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Steam Optimization Reduces Waste, Saves Water and Energy

January 22, 2019
Technology

Pulp and paper mills, oil and gas plants, and chemical plants account for 85 percent of all steam used in the world.

Nearly half of industrial facilities continue to use energy-intensive steam to transfer heat throughout the facility and to perform critical operations. Many of these systems were built when water was abundant and use water resources at an unsustainable rate. Optimizing and retrofitting these systems increase efficiencies that result in lower energy and water footprint for each product.While specialized vendors and consultants exist to help with major facilities upgrades, the “tune-up” specialist is often missing from the picture — and is needed.

 Cosmo FläktPulp Dryer Optimization

In April 26, 2017, a specialty fibers company reached out to the eSteamG Team, then working under the banner of Matrix Northwest, to determine whether our steam optimization services could generate the same types of improvements  at its facility in western Alberta.

An assessment indicated that a unique set of facility modifications to steam coils and condensate removal systems were needed to optimize the steam system and pulp dryer.

Based on the assessment, eSteamG implemented the project in four phases:

  • Phase 1 was an assessment of the Fläkt dryer and facility-specific parameters which identified key elements that could be optimized, the costs to perform the optimization, and the estimated gains in production and steam system efficiency.
  • Phase 2 implemented the recommended steam system changes and identified additional system problems restricting production output. This work was performed during a scheduled maintenance shut-down at the mill in late spring 2017.
  • Phase 3 implemented corrections to the additional problems identified in Phase 2 which included changing from condensate coils to steam coils and working on the steam system upstream from the dryer. The combined improvements increased Flakt dryer production capacity by roughly 50 percent.This work was done in September 2017.
  • Phase 4 resolved a plugging issue resulting from faulty condensate chemistry readings and some resulting copper corrosion. The result was record production far exceeding the company’s expectations.

The out-of-the-box solutions and collaboration eSteamG offered resulted in significant improvements in production leading to increased revenue and a significantly more stable system.

Offering end-to-end steam system optimization, eSteamG provides technical expertise in steam and industrial steam applications, focused on efficiency, productivity, and reliability.


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