Steam System Optimization – Energy and Emissions
Steam System Optimization – Energy and Emissions Eliminating steam losses reduces energy consumption—and corresponding fuel costs. It also helps the environment by cutting emissions, such as CO2, NOS, and SO2. But to achieve these benefits, you need to manage your steam system, rather than allow your steam system to manage you. Inveno has a proven track record of enabling our customers to minimize steam losses so they can go green while boosting their bottom line.
Benchmark Steam System Thermal Cycle Efficiency
Given today’s high energy costs, the average steam system thermal cycle efficiency rate of 58.9 percent is clearly unacceptable. Inveno’s engineers enable your plant to achieve the highest levels of steam system thermal cycle efficiency. We start by benchmarking your existing efficiency rate. This insight serves as a baseline upon which you can build to improve steam balancing, steam system energy management, steam venting, and flash steam recovery.
Steam Balancing: Create a Dashboard for Your Steam System
In addition to benchmarking your current efficiency level, you also need to map your steam balance to fully understand your steam system, including generation, distribution, end user processes and condensate recovery systems. We document your plant’s steam balance to give you a dashboard that you can use to make better decisions for improving steam balance and steam thermal cycle efficiency.
Eliminate Steam Venting to the Atmosphere
Steam venting to the atmosphere is one of the biggest sources of energy loss in any steam system. Fortunately, modern technologies eliminate the need to do so. Inveno has enabled more than 1,000 plants to use today’s flash steam recovery, pressurized condensate systems, thermocompressors, and vent condensers to improve their steam venting and substantially reduce energy use. We can help you integrate these technologies into your plants.
Find the Right Solution for Flash Steam Recovery
Flash steam recovery is necessary for achieving high steam system thermal cycle efficiency. Vent condensers, cascade systems and thermocompressors all recover flash steam. But you need the right solution for your steam and condensate system. For example, if you have a modulating process control system operating at a temperature of 212 degrees Fahrenheit or 100 degrees Celsius, pressured condensate systems are invalid; your best bet is to use a vent condenser for flash system recovery. We determine which solution best addresses the requirements for your processes to optimize efficiency gains.
Choose the Most Reliable and Efficient Pressurized Condensate System
Condensate must be delivered back to the boiler plant under pressure to increase steam system thermal cycle efficiency and avoid losses with flash steam or sensible energy. You have a choice of four different solutions: gravity, low pressure, medium pressure, and high pressure. With years of experience working with condensate systems, we can help you select the most reliable, energy efficient system for your plant.
Install Insulation to Reduce Energy Consumption
Insulating steam lines, condensate lines and process equipment can dramatically reduce energy consumption and emissions. Inveno’s Insulation Assessment program evaluates the condition of your existing insulation and helps you determine which type of insulation you should select, how to install the insulation, and how to service the insulation to optimize energy efficiency.
Improve Steam Venting with Thermocompressors
Steam thermocompressing is one of many ways a plant can improve its steam venting and thereby increase plant efficiency. With more than 30 years of experience with thermo compressing steam, we can help you determine what steam must be thermocompressed, which intermediate pressure to deliver the steam to, and how to balance the steam.
Recapture Energy via Vent Condensers
Vent condensers capture the energy from flash steam and deliver it to another heat source. Because they reduce fuel consumption, flash steam vent condensers have a payback period of less than a one year on most systems. We engineer the vent condenser to achieve the proper flash steam flow rates, heat sink flow rates, and pressures—and meet the appropriate codes—to ensure proper operation and efficiency.
Capture Steam Energy through Economizers
With today’s high fuel costs, any boiler that produces more than 12,000 pounds of steam per hour will benefit from an economizer. Economizers take energy from boiler operations, combustion flames, and gasses and, rather than discharging that energy into the atmosphere, capture it for productive use. Two types of economizers are available, non-condensing and condensing. Non-condensing economizers are relatively low cost and deliver efficiency gains of roughly 82 percent. Condensing systems are more expensive but can bring boiler efficiency above 94 percent. We can explain the pluses and minuses of each option for your operation to allow you to capture energy and improve efficiency in the most cost effective manner.
Remove Sediments and Extract Energy with Blow Down Systems
Water chemistry often causes boilers to develop sediments. Continuous and bottom blow down systems remove these sediments. All boilers need continuous blow down heat recovery to extract the energy from the boiler water before discharging it into the waste system. Larger boilers also require bottom blow down heat recovery. Many systems are available and making the selection can be confusing. Inveno’s engineers have installed hundreds of these systems. Let us help you determine the most effective system for reducing energy loss for your boiler system.
Ensure 100 Percent Steam Quality
All heat transfer systems require 100 percent steam quality unless the plant specifies otherwise. Lower steam ratings reduce heat transfer performance—and negatively impact your final product. Inveno’s engineers can measure your existing steam quality, determine the cause of any deficits (e.g. insulation, condensate, or piping) and develop a road map for correction to meet your steam and product quality goals.
Measure Steam Flow
Steam flow measurement provides a critical gauge of steam system performance. Maximum and minimum flow rates, piping configuration, and pressure tell you the efficiency of your plant and how much energy is being consumed. Inveno can work with any measurement solution manufacturer to give you your choice of options. The result? You achieve the most precise measurements so you can make better decisions about how to manage your system efficiently.