17.4% fuel reduction through hot water and condensate system improvements for a confectionery plant in Malaysia

100% flash steam was being vented. Condensate was partially recovered (70 – 75%) from the hot water system. Stalling and prolonged heating time issues were identified in the Hot Water System. Leaking traps further reduced overall system performance.

Forbes Marshall identified that the issue of condensate evacuation from the Hot Water PHE (plate heat exchanger) was due to the existing float trap. We replaced the trap with a steam-operated pump trap (SOPT) to address the issue of stalling and enable complete condensate evacuation from the PHE.

Leaking process traps were replaced with compact module two-orifice float traps (CMTOFT).

A FlashJet™ Pump was installed to recover flash steam and condensate.

A deaerator head was installed on the feedwater tank to enable the proper mixing of condensate, flash steam and make-up water.

Flash steam recovery improved to 90 – 95%

Condensate recovery improved from 70-75% to 95%

Average fuel consumption reduced from 2080 to 1719 MMBtu/month

Average makeup water consumption reduced from 775 to 383 m³/month (from 204K to 101K Gallons/month)

Annual monetary savings of MYR 155,520 (~USD 36,827 *converted based on exchange rate)