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com
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Energy Balance in a typical steam and condensate loop
Generation
100%

80%
Distribution losses
3-5%

Boiler House
Losses 15-18%
Trap &
Condensate 20%

Process demand
55%
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Condensate
Drained and
Flash steam
vented @3bar

Losses from traps
75 Kgs/hr
Moisture drained..
350 Kgs/hr
Feed Water Tank
@ 30 Deg C
Process demand
500Kgs/hr dry steam
Boiler required capacity
= 1010Kgs/hr
Typical Steam & Condensate Loop Coil Type
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The Issues
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FWT@ 90 Deg C
Moisture Drained 2%
Condensate Recovery 20%
Process Steam Demand
Reduced to 450 Kg/hr
The Solution : Shell Type Boiler
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Coil Type Boiler
Shell Type Boiler
The Difference
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Advantages
High dryness fraction 98.5%
Higher boiler efficiency 89%
Reduction in fuel bill by 30%
Higher plant output
Shorter heating cycle
Low maintenance
Steady steam output at fluctuating
loads
Boiler life of more than 20 years
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SOUNDS EXCITING !!!

A few more reasons to Change
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Parameters Fuel Savings Criteria
Consumption
Coil Type Boiler 48.75 lt/hr 28% Eff = 75%
dryness fraction = 80%
Coil Type Boiler 49.85 lt/hr 30% Eff = 75%
dryness fraction = 65%
Shell Type Boiler 35.49 lt/hr Eff = 89%
dryness fraction = 98%
Savings due to

Flash Steam recovery Right Trapping

Dry Steam generation

Temperature & Pressure Control
Low Cost of Ownership
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Actual Savings of
25 - 30%
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Industry Coil Boiler Shell Boiler
Pharma Industry in Pune
Heating period for 100 ml (Autoclave) 55 mins 35 mins
Heating period for 500 ml (Autoclave) 66 mins 50 mins
Distilled water o/p from Multicolumn 200 lit 275 lit

Bottling Company
Bottles produced per Minute (BPM) 340 500

Rubber Company
Batch Time 8 Hrs 6 Hrs
Pieces per month 109,000 167,000
Increased Productivity
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Coil Boiler Shell Boiler
Steam Quality Wet Dry Saturated
Constant Load Poor Steady

Fluctuating Load Water carry over as Steady due to sufficient
no steam space steam space

Instantaneous Loads Pressure Drop Steady Output
The 2 Qs .
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Less load on
ETP
Lower
treatment
cost
Lesser blow
down
cycles.
Condensate
recovery
Savings in Water
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Partial List of industries using Shell Type boilers

1. Food 13. Personal Products
2. Garments 14. Beverages
3. Chemicals 15. Packaging Industries
4. Cattle feed 16. Plastics
5. Dairy
6. Educational Institutes
7. Rubber
8. Hotels
9. Hospitals
10. Formulations
11. Pharmaceuticals
12. Glass

More than 200 boilers in operation in the industries which
traditionally used coil type boilers
Reference List
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The Old System
Feed Water Tank
@ 30 Deg C
35% Moisture
at 180 Deg C drained
Condensate Drained
and
Flash steam vented
@3bar

TD traps..!
850kg/hr 600 kg/hr
Pressure
Drop..

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High Pressure Drop
Frequent Coil Failure
Increased Cycle Times
High Load on ETP
High maintenance costs
Problems
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FWT@ 90 Deg C
Condensate at 95 Deg C
Condensate at 95 Deg C
recovered
Recoverable Flash
Steam @ 3 bar
1TPH boiler, dry steam load 550Kgs/hr
Changed
to FT
traps..!
No Pressure
Drop..

The Solution !
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o Fuel consumption reduced from 5 Tankers per 2 months to 4 tankers per 2 month.
(Saving of 6 tanker of 10000 Kg/Year)


o Reduced load on ETP Practically the ETP remains idle now.


o For a Drum Heating process The heating time has reduced from 10 hrs to 4
hours.


o Reactor heating process 14 hrs to 8 hrs. (Endothermic Reaction)

Results Speak for themselves
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Reduced water charges and treatment charges.
Reactor life improved. No knocking.
No pressure drop problem.
Reduced steam demand from 850 kgs/hr+ 600 kgs/hr=
1450 Kgs to 550Kgs/hr.
Increase of plant production.
Reduction in maintenance cost
Other benefits :
More improvements and Benefits
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