Recovering condensate from process equipment
Process equipment which use indirect steam for heating at different pressures is the other source where condensate is formed in significant quantities, once steam gives off its latent heat to the process. It is imperative to recover condensate from the process equipment.
Methods of Condensate Recovery from Process Equipment
There are several methods commonly used across plants to recover condensate. These methods not only impact the efficacy of recovery but can also have an impact on the process from which recovery is attempted.
The three methods of condensate recovery from process equipment are:
- Recovery by Steam Trap Pressure
This method connects steam traps directly to the condensate return header, relying on steam pressure to move the condensate. However, it introduces backpressure, reducing the efficiency of condensate evacuation and impacting heat exchange.
- Recovery using Centrifugal / Electrical Pumps
Condensate is collected in open tanks and pumped back using motor-driven centrifugal pumps. While commonly used, this method leads to heat losses, increased operating costs, and high maintenance due to cavitation and vapour locking.
- Recovery using Mechanical Pumps
Steam-operated mechanical pumps eliminate the need for intermediate tanks and electric pumps, improving energy efficiency, reducing heat loss, and ensuring higher system uptime. This method is safer and more cost-effective in the long run.
