Return of hot condensate from indirect steam using processes, besides saving 20% of fuel bill, reduces water usage and cuts feed water treatment bills.
As steam leaves the boiler it begins to lose its heat and turns into hot water. The hot water formed, known as condensate, is free of impurities.
Condensate does not require demineralization and can be returned directly to the feed water tank. This, besides reducing costs of demineralization, also reduces cost of addition of fresh water into the system.
Additionally, heat in condensate represents 20% of the fuel burnt in the boiler. An effective condensate recovery system ensures optimal feed water temperatures, improving boiler efficiency. Every 6°C rise in feed water temperature reduces the fuel bill by 1%.
A plant can significantly reduce its utility bills by effectively recovering and utilizing condensate.
1 tph of condensate at 3 bar g will
Save 136,000 kg coal each year
And reduce the derating of a 2 tph boiler from 15% to 5% (so you get a 200 kg boiler for free)
And reduce one's water and effluent treatment cost
And reduce CO2 emissions by 247,000 kgs
And reduce heat pollution
And save water (amounting to 3.2 Olympic sized swimming pools / about 600 tankers each year!)