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Case Study:

A detergent manufacturing plant in Egypt


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Problem
- High boiler fuel bill

- Excess water consumption
Objective
To improve condensate recovery factor and bring down energy costs in the plant.
Solution
The Forbes Marshall team conducted a detailed survey of the steam system at the plant. Opportunities were identified and following changes were made for savings in the steam and condensate circuit.

- Leaking / faulty traps were replaced with right size and type of traps.
          - Compact Module Twin Orifice Steam Traps for process trapping.
          - Compact Module Thermodynamic Steam Trap with IsoTub for mainline trapping.

- SteaMon steam flow meter was installed for accurate steam flow measurement.

- Conventional condensate tank replaced with flash vessel and steam operated pressure powered pump.

- Automation of the heating and cooling cycles of the bleacher and hot water generation for farm tanks area.
Benefits
- No steam loss through traps

- Flash Steam returned to process; direct steam injection reduced

- Reduction in chemicals consumed

- 20% reduction in boiler's annual natural gas bill

- 40% reduction in annual water bill for steam boilers