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

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.

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.

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