Energy Saving Opportunities Wagga Industry Workshop April 2017

Increasing Our Capabilities Flow meters Control valves, regulators and traps Isolation valves and ancillaries

4 Where Energy is Lost • • • Poor Lagging – Heat loss ,

5 How to Improve your Plant • • • Proper Lagging Automatic Blowdown Control

Many Areas for Energy Saving and Improvement Only time to look briefly at a

8 Flash Steam. . . WHAT IS FLASH STEAM. . . ? HOW IS

9 Flash Steam Condensate Return System Loss of Flash Steam 10 bar Steam Pressure

11 Approximate Amount of Flash Steam in Condensate Flash Steam 16% Water 84%

12 Flash Steam Recovery Requirements for Flash Steam Usage: • Enough condensate • Use

14 PID Before: Flash Steam Recovery DRG. No © Copyright. This drawing is the

15 PID After: Flash Steam Recovery DRG. No © Copyright. This drawing is the

16 Flash Steam Recovery Feed temperature from tank reduced to about 90 C

17 Flash Steam Recovery Big increase in water temperature after the heat exchanger

Case Study 1 Benefits to Customer. Rendering Plant NSW Benefit Water Savings Over $10,

21 Case Study 2 Abattoir Country NSW Australia Categories Benefit Steam Savings 2700 tonnes/annum

22 Other Flash Opportunities. Heat Recovery from Boiler Blowdown Flash steam taken directly into

23 Other Flash Recovery Opportunities. EVC- Exhaust Vapour Condenser Vent out Water condensate Water

B 850 Boilerhouse Energy Monitor The B 850 offers a cost effective solution for

YOU THE FLEXIBILITY YOU “ GIVES NEED WHEN MONITORING YOUR BOILERHOUSE EFFICIENCY ” B

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Energy Saving Opportunities Wagga Industry Workshop April 2017 Peter Hickey NSW Sales

Increasing Our Capabilities Flow meters Control valves, regulators and traps Isolation valves and ancillaries Engineered heat exchange packages Boiler controls and systems Steam distribution system Engineered systems Process and applications Boiler Energy services Condensate recovery system Boiler water treatment and blowdown Pumps and heat recovery Process Heat Transfer 2

3 Steam and Energy Usage

4 Where Energy is Lost • • • Poor Lagging – Heat loss , safey Issue Erratic Blowdown Control in Boiler Cold Boiler feed tank Poor Distribution Layout Leaking Steam /Condensate lines Unmaintained and leaking steam traps Poor process control Unharnessed waste energy – Flash Steam Inadequate Measuring and Monitoring

5 How to Improve your Plant • • • Proper Lagging Automatic Blowdown Control Pre-Heat Feed tank Efficient well drained and sized Distribution Layout Repair leaking pipework – money disappearing out the holes! Regular Steam Trap Audits (low lying fruit , big win!) Modulating Automated Control Flash Recovery System Boiler Monitoring Equipment and Meters

Many Areas for Energy Saving and Improvement Only time to look briefly at a couple • Flash Steam Recovery • Boiler Monitoring System

Flash Steam

8 Flash Steam. . . WHAT IS FLASH STEAM. . . ? HOW IS IT FORMED. . . ? WHAT CAN WE DO WITH IT. . . ?

9 Flash Steam Condensate Return System Loss of Flash Steam 10 bar Steam Pressure Boiler Feed Tank Condensate Return Steam Boiler

10 Flash Steam Recovery

11 Approximate Amount of Flash Steam in Condensate Flash Steam 16% Water 84%

12 Flash Steam Recovery Requirements for Flash Steam Usage: • Enough condensate • Use for low pressure steam • Application needs to be close to high pressure condensate source

13 Flash Steam Recovery

14 PID Before: Flash Steam Recovery DRG. No © Copyright. This drawing is the property of Spirax Sarco. It shall not be reproduced without the permission of Spirax Sarco. The detail shown is offered for information only. It is the End User / Contractor / Installers responsibility to check for correctness. Condensate/Energy from plant Feed Tank/ Deaerator Boiler Through to boiler CUSTOMER DETAIL

15 PID After: Flash Steam Recovery DRG. No © Copyright. This drawing is the property of Spirax Sarco. It shall not be reproduced without the permission of Spirax Sarco. The detail shown is offered for information only. It is the End User / Contractor / Installers responsibility to check for correctness. Condensate/Energy from plant Feed Tank/ Deaerator Boiler Through to boiler CUSTOMER DETAIL

16 Flash Steam Recovery Feed temperature from tank reduced to about 90 C

17 Flash Steam Recovery Big increase in water temperature after the heat exchanger

18 Flash Steam Recovery

19 FREME- Flash Recovery System

Case Study 1 Benefits to Customer. Rendering Plant NSW Benefit Water Savings Over $10, 000 savings per annum in water and chemical treatment Chemical Savings $3, 000 Energy Savings 18, 000 GJ per annum Carbon Reduction 1100 tonnes of CO 2 per annum Environmental/ Visual Impact Flash Steam stack is now far less 20

21 Case Study 2 Abattoir Country NSW Australia Categories Benefit Steam Savings 2700 tonnes/annum Reduction in Fuel bill 8% over first year Dollar Savings $95, 000 Payback time 6 months Environmental/ Visual Impact Big reduction of flash steam being wasted at the feedtank

22 Other Flash Opportunities. Heat Recovery from Boiler Blowdown Flash steam taken directly into a flash condensing deaerator head Blowdown inlet from TDS control valves Flash Vessel Thermostat Heat exchanger Steam distribution injects low pressure flash steam into boiler feedtank

23 Other Flash Recovery Opportunities. EVC- Exhaust Vapour Condenser Vent out Water condensate Water Steam vent in

24 B 850 BOILERHOUSE MONITOR ENERGY

B 850 Boilerhouse Energy Monitor The B 850 offers a cost effective solution for Boilerhouses that do not have a boiler energy monitoring facility YOUR BOILER “ UPGRADE PLANTS ENERGY MONITORING CAPABILITY 25 ” UNDERSTAND | MONITOR | OPTIMISE

YOU THE FLEXIBILITY YOU “ GIVES NEED WHEN MONITORING YOUR BOILERHOUSE EFFICIENCY ” B 850 Boilerhouse Energy Monitor The B 850 is compatible with all Spirax Sarco flowmeters and automated blowdown systems associated with steam boilers. ELM Pt-100 B 850 Ptx ILVA ELM Auto TDS MTL 10 Auto BBD 26

Energy Saving Opportunities Wagga Industry Workshop April 2017 Peter Hickey NSW Sales