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Case Study:

Improve Condensate Recovery Factor


Chemical

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Customer Details

A detergent manufacturing plant in Egypt
Problems

- High boiler fuel bill
- Excess water consumption
Objective

To improve condensate recovery factor and bring
down energy costs in the plant

Solutions

The Forbes Marshall team conducted a detailed survey of the steam system at the plant. Opportunities were identified and the following changes were made for savings in the steam and condensate circuit.
Leaking / faulty traps were replaced with right size and type of traps
Compact Module Twin Orifice Steam Traps for process trapping
Compact Module Thermodynamic Steam Trap with IsoTub for mainline trapping
SteaMon steam flow meter was installed for accurate  steam flow measurement
Conventional condensate tank replaced with flash vessel and steam operated pressure powered pump
Automation of the heating and cooling cycles of the bleacher and hot water generation for farm tanks area.
Benefits

- No steam loss through traps
- Flash Steam returned to process; direct steam
 injection reduced
- Reduction in chemicals consumed
- 20% reduction in boiler's annual natural gas bill
- 40% reduction in annual water bill for steam
 boilers
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