4% fuel reduction through condensate recovery at a beverage plant in Indonesia

A beverage plant in Sidoarjo, Indonesia was draining condensate from the High-Temperature Short-Time (HTST) cup section resulting in a lower boiler steam to fuel ratio. This resulted in higher fuel (palm shell) and water consumption. Forbes Marshall’s Pressure Powered Pump Package Unit was recommended and installed to recover the condensate.

Objective

PROBLEM

Condensate from the HTST cup section was being drained. Feedwater temperature was 27.7°C (81.8°F) and the condensate recovery factor was 0%. This resulted in a boiler steam to fuel ratio of 5.81 leading to higher fuel (palm shell) and water consumption.

Solution

SOLUTION

Based on our site observation we recommended the installation of a Pressure Powered Pump Package Unit (PPPPU). Once installed, the system was able to recover condensate from the HTST cup section at 88°C (190.4°F), improving the feedwater temperature to 54°C (129.2°F). This led to an improved steam to fuel ratio and increased overall energy efficiency.

Benefit

BENEFITS

Improved feedwater temperature from 27.7°C to 54°C (81.8 to 129.2°F)

Increased condensate recovery factor from 0% to 41%

Condensate recovered at 88°C (190.4°F)

Improved steam to fuel ratio from 5.81 to 6.1 Kilograms Steam/Kilograms Palm Shell (Pound Steam/Pound Palm Shell)

Reduced annual palm shell fuel consumption by 86,196 Kilograms (190K Pounds)

Reduced boiler makeup water by 5,249.16 Kilolitres (1.38 million Gallons) annually

Annual monetary savings of USD 8,351.66 (IDR 125,274,936)

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Products

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BM26A-8000

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Associated Services

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