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Un-recovered condensate must be replaced in the boiler house by cold make-up water with additional costs of water treatment and fuel to heat the water from a lower temperature.Īny condensate not returned needs to be replaced by make-up water, incurring further water charges from the local water supplier. The discharge from a single steam trap is often worth recovering. The ability of any trap to pass condensate relies upon the pressure difference across it, whereas a pumping trap or a pump-trap combination will be able to pass condensate irrespective of operational pressure differences (subject to design pressure ratings).Ĭondensate is a valuable resource and even the recovery of small quantities is often economically justifiable. Note: The term ‘trap’ is used to denote a steam-trapping device, which could be a steam trap, a pump-trap, or a pump and trap combination. Some of the apparent problem areas will be outlined and practical solutions proposed. This Module will look at two essential areas – condensate management and flash steam recovery. Condensate and flash steam discharged to waste means more make-up water, more fuel, and increased running costs. An efficient steam system will recover and use flash steam. The flash steam generated from condensate can contain up to half of the total energy of the condensate. Whether steam is produced in a boiler or from the natural process of flashing, it has exactly the same potential for giving up heat, and each is used successfully for this purpose. The terms live steam and flash steam are only used to differentiate their origin. Steam produced in a boiler by the process of adding heat to the water is often referred to as live steam. The amount of flash steam in the pipe is the most important factor when sizing trap discharge lines. Proportion of flash steam using Figure 14.1.3: The subject of flash steam is examined in greater depth in Module 2.2, ‘What is steam?’ A simple graph (Figure 14.1.3) is used in this Module to calculate the proportion of flash steam. This excess energy is available to evaporate some of the condensate into steam, the amount evaporated being determined by the proportion of excess heat to the amount of heat required to evaporate water at the lower pressure, which in this example, is the enthalpy of evaporation at atmospheric pressure, 2258 kJ/kg. The excess energy in each kilogram of the condensate is therefore 721 – 419 = 302 kJ. When it is released to atmospheric pressure (0 bar g), each kilogram of water can only retain about 419 kJ of heat. Hot condensate at 7 bar g has a heat content of about 721 kJ/kg. This can have the effect of choking undersized trap discharge lines, and must be taken into account when sizing these lines.Įxample 14.1.1 Calculating the amount of flash steam from condensate
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Condensate at 7 bar g will lose about 13% of its mass when flashing to atmospheric pressure, but the steam produced will require a space some 200 times larger than the condensate from which it was formed. However, the percentage volumetric change can be considerably more. A flash steam amount of 10% to 15% by mass is typical (see Module 2.2). The proportion of steam that will ‘flash off’ in this way is determined by the amount of heat that can be held in the steam and condensate. As a result of this drop in pressure, some of the condensate will re-evaporate into ‘flash steam’. Even then, it may be possible to collect the condensate and use it as hot process water or pass it through a heat exchanger where its heat content can be recovered before discharging the water mass to drain.Ĭondensate is discharged from steam plant and equipment through steam traps from a higher to a lower pressure. Only when there is a real risk of contamination should condensate not be returned to the boiler. An efficient steam system will collect this condensate and either return it to a deaerator, a boiler feedtank, or use it in another process. The remainder of the heat in the steam is retained in the condensate as sensible heat (enthalpy of water) (Figure 14.1.2).Īs well as having heat content, the condensate is basically distilled water, which is ideal for use as boiler feedwater. Saturated steam used for heating gives up its latent heat (enthalpy of evaporation), which is a large proportion of the total heat it contains. An efficient steam system will reuse this condensate.įailure to reclaim and reuse condensate makes no financial, technical or environmental sense. When a kilogram of steam condenses completely, a kilogram of condensate is formed at the same pressure and temperature (Figure 14.1.1). To supply heat for heating and process systems.To produce electrical power, for example in power stations or co-generation plants.Steam is usually generated for one of two reasons: