The Challenge
A leading textile plant in Western Indonesia faced multiple operational inefficiencies impacting energy consumption, water usage, and overall boiler performance. The key issues identified were:
1. Excessive blowdown, leading to heat and water loss.
2. Condensate discharge to the pit, causing wastage and reducing overall system efficiency.
3. Trap leakage, increasing steam consumption and energy costs.
The Objective
Forbes Marshall was engaged to address these challenges with a focus on:
1. Optimising energy savings to reduce operational costs.
2. Minimising water wastage by recovering condensate.
3. Enhancing boiler efficiency and overall plant performance.
The Solution
A comprehensive study of the plant was conducted to identify key areas of concern. Based on the findings, Forbes Marshall recommended and implemented the following solutions:
1. Boiler blowdown control system to regulate TDS levels and minimise heat loss.
2. Condensate recovery system to return recovered condensate to the feedwater tank.
3. Compact module thermodynamic traps for efficient trapping in headers and mainlines.
4. Automatic air vents for headers and dead-end sizing machines to improve air removal and steam efficiency.
The Results
The implementation of these solutions led to significant improvements:
1. Boiler TDS maintained at 3500 PPM, reducing unnecessary blowdown losses.
2. Condensate recovery from the sizing machine, effectively reducing water wastage.
3. 17% reduction in the annual fuel bill, contributing to cost savings.
4. Water consumption for processes was reduced by 87.8 m³ per month, promoting sustainable operations.
