STEAM SYSTEM OPTIMIZATION
Eliminate Steam Venting
Look across the roofline of your facility. Do you see venting of steam? Steam venting is one of the biggest and unnecessary sources of energy loss in any steam system. Inveno has helped numerous facilities eliminate venting of steam though various methods such as flash steam recovery, pressurized return systems, thermocompressors, and vent condensers.
Energy and Emissions
Eliminating steam losses reduces energy consumption but also helps the environment by cutting emissions, such as CO2, NOS, and SO2. Losses in the steam systems must be replaced by burning more fuel which therefore produces more emissions. Inveno Engineering has the experience and knowledge to assist facilities to reduce losses and reduce emissions.
A steam balance is a map of your entire steam system. It includes the generation, distribution, consumption, and condensate return systems. The steam balance provides an accounting of all the steam produced and where it is lost or consumed. The steam balance provides visibility into your steam system to identify opportunities to reduce losses or re-allocate thermal resources.
Thermal Cycle Efficiency
The thermal cycle efficiency is the overall efficiency of the entire steam system loop. It factors in the losses in the generation, distribution, consumption, and recovery systems. Inveno’s engineers evaluate the entire system to determine the current thermal cycle efficiency. This is the baseline and Inveno performs the analyses to identify opportunities to improve the thermal cycle efficiency. The baseline also serves as a benchmark to compare against other facilities which allows prioritization of investments for improvement.
Flash Steam Recovery
Flash steam is typically vented out the roof to the atmosphere. There are numerous methods to recovery flash steam such as vent condensers, cascade systems, and thermocompressors but you have to consider the source of the flash steam. Will the flash steam recovery impact the operation of the process? Is the process control in a modulating service where the system cannot tolerate any back pressure? Inveno Engineering has the experience to determine the best method for flash steam recovery that will not negatively impact your process.
Install and Repair Insulation to Reduce Energy Consumption
Insulation is generally an attractive way of reducing thermal losses in steam and condensate systems. The financial payback is typically short for new insulation but Inveno’s Insulation Assessment program evaluates the condition of your existing insulation and helps you determine which type of insulation you should select in order to optimize energy efficiency..
Pressurized Condensate Systems
As condensate from steam consumers discharges to a lower pressure, flash steam is created. Keeping the condensate under pressure allows it to retain more of its energy. The more energy that is retained in the condensate, the less fuel is consumed in the boiler. Not every condensate system can operate in pressurized mode, but Inveno’s engineers have the knowledge and experience to identify which systems are compatible. Inveno can also engineer the system to provide peak performance and reliability.
Recovery Energy Losses with Vent Condensers
Flash steam that is vented to the atmosphere is a loss and vent condensers capture the energy and deliver it to another consumer. Since vent condensers recover energy and therefore reduce fuel consumption, flash steam vent condensers typically have a payback period of less than one year on most systems. Inveno Engineering can help you specify and design the right system to recover energy from flash steam losses.
Capture Flue Gas Energy through Economizers
Economizer recovery flue gas energy that is wasted out the stack. Two types of economizers are available, non-condensing and condensing. Generally, any boiler that produces more than 12,000 pounds per hour of steam will benefit from a feedwater non-condensing economizer. Feedwater economizers capture energy from the combustion flue gases and transfer it into the feedwater to the boiler. Condensing economizer systems are more expensive but can increase boiler efficiency above 94 percent. Inveno Engineering can help you evaluate opportunities for both types of flue gas economizers.
Steam quality is a determination of the “dryness” of the steam exiting the boiler. Steam quality is impacted by mechanical properties and operation of the boiler but also by the chemical treatment. Low steam quality can impact heat transfer in the consumers and can affect piping longevity. Inveno’s engineers can measure your existing steam quality at the boiler or anywhere in your system. Inveno can also identify any component that is impacting the steam quality and develop a plan for correction.
Blow Down Heat Recovery
Minerals are in water that enters a boiler. As the water is converted to steam, sediments precipitate out and continuous and bottom blow down systems remove these sediments. A blow down heat recovery system extracts the energy from the boiler water before discharging it into the waste system. Numerous systems are available for continuous and even for bottom blowdown water but making the selection can be confusing. Inveno’s engineers have the experience to help you make the right selection to reduce the energy loss from your boiler blowdowns.
Measure Steam Flow
Steam flow measurement is essential to determine the performance parameters of the boiler and steam system. For example, steam flow data is required to determine pipe conveyance capacity, boiler load profile operating range, peaks and dips in demand, and surges that can impact response of the boiler. Inveno can help you answer what is the best meter for your installation. Having accurate data will help you make better decisions about how to manage your system efficiently.