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Case Study:

Reduce Specific Steam Consumption and Steam OPEX


Chemical

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Customer Details
A leading fragrance/speciality chemicals manufacturer in South Asia
Problems
High fluctuations and non-availability of desired pressure in some blocks leading to productivity issues

High specific steam consumption
Objective
To address the steam system (pressure drop) bottlenecks which were impacting production

To identify avenues to reduce the specific steam consumption and steam opex
Solution
The Forbes Marshall team conducted a detailed study of the plant,  identified the gaps, and defined corrective actions. An implementation plan was worked out with complete project management and technical supervision during the implementation, right up to documenting the savings.
Solutions were implemented, with appropriate products where required, for  

 Proper desuperheating of steam before supply to the process

 Addressing losses in the steam distribution network

 Steam trapping throughout the plant including for distillation columns and reactors

 Segregation of condensate based on pressure and optimising recovery of condensate and flash steam

 Addressing steam pressure drop and fluctuation issues in the distribution network and pressure optimisation of individual blocks

 Addressing condensate evacuation issues
Benefits
Reduction in steam consumption from 731TPD to 675TPD

Reduced specific energy consumption (Ton/Ton)
   Product 1 - 3.3 to 2.3   
   Product 2 - 8.06 to 7     
   Product 3 - 9.3 to 6
   Product 4 - 9.4 to 7      
   Product 5 - 36 to33       
   Product 6 - 2.9 to 2

14% improvement in condensate recovery factor (from 56% to 70%)

20 deg C rise in feedwater temperature

No water hammer or direct leaks thereby ensuring the safety of the steam network

Improved productivity due to steady pressure at all blocks and equipment including distillation columns and ejectors