Documente Academic
Documente Profesional
Documente Cultură
Heat losses
Total
Steam In pipes
Heat in
Generator Unwanted work
Steam
Machine radiation
Flash steam
Condenser
Pump
250
20 bar
200
Steam loss kg/hr
150
100 5 bar
50
0
0 1 2 3 4 5 6 7 8
Hole dia (mm)
2. Providing dry steam for the process:
Dry saturated steam can maintain a controlled temperature
required for the process by setting the steam pressure. Wet
steam reduces the heat transfer due to formation of water film
on the surfaces and also overloads steam traps and the other
condensate handling equipment.
Wetness in steam can be controlled by (i) proper lagging of steam
pipes (ii) by installing steam separators (driers) near the point of
steam usage.
Dry steam Wet steam
out in Dry steam Wet steam
out in
Drain
STEAM SEPARATORS
Drain
3. Using steam at the lowest acceptable pressure:
Condensate film
combustion
Air film
Steam
products
Gaseous
Scale
Scale
Chief barriers of heat transfer are steam film, air film, condensate film, scale,
metal surface and stagnant combustion gas film. Air offers 13000 times
greater thermal resistance than copper metal. Air and condensate
resistance can be brought down by using adequately located air vents and
condensate traps. Scale problems have to be tackled by using specified
quality of feed water for internal scale and periodic use of soot blowers
and scrapers for the external scale.
8. Condensate recovery:
The condensate contains around 15 to 25 % of the total heat of
steam. If it is properly collected, it can be reused in any of
the following ways.
a) As feed water to the boiler without any need for further
chemical treatment. It is estimated that a 6°C rise in feed
temperature saves 1% fuel bill on the boiler.
b) It can be used as a source of hot water for several other
applications.
c) It can be flashed into low pressure steam for use else-
where in the plant.
d) If the condensate is contaminated with corrosive liquids,
heat exchangers can be used to extract its heat.
9. Flash steam recovery:
14
12
10
Gauge Pr on trap (bar)
2
0
0 2 4 6 8 10 12 14 16 18 20
Flash Steam Produced (%)
Typical application of Flash steam recovery
Low pr.steam
High pr.steam
S.T
S.T S.T
Flash
Vessel
S.T
Types of traps:
1. Mechanical type:
Operates on the difference in density between condensate
and steam.
a) Float type: i) Plain float ii) Trip float
b) Bucket type: i) Open bucket ii) Inverted bucket
3. Thermodynamic Type:
Operates on the forces generated by flashing condensate
and steam flowing through orifice.
Used in Steam mains and steam separators, branch
mains leading to process equipment, driers, multi-plate
presses etc.
4. General type:
a) Impulse type
b) Pilot operator type
c) Labyrinth type
d) Ogden pump type
Applications:
Ogden pump type traps are some times used in Steam
mains and separators, Heat exchangers, Brewing copper,
Digesters etc.
After mashing, the beer wort is boiled with hops (and other
flavourings if used) in a large tank known as a "copper" or
brew kettle – though historically the mash vessel was used
and is still in some small breweries.
11. Proper sizing of Pipe lines:
Small diameter pipes cause higher pressure drop. But large sizes
cost money and increased radiation losses.
Sizing of short branches of steam pipes is done by setting a
steam velocity of 15 m/s. Higher velocities cause noise and
pipe erosion, particularly with wet steam.
Sizing of long pipe lines is done solely on pressure drop
considerations. Generally the steam velocity is to be kept
much less than 15 m/s to avoid excessive pressure drop.
Condensate pipes of small size will increase back pressure on the
traps, and if oversized would become capital intensive.
Since during start up, large amount of cold air, condensate (and
flash steam) have to be dealt with, in practice pipes are sized
for starting conditions only, when the load will be nearly
double the running load.
12. Reducing the work to be done by the steam:
All possible measures should be taken to avoid over working by
steam such as overheating of liquids, wastage of steam and
condensate for washing vessels and trays in chocolate factories,
keeping the laundry cloths too wet for drying on steam drums
(without proper squeezing of water) etc.
Condensate film
combustion
Air film
Steam
products
Gaseous
Scale
Scale
Chief barriers of heat transfer are steam film, air film, condensate film, scale,
metal surface and stagnant combustion gas film. Air offers 13000 times
greater thermal resistance than copper metal. Air and condensate
resistance can be brought down by using adequately located air vents and
condensate traps. Scale problems have to be tackled by using specified
quality of feed water for internal scale and periodic use of soot blowers
and scrapers for the external scale.
8. Condensate recovery:
The condensate contains around 15 to 25 % of the total heat of
steam. If it is properly collected, it can be reused in any of
the following ways.
a) As feed water to the boiler without any need for further
chemical treatment. It is estimated that a 6°C rise in feed
temperature saves 1% fuel bill on the boiler.
b) It can be used as a source of hot water for several other
applications.
c) It can be flashed into low pressure steam for use else-
where in the plant.
d) If the condensate is contaminated with corrosive liquids,
heat exchangers can be used to extract its heat.
9. Flash steam recovery:
14
12
10
Gauge Pr on trap (bar)
2
0
0 2 4 6 8 10 12 14 16 18 20
Flash Steam Produced (%)
Typical application of Flash steam recovery
Low pr.steam
High pr.steam
S.T
S.T S.T
Flash
Vessel
S.T
Types of traps:
1. Mechanical type:
Operates on the difference in density between condensate
and steam.
a) Float type: i) Plain float ii) Trip float
b) Bucket type: i) Open bucket ii) Inverted bucket
3. Thermodynamic Type:
Operates on the forces generated by flashing condensate
and steam flowing through orifice.
Used in Steam mains and steam separators, branch
mains leading to process equipment, driers, multi-plate
presses etc.
4. General type:
a) Impulse type
b) Pilot operator type
c) Labyrinth type
d) Ogden pump type
Applications:
Ogden pump type traps are some times used in Steam
mains and separators, Heat exchangers, Brewing copper,
Digesters etc.
After mashing, the beer wort is boiled with hops (and other
flavourings if used) in a large tank known as a "copper" or
brew kettle – though historically the mash vessel was used
and is still in some small breweries.
11. Proper sizing of Pipe lines:
Small diameter pipes cause higher pressure drop. But large sizes
cost money and increased radiation losses.
Sizing of short branches of steam pipes is done by setting a
steam velocity of 15 m/s. Higher velocities cause noise and
pipe erosion, particularly with wet steam.
Sizing of long pipe lines is done solely on pressure drop
considerations. Generally the steam velocity is to be kept
much less than 15 m/s to avoid excessive pressure drop.
Condensate pipes of small size will increase back pressure on the
traps, and if oversized would become capital intensive.
Since during start up, large amount of cold air, condensate (and
flash steam) have to be dealt with, in practice pipes are sized
for starting conditions only, when the load will be nearly
double the running load.
12. Reducing the work to be done by the steam:
All possible measures should be taken to avoid over working by
steam such as overheating of liquids, wastage of steam and
condensate for washing vessels and trays in chocolate factories,
keeping the laundry cloths too wet for drying on steam drums
(without proper squeezing of water) etc.