END-TO-END-STEAM SOLUTIONS FOR PROCESSES SUCH AS SOLVENT EXTRACTION, DISTILLATION, AND 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 |
| Lower Steam Pressure Generated, Which Results in Reduced Dryness Fraction of Steam. | Boiler designed for operating pressure requirements Pressure Reducing Station for required process pressure | Steam economy as at low pressure latent heat is more Dry saturated steam No scale deposition on steam pipeline and accessories |
| Boiler Efficiency | 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 Feed Water Temperature | Feed Water 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 savings |
| Problem | Solution | Benefits |
| Huge Steam Consumption due to Improper Trapping | Process Trap for Indirect Steam Proper Float Trapping Modules Online Condensate Removal Testing Facility Vacuum Breaker Condensate Recovery System | Proper mixing of bran as dough with steam, hard and uniform pallet formation,Increased steam savings Proper trapping resulting in condensate removal Process temperature achieved in shorter time due to proper trapping Fuel and water savings with condensate recovery |
| Higher Pressure Than Rated, Open Steam is Used Without Pressure Reduction but By Throttling the Valve | Pressure Reduction Station | Increased steam savings due to higher latent heat at low pressure Elimination of manual throttling of valves for direct injections Improved pallet quality Controlled moisture addition for direct injections via pressure regulation |
| Smaller Steam Line Size than Required | Proper Line Size for Smaller Pressure | Optimum line size helps to avoid moisture carryover and higher radiation losses |
| No Provision of Automatic Air Venting | Automatic Air vent For Steam Inlet Line to Equipment and Header | In case of air free steam circuit, heat transfer rate increases and steam temperature exactly corresponds to steam pressure as per steam table for dry saturated steam |
| Problem | Solution | Benefits |
| Poor Dryness Fraction of Steam | Moisture Separator with Baffle Design | Moisture removal before distillation ensures hard and unform Palletization Increased processing capacity |
| Heaters Line Size |
At Reduced Pressure, Proper Line Size Should be Designed At Lower Pressure, Bigger Line Size is Required than Higher Pressure for Same Steam Load |
Required steam quantity as per pressure can be achieved |
| Higher Pressure Than Rated, Open Steam Is Used Without Pressure Reduction but By Throttling the Valve | Pressure Reducing Station | Constant downstream pressure is maintained, resulting in steam savings |
| Improper Trapping | Online Pumping Trap |
Pumping trap evacuates the condensate from the heat exchanger even in vacuum conditions, resulting in no bypass opening and steam savings Uniform and trouble-free operations |
| Inadequate Temperature of Oil Resulting in Colour, Separation and Flashing of Hexane | Automatic Temperature Control PID Based System | Cost savings with uniform temperature profile with PID control valves all-important ingredients and properties of oil are maintained, giving premium for colour and quality |
| Problem | Solution | Benefits |
| Improper Pressure Profile for Direct and Indirect Steam | Uniform and Optimised Automatic Pressure Reduction | Huge steam and hexane saving Electrical power saving Hexane traces can be reduced and reboiler load can also be reduced Good recovery of hexane and improved quality of DOC No odour and no final moisture in range of 10-11% ensures no fungal reactions in case of storing for few days |
Due to Under Sized Traps, Steam Loss and Heating Surface Area Becomes Underutilized Increase in the Heat Transfer Responsibility, Resulting in Higher Temperature and Inadequate Profile of the Meal at Outlet | Proper Trapping and Selection of Trap Modules | Proper trapping helps to cater load in each section, hence there is no need to open any bypass Steam savings |
If the Final Meal Temperature is not Maintained, Overheating Can Occur Increase in Condensate Load And Hexane Loss | OPID Based Temperature Control System | Steam economy as only required steam quantity is used. Else, excess steam can lead to increase in the meal temperature due to which the quality of DOC is compromised |
| No Air Venting | Automatic Air vent in SS Construction Working on Thermostatic Principle | Inrush air in system works as insulator between steam and condensate, so it is important to remove during start up quickly |
| Problem | Solution | Benefits |
| Most Of the Plants have a Condensate recovery factor as 20 to 30 % | Condensate Recovery System | 95% Condensate recovery factor can be achieved Increased fuel savings Reduced Water Consumption |
| 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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