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Energy Balance in a typical steam and condensate loop
Generation 100%
80%Distribution losses
3-5%
Boiler House Losses 15-18%
Trap & Condensate 20%
Process demand 55%
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Condensate Drained and Flash steam
vented @3bar
Losses from traps – 75 Kgs/hr
Moisture drained.. 350 Kgs/hr
Feed Water Tank@ 30 Deg C
Process demand 500Kgs/hr dry steam
Boiler required capacity = 1010Kgs/hr
Typical Steam & Condensate Loop Coil Type
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High Fuel Bill !!!Poor Product
Quality !!!
High Water
consumption !!!
Corr
osio
n of
Equi
pmen
t !!!
Wet Steam !!!
Poor Life of the Coil
boilers !!!
High Cycle Times !!!
High Steam Loads !!!
The Issues
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FWT@ 90 Deg C
Moisture Drained 2%
Condensate Recovery 20%
Process Steam Demand Reduced to 450 Kg/hr
The Solution : Shell Type Boiler
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Coil Type Boiler Shell Type Boiler
The Difference
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Advantages
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SOUNDS EXCITING !!!
A few more reasons to Change
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Parameters Fuel Savings Criteria Consumption
Coil Type Boiler 48.75 lt/hr 28% Eff = 75% dryness fraction = 80%
Coil Type Boiler 49.85 lt/hr 30% Eff = 75% dryness fraction = 65%
Shell Type Boiler 35.49 lt/hr Eff = 89% dryness fraction = 98%
Savings due to
Flash Steam recovery Right Trapping
Dry Steam generation
Temperature & Pressure Control
Low Cost of Ownership
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Actual Savings ofActual Savings of
25 - 30%25 - 30%
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Industry Coil Boiler Shell Boiler
Pharma Industry in Pune
Heating period for 100 ml (Autoclave) 55 mins 35 mins
Heating period for 500 ml (Autoclave) 66 mins 50 mins
Distilled water o/p from Multicolumn 200 lit 275 lit
Bottling Company
Bottles produced per Minute (BPM) 340 500
Rubber Company
Batch Time 8 Hrs 6 Hrs
Pieces per month 109,000 167,000
Increased Productivity
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Coil Boiler Shell Boiler
Steam Quality Wet Dry Saturated
Constant Load Poor Steady
Fluctuating Load Water carry over as Steady due to sufficient
no steam space steam space
Instantaneous Loads Pressure Drop Steady Output
The 2 Q’s ….
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Savings in Water
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Partial List of industries using Shell Type boilers –
1. Food 13. Personal Products2. Garments 14. Beverages3. Chemicals 15. Packaging Industries4. Cattle feed 16. Plastics5. Dairy6. Educational Institutes7. Rubber8. Hotels9. Hospitals10. Formulations11. Pharmaceuticals12. Glass
More than 200 boilers in operation in the industries which traditionally used coil type boilers
Reference List
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The Old System
Feed Water Tank@ 30 Deg C
35% Moisture at 180 Deg C drained
Condensate Drained and
Flash steam vented @3bar
TD traps..!
850kg/hr600 kg/hr
Pressure Drop..
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Problems
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FWT@ 90 Deg C
Condensate at 95 Deg C
Condensate at 95 Deg Crecovered
Recoverable Flash Steam @ 3 bar
1TPH boiler, dry steam load – 550Kgs/hr
Changed to FT
traps..!
No Pressure Drop..
The Solution !
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o Fuel consumption reduced from 5 Tankers per 2 months to 4 tankers per 2 month.
(Saving of 6 tanker of 10000 Kg/Year)
o Reduced load on ETP… Practically the ETP remains idle now.
o For a Drum Heating process – The heating time has reduced from 10 hrs to 4 hours.
o Reactor heating process – 14 hrs to 8 hrs. (Endothermic Reaction)
Results Speak for themselves
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More improvements and Benefits
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