Along with energy conservation, the unit includes the following advantages:

1. The discharged remaining flash steam may be recovered to preheat your boiler make-up water.
2. The up to 50% reduction in the volume of make-up water and water treatment chemicals constitutes a substantial saving in costs....
3. The reduction of make-up water will improve water quality and decrease the need for boiler blowdown.
4. The decreased oxygen and carbon dioxide in the condensate can reduce corrosion in the boilers & entire condensate system and in production equipment.

Installation of the recovery system increases the volume and temperature of the condensate which in turn increases fuel savings and reduces water consumption and treatment chemicals.

The increase in boiler feed water quality leads to an increase in steam quality that in turn reduces the required blow down volume thus further increasing the energy savings.

The increased water temperature decreases the oxygen content of the steam.  This reduces corrosion of the piping and equipment which in turn reduces down time, repair and maintenance.

1. Increased in energy and saving.
2. Increased in efficiency with reduced power consumption.
3. Minimum space requirement.
4. The system is designed to withstand high temperatures and pressures while also maintaining an efficient continuous discharge pressure.
5. Recovers condensate at elevated temperatures directly to the boiler, saving energy.
6. The lost flash steam can be recovered by preheating the boiler make-up water.

EXAMPLE OF HOW PATENTED STEAMPRO  HIGH- PRESSURE- CONDENSATE- RECOVERY SAVES
                          
Assuming boilers running at 10 ~ 11 bars steam pressure and returning the condensate at 0 bars.  Condensate at a pressure of 0 bar returns to the boiler at 100oC or lower.  We may want to return the condensate at higher pressures to reduce the energy consumption.

Let us return the condensate to the boiler at, say, 4 bars.  Your operating equipment will have a good pressure differential of 10 – 4 = 6 bars.  Some of the equipment may need to use a lower steam pressure near or below 4 bars; the condensate from this equipment will need to be rerouted or not recovered.

Example Savings 1: From Condensate Returned at Higher Temperature

At a return pressure of 4 bars, the temperature of the condensate is 152oC and it carries an energy of 640 KJ/kg compare to condensate at atmospheric of 100oC and 418 KJ/kg.  If we conservatively assumed that 80% of the condensate maybe recovered due to losses and boiler blow down.  The total energy for a kilogram of steam is 2,678 KJ/kg from water equal to 25oC.  Therefore, the saving is (640 – 418) / 2678 x 0.80 = 0.066 or 6.6%.

Example Savings 2: From Reduction of Flash Steam

Recovering the condensate at a pressure of 4 bars instead of 0 bars will also reduce the formation of flash steam.  Steam cannot be returned to the boiler.  Both the energy and the water in the flash steam will be a total loss to the atmosphere.  The flash steam rate from a steam pressure of 10 bars maybe calculated as follows:

1. At 0 bars condensate return pressure, (781 – 418) / 2258 x 100 = 16.1%
2. At 4 bars condensate return pressure, (781 – 640) / 2109 x 100 = 6.7%

This is a saving of 9.4% of the total energy.  Assuming that 10% of the condensate is not recovered or lost, the total saving is 9.4 x 0.90 = 8.5%.

The total energy saving of a high pressure condensate recovery system is 8.5 + 6.6 = 15.1%.  The total energy saving is larger for increased condensate return pressure.  Setting a condensate recovery pressure of 4 bars will provide you with handsome energy saving and ensure a good useful life expectancy of the high pressure condensate return pump(s).

Example Savings 3: From Lesser Water and Water Treatment Chemicals

Your boiler makeup (feed) water is reduced by 8.5%, a recovery of your flash steam.  You will have saving in water and boiler water treatment chemicals.  Because of the reduction in boiler makeup water, your need for boiler blow down is also reduced.  We have not included the aforementioned savings in our calculations.

The calculated saving of 15.1% (6.6% of Savings 1 and 8.5% of Savings 2 only) is conservative.  A conservative 15.1% savings will be achieved if install our Patented SteamPro High Pressure Condensate Recovery Unit and slightly modified part of your condensate recovery system.

 Written By:
Dr Michael Troy
(On November 2005 at Kuala Lumpur, Malaysia)

 Note:
This write-up shall be used with the permission of SteamPro Conservation Sdn Bhd and is not meant for public usage or circulation.

1. The Advantages:

• Elimination of steam leaks through oversized, worn, malfunctioning or failed steam traps.
• Complete and continuous condensate removal.
• Unmatched extended use life.

2. The Results:

• Immediate reduction of steam related fuel consumption of 12-54%. First year savings remain effective in years following conversion.
• Immediate improved heat transfer of all equipment.
• Immediate reduced production time for steam serviced equipment.
• Immediate improved process temperature control.
• Immediate improved humidity control.
• Elimination of potential freezing hazards, water hammer, sub cooling, CO2 corrosion and other forms of mechan­ical damage.
• Improvements in water quality and corrosion reduction are reported but are difficult to quantify at this time.
• Immediate elimination of normal trap testing, trap re­moval, trap reconditioning labor, trap spare parts purchase, trap spare parts inventory, trap replacement inventory and trap replacement labor. Trap maintenance crews may be reassigned.