Objective:
We surveyed a leading textile plant in Indonesia. The survey’s primary objective was to recover condensate and flash steam back to the boiler.
Issues:
The plant was not recovering condensate and flash steam was being vented..
Solution:
Our engineer studied the process, calculated the quantity of condensate recoverable and established the size of the pump required. Our engineer also worked out two options to recover flash steam i.e. recovery to the boiler feed water tank or recovery within the process area. During discussions with the customer, our engineer established that the scouring temperature was 60oC and as per the plant, raising the scouring temperature further would be beneficial. Accordingly, it was decided to recover flash steam to heat scouring water.
Benefits:
a. Process water temperature for scouring increased from 60℃ to 87℃ by using flash steam.
b. Improved condensate recovery factor by 39% and condensate return temperature from 98℃ to 105℃.
c. Improved feedwater temperature from 40℃ to 55℃.
d. Improved the steam to Fuel ratio from 5.18 to 5.46.
e. Reduced fuel consumption by 288 tons/year thereby reducingCO₂ emissions by 523,091 kg per year.
f. Reduced freshwater consumption by 15,552 m³/year.
g. Reduced plant opex by 32,401 USD/annum.
