Debottlenecking a bottle washer, saving fuel for a aerated beverage MNC in Thailand

Forbes Marshall conducted a plant-wide energy audit for a beverage MNC in Pathum Thani, Thailand. During our assessment we observed the Bottle Washer steam traps were being bypassed. This led to local drainage of condensate and loss of steam. Detailed investigation indicated the plant was facing significant variation in their process temperature for Bottle Washer Line A. Plant personnel explained that bypassing the traps helped them achieve the required temperature.

a table showing variations in bottle washer temperature found during a plant energy audit at a beverage manufacturer

before and after images of a beverage manufacturing plant showing difference in temperature in the recovered condensate from a bottle washer

before and after images of a beverage manufacturing plant steam bypass from a bottle washer in Thailand

a picture showing a PPPPU model condensate recovery pump installed inside a beverage plant in Thailand

PROBLEM

They were facing delays in heating time and temperature variation in their Bottle Washer Line A (details available in the image slideshow). On closer inspection, we found that the condensate temperature at the outlet was 48.5°C (119.3°F) indicating condensate stalling in the heat exchanger coil. The existing air-operated condensate recovery pump was inoperational and condensate from the Bottle Washer was being drained.

SOLUTION

Based on our audit findings, the plant implemented the following recommendations for Bottle Washer Line A.

We installed a steam-operated pump trap (SOPT) to address the issue of condensate evacuation from the Bottle Washer.
A pressure powered pump package unit (PPPPU) was installed to transfer condensate to the boiler feedwater tank, replacing the existing inoperational pump.
A condensate recovery meter was also installed for accurate measurement.