17.4% fuel reduction through steam and condensate system improvements for a MNC confectionery plant in Malaysia

A confectionery plant in Selangor, Malaysia was facing several issues with its steam and condensate system. Flash steam was being vented. Condensate was partially recovered (70 – 75%) from the hot water system. Stalling and prolonged heating time issues were identified in the Hot Water System. Leaking traps further reduced overall system performance. Forbes Marshall recommended energy conservation solutions to address the issues in the Hot Water System and improve condensate and flash steam recovery.

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Forbes Marshall FlashJet Pump used for flash steam and condensate recovery installed inside a confectionary manufacturing plant in Malaysia

PROBLEM

100% flash steam was being vented. Condensate was partially recovered (70 – 75%) from the hot water system. Stalling and prolonged heating time issues were identified in the Hot Water System. Leaking traps further reduced overall system performance.

SOLUTION

Forbes Marshall identified that the issue of condensate evacuation from the Hot Water PHE (plate heat exchanger) was due to the existing float trap. We replaced the trap with a steam-operated pump trap (SOPT) to address the issue of stalling and enable complete condensate evacuation from the PHE.

Leaking process traps were replaced with compact module two-orifice float traps (CMTOFT).

A FlashJet™ Pump was installed to recover flash steam and condensate.

A deaerator head was installed on the feedwater tank to enable the proper mixing of condensate, flash steam and make-up water.