Efficient Steam Systems

Thermax Limited – Corporate Presentation Thermax Limited – Corporate Presentation Thermax – Cooling & Heating Division

Piping Design Consultancy

CONSULTANCY SERVICES FOR:

• Greenfield projects

• Re-engineering of existing plants

• Present system hookup with the new plant / line

• Complete turnkey execution for piping

EXPERTISE INCLUDES:

• Selection of equipment

• Complete piping design

• Design of condensate recovery systems

• Selection and sizing of pressure reducing stations

• Trap selection and sizing

• Insulation design

• Design of waste heat recovery systems

UTILITIES COVERED:

• Boiler house & steam distribution systems

• Thermic fluid systems

• Chilled water systems

• Compressed air systems

Thermax Limited – Corporate Presentation Thermax Limited – Corporate Presentation Thermax – Cooling & Heating Division

Energy Audit Services

Steam Audit Services

Water Audit Services

Power Audit Services

TM

TM

TM

TM

TM

TM

Compressed Air Audit Services

Comprehensive Audit Services

Thermic Fluid Audit Services

At Thermax, we have a Utility Cost Reduction team with experts from diverse disciplines. Our

team is well equipped with technical & instrumental resource to undertake plant utility audit to

optimize the present operational cost. We also extend our expertise for implementation of

energy conservation measures on a turnkey basis. On the basis of the study & measurements

conducted at site we provide solutions, to improve the overall efficiency of the system and

reduce operating costs.

The scope of utilities covered by us is as below -

• Steam System

• Thermic Fluid System

• Compressed Air System

• Refrigeration, Air Conditioning & Cooling Towers

• Electrical Power & Lighting system

Variable Spray Desuperheaters are not “Multiple Mechanical Spray” where nozzle exposes

sequentially.

Spray method : Swirling hollow cone spray pattern of injected water directly in to steam line.

Sizes & Pressure ratings : 15 NB to 100 NB water inlet size. 150 # to 4500 # pressure ratings.

Can be mounted on 4” to 78” of steam pipeline.

Can be mounted on any existing pipe line or on long radius bends.

Good until turndown ratio of 80:1

LATEST TRENDS IN PRESSURE REGULATION…

PILOT OPERATED

DIRECT ACTING

CONTROL VALVE

MULTISPRING ACTUATOR

SPRING CYLINDER

LINEAR ACTUATOR

BELLOW SEAL VALVES…THE ULTIMATE CHOICE

INSTAHEAT – INSTANT HOT WATER GENERATOR FOR

PROCESS HOT WATER REQUIREMENT IN BREWERY

CONDENSATE HEAT RECOVERY – WHY ? Steam when used as a heating medium, around 75% percent of total energy is used in the heating process, which is termed as latent heat.

If one recovers the condensate, remaining 25% energy which is normally wasted through steam trap discharge, is recovered as sensible heat of condensate water & latent heat of flash steam.

FLASH STEAM HEAT RECOVERY A 10 bar(g) condensate discharged from steam trap at atmospheric pressure.

The amount of flash steam will be 15% of the total condensate.The energy content of flash steam shall be about 50% of the total energy content of condensate.

Advantages of Condensate & Flash steam Recovery

Comparison of Float Traps

CONVENTIONAL FLOAT TRAP • Fusion welded ball float eliminates issue of ball

puncture.

• Operates at very low differential of 0.01 bar.

• Facilitates easy changeover of direction in a same

model.

• Single differential pressure makes trap suitable for

various operating pressures (no differential pressures

like 4.5, 10 & 14)

• Only one moving part - slide valve

• Proportional control action – 45 Degree of float

ensures 0 to 100% opening of the outlet port

• No loss of live steam

RIFOX Ball Float Trap with Rotary Slide Mechanism

Troubled by Thermodynamic Steam Traps….

Replace with Bi-Metallic & save upto 5 Ton Steam/annum/trap...

WATER EXTRACTOR

STOP ABUSE OF COMPRESSED AIR….

USE LIQUID DRAINER ….. NOT ELECTRONIC DRAIN TRAP……

Save 3 to 4 CFM air per drain point per hr…..

Steam Accessories / RIFOX Technology

14

High Pressure Condensate Recovery System (HPCRS) is

applicable in a situation where recoverable condensate is more than

80% of the total steam consumption. In this the condensate is

recovered and injected into boiler shell.

The heat of both flash steam & condensate cannot be held by BFW

in a FW tank in conventional system as temperature is likely to

cross 100 deg C.

The system is estimated to give fuel saving between 15 to 20%,

when compared with conventional atmospheric condensate

recovery system. Due to PLC based operation it is completely

automatic without any user intervention.

Benefits of HPCRS • Significant fuel saving.

• Boiler Operating Capacity is enhanced

• Better response of boiler for fluctuating

steam demand

• Improved steam quality.

Potential Industry for HPCRS • Corrugated Box Manufacturing

• Plywood Industry

• Tyre Manufacturing

• Rice Mills

• Tea Industry / Paper Industry

High Pressure Condensate Recovery System

THANK YOU…….