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Case Study:

Improve Productivity and Reduce Steam Consumption


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Customer Details

A paper mill in North India
Problems

- Low productivity due to severe condensate evacuation issues
- Poor condensate recovery
- Very high back pressure (1.5 barg) in main common tank
- Frequent failures of S&C components and leakages
- High specific steam consumption (1.8-1.9)
Objective

To improve productivity and reduce energy consumption
Solutions

Installation of an engineered thermal grouping cascade based system for effective utilisation of flash steam, along with with the following solutions

- Fixed bend stationary siphon
- Steam flow meter and condensate flow meter
- Pressure, differential and level control loops
- Glandless piston valve
- Compact module thermodynamic traps
- Mini distributed control system
Benefits

- Improved condensate removal at lower differential pressure
- Reduction of specific steam consumption by 1.1 ton per ton of paper
- Improvement in condensate recovery - from 55% to 85 %
- 5 % saving in fuel consumption
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