Fig. 1. Direct steam humidi cation provides immediate response.

Oxygen corrosion inhibitors

Blends of emulsi ers.

— Edited by Joseph L. Foszcz, Senior Editor, 630-288-8776, jfoszcz@reedbusiness.com PLANT

Comparison of humidi cation methods

Steam- Ionic bed

Maintenance Low High Medium Low High

A health problem solved

IIoT, Industrie 4.0

3010 Highland Parkway Suite 325

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