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Case Study:

Optimise Specific Steam Consumption


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Customer Details

A kraft paper mill in Eastern India.
Problems
Impact on machine production due to poor condensate evacuation.

Poor condensate recovery (65%).

High back pressure (2.5 barg) in main common tank.

Boiler pressure not maintained.

High specific steam consumption (2.1-2.2 ton per ton of paper).
Objective

To optimise specific steam consumption with improve productivity and condensate recovery factor.
Solution

Forbes Marshall carried out a detailed study of the plant and engineered a thermal grouping cascade
based solution for effective utilisation of flash steam, along with with the following solutions :
- Steam flow meter and condensate flow meter.
- Pressure, differential and level control loops.
- Mini distributed control system.
Benefits
Specific steam consumption brought down to 1.6 - 1.7 ton per ton of paper.

Improvement in condensate recovery - from 55% to 90%.

Boiler pressure maintained at desired levels.

Realtime monitoring and control of all parameters.

6% increase in productivity.