28% fuel consumption reduction through improvements in the steam and condensate system for a confectionery plant in Indonesia

Traps were leaking and some were being bypassed

100% flash steam was being vented

Condensate was being recovered by an electric pump and condensate recovered temperature was low at 50-60°C (122-140°F)

Feedwater temperature was 46°C (114.8°F)

Forbes Marshall recommended and implemented the following thermal energy conservation solutions in the plant to address these issues:

• Leaking traps were replaced by single orifice float traps (SOFT31).
• The electric pump was replaced by a FlashJet™ Pump (FJP) to improve condensate and flash steam recovery.
• A deaerator head was installed to enable the proper mixing of condensate, flash steam and makeup water.
• A steam injector was installed.

Flash steam now being recovered to the local hot water system

Condensate return temperature increased from 50-60°C to 90-95°C (122-140°F to 194- 203°F)

Feedwater temperature increased from 46 to 90.6°C (114.8 to 195.1°F)

Steam to fuel ratio increased from 8.4 to 10.8 Kilogram steam/m³ gas (0.53 to 0.67 Pounds steam/scf gas)

Fuel consumption reduced from 81,572 to 63,187 m³/month (2.8 million to 2.2 million ft³/month) despite an increase in steam generation from 515,613 to 622,683 Kilogram steam/month (1.1 million to 1.3 million Pounds steam/month)

Fuel savings increased by 18000 m3 gas/month (635,665 ft³ gas/month) (i.e. 28%)

Annual steam savings of 62.3 Tonnes (137K Pounds)

Annual water savings of 10,582 m³ (373,689 ft³)

Annual monetary savings of USD 71,500 (~IDR 1,194,264,192 *converted based on exchange rate)