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 |
| Due To Fluctuating Load, Boiler Efficiency In A Few Plants Is Reduced To 65-70% | Operate The Boiler Nearer to Design Pressure | Reduction in process steam demand because of more heat content |
| Non-Uniform Blowdown | Auto Blowdown system | Maintaining TDS levels along with blowdown heat recovery can lead to additional saving of 3% fuel |
| Operating Pressure Is Less Than the Required Plant Pressure | Operate The Boiler Nearer to Design Pressure Add Pressure Reducing Station | Reduction in process steam demand because of more heat content. Increased fuel savings. |
| Lower Feed water temperature | Feed water management system | Directly reduces Fuel consumption. |
| Lower Variation From 10% To 70% Leads to Frequent On/Off Operation of Boiler | Efficiency Monitoring System | Saving of 6-7% can be realized by avoiding the inconsistency in damper adjustment and optimising the O2% by monitoring and controlling these parameters online |
Problem |
Solution |
Benefits |
| Actual Temperature 110 Deg C And Pressure 3-3.5 Bar(G) Against Required 80 Deg C @ 1-2 Bar(G). | Properly Sized Pressure Reducing Station to Set Pressure @1-2 Bar(G) | At lower Pressure Latent heat is higher so there is steam saving through PRS. Impact on grain colour |
| Improper Trapping Generally 50% Thermodynamic Traps, 35% Float Traps And 15% IB Traps | Properly Sized, Ball & Float Traps Modules | Increased fuel savings |
| No Precise Temperature Control | Pid Based Temperature Control System | Ensures optimum temperature setting and usage |
Problem |
Solution |
Benefits |
| Improper Trapping Observed, generally 50% Thermodynamic Traps, 35% Float Traps And 15% IB Traps | Correctly Sized Trap Module | Steam saving |
| Temperature Is Not Maintained 120 Deg C @3-4 Bar(G) | PID Based Temperature Control System with Properly Sized Pressure Control Loop | Ensures optimum temperature setting and usage |
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 |
Problem |
Solution |
Benefits |
| Actual Pressure Is More Than Required Pressure, Temperature Required 80-100 Deg C | Pressure Reducing Station | Increased steam savings |
Problem |
Solution |
Benefits |
| Higher Steam Consumption in The Process | Can Be Optimized To 70% Of the Total Steam Consumption In Each Press for Bladder, Usage of Float Trap Will Remove the Condensate as Soon as It Forms | Helps in optimizing curing time, thus reducing the excess steam consumption. Separate condensate recovery system will help to maximize CRF% |
| The Platens Are Arranged in A Series Layout, Steam Enters the Top Platen, Steam and Condensate Passes Through Flexible Piping to The Second. It Is Seen That Lower Platens Are Less Effective Than First One | Use A Steam Pressure Which Is Required for Bottom Platens Like Top.Properly Sized Two Separate Pressure Reducing Station | Helping in reducing the energy loss and excess steam consumption. |
Problem |
Solution |
Benefits |
| Conventional System Unable to Maintain Accurate 175 Deg C And Steam Pressure Is Used 10 Bar(G) | Correctly Sized Instantaneous Hot Water Generator Design to Give Water At 175 Deg C At Constant Pressures | Increased steam saving |
Problem |
Solution |
Benefits |
| Temperature Is Not Maintained 145 Deg C @3-4 Bar(G) | Pressure Reducing Station | Increased steam saving |
| Improper Trapping Leads Bypass Opening So Heavy Loss and Not Able to Maintain the System Parameters | Properly Sized Ball & Float Traps | Increased steam saving |
| Temperature Is Not Maintained 145 Deg C @3-4 Bar(G) | Pressure Reducing Station | Increased steam saving |
Problem |
Solution |
Benefits |
| Temperature Requirement 180 Deg C | Properly Sized PID Based TCS | Steam saving, rejection reduction |
| Direct Steam for Initial Shaping Required 1-3 Bar(G) | Pressure Reducing Station | Reduction in rejection as well as steam saving |
| Direct Steam for Final Shaping Required 14 Bar(G) | Separate Pressure Reducing Station | Improvement in quality, reduction in rejection as well as steam saving. |
Problem |
Solution |
Benefits |
| Most Of the 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 81%. |
Problem |
Solution |
Benefits |
| Most Of the Plant Have Huge Problem in 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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