Pure Steam Generator
Aqua Solutions is one of the leading Manufacturer, Supplier and Exporter of Pure Steam Generator
A Pure Steam Generator is a specialized system used to produce pure, high-quality steam that meets strict pharmaceutical, biotechnology, and healthcare standards. This pure steam is free from contamination, pyrogens, endotoxins, and non-condensable gases.
Pure steam is sterile and contaminant-free steam generated from purified water (PW or WFI). It is mainly used in processes where high purity and sterility are critical.
Working Principle of Pure Steam Generator :
A Pure Steam Generator produces high-purity, sterile steam used mainly in pharmaceutical, biotech, and healthcare applications such as sterilization, SIP (Steam-in-Place), and humidification. Its operation is based on the principles of evaporation, separation, and continuous purification.
A Pure Steam Generator works by :
Using purified water as feed
- Heating it using plant steam
- Evaporating and separating pure steam from contaminants
- Delivering sterile, dry, high-purity steam for pharmaceutical and healthcare needs
Feed Water Pre-Treatment:
Pure steam generation begins with Purified Water (PW) or Water for Injection (WFI) as feed. This water is typically Pre-heated, DE aerated (removal of dissolved gases) and fed into the evaporator section
Heating and Evaporation:
A heating medium (usually plant steam) flows through jackets or coils around the evaporator. The heat causes the feed water to boil rapidly. Phase separation occurs water → steam. Only lightweight vapor rises upward, while heavier impurities stay below.
Separation of Impurities:
The generated steam passes through Primary separation chamber, Cyclonic separator / centrifugal separator and Gravity baffle plates. These units remove Water droplets, Entrained particles, Non-condensable gases and Pyrogens & endotoxins (by thermal destruction). The Outcome → Dry, high-quality, pure steam.
Continuous Distillation Action:
A PSG works on the thermo-syphon principle like … Feed water is continuously circulated. Steam is continuously generated. Impurities settle at the bottom and are continuously drained. This ensures steam quality stays consistent.
Output of Pure Steam:
The purified steam is then supplied to sterilizers (autoclaves). It is used for SIP (Steam-in-Place) and for humidification in cleanrooms. It is condensed to produce WFI in some systems (optional). Pure steam is non-toxic, non-pyrogenic, and sterile, meeting pharmacopeia and regulatory standards (e.g., EN285).
Automatic Control & Monitoring:
Advanced PSGs include Pressure control, Temperature control, Feed water conductivity monitoring, Level sensors and Safety interlocks. These ensure stable and validated steam production.
Key Features of a Pure Steam Generator :
Pharmaceutical-Grade Pure Steam Production produces sterile, pyrogen-free steam that meets stringent pharmacopeial standards such as USP, IP, BP, EN285, and cGMP requirements. The steam is dry, saturated, and clean, suitable for direct contact sterilization, SIP (Sterilization-in-Place), and humidification in controlled environments.
All steam-contacting parts are made of high-grade stainless steel (typically SS316/SS316L) to resist corrosion and prevent contamination. Electropolished internal surfaces and orbital welded joints minimize crevices and microbial adhesion, improving cleanliness and reducing maintenance.
Advanced Steam Purification & Separation Employs multi-stage separation technologies — including gravity, centrifugal, or spiral separators to remove water droplets, impurities, and non-condensable gases. Some designs include non-condensable gas removal (NCGR) systems to enhance steam quality.
Heat Exchanger & Evaporation Technology uses double tube-sheet heat exchangers and optimized evaporation columns to prevent cross-contamination between feed water and steam and to improve heat transfer efficiency. Falling film or rising film evaporation provides efficient steam generation and high dryness.
PLC/HMI-based control systems allow fully automated operation, precise monitoring, alarms, and data logging often compliant with regulatory standards like 21 CFR Part 11. It includes instrumentation such as conductivity meters, level controls, and pressure sensors to maintain consistent steam quality.
PSG units are built with compact skid-mounted designs for easier installation, space savings, and simplified maintenance. Features like sanitary tri-clamp fittings make preventive maintenance and part replacement faster and cleaner.
Some models incorporate energy recovery systems (e.g., steam condensate preheating) to reduce operating costs. Optional SCADA integration and stand-by systems help maintain up time and facilitate centralized monitoring
Types of Pure Steam Generators:
Main Types of Pure Steam Generators (PSG) used in pharmaceutical, biotech, food, and healthcare industries.
- Shell & Tube Pure Steam Generator : Uses a shell-and-tube heat exchanger where feedwater is heated by plant steam to produce pure steam.
- Thermosyphon Pure Steam Generator : Works on natural circulation (no mechanical pump) due to density differences in heated water.
- Electrical Pure Steam Generator : Uses electric heaters to generate pure steam from purified or WFI-grade feedwater.
- Multiple-Effect Pure Steam Generator : Uses multiple evaporation stages to optimize steam consumption.
- Hybrid Pure Steam Generator : Combines steam-driven and electrical heating methods for flexibility.
- Clean Steam Generator (CSG) : Produces “clean steam” using treated feedwater—primarily for sterilization in hospitals or small plants.
- Skid-Mounted Modular Pure Steam Generator : Fully assembled, compact skid systems ready for installation.
Application Industries of Pure Steam Generators (PSG) :
- Pharmaceutical Industry : Sterilization of equipment, vessels, and pipelines (SIP)
- Biotechnology Industry : Sterilization of fermenters & bioreactors
- Healthcare & Hospitals : Sterilizers/autoclaves for surgical instruments
- Food & Beverage Industry : Sterilization of pipelines & tanks
- Cosmetics & Personal Care : Sterilization of mixers, vessels, and pipelines
- Dairy Industry : Sterilizing milk processing equipment
- Nutraceuticals & Herbal Extract Manufacturing : Sterilization of extraction vessels
- Medical Device Manufacturing : Sterilizing equipment and components
