No More Steam Traps: Simplifying Steam Systems with Jetomat Technology in Paper Industry
What Jetomat Replaces & Why It Matters
Traditional dryer groups use throttling valves plus many steam traps. This setup wastes Live & flash steam, leaves thicker steam condensate films in cylinders, & dem&s heavy maintenance. Replacing the throttling function with a steam jet thermocompressor (Jetomat) recovers flash steam & stabilizes pressure & velocity—without relying on dozens of traps. In a corrugated-paper dryer retrofit, the outcome was striking: ~32% steam saved & no need to use a steam trap on the section.
Proven Numbers from Paper Machines
On a paper machine running valve control at 15 barg → 6.5 barg & ~3,200 kg/h, swapping valves for steam jet ejectors cut specific steam from 2.6 t/ton to 2.2 t/ton—about 15% savings—while improving heat distribution & production speed.
How It Works
A Jetomat uses motive steam through a precisely engineered nozzle design to create suction, entrain low-pressure flash steam, & then recompress the mix in a diffuser & nozzle assembly. The thermocompressor working principle turns “waste” into useful steam, forming a built-in flash steam recovery system that feeds the dryer section—no extra moving parts, no pumps.
Jetomat
Thinner Condensate Film = Better Heat Transfer
Paper cylinders dry more uniformly when the condensate layer is thin & fast-moving. With a steam compressor (thermo/jet), steam velocity across the heating surface rises, the condensate film thins, & the heat transfer solutions improve—raising effective surface temperature & cutting start-up time.
(The Baelz data shows higher surface temps & shorter start-up with the ejector vs valve control.)
Trap Count Collapses
Valve-&-trap layouts often need a trap per cylinder. With a thermo vapor re-compressor, condensate & flash steam are continuously drawn & reused, so trap counts plummet (or, in some dryer groups, become unnecessary). Baelz shows a valve system with 7 traps versus an ejector solution with 2 traps & a near-flat temperature profile (≈1 °C drop along the drum, versus ~15 °C with valves).
Uniform Drying → Smoother Run, Higher Throughput
Higher average steam velocity & uniform heat distribution mean steadier moisture profiles & fewer sheet defects. The paper case notes higher production speed as a recurring benefit once ejectors replace valves.
Water, Chemicals, & Boiler Benefits
When you stop venting flash & keep condensate in the loop, make-up steam & condensate losses shrink. In the corrugated/paper retrofit, the mill reported ~80% lower boiler feedwater & chemical consumption after installing the Jetomat—because more energy & water stay inside the heating systems loop.
Energy Savings That Show Up on the Bill
Across applications, compression-mode ejectors commonly deliver 10–30% direct steam savings. That’s fuel, CO₂, & cost—gone. In the food sector example (different process, same physics), the right-sized ejector delivered €14,880/month (~ 187 Lacs / Year) savings with 1.68-month payback—illustrating how fast a properly engineered heat recovery system can return cash, even outside papermaking.
Why Ejectors Beat Throttling Valves on Heat Transfer
Valves only drop pressure; they don’t recirculate. A steam jet compressor recirculates part of the steam/condensate flow, raising internal velocities & the heat transfer coefficient K—so more of your steam heats product (& less is “lost energy to atmosphere”). That’s foundational thermodynamics you can feel in lower specific steam (see Point 2).
“No More Steam Separator?”—System Simplification
Because the vapor compressor action of a Jetomat re-uses flash & maintains stable conditions, you often simplify ancillary steam equipment (e.g., vents, flash tanks, or a dedicated steam separator point for that section). Net-net: fewer fittings, fewer leaks, fewer headaches. (Engineering layouts in Baelz docs show simplified dryer groups when ejectors are applied.)
Control That Matches Paper Reality
Dryer sections see load swings—grade changes, speed changes, moisture targets. Ejector-based control can be implemented on discharge pressure (p04), condensate outlet temperature (t03), or even drum surface temperature—giving you the tuning you wish your throttling valve had.
From “Trap Failures” to “Maintenance-Light”
Every trap you remove is one less failure mode. Ejectors have no moving parts in the flow path; they’re robust by design. Plants that struggled with trap surveys, stuck floats, & leakage find the thermo compressor path remarkably maintenance-light—while still saving energy. (The Bursa case literally states “No need to use a steam trap.”)
At One Paper Plant in India Same Thermocompressor is in Operation Since 1998
A Note on Design & Sizing
Right-sizing the thermocompressor design is key. In another industry case, re-calculation downsized the ejector from DN150 to DN100, fixing chronic venting & delivering rapid ROI. The lesson transfers to paper: get the pressure/flow balance right, & the thermo compressor working principle does the rest.
Quick Wins, Scalable Mill-Wide
Start with the hungriest group (e.g., a top dryer group) & measure the delta in flash steam recovery system performance, specific steam, & sheet stability. Many mills scale the approach across multiple groups once the first section shows 15–32% steam reductions with better quality.
Quick Reference (Paper-Focused Payoffs)
Specific Steam: 2.6 t/ton → 2.2 t/ton (≈15% cut) after replacing valves with steam jet ejectors.
Section Steam Use: ~32% reduction; 80% drop in boiler feedwater & chemicals; no traps needed on the section.
Quality & Speed: Higher steam velocity + thinner condensate layer → better heat distribution, higher production speed.
Get a Free Dryer Section Evaluation
Want to quantify the Jetomat opportunity on your machines? Book a free evaluation. We’ll review pressures/flows, simulate a condensate & flash steam recovery system, & estimate specific-steam savings for your line. If a trial section hits the numbers above, you scale mill-wide with confidence.