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

2. 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

3. Condensate Recovery & Flash Steam
Steam and Energy Usage

4. 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

5. 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

6. Many Areas for Energy Saving and Improvement
Only time to look briefly at a couple
Flash Steam Recovery
Boiler Monitoring System

7. Condensate Recovery & Flash Steam

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

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

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

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

12. 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

13. 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

14. 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

15. 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.

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

17. 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

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

19. FREME- Flash Recovery System

20. 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

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

22. 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

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

24. B850
BOILERHOUSE ENERGY MONITOR
Pictures are CAD.

25. “ ” 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.

26. 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

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