SOLUTIONS OVERVIEW


Are you disposing of your system’s most valuable resource?


It’s no longer enough to strike a good deal on energy supplies or achieve high levels of productivity: now we are expected to do both, while complying with a complex web of regulation. Striking the right balance can make that crucial, tangible contribution to your company’s revenue flow but, with ageing equipment and economic uncertainty coming into play, the potential to achieve this balance is virtually impossible. That is, until we consider our use of condensate and the heat we may have otherwise wasted.


The value of condensate


It’s widely known that condensate is hot, but it’s only when we consider how this translates to heat energy that we realise how useful it is as a resource. The condensate generated by the steam heating system will normally have about 25% of the energy that the steam had and contains little to no dissolved solids. If the condensate is merely discharged from the system and, subsequently, disposed of, then that valuable energy resource is thrown away with it. This is an easily avoidable waste that few of us can afford.


Draining condensate, rather than re-using it, can trigger water and effluent management costs, which can be significant. Similarly, draining condensate can make it harder for us to comply with the regulatory standards around environmental effluent. In many countries, including the UK, condensate often has to be cooled before it can be drained. This, again, often comes at an extra cost.


The uses of condensate


We might now realise that condensate – and the heat energy it carries – is too valuable to be tipped down the drain, but how can it be put to better use?


1. Boiler feedwater •


• • The recovery process


As you’re well aware by now, steam is usually generated for most industrial and process industries. How it is recovered can be broadly summarised in three steps.


Reduces need for (and cost of) fresh water


Reduces need for (and cost of) treatment chemicals


Requires much less energy than cold make-up water.


2. Flash steam recovery


• Recovers up to 80% of the energy from the rejected Total Dissolved Solids (TDS) water


• • • Saves on fuel


Reduces carbon dioxide emissions


Eliminates unsightly plumes of steam.


1. Steam traps are used to remove condensate from the steam system. A steam trap survey can offer invaluable insight into the performance of a given system and will almost certainly reveal impressive savings potential through reduced fuel consumption, fuel emissions, water and effluent charges.


2. Pumps are used to return any condensate not captured by steam traps to the boiler feedtank.


3. Condensate is mixed with other types of feedwater to heat it within the feedtank.


Condensate recovery is one process that is genuinely capable of boosting boiler efficiency, saving energy, enhancing equipment lifespan and complying with legislation – all of which can, in turn, generate substantial savings to those who use steam systems.


It may not play the leading role in the steam system, but condensate recovery is undeniably the unsung hero of the boiler house.


FIND OUT MORE


The unsung hero of boiler house efficiency: How condensate recovery can transform steam system performance is available to download from sxscom.uk/boilerhouseefficiency


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