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Case Study:

A paper mill in North India


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Problem
- Low productivity due to severe condensate evacuation issues

- Poor condensate recovery

- Very high back pressure (1.5 barg) in main common tank

- Frequent failures of S&C components and leakages

- High specific steam consumption (1.8-1.9)
Objective
 
To improve productivity and reduce energy consumption.
Solution
Installation of an engineered thermal grouping cascade based system for effective utilisation of flash steam, along with with the following solutions

- Fixed bend stationary siphon

- Steam flow meter and condensate flow meter

- Pressure, differential and level control loops

- Glandless piston valve

- Compact module thermodynamic traps

- Mini distributed control system 
Benefits
- Improved condensate removal at lower differential pressure

- Reduction of specific steam consumption by 1.1 ton per ton of paper

- Improvement in condensate recovery - from 55% to 85%

- 5% saving in fuel consumption