Condensate Recovery System
Steam is a very effective heat transfer medium, due to easy transportability and high heat content,it is used in process industry for direct and indirect heat transfer.
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When steam is used for indirect heat transfers in heat exchanger,reactor and other indirect heating equipment it gives off its latent heat(useful heat) to process and converts itself into liquid from known as condensat.This high pressure condensate when released to atmospheric pressure can no longer hold high heat content.The excess heat is released as Flash steam.
High pressure condensate is at almost the same pressure as steam and contains around 15 to 20% heat of fuel.This heat if recovered shall reduce fuel consumption to the extent of 20%.
In addition to the fuel savings, boiler quality water is also recovered, and is used in boiler.This has effect of reduce cost of water and water treatment chemicals.Further good quality boiler feed water reduces the blowdown losses resulting in fuel savings.To summarize,the efficient condensate recovery system will ensure
- High temperature feed water
- Good quality boiler feed water
- lower blowdown losses
- lower water treatment looses
Our CRS is an integrated system comprising of a Flash Steam Generator, Steam operated Condensate Transfer Pump and Dearetor Unit with immersion tube.
This system recovers efficiently flash steam,hot condensate and feed them to the feed water tank through a well designed Deareator unit with immersiion tube.
Our CRS is a state of the art system using latest engineering practices, designed to give you savings in fuel cost year after year after year.
AUTOMATIC CONDENSATE TRANSFER SYSTEM
VSTEC is a plug in systemspecifically designed to collect and pump hot condensate, commonly returned for use as boiler feed water.The whole system is capable of handeling capacities up to 5500 kg/hr. Operated by stean or compressed air can be tailored to meet a wide variety of condenste handling applications.Higher flow handelin capacity up to 16000kg/hr available in duplex and triplex pumps.
- High discharge per stroke of 42 liters per stroke
- Pump body desingned to ASME Sec.VIII Div.I BPVC Code
- High Condenstae temperature return-No cavitation problem
- Unaffected by water hammer-No NPSH problems
- Minimum moving parts ensuring high up time
- Adequate receiver capacity-No Overflows
- Simple solution for condensate pumping
- Packaged Pump-Easy to install
- Built in Digital Flow Indicato
- Componenets desingned for high cycle life
- Suitable for outdoor installation-Weather Proof design IP 65
- Microprocessor based control with 16 charecter display for flow
- Flow indecator and totaliser with non volatile memory
ATMOSPHERIC FLASH SYSTEM
When high pressur condensate is discharged from steam traps to low pressure condensate return lines, excess energy is released in the form of flash steam.This flash steam can be used to heat boiler feed water or for low pressure steam application
GENERATS LOW PRESSURE FLASH STEAM
- Adequately sized to minimize pressure drop
- Steam trap sized to handle condensate at low pressure differance to be fitted at condensate outlet
- Designed with optimum seperation velocity to et dry steam
ATMOSPHERIC DE-AERATOR with IMMERSION TUBE
Atmospheric De-aerator Head is designed to remove dissolved gases and oxygen from the feed water by proper mixing of condensate,flash steam and cold make up.Solubility of oxygen and other dissolved gases decreases with rise in temperature and they are released from solution. These gases are then released through the air vent fitted on the de aerator head.
The mixing action takes place by suitably locating the nozzles and providing spray screens and baffles.A Thermax flash condensing de-aerator head consists of three parts.
- Adequately sized to minimize pressure drop
- Steam trap sized to handle condensate at low pressure differance to be fitted at condensate outlet
- Designed with optimum seperation velocity to et dry steam
- Atmospheric De-aerator head, which is bolted to the top of the tank and is supplied with connection for cold make up, condensate return,flash steam and recirculation.
- An immersion tube which distributes the mixed fluids into the tank
- A guide nozzle for mounting the immersion tube.
- recirculation system(optional)
Pressure reducing & Desuperheating station
Good steam engineering practice is to generate steam at high/maximum working pressure, distribute at higher pressure and utilize at low pressure with pressure reduction.
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It is recommended to operate the boilers close to maximum operating/design pressure.This ensures good quality of steam with high dryness fraction.Process equipments are normally designed for much lower pressure of steam.
ADVANTAGE OF PRESSURE REDUCTION
- Steam is transported to the point of utilization at higher pressure.This permits use of smaller pipe diameters leading to reduce steam piping and insulation cost.
- Reduce plant equipment cost due to use of small thickness plantes leading to substantial savings in initial plant cost
- lower blowdown losses
- Gives more latent heat, per Kg of steam to industrial equipment like heat exchangers, jacketed kettles, distillation column re- boilers, etc.
- resulting in lower fuel consumption.
Pressure reducing Valve (TPRV)
APPLICATION:
- Pressure reduction for saturated steam and compressed air
RANGE::
- Capacity: 250 Kg/h Max
- Size 15, 20, 25 mm NB
MOC:
- Body SG Iron GGG 40.3
- Internals SS
FEATURES:
- Special set pressure locking arrangement
- Suitable for steam and compressed air
- Compact design fully self acting
- No external signal required for down stream pressure control
- Operates even on low flow conditions
- Both IBR Certified & Non IBR pressure reducing valve available
TECHNICAL SPECIFICATIONS:
| # |
Specs |
Values |
| 1 |
Design pressure body |
PN 25 |
| 2 |
Max upstream pressure |
19 Kg/cm2(air) |
| 3 |
Max downstream pressure |
8.6 Kg/cm2 |
| 4 |
Designed temperature |
210 degree cel. |
| 5 |
End connection screwed |
BSP/NPT |
| 6 |
Down stream set pressure range |
0.14 to 1.7/1.4 to 4/3.5 to 8.6 Kg/cm2 |
Pressure Reducing Stations
Superior quality designed pressure reducing station as a ready to install equipment gives the following distinct advantages
Advantages
- Designed as per best steam engineering practices.
- Assured consistent downstream reduced pressure.
- Superior quality of components and best workmanship.
- Savings in erection and commissioning time.
- Reduces fuel consumption.
- Excellent network of our reprensentatives ensure timely commissioning and technical support.
- We offer single point contact for all Sream Accessories and steam Boilers.
PRESSURE REDUCING & DESUPERHEATING STATION (PRDS)
PRDS systems are designed to reduce the steam pressure to operating pressure and also bring the outlet steam temperature closer to that of saturation.
Suitably designed pressure reducing valve installed on superheated steam line, reduces steam pressure to desired operating pressure.During this process the steam temperature also reduces following superheated steam curve, however the degree of superheat remains unaltered.
The steam temperature is reduced close to saturation by injecting water into high velocity steam by controlled water flow through water control valve.
Conventionally steam pressure reduction and temperature reduction were done in two different units. Now both these functions are carried in one unit which is combined pressure reducing and desuperheating valve.
DESUPERHEATING SYSTEMS (DSH)
De superheating systems are designed to reduce the temperature of superheated steam close to that of saturation.The steam temperature is reduced close to saturation by injecting water into high velocity steam by controlled water flow through water control valve
Fixed Nozzle De- super heater
- The Simplest Design in De super heater family.
- mainly used when the pressure difference between the main steam line and spray water in high.
- inline type assembly for steam line size 6″ NB and above.
- Mini cooler for steam line size up to 4″.
- Maximum Turn down 3:1.
VENTURI DE- SUPERHEATER
- Mainly used when the pressure difference between the main steam line and spray water is low.
- better mixing of spray water with main steam by swirling action.
- Maximum Turn down 8:1
VARIABLE NOZZLEDE-SUPERHEATER
- Best Design in De-superheating Family.
- Constant Pressure Drop Across the nozzle.
- High Turn Down up to 16:1.
- Better Downstream Temperature Control.
Steam traps and accessories
Steam traps are a vital component of the steam distribution system. Though not realised often but improper selection and lack of maintenence can make these Steam traps malfunction and thus loss of huge amount of energy.
We offer all types of traps for process needs along with other accessories.
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1.THERMODYNAMIC STEAM TRAP (TTD-YS-32/TTD-YS-42)
APPLICATION:
- To remove condensate from steam headers and distribution piping
RANGE:
- Capacity: Refer product catalogue
- Size: 15,20,25 mm NB
2. FLOAT TRAP WITH THERMOSTATIC AIR VENT(SLR-TFT-TV-N/TFT-TV-H)
APPLICATION:
- To remove condensate from steam jackets/coils of steam consuming equipment
RANGE:
- Capacity : Refer product catalouge
- Size: 15,20,25 mm NB/ 40,50 mm NB
3. THERMOSTATIC STEAM TRAP (TTS-FS-SS)
APPLICATION:
- Recommended for steam tracer lines
RANGE:
- Capacity : Refer product catalogue
- Size: 10, 15, 20, 25 mm NB
4. BIMETALLIC TRAP (TBM)
APPLCATION:
- To remove condensate from steam headers/equipment consuming superheated steam
RANGE:
- Capacity: Refer product catalogue
- Size: 15,20,25 mm NB
5. AIR AND GAS ELIMINATOR (TAE-N/ TAE-25)
APPLICATION:
- To remove non condensable gases/ air from liquid storage system.
RANGE:
- Capacity: Refer product catalogue
- Size: 15, 20, 25 mm NB for TAE-N & 25 mm NB for TAE-25
6.LIQUID DRAINER (TLD-FT-N/ TLD-FT-H)
APPLICATION:
- To remove water from compressed air lines
RANGE:
- Capacity : Refer Product Catalogue
- Size : 15, 20, 25 mm NB/ 40, 50 mm NB
7.VACCUM BREAKER (TVB-16/TVB-25)
APPLICATION:
- To prevent creation of vaccum in piping or equipment
RANGE:
APPLICATION:
- Suitable for all kinds of steam boilers ranging from 50 kg/h to 16 TPH,
- Thermic fluid heaters ranging from 50000kCal/h o 25 lac kCal/h & hot water generators ranging from 50000kCal/h to 25 lac kCal/h
RANGE:
- Pressure jet technology 10 kW to 22500 kW
- Rotary cup burners 1.12 MW to 47.44 MW
TECHNICAL SPECIFICATIONS:
- Modulation type:On/Off ; 2stage; (Hi-low); 3 satge; Modulating
- Fuels: HSD/LDO/F.O/NG/LPG/Other gas based on composition
- Simultaneous firing of liquid fuel & bio gas is possible
- Heat recovery possible with preheated combustion air of 250 deg cel max can be used in dual bloc burners
- High/low pressure gas train modules
- Ring Main system for heavy oil available on request
Waterpreheater, Economizers and Airpreheaters
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WATER PREHEATER:
An atmospheric water preheating system used at the outlet of solid fuel fired boiler, resulting in improvement of efficiency by 3-4%
ECONOMISER:
It is a forced-flow,once-through,convection heat -transfer device, covered under IBR act,designed to suit almost all fuels with all operational safety
AIR PREHEATER:
Air preheater for oil/gas fired boiler.It incorporates a corrosion management system ensuring that the metal temperature is always above the sulphur dew point,thus improving the efficiency without sacrificing the life of down stream equipent/instruments.
Air preheater for thermic fluid heater.It is an energy saving air preheater used on thermal oil heaters resulting in improvement of efficiency to the tune of 3-5%
INTRODUCTION
Thermax range of control valve with pneumatic & electrical actuators are designed to provide presise control for hot water,steam and thermal oil for flow,pressure and temperature control applications.
It is imortant to achive complete valve shut off, to prevent leakage thateither could contaminate a process fluidor result in production loss.Also valve tightess ensure prevention of erosion damage that normally occures on a high velocity steam leak across seating surface.Thermax helps in proper solution of valves, considering all reprised parameters.
DESUPERHEATING SYSTEMS (DSH)
De superheating systems are designed to reduce the temperature of superheated steam close to that of saturation.The steam temperature is reduced close to saturation by injecting water into high velocity steam by controlled water flow through water control valve
Features
- Complete range of 2 way and 3 way of control valves, with option of pneumatic and electrical actuator.
- Specially designed for high temperature application, with extended bonnet as default offering.
- Body with top entry trim and bolted bonnet facilitates easy access to all internal parts for online inspection, maintenance and trim replacements.
- Stream line flow path provide large flow capacity.
- Variety of trim option available for precise flow control.
- Zero emission valve due to low fugitive emission Graphoil gland packing.
- Stellited internals ensures zero leakage through ports.
Benefits
- Applicable for both regulating and on- off functions.
- Choice available for low and high thrust requirements.
- The actuator are lightweight and compact,due to multispring arrangement.
- The actuators are field reversible without demanding addition or deletion of parts.
- Ensures a long listing service life, due to rigid construction and durable components.
- Minimum maintenance required.
- Rolling diaphragm construction provides constant effective area throughout the stroke.
- Hand wheel arrangements as Top mounted or Side Mounted configurations, aslo available
- Easy to mount various accessories.
THERMAX ELECTRICAL ACTUATOR
Thermax Electrical Actuator type is designed liner for remote control of globe control valves.these actuators are designed for on- off application and they are customer friendly and guarantee precise control every time, with repeated operations also.
The special designed features of this actuator give value addition to our customers in following ways:
Accessories: Positioner card (for prop) & Hand wheel (As default) Limit Switch & Position Transmitter(As optional)
Features & Benefits
- Ensures improved control and positioning accuracy..
- Easy to intregate in control loops and/ or Distributed Control System(DCS)
- Modular designs ensures common parts.
- Easy to install and maintain.
- Ensures troble free operation.
- Helps in reducing spare parts and inventory costs.
- Optical running & position indecation ensures checking of actuator operation.
- Highly reliable & hence downtime is almost nil.
- Dust and waterproof (IP65/IP67) protection ensures smooth operation at extream condition.
From Thermax we have a full-fledged utility cost reduction team of experts drawn from diverse disciplines.Equipped with technical and instrumental resources to undertake total plant audits, the team can optimize operational costs through innovative energy efficiency solutions that offer quick paybacks. We have the expertise to implement energy conservation solution on a turnkey basis. we also undertake system and process study to improve productivity and bring down product costs.
Energy Conservation Services(ECS)
Around the world, energy cost forms a significant part of operational costs, as high as 30% in process industries.Technological changes have also forced organizations to re-look at energy management.Today with increased overheads and shrinking profit margines,there is an urgency to optimise energy cost and utilisation.
Thermax offers Energy Audits Services in Following Areas:
- Steam and Condensate
- Thermic Fluid
- Electricity
- Compressed Air
- Refrigeration
- Cooling Tower
Energy saving in action
On the basis of preliminary data collected from the client through standard questionnaire, an expert/ team of experts will be deputed for field studies.They will study the plant and conduct detail studies on utilities.The data collected during the audit will be analyzed to identify the energy conservation measures. Finally a detailed audit report will be submitted covering following aspects
- Energy conservation recommendation with short term, Long term proposals.
- Prioritizing the project base on payback.
- Basic engineering and product specifications.
This phase is followed by implementation and performance monitoring of energyconservation proposals and supported by expert services from Thermax for training of the plant operators.
