ONE OF THE MOST DIVERSE INDUSTRIES WITH A WIDE PRODUCT RANGE AND COMPLEX PROCESSES, STEAM PLAYS AN IMPORTANT ROLE IN PROCESSES SUCH AS CANNING, FREEZING, FERMENTATION, PASTEURISATION, SMOKING & STERILIZATION
| Problem | Solution | Benefits |
| Getting Steam at the rated Capacity and Pressure | Steam Boilers / Thermic Fluid Heaters | Boilers and heaters of optimum capacity can help in efficient steam production Correctly designed boilers can help save production and fuel costs greatly |
| Problem | Solution | Benefits |
Many Plants having 17.5 bar(g) Design Pressure have a Limitation of Operating Boiler only up to 14-15 Bar(g) Radiator Coils in the Air Drier Section Designed for 25-32 Bar(g) are not able to run on Full Capacity |
Boiler Designed for Operating Pressure Requirements | Dryer can run smoothly, which helps increase the productivity of powder plant for which radiator coils are designed Low pressure processes can be operated with the help of pressure reducing stations |
| With Sudden Peak Demand Requirements, Boiler Pressure Drops, Resulting in Water Carryover, Steam Quality Degradation and Increased Process Time | Efficiency Monitoring System | Ensures adequate combustion through I/D and FD control systems |
| Non Uniform Blowdown | Auto Blowdown System | Adequate blowdown eliminates scale carry over and results in heat loss optimization Avoids excess chemical dosing and ensures optimum level of TDS of the water inside boiler |
| Lower Feedwater Temperature | Feedwater Management System | Directly reduces fuel consumption |
| Water Carryover | Moisture Separator | Ensures removal of moisture carry over to the process resulting in dry steam to the process which helps in improving productivity, quality and fuel saving as well |
| Problem | Solution | Benefits |
| Huge Steam Consumption due to Improper Trapping | Maintaining Time and Temperature Combination I.E. Critical Control Point | Reduces steam consumption Accuracy in process temperature ensures critical control points achieved |
| Higher Pressure than Rated, Open Steam is Used without Pressure Reduction but by Throttling the Valve | Pressure Reducing Station | At lower pressure latent heat is higher so there is steam saving through PRS |
| Smaller Steam Line Size than Required | Correct Line Sizing as Per Required Steam Flow on Given Pressure | Smaller line size always creates pressure drop issues as per Barnauli’s principle and to get the same flow velocity of steam increases resulting moisture carryover |
| No Provision of Automatic Air Venting | Automatic Air vent For Steam Inlet Line to Equipment and Header | Automatic air vents eliminate barrier of heat transfer between steam to condensate |
| Problem | Solution | Benefits |
| Poor Regeneration Efficiency in Pasteurizer | PHE Based Instantaneous Hot Water Generator Along with PID Based Temperature Control Skid Steam Operated Pumping Trap to Ensure Stalling Conditions Can Be Avoided |
In regeneration, the heat of pasteurised milk is used to preheat cold incoming milk. The cold milk also serves to cool the hot, thus economizing the water and energy Regeneration efficiency of up to 94-95% can be achieved |
| Energy Loss: Steam and Condensate Loss Due to Opening of Trap Bypass and Local Drainage of Condensate | Pumping Trap Skid | Steam saving due to stopping bypass opening. |
| Productivity Loss: Drop in Hot Water Temperature & Hence Repeat Pasteurization Cycle (Opening of Flow Diversion Valve) | Instantaneous Hot Water Generator with PID Temperature Control Skid | Increased productivity |
| Equipment Uptime: Water Logging and Hammering Resulting into PHE Gaskets Failure Which Leads to Contamination | Proper Condensate Evacuation Is Only Possible by Pumping Trap to Take Care of Stalling Conditions as Well | Increased equipment life |
| Problem | Solution | Benefits |
| Ghee Process – If Temperature Increases above the Set Point, then the Ghee Gets a Burnt Flavour | PID Based Temperature Control System | Increased productivity, quality and steam saving |
| Higher Temperature Results in Lower Production Volume | Group Trapping, Bypass Opening should be Avoided by Correctly Sized Ball & Float Traps | Reduced steam consumption and batch times, if bypass of the trap is not opened and processes run smoothly |
| Lower Temperature Impacts the Colour and Flavour of the Ghee | Correctly Sized Ball & Float Trap as per Load | Condensate evacuation results uniform heat transfer so continuously in each batch ghee is properly cooked and quality improves |
| Problem | Solution | Benefits |
| Condensate Evacuation Problem due to Group Trapping | Correctly Sized Traps | Increased productivity and steam saving |
| Condensate Evacuation Problem due to Group Trapping | Replace Group Trapping to Individual Trapping for each Coil of Radiator | Steam and condensate saving Heat exchanger (radiator coil life) enhancement |
| Problem | Solution | Benefits |
| Higher Temp Results in Lower Protein Content, Impacts Quality Lower Temp Results in Bacteria Not Killed Resulting in Low Shelf Life | PID Based Temperature Control System | Increased productivity, steam saving |
| Problem | Solution | Benefits |
| Many Plants are not Recovering Flash Steam and Condensate | Condensate should be Recovered by Online Steam Operated Condensate Recovery System | It helps in reduction of makeup water consumption, no need to recover evaporator water where chances of contamination are much higher. All indirect injection will lead to Condensate Recovery Factor of 90% |
| Problem | Solution | Benefits |
| Many Plants Have a Huge Problem with Valves Leaking Steam | Seatless and Glandless Valves | Piston Valves are class VI valves and by using them we can create a plant having zero steam leak Also ensures minimal pressure drops, safe working environment |
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