Energy Saving Opportunities Wagga Wagga Industry Workshop April 2017 Peter Hickey NSW Sales

Increasing Our Capabilities Control valves, regulators and traps Isolation valves and ancillaries Engineered heat exchange packages Flow meters Boiler controls and systems Steam distribution system Engineered systems Process and applications Energy services Process Heat Transfer Boiler Condensate recovery system Boiler water treatment and blowdown Pumps and heat recovery

Condensate Recovery & Flash Steam Steam and Energy Usage

Where Energy is Lost 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 Lots of differnet areas to save – even if process /production is running satisfactorily

How to Improve your Plant 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

Condensate Recovery & Flash Steam

Condensate Recovery & Flash Steam WHAT IS FLASH STEAM...? HOW IS IT FORMED...? WHAT CAN WE DO WITH IT...?

Condensate Recovery & Flash Steam Condensate Return System Condensate Return Boiler Feed Tank 10 bar Steam Pressure Loss of Flash Steam Steam Boiler

Condensate Recovery & Flash Steam Flash Steam Recovery Common site around the country

Approximate Amount of Flash Steam in Condensate Condensate Recovery & Flash Steam Approximate Amount of Flash Steam in Condensate Flash Steam 16% Water 84%

Condensate Recovery & Flash Steam 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 Timber kiln Dryers, Rendering Plants are ideal

Condensate Recovery & Flash Steam Flash Steam Recovery Typical overheating feed tank ( maybe add piture here of feed tank venting to atmosphere) This is at an Abbatoir- up to 1500kg/h of Flash Steam can be lost per our. That converts to about 200kg per hour of carbon being emitted – associated with the wasted energy and steam

Condensate Recovery & Flash Steam PID Before: Flash Steam Recovery CUSTOMER DETAIL © 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. DRG. No Condensate/Energy from plant Feed Tank/ Deaerator Boiler Instead of condensate going straight back to feed tank - we separate the flash steam and use it to pre-heat the boiler feedwater after the pumps. Through to boiler

Condensate Recovery & Flash Steam PID After: Flash Steam Recovery CUSTOMER DETAIL © 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. DRG. No Feed Tank/ Deaerator Boiler Through to boiler Condensate/Energy from plant Instead of condensate going straight back to feed tank - we separate the flash steam and use it to pre-heat the boiler feedwater after the pumps.

Condensate Recovery & Flash Steam Flash Steam Recovery Feed temperature from tank reduced to about 90C Reduced-’manageable feed tank temperature

Condensate Recovery & Flash Steam Flash Steam Recovery Big increase in water temperature after the heat exchanger Flash steam is now pre-heating the boiler feedwater after the pumps – where the water is at a high pressure and can be heated more than 100C. Have seen this up to 140C

Condensate Recovery & Flash Steam Flash Steam Recovery After Flash recovery system is fitted all the excess energy has been quenched and used.

FREME- Flash Recovery System

Case Study 1 Benefits to Customer- Rendering Plant NSW 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 Less visual Pollution Reduced water usage Reduced chemical usage Reduced carbon output and wasted energy

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 Less visual Pollution Reduced water usage Reduced chemical usage Reduced carbon output and wasted energy

Condensate Recovery & Flash Steam Other Flash Opportunities- Heat Recovery from Boiler Blowdown Steam distribution injects low pressure flash steam into boiler feedtank Flash Vessel Flash steam taken directly into a flash condensing deaerator head Blowdown inlet from TDS control valves Thermostat All plant have the opportunity for Blowdown Energy Recovery Heat exchanger

Other Flash Recovery Opportunities- EVC- Exhaust Vapour Condenser Vent out Water condensate Water Many more – these are just a few Steam vent in

B850 BOILERHOUSE ENERGY MONITOR Pictures are CAD.

“ ” B850 Boilerhouse Energy Monitor UPGRADE YOUR BOiLER PLANTS ENERGY MONITORING CAPABILITY B850 Boilerhouse Energy Monitor ” The B850 offers a cost effective solution for Boilerhouses that do not have a boiler energy monitoring facility UNDERSTAND | MONITOR | OPTIMISE Pictures are CAD.

B850 Boilerhouse Energy Monitor “ gives you the flexibility you 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 MTL 10 Auto BBD Auto TDS Pt-100 Ptx B850 ILVA ELM Available inputs: 6 x 4-20mA active. 3 x pulse. 3 x RTD 4 wire (3 wire compatible). Available outputs: 4 x pulse/relay (can be used as either a relay alarm or as a digital pulse output). 1 or 2 x 4-20mA available as optional extras. Communications: RS485 for Modbus RTU RJ45 Ethernet connection for Modbus TCP or web browser interface

Energy Saving Opportunities Wagga Wagga Industry Workshop April 2017 Peter Hickey NSW Sales