Presentation Outline:: Energy Saving in Steam & Condensate System

ENERGY SAVING IN STEAM &
CONDENSATE SYSTEM
Intro Properties System Losses Measures Summary
Presentation Outline:
Introduction
Properties of steam
Losses in steam system
Energy saving measures
Summary
1
© Assoc. Prof. Dr. Mohd Hariffin Boosroh College of Graduate Studies 44

CONDENSATE SYSTEM
Introduction:
Major applications:
Power generation Process heat Space heating
100%
90%
80%
70% 47% 60% 43%

Energy Use (%)
60%
50%
40% 61% 85% 69%

30%
20% 40% 35%
10%
0%
Steam
Food Pulp and Paper Chemicals Petroleum Stone/Clay/Glass Primary Metal-Based Other
Fuel Refining Metals Durables Manufacturing
Electric Industry
2
CONDENSATE SYSTEM
Introduction:
Major applications:
Typical pressure Steam consumption

Type of installation Description
(psig) (lb/hr)
Bakeries Dough room, 8 ft long 10 4
Hospitals Sterilizers, per 100 in3 40-50 6
Laundries Steam irons, each 100 4
Plastic moulding Each 12-15 ft2 surface 125 29
Paper mill Wood pulp, per 100 lb 50 372
Tire shops Truck molds, large 100 87

3

CONDENSATE SYSTEM
Introduction:
Major applications: Steam in Power generation
4
CONDENSATE SYSTEM
Introduction:
Major applications: Steam in Process Heating
Steam cleaning
Essential Oil Extraction Process
5

CONDENSATE SYSTEM
Introduction:
Major applications: Steam in Process Heating
Palm oil mill
6
CONDENSATE SYSTEM
Introduction:
Major applications: Steam in Space Heating
7

CONDENSATE SYSTEM
Properties of Steam:
Phases of pure substances:
8
CONDENSATE SYSTEM
Phases of water:
State 1 : compressed liquid water

(or subcooled liquid)
State 2 : saturated liquid water
State 3 : saturated liquid-
vapour mixture (wet steam)
State 4 : saturated steam
State 5 : superheated steam 9

CONDENSATE SYSTEM
Major steam properties:
Pressure P kPa psi
Temperature T ⁰C ⁰F
Specific enthalpy h kJ/kg Btu/lb
Specific internal energy u kJ/kg Btu/lb
Specific volume v m3/kg ft3/lb

Major steam
properties Specific entropy s kJ/kg⋅K Btu/lb⋅R
Saturation Temperature Tsat ⁰C ⁰F
Enthalpy of sat. vapour hg kJ/kg Btu/lb
Enthalpy of sat. liquid hf kJ/kg Btu/lb
Enthalpy of evaporation hfg kJ/kg Btu/lb

10
CONDENSATE SYSTEM
Terms & definitions:
Enthalpy (h) Energy content of a flowing medium
Entropy (s) Thermodynamic property that accounts for

process irreversibilities (i.e. quality of energy)
Condensate Liquid produced when steam condenses
Sensible heat Heat that gives rise in the measurable

temperature of the water
Latent heat Heat that changes phase of water without

change in temperature
Flash steam Steam generated when condensate pressure

rapidly drops at a given temperature
11

CONDENSATE SYSTEM
Steam System:
Steam sub-systems: boiler, distribution, utilisation, condensate return
Typical Steam System
12
CONDENSATE SYSTEM
Steam System:
Major components in steam system:
System Components
Boiler plant Boiler, furnace, air preheater, economiser,

fan/blower, boiler drum
Distribution Piping, steam traps, air vents, valves,
pressure reducing stations
End use Steam turbines, heat exchangers, coils,
system jacketed kettles, vacuum breakers
Condensate Flash tanks, condensate pumps, valves,
return pipings
13

CONDENSATE SYSTEM
Steam System:
Steam traps:
• Function: to remove condensate and vent non-
condensable gases from steam system
14
CONDENSATE SYSTEM
Steam System:
Steam traps:
• Types of steam traps: Thermostatic, Thermodynamic, Mechanical
• Thermostatic:
• Use temperature differential to separate steam & condensate
• Designs: bellows, bimetallic
Bellows Bimetallic
15

CONDENSATE SYSTEM
Steam System:
Steam traps:
• Thermodynamic:
• Use difference in kinetic energy
(velocity) of steam & condensate
• Designs: disc, piston, lever, orifice
Disc
16
CONDENSATE SYSTEM
Steam System:
Steam traps:
• Mechanical:
• Use difference in density between steam & condensate
• Designs: ball float, float & lever, inverted bucket, open
bucket
Float Inverted bucket
17

CONDENSATE SYSTEM
Steam System:
Steam traps:
18
CONDENSATE SYSTEM
Steam System:
Steam traps:
• Poor selection/maintenance of steam trap can cause:
• Water hammer • Poor heat transfer
• Steam leak • System corrosion
19

CONDENSATE SYSTEM
Steam System:
Steam traps:
• Selection criteria of steam trap:
• Continuous or intermittent removal of condensate
• System temperature & pressure
• Range of load on the trap
• Rate of change of load on the trap
20
CONDENSATE SYSTEM
Steam System:
Key operating parameters:
Steam production rate
Make-up water
flow rate
Feedwater
flow rate
Fuel flow rate
Blowdown flow rate Chemical input flow rate

21

CONDENSATE SYSTEM
Steam System:
Approaches to determine process steam requirement:
Steam consumption table:
Provide quick & rough estimate
Typically provided by steam system manufactures and
industry standards
System mass & energy balances:
Comprehensive mass & energy balances analysis
More elaborate & usually more accurate
Require accurate measurement of steam properties
22
CONDENSATE SYSTEM
Steam System:
Approaches to determine process steam requirement:
Steam consumption table: Example
Typical pressure Steam consumption

Type of installation Description
(psig) (lb/hr)
Bakeries Dough room, 8 ft long 10 4
Hospitals Sterilizers, per 100 in3 40-50 6
Laundries Steam irons, each 100 4
Plastic moulding Each 12-15 ft2 surface 125 29
Paper mill Wood pulp, per 100 lb 50 372
Tire shops Truck molds, large 100 87
23

CONDENSATE SYSTEM
Losses in Steam System:

Losses in steam system occur at:
Boiler system 20-25% Trapping system

20-25%
Distribution system 40-45% Condensate return system
24
CONDENSATE SYSTEM

Losses in steam distribution system:
• Insulation losses:
• Typical surface temperature: 90 – 260ºC
• Typical bare surface losses: 316 – 1800 kJ/hr
• Includes losses at joints, flanges, valves
25

CONDENSATE SYSTEM

Steam Temp. Heat loss Heat losses from bare steam lines
Pressure Per hour
(psig) (F) (btu/sqft.hr)
15 250 452
35 280 556
50 298 595
75 320 716
100 338 805
125 353 864
150 355 876
175 377 989
26
CONDENSATE SYSTEM

• External leaks:
• Steam leaks to atmosphere
• Usually visible and/or audible
• Internal leaks:
• Steam leaks inside steam
system e.g. valves in
bypasses around steam
traps
• Usually invisible
27

CONDENSATE SYSTEM

Losses in steam
distribution system:
Heat loss from

steam leaks
28
CONDENSATE SYSTEM

• Inactive piping:
• Dead or unused piping in the steam distribution system
• Need to be isolated e.g. blank-off
Steam Temp. of steam mixed with % air
• Accumulation of air & non- Pressure
condensable gases in distribution (psig) 0% 10% 20% 30%
system: 10 240 234 228 221
• It reduces steam partial pressure 25 267 261 254 246

as well temperature 50 298 291 283 275
• It also forms insulation barrier => 75 320 313 305 295

reduces heat transfer 100 338 330 322 312
• May also block steam flow

29

CONDENSATE SYSTEM

Losses in steam trapping system:
• Trap flash losses:
• Sensible energy losses through “flashing”
phenomena
• Steam trap leak:

• Sensible energy losses through
“flashing” phenomena
• Caused by slow/partial closing or
failure to close
30
CONDENSATE SYSTEM

Trap Steam loss (lbs/hr) for a given

Orifice steam pressure (psig)
diameter
(inches) 15 100 150 300
1/32 0.85 3.3 4.8 -
1/16 3.4 13.2 18.9 36.2
1/8 13.7 52.8 75.8 145
3/16 30.7 119 170 326
1/4 54.7 211 303 579
3/8 123 475 682 1303

31

CONDENSATE SYSTEM

Percent of condensate flashed, lb steam/lb condensate

High-pressure
Condensate Low-pressure steam (psig)
(psig)
50 30 15 5
200 10.4 12.8 15.2 17.3
150 7.8 10.3 12.7 14.9
100 4.6 7.1 9.6 11.8
75 2.5 5.1 7.6 9.9
32
CONDENSATE SYSTEM

Losses in condensate return system:
• Condensate return piping:
• Need to be adequately sized and insulated
• Condensate pump:
• Need to be carefully select suitable pump
• Filtration & cleanup:

• Filtration: Strainers to catch particulates
• Cleanup: condensate polishers to remove dissolved
contaminants
33

CONDENSATE SYSTEM
Energy Saving Measures:

General rules:
* Economy of scale
Produce steam at highest
* To overcome line losses
possible pressure & temperature
* To satisfy highest pressure user
* Less flash steam loss

Utilize steam to process use at
* Provide more latent heat available
lowest possible pressure & temp.
for useful work
* Use pressure reducing valves

Expand steam from high to lower
* General rule: pressure drop < 20%
pressure thru most efficient means
of maximum system pressure
* 11⁰F increase in feedwater input

Generate maximum steam from
or condensate return temperature
process waste heat recovery
=> 1% increase in efficiency
34
CONDENSATE SYSTEM

Some tips:
Insulate steam distribution General rule: any surface over 120⁰F

& condensate return lines should be insulated
Insulated steam distribution line Hot water tanks

35

CONDENSATE SYSTEM

Some tips:
Regular maintenance reduces

Inspect & repair steam traps
trap losses to < 5%
Can contain >10% of total energy

Return condensate to boiler
Can save water, fuel, chemicals
• Saves energy, water and chemicals

Minimize boiler blowdown
• Typically 4-8% of feedwater flow rate
36
CONDENSATE SYSTEM

Some tips:
• Can be used to
Recover heat from blowdown
preheat makeup water
37

CONDENSATE SYSTEM

Some tips:
Utilise waste steam for other Example: vapour absorption

use refrigeration cycle
38
CONDENSATE SYSTEM

Some tips:
Utilise waste steam for other Example: as steam driven

use compressor
39

CONDENSATE SYSTEM

Some tips:
Flash high-pressure •Get low-pressure steam

condensate •Attractive when not economical
to return condensate to boiler
* On uninsulated valves & fittings

Install removable insulation
* Also improve safety
Removable insulation
on valves & fittings
40
CONDENSATE SYSTEM

Some tips:
Replace pressure relief valve

Bakpressure turbine reduces
(PRV) with backpressure
steam pressure & generate work
turbogenerators
Backpressure turbine
41

CONDENSATE SYSTEM

Some tips:
To remove dissolved gases (e.g.

Use deaerators O2 < 5 ppb) to prevent corrosion,
partial pressure reduction & temp
42
CONDENSATE SYSTEM
Summary:
Steam: cheap, effective & efficient medium of heat transfer
Phases of steam: compressed liquid, saturated liquid, saturated
mixture, saturated vapour, superheated
Major components in steam system: boiler, distribution, end use,
condensate return
Major losses: steam leaks, insulation, flashing, non-condensable
gases
Some energy saving opportunities: leak repair, insulation, steam
trap, waste heat recovery from blowdown, flash steam,
condensate return
43

CONDENSATE SYSTEM
Further Readings:
Witte, L.C., Schmidt, P.S., Brown, D.R., Industrial Energy Management and
Utilization, Hemisphere Publishing, 1998
Ibrahim, K., Lalchand, G., Yusof, M.A., Majidi, M.I., Energy Efficiency: A
provate sector initiative, CETREE, 2002
Kennedy, W.J., Turner, W.C., Capehart, B.L., Guide to Energy Management,
The Farmont Press, 1994
Efficient use of process steam, TLV Co. Ltd, 1999
Payne, G.A., Managing energy in commerce and industry, Butterworths,
1984
44
CONDENSATE SYSTEM
Example:
A boiler produces saturated steam at 450 kPa and operates for 5,000
hours per year. A continuous blowdown system removes water at the rate
of 10 kg/min. The maximum temperature at which the blowdown may be
discharged into a drain is 50ºC. Make-up water at 30ºC enters the boiler
system at the rate of 50 kg/min.
If a blowdown heat recovery system with a heat transfer efficiency of 90%
were installed, at what rate would heat be transferred to the make-up
water? What would be the temperature of the make-up water exiting the
heat recovery unit, and what would be the annual energy savings?
Assume that the blowdown and make-up water as saturated water.
45

CONDENSATE SYSTEM
Example 2:
A steam distribution system with a working pressure of 10 psig is fitted

with a steam trap. However, steam is found to be leaking continuously
from the steam trap orifice. Given that the steam distribution system
operates at an average of 5000 hours a year, diameter of the steam trap
orifice is ¼ inch, and the steam is generated from a boiler with 82%
efficiency, estimate the annual cost of energy loss due to the leaking
steam trap.
Atmospheric pressure is 14.7 psi, latent heat of steam at 10 psig is 952.2

Btu/lb, and fuel price is RM35.5 per million Btu
46

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ENERGY SAVING IN STEAM &

ENERGY SAVING IN STEAM &

70% 47% 60% 43%

40% 61% 85% 69%

Typical pressure Steam consumption

Bakeries Dough room, 8 ft long 10 4

Hospitals Sterilizers, per 100 in3 40-50 6

Laundries Steam irons, each 100 4

Plastic moulding Each 12-15 ft2 surface 125 29

Paper mill Wood pulp, per 100 lb 50 372

Tire shops Truck molds, large 100 87

ENERGY SAVING IN STEAM &

Essential Oil Extraction Process

ENERGY SAVING IN STEAM &

Palm oil mill

ENERGY SAVING IN STEAM &

State 1 : compressed liquid water

ENERGY SAVING IN STEAM &

Specific enthalpy h kJ/kg Btu/lb

Specific internal energy u kJ/kg Btu/lb

Specific volume v m3/kg ft3/lb

Saturation Temperature Tsat ⁰C ⁰F

Enthalpy of sat. vapour hg kJ/kg Btu/lb

Enthalpy of sat. liquid hf kJ/kg Btu/lb

Enthalpy of evaporation hfg kJ/kg Btu/lb

Enthalpy (h) Energy content of a flowing medium

Entropy (s) Thermodynamic property that accounts for

Condensate Liquid produced when steam condenses

Sensible heat Heat that gives rise in the measurable

Latent heat Heat that changes phase of water without

Flash steam Steam generated when condensate pressure

ENERGY SAVING IN STEAM &

Typical Steam System

Boiler plant Boiler, furnace, air preheater, economiser,

ENERGY SAVING IN STEAM &

ENERGY SAVING IN STEAM &

ENERGY SAVING IN STEAM &

ENERGY SAVING IN STEAM &

Fuel flow rate

Blowdown flow rate Chemical input flow rate

ENERGY SAVING IN STEAM &

Typical pressure Steam consumption

ENERGY SAVING IN STEAM &

Losses in Steam System:

Boiler system 20-25% Trapping system

Losses in Steam System:

ENERGY SAVING IN STEAM &

Losses in Steam System:

100 338 805

125 353 864

150 355 876

175 377 989

Losses in Steam System:

ENERGY SAVING IN STEAM &

Losses in Steam System:

Heat loss from

Losses in Steam System:

• It reduces steam partial pressure 25 267 261 254 246

• It also forms insulation barrier => 75 320 313 305 295

• May also block steam flow

ENERGY SAVING IN STEAM &

Losses in Steam System: