How Steam Expansion Turbines Can Help Recover Energy Embodied in Pressure Drops
Steam is an incredibly versatile and efficient energy source, but often it needs to be reduced in pressure in order to be used in different processes. For instance, steam is typically generated at 120 to 150 psig, but this pressure can be reduced to as low as 10-15 psig for use in different processes. This pressure reduction is typically achieved by using a pressure reduction valve (PRV), but this does not recover the energy embodied in the pressure drop.
What Are Steam Expansion Turbines?
Fortunately, there is a way to recover the energy that is otherwise lost through pressure drops thanks to micro scale backpressure steam turbines. These turbines can be used to capture the energy that is otherwise lost, allowing it to be used in other processes. Several manufactures produce these turbines, such as Turbo steam.
Applications of Steam Expansion Turbines
The potential for application of steam expansion turbines will depend on the particular application and steam system used. Applications of this technology have been commercially demonstrated for campus facilities, pulp and paper, food, and lumber industries and so on.
Steam expansion turbines are an effective way to recover energy lost through pressure drops in a steam system, allowing it to be reused in other processes. This technology has been successfully implemented in a variety of industries, making it a viable solution for many operations.
How to Save Energy in Industrial Operations
Industrial operations are some of the most energy-intensive activities in the world. It takes a lot of energy to power these operations, and with rising energy costs, it’s important to ensure that your industrial operations are as energy efficient as possible. Here are some tips and tricks to help you save energy in your industrial operations.
Steam Trap Replacement
One of the best ways to save energy in industrial operations is to replace your steam traps. Steam traps are necessary for releasing condensate, air and non-condensable gases from steam systems. Over time, steam traps can become clogged, which can cause pressure and temperature imbalances, leading to wasted energy. Replacing your steam traps regularly is essential to ensure your steam system is running at its most energy-efficient.
Condensate Recovery
Condensate recovery is another great way to save energy in industrial operations. Condensate is water that has been condensed from steam and can be reused, rather than releasing it into the atmosphere. By using condensate recovery systems, you can capture and reuse condensate, reducing the amount of energy needed to produce steam.
Piping Insulation
Insulating your piping is another great way to save energy in industrial operations. Heat loss through piping can lead to a loss of energy, and by insulating your piping, you can reduce this heat loss and make your industrial operations more energy-efficient.
Boiler and Furnace Tuning
Boilers and furnaces are essential for industrial operations, and tuning them can help to save energy. Tuning your boilers and furnaces is a great way to ensure they are running at their most efficient and to reduce energy loss.
Compressed Air Leaks
Compressed air leaks can be a major source of energy loss in industrial operations. Leaks can lead to wasted energy and can add up to large amounts of energy loss over time. It’s important to regularly check for compressed air leaks and repair them as soon as possible to ensure your industrial operations are as energy-efficient as possible.
Preventive Maintenance of Energy System Components
Preventive maintenance of energy system components is essential for ensuring energy efficiency in industrial operations. Components such as heat exchangers, pumps, fans, compressors, turbines, furnaces and boilers should be regularly checked and maintained to ensure they are running at their most energy-efficient.
Conclusion
Saving energy in industrial operations is essential for reducing energy costs and emissions. There are many ways to save energy in industrial operations, from replacing steam traps and recovering condensate to insulating piping and maintaining energy system components. By taking the time to implement these energy-saving measures, you can ensure your industrial operations are as energy-efficient as possible.
Optimizing Live Steam Consumption in Process Plants
Live steam is an integral part of any process plant, used for heating, cooling and power generation. It is an important factor in the overall efficiency of the plant, and its proper use can help to maximize productivity and minimize energy costs. In this article, we will explore some of the ways in which the amount of live steam used can be optimized.
Pressure Manipulation
One of the most effective ways to optimize the amount of live steam used is to adjust the operating pressure. By doing this, it is possible to reduce the amount of steam needed while still achieving the same desired results. This can be achieved through the use of advanced process control systems, which can monitor and adjust pressure levels as needed.
Minimizing Water Usage
Another way to optimize the use of live steam is to minimize the amount of water used. This can be done by using the lowest quality water possible for de-Salter operations, avoiding water slipping through with crude during desalting, and minimizing the water-wheel in the plant. Additionally, monitoring the steam condensate receivers and reporting low levels can help to ensure that the plant is not using more water than necessary.
Optimizing Heat Exchangers and Steam Heaters
Using minimum steam pressure whenever possible in heating, and recommending larger surface area to the pinch-steam-pressure heater, can help to optimize the efficiency of these components. Additionally, treating and recycling blow down to force lower cycles of concentration in cooling towers and boilers can help to reduce the amount of live steam needed.
Compressed Air Management
Compressed air is another common energy source used in process plants. Proper management of compressed air can help to reduce energy costs and minimize waste. This can be done by eliminating inappropriate uses, fixing leaks, and matching system supply with demand. Additionally, cleaning inlet filters to air compressors to reduce pressure drop and power consumption, and using a variable speed drive for air compressors, can help to maximize the efficiency of compressed air systems.
Other Optimization Strategies
Other optimization strategies that can help to reduce the amount of live steam used include maximizing heat recovery in heat trains, minimizing recycles to pumps and compressors, optimizing refrigerant sub-cooling, and using a systems approach while operating and maintaining a compressed air system. Additionally, adopting a plant-wide compressed air management policy, and optimizing the pre-cooling/pressure drop in cooling inlet to compressor, can help to reduce energy costs.
Conclusion
Live steam is a necessary part of any process plant, and optimizing its use is an important part of maximizing efficiency and minimizing energy costs. By using the strategies outlined in this article, it is possible to reduce the amount of live steam used while still achieving the desired results.