Cover Story

Boost Steam-System
Efficiency by Improving
Condensate Recovery
Pressurized condensate-return systems and flash-steam vent condensers offer opportuniti
for fuel cost savings in a plant’s steam system. Here’s how to take advantage

P
ressurized ' t !H. Kelly Paffel
steam- Inveno Engineering, LLC
condensate uZ
systems ;
can provide plants ■■
11 9 *
with a minimum of
between 15 and 35% IN BRIEF
savings in fuel costs PRESSURIZED
when compared to 'E CONDENSATE
conventional atmo- ™ RECOVERY
spherically vented INCREASE EFFICIENCY
steam-condensate k < ft AND REDUCE COSTS
systems. That is a
tremendous oppor­ STANDARD CONDENSATE
tunity for chemical RETURN SYSTEM
process industries EXAMPLE STEAM
(CPI) facilities, since PROCESS CONDITIONS
fuel prices have IMPLEMENTING
risen and are ex- FIGURE 1. Pressurized condensate tank systems, like the one shown here, can help maximize
PRESSURIZED SYSTEMS
pected to increase efficiency in a plant's steam generation
even further. The surized condensate systems and explains ENERGY SAVINGS
pressurized condensate system should not how to evaluate whether the technology COMPONENTS
be thought of as a luxury; rather, it should could be a cost saver at your plant. REQUIRED
be considered a necessary component to
GETTING STARTED
maximize and increase the efficiency of a Pressurized condensate recovery
plant’s steam system (Figure 1). Pressurized condensate recovery systems
Unfortunately, it is not possible to imple­ operate continuously at pressures above 15
ment high-pressure condensate return sys­ psig, and the condensate recovery system is
tems for all steam plants and all steam ap­ not vented to the atmosphere. The pressure
plications (see box, p. 37). Therefore, properin the condensate system is sustained by the
preliminary engineering assessment, designdynamics of the system or by a systematic
review and knowledge of the application arecontrol process loop. Typical condensate
necessary to ensure a successful conden­ systems operate with backpressure because
sate system. In the examples discussed in their condensate line is improperly sized for
this article, energy savings of $226,700 weretwo-phase flow and because plants often
achieved by implementing a 50-psig pres­ neglect steam-trap stations blowing steam
surized steam-condensate system. The proj­into the condensate line. These items alone
ect was implemented at a cost of $305,400, can cause unwanted and uncontrollable
yielding a 1.3-year payback. pressure in the condensate recovery system.
This article provides information on pres- A pressurized condensate-recovery sys-

CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM FEBRUARY 2019 33

 Cover Story
VCHTTO
ATMOSPHERE
flOW METER
oo
____
TEMPERATURE TRANSIRTTER

MOM PRESSURE STEAM

c
TEMPERATURE
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T00EAE AATOA FOR HEATING FEEOWATER 100*1 PRISSURt
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PUMPEO CONDENSATE CONOENSATEFIOW PERCENTAGE Of CONOENSATE OPERATING
ROW TO DEAERATOR TO CONDENSATE TANK CONDENSATE LOSS PRESSURE

PUMPED CONDENSATE OETMNO A

CONOENSATE LOSS
CONOtNSATI HOG
OR INCH VI n TAW*. M LBS PER HOUR

FIGURE 2. The diagram shows tem differs in that the condensate-return- densate system is the remarkable energy
the layout of an atmospheric line pressure is systematically controlled andsavings that plants can often achieve with
condensate system. Detail No.
9 shows where vented steam managed to a predetermined set point that a low implementation cost. Any condensate
Is lost matches the peak performance level of the that is not contaminated in a process appli­
steam system process and integrates into cation needs to be returned to the boiler to
the dynamics of the steam balance. complete the steam system’s thermal cycle
Four classifications of condensate sys­ and increase efficiency. Steam condensate
tems are used in plants today: contains a high quantity of sensible energy. If
1. Gravity or atmospheric condensatethe sys­
sensible energy is not properly returned
tem (condensate line pressure is main­ to the boiler operation, a large percentage, if
tained at or close to 0 psig) not all, of this energy is lost.
2. Low pressure (1 to 15 psig) Condensate that is returned to the boiler
3. Medium pressure (16 to 99 psig) operation will require the condensate tem­
4. High pressure (100 psig or higher) perature to be raised to the saturated tem­
Pressurized condensate system technol­ perature of the steam boiler’s operating
ogy is not new in the steam world. These pressure. To accomplish this task, energy is
systems can be documented back to 1941. introduced at the deaerator and the boiler.
Though the technology may be considered The deaerator will add energy to heat the
old, it has been overlooked over the years condensate to a temperature where non­
due to relatively inexpensive fuel prices. As condensable gases will be removed from
fuel prices have risen and, with them, the the fluid. The boiler will add the energy for a
need for optimization to reduce overall opera­phase change to occur at the boiler operat­
tional costs, industrial plants are paying more
ing pressure.
attention to pressurized condensate systems,The higher the temperature or pressure
because they have proven to be a significant (direct relationship in steam) of the con­
way to decrease expenses. In fact, these densate being returned to the boiler plant,
systems are considered to be among the the less energy that is required to raise the
top three items for optimizing a steam sys­ temperature of the condensate back to the
tem, and have a very attractive payback for saturated temperature of the boiler operat­
the investment. Figure 2 shows a steam sys­ ing pressure.
tem with atmospheric venting, while Figure 3 Theoretically, the most efficient system
shows the same steam system with a pres­ would be a condensate return system con­
surized flash-recovery line to the deaerator.trolled at a pressure as close to the boiler
operating pressure as possible. In a perfect
Increase efficiency and reduce costs system, the steam system would operate
The best reason to use a pressurized con- at 150 psi, and the pressurized condensate
34 CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM FEBRUARY 2019
 ATMOS

I. mmi 10
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aOWUCTER
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MAKE UP WATER
OCTAL NO®
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PRESSURE
TEMPERATURE
TRANSMITTER

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WATER IN
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DCTMLNO ® OCTAL NO O OCTAL NO 0 OCTMLNO 0

PUMPED CONDENSATE OONOCNSATE FLOW PERCENTAGE Of OONOCNSATE OPERA PNG
ROW TO DOE RA TOR TO OONOCNSATE TANKOONOCNSATE LOSS PRESSURE

PUMPCO OONOENSATE

M CONCMNSAIE HOC
i n m e > .< m m
OCTAL NO O
CCNCCNSATE LOSS
X LBS PER HOUR

system would operate at 149 psi. However, steam-trap station differential and eleva- figure 3. a pressurized
the limitation is the type of steam and con­ tions. With these variables in the system condensate return is shown in
this diagram. The flash steam
densate system. The plant must consider a typical target for the pressure differential at detail No. 9 is delivered to
elements such as line sizes, distances, between the steam supply and condensate the deaerator

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CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM FEBRUARY 2019 35

 • Detail 12: Makeup water flowrate to
deaerator
CONTROLLER
• Detail 13: Deaerator operating

o
Ansa
pressure
• Detail 14: Steam flow to deaerator for
TEMPERATURE
TRANSMITTER '
■1 heating feedwater

Standard condensate-return
PROCESS
TEMPERATURE
system
= 320 F
MEAT EXCHANGER
I A standard condensate system, where
condensate is recovered into an atmo­
©© spheric condensate tank system, will
have inherent energy losses. These en­
ergy losses include the following:
© • Condensate is allowed to cool to
i
212°F
• A large amount of flash steam is gen­
FIGURE 4. This diagram shows the high-return is between 30 and 45%. All pres­ erated
temperature process outlet temperaturesurized condensate systems must be • Flash steam is allowed to escape to
at 320'F
thoroughly evaluated before selecting the atmosphere
the condensate return-line pressure. • Flash steam losses increase the quan­
To determine the cost savings of a tity of makeup water required
standard condensate system versus a All condensate and makeup water,
pressurized condensate system, it is which will become boiler feedwater,
important to review all operational pa­ will require energy input to bring the
rameters. Figures 2 and 3 both show energy level up to the saturated tem­
the following elements of the steam perature of the boiler operating pres­
and condensate system: sure. Reducing the differential energy
• Detail 1: Boiler operating steam levels (condensate and makeup water)
pressure to the boiler saturated energy level will
• Detail 2: Fuel input into the boiler, Btus
increase the steam system’s thermal
• Detail 3: Steam flow output from the cycle efficiency.
boiler, Btus
• Detail 4: Steam flow, Btus Steam process conditions
• Detail 5: Condensate system operat- Table 1 shows values for an example
ing pressure steam application in a process plant.
• Detail 6: Percentage of condensate A steam requirement for the process
loss application is rated at 24,000 Ib/h
• Detail 7: Condensate loss, Ib/h (provides 24,000 Ib/h of condensate).
• Detail 8: Condensate flow to tank, Ib/hCondensate is drained from the steam
• Detail 9: Flash steam flowrate, Ib/h process through a standard steam-trap
• Detail 10: Pumped condensate to station. The steam trap station dis­
deaerator charges condensate into a vented con­
• Detail 11: Condensate Btus to densate receiver system. When con­
deaerator densate is drained from the process at a

TABLE 1. DETAILS OF A TYPICAL STEAM APPLICATION IN A PROCESS PLANT TABLE 2. SUMMARY OF ENERGY LOSSES
Application Steam process IN A TYPICAL
VENTED CONDENSATE-RETURN SYSTEM
Steam pressure supplied to the process
150 psi {before a control valve) equivalent
Summary of operational costs
Steam temperature 366°F
Boiler fuel cost (yearly) 51.167.301
Steam pressure at the process 150 psi pressure
Flash steam losses 5162,043
Steam flowrate 24,000 Ib/h (minimum)
Steam for deaerator operation 564,657
Operation 8,760 h/yr
Total energy loss cost 5226,700
Condensate line pressure 0 psig (vented to the atmosphere and mechanically
pumped back to the boiler plant) The atmospheric system has a total energy loss of 5226,700/
yr as a result of flash steam loss, deaerator steam require­
Cost of steam (per thousand pounds)S5.24 ments to heat the low-temperature and makeup water, in
addition to the cost of additional chemicals.

36 CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM FEBRUARY 2019

 WHEN PRESSURIZED CONDENSATE RECOVERY IS NOT POSSIBLE: VENT CONDENSERS FOR FLASH-ST
RECOVERY ON MODULATING STEAM SYSTEMS

T
ie operational design of modulating (heat exchanger) will consume the flash
steam systems requires the conden- o steam by heating air. water or some other
- sate to be recovered by a gravity (0 ii process fluids. The vent condenser is de­
psig) condensate system, so pressurized signed for the application to ensure proper
condensate recovery is not an option. In operation. A standard shell-and-tube heat
these cases, a typical system will incorpo­ exchanger functions in this application. The
rate a condensate receiver that allows the <> process fluid consumes the flash steam and
flash steam to vent to the atmosphere. The allows the condensate to drain back into the
©
venting of the flash steam ensures the con­ condensate tank. Therefore, the flash steam
densate receiver is never pressurized. The is consumed and the condensate is recov­
use of vent condensers for flash-steam re­ ered. In the case of a modulating-steam
covery in modulated steam systems is de­ process condition, the process steam sys­
scribed below. t
FLASH STEAM
tem should use the lowest steam pressure,
therefore producing the least amount of flash
Flash-steam recovery in modulating CONDENSATE steam possible.
steam conditions The shell-and-tube heat exchanger de­
With today's energy pricing and the need signed for a condenser applications is the
to reduce emissions, a plant’s steam/con­ PUMPED CONDENSATE typical heat-transfer design used in flash
densate systems cannot afford to vent flash steam condensers. Other heat exchanger
steam to the atmosphere. To prevent the units that can be used are spiral, plate-and-
flash steam loss to the atmosphere, plants frame, and fin-coil units (heating units for air
can install devices, such as flash-steam vent or process gases). Materials and installation
condensers in the flash-steam vent line. VFD CONDENSATE CONTROL considerations will vary depending on the
Depending on the installation costs, application. All vented condensers are en­
plants can usually recover the cost of a gineered for the application.
flash-steam vent condenser within ten op­ mxtuiiMtaui Fluid for the condenser To condense the
erational months.
There are two main cost-saving benefits
! If. flash steam, the condenser requires a fluid
temperature of less than 160°F (general
| ruunruii
for a flash-steam vent condenser: it allows consideration). The fluid can be a liquid or
a plant to recover the flash-steam energy, vapor, depending on the application. If there
which can be used to heat a fluid for a pro­ is an insufficient quantity of cooling fluid for
cess: and it reduces emissions by recovering the flash steam in a liquid cooling system,
the flash-steam energy. The boilers will not then the plant should consider using a Hash-
have to produce as much steam, thereby steam bypass or some other method to pre­
<H> COMXNSAU CONTROL
lowering emissions from the boiler operation. vent the cooling liquid from absorbing too
When condensate and flash steam (two-phase much energy and changing from a liquid to a vapor
flow) is discharged from a modulating steam/con­ I and causing water hammer.
densate process, it means the process applica­ Heating air is another application for a vent con­
tion has a steam-control valve that modulates the denser. The bottom diagram in Figure 5 shows
steam to the process. The control valve tan oper­ the air passed over a tube fin configuration with
ate from 0% (full closed) to 100% (full open) and the flash steam inside the tube. The lower tem­
anywhere in between (Figure 5, top diagram) The perature air condenses the flash steam, and the
steam pressure after the steam-control valve and condensate is allowed to drain back into the con­
before the process heat exchanger can vary (P2 | FlttfiMMft densate tank.
reading) depending on process conditions. The Pressure on the condensate tank When
pressure at P2 can range from the full line pres­ Co*d*n»l* choosing a vent condenser, the plant must select a
sure being delivered to the steam control valve design that does not create significant pressure for
(P1) all the way down to zero pressure. the condensate receiver tank. The flash steam vent
In this case, the flash steam cannot be recov- line from the condensate tank to the condensing unit
ered in a pressurized flash tank, or a high-pres­ velocities should not exceed 900 ft/min.
sure condensate-return system. Instead, the Required information. For successful vent-con­
condensate flow from the process has to be dis­ Wd ttndtttiM wfllrv
denser purchase, installation and operation, opera­
charged into a condensate line with pressure at tors should know the following parameters:
0 psig (P5) and delivered to a vented con­ FIGURE 5. A modulated steam-condensate process 1. Condensate flowrate (maximum, minimum
densate receiver tank that is operating at orhas a control valve (top) and a receiver tank vented and normal)
to
close to zero pressure. the atmosphere (upper middle). A flash-steam con­ 2. Flash steam flowrate (maximum, mini-
denser (lower middle) can be used to heat air (bottom) mum and normal)
Flash-steam vent condenser operation 3. Cooling fluid flowrate (maximum, mini­
The upper middle diagram of Figure 5 depicts the typical conden­ mum and normal)
sate-receiver-tank arrangement, where the flash steam is allowed Before to installing a condensate tank with a vent condenser, first locate
be vented to the atmosphere. The energy loss and emission factors and document the different flash-steam vent lines that are discharg­
today permit this loss in the system. ing to the atmosphere. Next, determine the flash steam lost to the
A flash-steam vent condenser is incorporated into the system to atmosphere. Then calculate the projected energy loss and emissions
recover the flash steam by using an external heat exchanger (con- reductions and determine what types of cooling fluids are available J
denser), as shown in the lower middle diagram. The vent condenser

CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM FEBRUARY 2019 37

 Cover Story
TABLE 3. STANDARD VENTED CONDENSATE SYSTEM OPERATING AT ATMOSPHERIC CONDITIONS
EXAMPLE 1: OPERATION AT ATMOSPHERIC CONDITIONS
Detail 1: Boiler operating at steam pressure (psig) 150 Total cost of producing steam at flowrate $1,102,658.20
Detail 2: Fuel input to boiler: Btus required to produce28,703,191
steam Detail 3: Steam flow (Ib/b) 24,000
Cost of steam per thousand lb $5.24 Hours of operation/yr 8,760
Btus (per lb): Total at 150 psig 1,196 Btus latent (per lb): Steam energy at 150 psig 857
Btus sensible (per lb): Condensate at 150 psig 339 Cost per Btu SO.00000439
Detail 4: Total Btus to process 28,703,191
Detail 5: Condensate line operating pressure 0 Btus (per lb) steam at 0 psig 970
Percentage of flash steam 16.3% Btus (per lb) condensate at 0 psig 180
Detail 6: Percentage of condensate loss 10% Btus (per lb) total Btus at 0 psig 1,150
Detail 7: Condensate loss (Ib/h) 2.400 Detail 8: Condensate flow to condensate tank 21.600
Detail 9: Flash steam flowrate (Ib/h) 3,527 Detail 10: Condensate flow rate (Ib/h) 18,073
Detail 11: Condensate Btus to deaerator 3,255,814 Detail 12: Makeup water flow rate (Ib/h) 5,927
Detail 13: Sensible energy in deaerator at operating pressure
208 Makeup water Btu requirement to achieve deaerator
877,191
sensible energy level
503,378
Detail 15: Btus to increase condensate to deaerator operating Total Btu requirement for deaerator 1,380,568
pressure
Steam flow to deaerator 1,407 Cost of steam for deaerator S64,657.45
988
Btus in the boiler operation to produce steam at operating Total Btu requirement for boiler fuel per year 207,710,033,609
pressure
Cost of fuel per decatherm S4.30 Boiler efficiency 81%
Yearly boiler operating cost $1,102,658.20

given pressure (150 psi) and passes through nated by the dynamics of the pressurized
a steam trap station to a lower pressure system. Pressurized systems have several
(0 psi at 212°F), then a percentage of the benefits, as follows:
condensate will flash to steam. The vented 1. The pressurized system will increase the
condensate receiver tank allows the flash condensate temperature or sensible en­
steam to be vented to the atmosphere and ergy level. The condensate temperature
ultimately leads to a loss of energy, and the in the pressurized system is now at the
flash steam loss will increase the quantity of temperature of the deaerator or higher.
make-up water. The condensate is allowed Therefore, the deaerator does not require
to be reduced to 212°F, which will require an essential steam (energy) to heat the con­
influx of energy at the deaerator and boiler densate, saving essential steam.
to achieve phase change at 150 psig. The 2. Another benefit to pressurized condensate
deaerator will use essential steam (steam off is that condensate has not been exposed
the main header) to heat the low-tempera­ to the atmosphere and has not absorbed
ture condensate and make-up water up to any noncondensable gases. The conden­
the operating saturated conditions of the de­ sate does not have to go through the de­
aerator operating pressure. aerator process. In several types of instal­
lations, the condensate can be delivered
Implementing pressurized systems directly into the boiler.
Quantifying the losses in terms of money 3.It will reduce makeup water usage. With
is the first step to developing an improve­ the flash steam being recovered in a pres­
ment plan (Table 2). Pressurized conden­ surized system, no flash steam is lost.
sate systems are an excellent method for Thus, the only need for makeup water is
reducing these losses by 75% or more, to replenish the deaerator's noncondens­
depending on the existing operating condi­ able vent losses. The makeup costs are
tions of the steam and condensate system. negligible in a pressurized system. Reduc­
Understanding the dynamics of the current ing makeup water also will reduce boiler
system as well as the dynamics of imple­ blowdown, thus reducing another energy
menting a pressurized system will lead to loss in the boiler operation.
successful implementation. 4. It will reduce the flash steam quantity that
In a pressurized condensate system, typi­ is generated, which will reduce the con­
cal losses will be greatly reduced or elimi- densate pipe sizing requirements and re-
38 CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM FEBRUARY 2019
 Before changing an industrial steam system into a
pressurized condensate system, the first step is to
ensure that the steam/condensate system and the steam
processes will be able to operate under the new conditions

duce the condensate losses (1 lb of flash A non-modulating steam condition refers

steam is 1 lb of condensate).
5. It will reduce the energy differential (con­
densate versus boiler operating condition).
This will reduce the amount of fuel input
into the boiler to raise the feedwater to the
appropriate phase-change temperature.
6. It will enable the plant to use the flash
steam from a pressurized system.
Before changing an industrial steam sys­
tem into a pressurized condensate system,
the first step is to ensure that the steam/
condensate system and the steam pro­
cesses will be able to operate under the
new conditions. Condensate and flash
steam (two-phase flow) discharging from
a non-modulating or elevated-temperature
process can operate in a pressurized con­
densate system.
to a steam system process where no con­
trol valve modulates the steam flow into the
process to maintain a desired temperature
or pressure. A process steam system that
lacks a modulating steam-control scheme
for the process provides a constant steam
pressure to the process. Therefore, if the
condensate recovery system has a con­
trolled pressure, there is a constant pressure
differential across the steam trap stations or
condensate discharge control valve.
In a high-temperature process where the
process temperature is higher than the pres­
surized condensate system, there will be dif­
ferential pressure across the drain devices,
such as the steam trap station or conden­
sate discharge control valve. For example, as
shown in Figure 4, if the process temperature

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 Cover Story
TABLE 4. SAME STEAM SYSTEM AS SHOWN IN TABLE 3, BUT OPERATING WITH A PRESSURIZED CONDENSATE SYSTEM:
STEAM PRODUCTION COST IS REDUCED
EXAMPLE 1: OPERATION WITH PRESSURIZED CONDENSATE SYSTEM
Detail 1: Boiler operating at steam pressure (psigl 150 Total cost of producing steam at flowrate $940,600.59
Detail 2: Fuel input to boiler: Btus required to produce28,703,191
steam Oetail 3: Steam flow (Ib/h) 24.000
Cost of steam per thousand pounds S4.81 Hours of operation per year 8,760
Btus (per lb): Total at 150 psig 1,196 Btus latent (per lb): Steam energy at 150 psig 857
Btus sensible (per lb): Condensate at 150 psig 339 Cost per Btu S0.00000402
Steam flow from the boiler (deaerator and process) Detail 4: Total Btus to process 28,703,191
Detail 5: Condensate line operating pressure 50 Btus (per lb) steam at 50 psig 912
Percentage of flash steam 7.8% Btus (per lb) condensate at 50 psig 267
Detail 6: Percentage of condensate loss 10% Btus (per lb) total Btus at 50 psig 1,179
Detail 7: Condensate loss (Ib/b) 2,400 Detail 8: Condensate flow to condensate tank 21,600
Detail 9: Flash steam flowrate (Ib/h) 1,687 Detail 10: Condensate flowrate (Ib/Ti) 19,913
Detail 11: Condensate Btus to deaerator 5,323,644 Detail 12: Makeup water flowrate (Ib/h) 4,087
267
Detail 13: Sensible energy in deaerator at operating pressure 604,841
Makeup water Btu requirement to achieve deaerator
sensible energy level
0
Detail 15: Btus to increase condensate to deaerator operating Total Btu requirement for deaerator 604,841
pressure
Steam flow to deaerator 656 Cost of steam for deaerator SO.OO
Btus in the boiler operation to produce steam at operating
929 Total Btu requirement for boiler fuel per year 181,579,443,953
pressure
Cost of fuel per decatherm $4.30 Boiler efficiency 83.0%
Yearly boiler operating cost S940,600.59

is at 320°F, steam pressure to the process versus $0.00

has to be higher than 75 psig. With steam Implementation of a condensate system
pressure of 75 psig to the heat exchanger, that is operating at 50 psig instead of 0 psig
P4 (in the example) will have a pressure of 70
resulted in a savings of $226,700.
psig or greater, and the condensate line pres­The new pressurized condensate system
sure could operate at 30 psig. now operates as follows:
Here are some examples of steam sys­ 1 .Condensate line now operates at 50 psig
tems and processes that may be candidates2. Flash is operating at 50 psig with the flash
for pressurized condensate return setups: steam going to the deaerator
• Steam tracing 3. Deaerator is operating at 50 psig
• Process ovens 4.Condensate is directed to the storage side
• Process heating systems of the deaerator
• Steam line condensate removal steam 5. The steam system is balanced and the
trap stations steam-system thermal cycle efficiency is
• Paper machines increased
• Rubber processes Tables 3 and 4 provide details of the steam
• Press operations production costs and savings for pressur­
• Reboilers ized condensate-return system (Table 4)
• Corrugators versus the atmospherically vented system
(Table 3).
Energy savings
Using the same example of an atmospheric Components required
condensate system and implementing a Several components are required to imple­
pressurized condensate system (increase ment a pressurized condensate system.
the condensate pressure to 50 psig), the op­Pressure control system. A pressure con­
timization results are as follows: trol system controls the condensate pres­
sure to a predetermined set point. The con­
• Boiler fuel cost (yearly): $1,167,301 versus
$940,601 densate pressure must be managed. One
• Flash steam losses: $162,043 versus method is to use a backpressure control
$0.00 valve with a controller. An easier method
• Steam for deaerator operation: $64,657 is to use a flash tank discharging into the
40 CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM FEBRUARY 2019
steam system that has a controlled and little to no downside. The first Author
steam pressure. step in moving toward this technol- ■ Kelly Paffel currently serves as
Flash tank or deaerator. Installing a ogy is for plant personnel or an out- I technical manager at stcan engi-
| neenng firm Irrveno Engineering.
flash tank system that delivers flash side firm experienced in pressurized LLC (7320 East Fletcher Ave,
steam to a controlled steam sys- condensate systems to conduct Tampa, FL 33637; Phone: 239-
tern is an excellent way to operate a steam and condensate assess- 289-3667; Website: www.iiiveno-
1 eng.com; Email: kelly.paftet@tn
the pressurized condensate system, ment. The assessment will provide venoeng.com). Paffel has 41 years
One user of flash steam is the deaer- the knowledge of the benefits of of experience in steam and power
ator, which normally operates below pressurized condensate system lecturer who has published many operations, and is an experienced
technical papers on the
15 psig. Most steam systems have and, more importantly, the cost of topics of steam system design and operation He is known
several operating steam pressures, implementation. ■ for writing "Steam System Best Practices." which are used
by plants and engineers globally to ensure proper operation
so the flash steam can accept the Edited by Scott Jenkins of steam and condensate systems, www.invenoeng.com
cascaded steam.
Another method uses a thermo­
compressor to raise the flash steam's
pressure and reintroduce it into
the steam processes or deliver the
steam into a plant steam-system, ZEECO
pressure-distribution system. Install­ r
ing a new deaerator or using the cur­ V
rent deaerator, which can operate at
r
a higher pressure, is a third method
of receiving the pressurized conden­
sate. The deaerator is operated at a
predetermined operating pressure
that is the same as the pressure in
the pressurized condensate system. ,
The condensate temperature is al­ A
ready elevated, and there will be a re­
duced quantity of flash steam, which A.
is normally consumed by heating the- ^ ® -
makeup water.
vr
Pressurized condensate. Pressur­
ized condensate does not have to
be deaerated and can be pumped A\
directly back into the boiler. Since
the condensate has not been ex­
3iM
1
posed to the atmosphere, it has not i
had the opportunity to take up any
noncondensable gases.
Condensate-line sizing. Conden­ Wi
sate-line sizing always needs to
be checked to ensure that it has I I
the proper design to operate in a
pressurized operation. Typically, •1:11
the condensate-line size required
is reduced by the lower quantity
of flash steam, which normally re­ REAL-TIME, DIRECT FLARE MONITORING CHANGES EVERYTHING.• •
i
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quires more area in atmospheric or the Refinery RTR rule It does not contact any corrosive waste streams and can be installed while the flare is in service.
very low-operating-pressure con­ If you want to enhance operating efficiency, reduce emissions, and accurately monitor key metrics l*e smoke index
densate lines. Velocities are also re­ and combustion efficiency in real time, go with FlareGuardian Go Zeeco.
duced due to the lower flash-steam
quantity, thus eliminating the nor­ Zeeco.com/FlareGuardian

mal water-hammer issues with high Zeeco Inc. I +1 (918)258-8551 I Zeeco.com

condensate-line velocities.
Getting started
There are many reasons to imple­
ment a pressurized condensate
system, if it is possible to do so,
ZEEC0
'
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CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM FEBRUARY 2019 41