Steam losses in process industry 1

[zamu2010]

Hi folks,
I am investigating steam losses in a process plant.Generally most of the steam is recycled as condensate to the boiler but still there are some losses and need some make-up water for boiler. Is there any rule of thumb for these steam losses.??
Thanks in advance for your help on the subject

 

[Drexl]

Hi, don't know your system or purpose of investigation but usually the "losses" are mostly in the form of blow-down from the boiler. Then we are talking a few percent of the steam capacity of the boiler.

 

[zamu2010]

Hi Drexl,
Thanks for your reply.
How much is this few percent of Boiler capacity? 3-5%??

 

[ione]

The blowdown rate can be computed using this formula:
BD = (F*S)/(B – F)
Where:
BD = blowdown rate (kg/h), to be restored through makeup water
F = Feedwater TDS (ppm)
S = Steam production (kg/h)
B = Required boiler water TDS (ppm). This value depends on the specific type of boiler installed.
You may also want to take into account steam leakage losses

The link below reports a graph showing the amount of steam lost through leaks, correlating steam pressure and hole size on the pipes.

http://www.spiraxsarco.com/resource...eam-distribution/steam-mains-and-drainage.asp

 

[25362]

It also depends of the amounts used for stripping operations, on vacuum ejectors, steam tracing discharging to the atmosphere, burner steam atomization, fired heaters velocity steam, vaporization from condensate collecting tankage, etc.

Many years ago, much before energy costs started to raise, I used to work for an oil refinery in which the make-up was at the 40% level.

 

[rmw]

You need to do a steam trap audit to find out how many are blowing off to atmosphere, or leaking themselves. I suspect you will find more losses there than you will like.

rmw

 

[MJCronin]

Investigation of "steam losses in process plants" seems to be about as open ended as investigating corruption in government.

You will find a lot in some places.....not so much in others.

Steam is expensive...good plant managers keep a close eye on fuel consumption and condensate return.

 

[jistre]

For what it's worth, I worked with an old salty engineer who had lots of fun phrases. One was, "You show me a plant with old steam traps, and I'll show you a plant that is leaking money."

Again, FWIW, just the sayings of a very experienced engineer I used to work with.