PAPTACPAPTACMontréal Montréal

February 2006February 2006

Steam and Steam and Condensate Condensate

Closed SystemClosed System(SCCS)(SCCS)

100 % condensate return100 % condensate return

Reality or Utopia ?Reality or Utopia ?

lalondelalondesyssysthermiqthermiqueue incinc

The The SSteam and team and CCondensate ondensate CClosed losed SSystem Groupystem Group (SCCS) (SCCS)

Expertise in how to use steam without Expertise in how to use steam without losseslosses

A unique system technology developed & A unique system technology developed & improved since 1984. improved since 1984.

Currently installed in over 52 mills Currently installed in over 52 mills Caddet : Caddet : http://http://www.caddet.orgwww.caddet.org/public//public/uploadsuploads//pdfspdfs/Brochure/r125.pdf /Brochure/r125.pdf 2005 Paptac Energy Award : 2005 Paptac Energy Award :

http://oee.nrcan.gc.ca/cipec/ieep/newscentre/newsletter/cipec_vol_IX_3.cfm?attr=24#dhttp://oee.nrcan.gc.ca/cipec/ieep/newscentre/newsletter/cipec_vol_IX_3.cfm?attr=24#d

Energy Saving AchievementsEnergy Saving Achievements Eliminate steam & condensate Eliminate steam & condensate

losses losses Stop flash steam, steam trap & pump gland lossesStop flash steam, steam trap & pump gland losses

Better control & efficiency of Better control & efficiency of thermal equipmentthermal equipment Eliminate excessive pressure, temperature & Eliminate excessive pressure, temperature & flow drops Modify steam side control flow drops Modify steam side control Control on the condensate side Control on the condensate side

Reduce fossil fuel & green house Reduce fossil fuel & green house gasesgasesMore than 10 % steam savingsMore than 10 % steam savings1000 lbs of steam = 10.8 U.S. gallon of bunker oil = 0.13 tonne of CO1000 lbs of steam = 10.8 U.S. gallon of bunker oil = 0.13 tonne of CO22 gas gas 1 tonne of steam = 90.2 liter of bunker oil = 0.28 1 tonne of steam = 90.2 liter of bunker oil = 0.28 tonne of COtonne of CO22 gas gas1 tonne of steam = 82.3 meter1 tonne of steam = 82.3 meter33 gas gas = 0.16 tonne of CO= 0.16 tonne of CO22 gas gas

Basic Principles of the Basic Principles of the Steam and Condensate Closed Steam and Condensate Closed

System (SCCS)System (SCCS) Use of saturated steam at 0 deg superheatUse of saturated steam at 0 deg superheat

Usually steam enters heat exchanger with 10 Usually steam enters heat exchanger with 10 ººC or more of C or more of superheatsuperheat

Mechanically remove non-condensible gases on Mechanically remove non-condensible gases on thethe steam sidesteam side

Typically ignored or conventionally done on condensate side and amines Typically ignored or conventionally done on condensate side and amines have to be addedhave to be added

Return condensate to the deaerator &/or a flash Return condensate to the deaerator &/or a flash tank at the highest possible pressure & tank at the highest possible pressure & temperature using mechanical force of steam temperature using mechanical force of steam pressure to return condensatepressure to return condensate Usually, condensate was vented to an atmospheric tank and pumpedUsually, condensate was vented to an atmospheric tank and pumped

No condensate tank, no pumpNo condensate tank, no pumpNo flash steam to atmosphere, no use of electrical power, lower maintenanceNo flash steam to atmosphere, no use of electrical power, lower maintenance

SCCS METHODSCCS METHOD BENEFITSBENEFITS Convert heat exchangers, evaporator, black Convert heat exchangers, evaporator, black

liquor heaters etc, to full pressure steamliquor heaters etc, to full pressure steam Control process heat exchanger on the Control process heat exchanger on the

condensate side condensate side Control heat exchangers to less than Control heat exchangers to less than ±± 1 1 °°F F Condensate returned under full pressure to Condensate returned under full pressure to

steam plantsteam plant Better control & efficiency of thermal Better control & efficiency of thermal

equipmentequipment Control all steam system vents to Control all steam system vents to

atmosphere (without steam loss) with atmosphere (without steam loss) with mechanical Omechanical O2 2 && COCO2 2 eliminators eliminators

Guaranteed boiler water make-up reduction Guaranteed boiler water make-up reduction Up to 10 % total steam savingsUp to 10 % total steam savings

LastLastlalondelalondesyssysthermiquthermiqu

ee Steam and Steam and Condensate Closed Condensate Closed

System resultsSystem results

Average Steam Average Steam production per hourproduction per hour

Before : 438 667 lbs/hourBefore : 438 667 lbs/hour

After : 400 000 lbs/hourAfter : 400 000 lbs/hour

Power GenerationPower Generation

Before : 13.14 MWBefore : 13.14 MW

After : 14.58 MWAfter : 14.58 MW

Natural gaz Natural gaz consumptionconsumption

Before : 47 791 mBefore : 47 791 m33/day/day

After : 21 678 mAfter : 21 678 m33/day/day

Water regenerationWater regeneration

Before : 6Before : 6/day/day

After : 3After : 3/day/day

As an exemple, deaerator As an exemple, deaerator steam demandsteam demand

Before : 39 621 lbs/hourBefore : 39 621 lbs/hour

After : 17 069 lbs/hourAfter : 17 069 lbs/hour

Pulp ProductionPulp Production

SameSame

MUCH MOREMUCH MORE……

February 2005February 2005

Energy conservation awardsEnergy conservation awardsare presented to individuals working in are presented to individuals working in

the industry who submit the best the industry who submit the best examples of energy conservation examples of energy conservation

opportunities applied in Canada. Les opportunities applied in Canada. Les Papetières du Québec sponsors this Papetières du Québec sponsors this

competition.competition.1st Prize1st Prize : : Jack Smith (Tembec – Smooth Rock Jack Smith (Tembec – Smooth Rock

Falls) for his Falls) for his Steam and Condensate OptimizationSteam and Condensate Optimization..

February 2005February 2005

Working with the mill in this effort, from the beginning, Working with the mill in this effort, from the beginning, has been Systhermik Canada inc. (has been Systhermik Canada inc. (lalondelalondesyssysthermique thermique

incinc.). Their expertise revolves around closed system .). Their expertise revolves around closed system approaches towards handling steam and condensate.approaches towards handling steam and condensate.

The first prize was attributed forThe first prize was attributed for : :

Innovation, creativity, originalityInnovation, creativity, originality

Applicability in the pulp and paper Applicability in the pulp and paper industryindustry

Size of savings and cost-effectivenessSize of savings and cost-effectiveness

Installation and implementationInstallation and implementation

Environmental impactEnvironmental impact

Basic Questionnaire for Energy Conservation Basic Questionnaire for Energy Conservation CalculationsCalculations

1.1. Operation in days ______ / yrOperation in days ______ / yr2.2. Steam production (approx)Steam production (approx)

SummerSummer ______ lbs/hr or ______ tons/hr______ lbs/hr or ______ tons/hrWinterWinter ______ lbs/hr or ______ tons/hr______ lbs/hr or ______ tons/hrAverageAverage ______ lbs/hr or ______ tons/hr______ lbs/hr or ______ tons/hr

3. 3. Total steam productionTotal steam production ______ lbs/yr or ______ ton/yr______ lbs/yr or ______ ton/yr4.4. Boiler feed water flowBoiler feed water flow

SummerSummer ______ US gpm or ______ l/min______ US gpm or ______ l/minWinterWinter ______ US gpm or ______ l/min______ US gpm or ______ l/minAverageAverage ______ US gpm or ______ l/min______ US gpm or ______ l/min

5.5. Process direct steam injection in % of steam production :Process direct steam injection in % of steam production : ____ %____ %6.6. Continuous blowdown in % of steam production :Continuous blowdown in % of steam production : ____ %____ %7.7. Boiler water make-up in % of steam production :Boiler water make-up in % of steam production : ____ %____ %8.8. Steam pressures in plantSteam pressures in plant

Pressure 1  _____ psig, or ______ Pressure 1  _____ psig, or ______ KPaKPa         Pressure 2  _____ psig, or ______ Pressure 2  _____ psig, or ______ KPaKPa   Pressure 3  _____ psig, or ______ Pressure 3  _____ psig, or ______ KPaKPa

Pressure 4  _____ psig, or ______ Pressure 4  _____ psig, or ______ KPaKPa9. 9. Deaerator pressure :Deaerator pressure : ______ psig,______ psig, ______ ______ KPaKPa10.10. Make-up water temperature in :Make-up water temperature in : ______ ______ °°F, orF, or ______ ______ °°CC11.11. Steam production cost in $ / 1000 lbs ______ or/tons ______Steam production cost in $ / 1000 lbs ______ or/tons ______