Beverage to fuel ratio improved by 34% for a beverage MNC in Malaysia

An aerated beverage MNC in Negeri Sembilan, Malaysia was facing several issues with its steam and condensate system. Six warmers were experiencing pressure and temperature fluctuations and were running at reduced RPM (revolutions per minute). The pasteuriser was facing temperature variations and reduced throughput. Condensate recovery factor was 55% and flash steam was being vented. Forbes Marshall conducted a plant study and recommended thermal energy conservation solutions to improve the steam and condensate system for 6 production lines.

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PROBLEM

Six Warmers were affected by pressure and temperature fluctuations, causing them to operate at reduced RPM. The pasteuriser experienced inconsistent temperatures and lower throughput, while condensate recovery was limited to 55% and flash steam was being vented.

SOLUTION

Forbes Marshall conducted a plant study. We recommended and implemented the following at 6 production lines:

Replaced the float trap with a steam-operated pump trap (SOPT) for all six Warmers
Replaced the float traps with steam-operated pump traps (SOPT) at the Pasteuriser
Replaced the condensate collection tank and electrical pumps with six FlashJet™ Pumps (FJP)
Installed two steam flow meters

BENEFITS

Six Warmers:

Consistent pressure and temperature achieved
Running at Rated RPM

One Pasteuriser:

Trap bypass valve no longer opened, ensuring no steam loss
Temperature maintained consistently
Running at rated throughput

Six Condensate recovery lines:

100% flash steam recovered
Condensate recovered at 100°C (212°F)
The FJP solution is compact, saves space and consumes zero electricity

Overall:

Beverage to fuel ratio increased from 91 to 122 Litres/sm³ natural gas (0.68 to 0.91 Gallons/SCF gas). This resulted in 920,142 Litres (243K Gallons) of additional beverage produced annually.
Condensate recovery improved from 55% to 90%
Condensate temperature improved from 80 to 100°C (176 to 212°F)
Flash steam recovery increased from 0% to 100%
Average fuel consumption reduced from 16,596 to 15,809 MMBtu/month
Average makeup water consumption reduced from 5.8 to 2.4m³/day (1,532.2 to 634 Gallons/day)
Reduced annual carbon emissions by 671,458 Kilograms (1.48 million Pounds)
Annual monetary savings of USD 133,610 (~MYR 563,901 *converted based on the exchange rate)