STEAM SOLUTIONS FOR THE PHARMACEUTICAL INDUSTRY CONSIDERING VARIOUS PARAMETERS SUCH AS HEAT LOAD FLUCTUATIONS, QUALITY AND SAFETY NORMS
| 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 |
| Pressure Drop due to Peak Load Conditions | Operate The Boiler Nearer to Design Pressure Pressure Reducing Station | Reduction in process steam demand because of more heat content Increased fuel savings |
| 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 Feed Water Temperature | Feed Water Management System | Directly reduces fuel consumption. |
| Lower Variation from 10% to 50% Leads to Frequent On/Off Operation | Efficiency Monitoring System | Fuel Savings |
| Problem | Solution | Benefits |
| 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 |
| Condensate Draining Due to Fear of Contamination | Universal Process Module or Condensate Contamination Detection System | Pure Condensate Recovery |
| No Precise Temperature Control | PID Based Temperature Control System | Ensures optimum temperature setting and usage |
| Problem | Solution | Benefits |
| Improper Trapping | Trap Module Preferably SS Trap | Increased steam savings |
| No Precise Temperature Control | PID Based Temperature Control System | Ensures optimum temperature setting and usage |
| Direct Steam Injection/Jacket Based Hot Water Systems | Install Instantaneous Hot Water Generator PID Based Control | accurate temperature control, saves time for hot water preparation |
| 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 |
| Thermodynamic Traps / Inverted Bucket Traps are Installed, resulting in Steam Loss and Increased Batch Timing | Properly Sized Traps | Increased steam savings |
| Problem | Solution | Benefits |
| Actual Pressure is more than Required Pressure | Pressure Reducing Station | Increased steam savings |
| Thermodynamic Traps / Inverted Bucket Traps are Installed, Resulting in Steam Loss and Increased Batch Timing | Properly Sized traps | Increased steam savings |
| 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 |
| Thermodynamic Traps / Inverted Bucket Traps are Installed, Resulting in Steam Loss and Increased Batch Timing | Properly Sized Traps | Increased steam savings |
| 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 95% |
| Problem | Solution | Benefits |
| Many Plants Have a 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 Ensures minimal pressure drops, safe working environment |
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