Saving 8.9% fuel annually through condensate and flash steam recovery at a cocoa processing plant in Indonesia

A leading cocoa processor in Indonesia was partially draining condensate and venting flash steam. These inefficiencies led to higher fuel consumption, poor steam to fuel ratio, and increased operational costs. Forbes Marshall recommended installation of a flash vessel with a steam operated condensate recovery pump.

Objective

PROBLEM

The plant was looking for avenues to save more fuel. Their gas consumption was 214,989Nm3/month (7.9 million SCF per month) with a steam to fuel ratio of 8.75.

Solution

SOLUTION

We conducted a detailed walkthrough of the plant and recommended a comprehensive solution, which included a condensate and flash recovery system (flash vessel and a Pressure Powered Pump Package Unit PPPPU). This enabled recovery of high temperature condensate and flash steam. This led to an improvement in feedwater temperature and boiler steam to fuel ratio, substantially reducing gas consumption.

Benefit

BENEFITS

Improved feedwater temperature from 75.6°C to 93–95°C (168°F to 199.4-203°F)

Increased steam to fuel ratio from 8.75 to 12.74

Reduced gas consumption from 214,989 to 195,950 Nm3/month (7.9 million to 7.2 million SCF per month)

Annual monetary savings of USD 77,678

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Products

Logo Image: MachPulse by Forbes Marshall

MachPulse™

Aqua2Trans 2 Wire Transmitter

BM26A-8000

Multi-utility Process Trap MuPT

Marshall E Series Electric Industrial Steam Boiler Isometric View

Marshall E Series Electric Steam Boiler

QualSteam Pressure and Temperature Control Valve for Steam

QualSteam™

Ammonia Analyser

BM26A-1000

BM26A-6000

BM26A-3000

Associated Services

Process Optimization

Process Optimization

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Improving Uptime

Improving Uptime

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Forbes Marshal Digital

Forbes Marshal Digital

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Associated Services

EverSense for Condensate Recovery Factor