Improving the steam to fuel ratio by 34% by implementing a condensate recovery system for a pharmaceutical manufacturing plant in India using FM Digital

A pharmaceutical manufacturing plant in Telangana, India was facing a high steam pressure drop and higher fuel usage, leading to their increasing fuel bills. They partnered with Forbes Marshall Digital began in June 2025 with a shared objective of reducing costs, improving the steam to fuel ratio and sustaining boiler efficiency using EverSense for Plant-wide Performance, a Forbes Marshall Digital sustenance service.

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PROBLEM

High steam pressure drop (1.5-2.5 barg i.e., 21.8-36.3 psig) causing unstable steam distribution and increased fuel consumption.

Low steam to fuel (S:F) ratio of 3.5, resulting in higher fuel costs.

No condensate recovery system leading to high makeup water usage and low feedwater temperature of 30°C (86°F).

Steam losses due to faulty traps, trap bypassing, and improper trap selection.

SOLUTION

Forbes Marshall conducted a plant audit and identified process gaps which were causing increased fuel bills at the plant.

Post the audit, EverSense for Plant-wide Performance, a digital sustenance service was implemented. Through this, all key parameters including condensate recovery factor (CRF), steam to fuel ratio, feedwater temperature, pressure drop, and trap uptime were monitored 24×7. Monthly performance tracking and gap analysis reports were generated.

Improved steam trap management by reducing bypass operation, enhancing trap uptime, selecting correct traps for stalling conditions, and ensuring condensate recovery from all equipment.

Shifted DHU from electricity to steam, reducing operating costs and improving steam to fuel ratio and boiler efficiency by increasing the steam load.

Optimised boiler operation by increasing steam load and enhancing operating practices, including improved flue gas heat recovery.

A condensate recovery system was installed: Correct steam traps and steam-operated pressure powered pump (PPPPU) and a FlashJet Pump (FJP), improved and optimised condensate and flash steam recovery.

Improved overall system efficiency by reducing pressure drop through proper line sizing and pressure reducing stations (PRS). Enhanced the steam to fuel ratio through higher feedwater temperature, increased steam load, and flue gas heat recovery.