Energy Saving Opportunities
Wagga Wagga
Industry Workshop
April 2017
Peter Hickey
NSW Sales
Increasing Our Capabilities
Flow meters
Control valves,
regulators and traps
Isolation valves
and ancillaries
Engineered heat
exchange packages
Boiler controls
and systems
Steam distribution system
Engineered
systems
Process and
applications
Boiler
Energy
services
Condensate recovery system
Boiler water
treatment and
blowdown
Pumps and heat recovery
Process Heat
Transfer
2
3
Steam and Energy Usage
4
Where Energy is Lost
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Poor Lagging – Heat loss , safey Issue
Erratic Blowdown Control in Boiler
Cold Boiler feed tank
Poor Distribution Layout
Leaking Steam /Condensate lines
Unmaintained and leaking steam traps
Poor process control
Unharnessed waste energy – Flash Steam
Inadequate Measuring and Monitoring
5
How to Improve your Plant
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Proper Lagging
Automatic Blowdown Control
Pre-Heat Feed tank
Efficient well drained and sized Distribution Layout
Repair leaking pipework – money disappearing out the holes!
Regular Steam Trap Audits (low lying fruit , big win!)
Modulating Automated Control
Flash Recovery System
Boiler Monitoring Equipment and Meters
Many Areas for Energy Saving and
Improvement
Only time to look briefly at a couple
• Flash Steam Recovery
• Boiler Monitoring System
Flash Steam
8
Flash Steam ...
WHAT IS FLASH STEAM...?
HOW IS IT FORMED...?
WHAT CAN WE DO WITH IT...?
9
Flash Steam
Condensate Return System
Loss of Flash
Steam
10 bar Steam
Pressure
Boiler
Feed
Tank
Condensate Return
Steam Boiler
10
Flash Steam Recovery
11
Approximate Amount of Flash
Steam in Condensate
Flash Steam 16%
Water 84%
12
Flash Steam Recovery
Requirements for Flash Steam Usage:
• Enough condensate
• Use for low pressure steam
• Application needs to be close to high
pressure condensate source
13
Flash Steam Recovery
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PID Before: Flash Steam Recovery
DRG. No
© Copyright. This drawing is the property of Spirax Sarco. It shall not be reproduced without the permission of Spirax Sarco. The
detail shown is offered for information only. It is the End User / Contractor / Installers responsibility to check for correctness.
Condensate/Energy
from plant
Feed Tank/
Deaerator
Boiler
Through to boiler
CUSTOMER
DETAIL
15
PID After: Flash Steam Recovery
DRG. No
© Copyright. This drawing is the property of Spirax Sarco. It shall not be reproduced without the permission of Spirax Sarco. The detail shown is
offered for information only. It is the End User / Contractor / Installers responsibility to check for correctness.
Condensate/Energy
from plant
Feed Tank/
Deaerator
Boiler
Through to boiler
CUSTOMER
DETAIL
16
Flash Steam Recovery
Feed temperature
from tank reduced to
about 90C
17
Flash Steam Recovery
Big increase in
water
temperature
after the heat
exchanger
18
Flash Steam Recovery
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FREME- Flash Recovery System
20
Case Study 1
Benefits to CustomerRendering Plant NSW
Benefit
Water Savings
Over $10,000 savings per
annum in water and
chemical treatment
Chemical Savings $3,000
Energy Savings
18,000 GJ per annum
Carbon
Reduction
1100 tonnes of CO2 per
annum
Environmental/
Visual Impact
Flash Steam stack is now far
less
21
Case Study 2
Abattoir Country NSW Australia
Categories
Benefit
Steam Savings
2700 tonnes/annum
Reduction in Fuel bill
8% over first year
Dollar Savings
$95,000
Payback time
6 months
Environmental/
Visual Impact
Big reduction of flash
steam being wasted at
the feedtank
22
Other Flash OpportunitiesHeat Recovery from Boiler Blowdown
Flash steam taken directly into a
flash condensing deaerator head
Blowdown
inlet from
TDS
control
valves
Flash
Vessel
Thermostat
Heat exchanger
Steam distribution
injects low pressure
flash steam into
boiler feedtank
23
Other Flash Recovery OpportunitiesEVC- Exhaust Vapour Condenser
Vent out
Water
condensate
Water
Steam vent in
24
B850
Boilerhouse Energy Monitor
The B850 offers a cost effective
solution for Boilerhouses that do not
have a boiler energy monitoring
facility
YOUR BOILER
“ UPGRADE
PLANTS ENERGY
MONITORING CAPABILITY
25
”
UNDERSTAND | MONITOR | OPTIMISE
YOU THE FLEXIBILITY YOU
“ GIVES
NEED WHEN MONITORING YOUR
BOILERHOUSE EFFICIENCY
”
B850
Boilerhouse Energy
Monitor
The
B850 is compatible with all Spirax Sarco flowmeters and automated blowdown systems
associated with steam boilers.
ELM
Pt-100
Pt-100
B850
Ptx
ILVA
ELM
ELM
Auto TDS
MTL 10
Auto BBD
26
Energy Saving Opportunities
Wagga Wagga
Industry Workshop
April 2017
Peter Hickey
NSW Sales