How do you calculate condensate recovery?

Energy Calculations for Return Condensate

(hc – hm) = Energy Loss per Pound.
44,000 lbs of steam = 44,000 lbs of condensate (90 percent Return) = 39,600 lb.
39,600 lb x 157.33 (BTU/lb) = 6,230,268 BTU.
6.230268 x $15.30 = $95.32 per hour.
$95.32 x 8,760 (hours/year) = $835,003.20 per year.

What is a condensate return?

Return Condensate to the Boiler. When steam transfers its heat in a manufacturing process, heat exchanger, or heating coil, it reverts to a liquid phase called condensate. An attractive method of improving your power plant’s energy efficiency is to increase the condensate return to the boiler.

What are the benefits of condensate recovery?

Benefits of Condensate Recovery

Significant savings on energy costs.
High boiler feed water temperature minimises dissolved oxygen and therefore helps prevent corrosion.
Reduces the total dissolved solids (TDS) in the boiler feed water.
Minimises the need for makeup water and associated costs.

How can I improve my condensate recovery?

In order to improve the condensate in the existing system, the steam traps play a very important role. The type of steam trap also plays an important role. If the steam traps function to their fullest ability then there will be an increase of condensate recovery by approximately 10%.

How much is a ton of condensate?

A general rule of thumb is that . 1 to . 3 gallons of condensate is produced for every ton-hour.

How does a condensate recovery system work?

What is Condensate Recovery?

As heated feedwater, by sending hot condensate back to the boiler’s deaerator.
As pre-heat, for any applicable heating system.
As steam, by reusing flash steam.
As hot water, for cleaning equipment or other cleaning applications.

How do you get condensate?

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. Condensate is discharged from steam plant and equipment through steam traps from a higher to a lower pressure.

Which of the following is advantage of condensate recovery pump?

Condensate is an excellent source of feed water as it is relatively pure (compared to most water supplies) being condensed water vapor. Condensate can also be used as the hot process water to use the enthalpy for heating coils or heat exchange units.

How does a condensate return system work?

In a pumped condensate return system, the flashing condensate is discharged into a vented tank, from which the flash steam is removed. The condensate must be pumped from the vented tank to the collecting tank, and then pumped from the collecting tank to the boiler.

How deep is a condensate trap?

If a unit were to be operating at minus 6 inches WC maximum negative plenum pressure then the trap height, per the guidelines shown in Figure 1a, requires 7 + 3½ + 1½ + 1 inches of height from under the floor or about 13 inches below the floor level.

How much condensate does a 5 ton AC produce?

How much condensation does a 5 ton air conditioner produce? The amount of condensation generated by the device varies and increases with increasing external humidity. Most modern air conditioning systems produce between 5 and 20 liters of water per day.

What temp is condensate?

For example on a closed system with steam at 10 barg [145 psig], condensate can be recovered with a temperature of 184 °C [363 °F] if it is sent to a Deaerator or similar system which captures the higher heat of the higher temperature liquid.

What are the reasons for condensate recovery and return?

An introduction to the reasons for condensate recovery and return, including energy costs, water charges, effluent restrictions and water treatment costs. Includes sample calculations for potential savings Steam is usually generated for one of two reasons:

How does condensate recovery work in a steam boiler?

If 1 t/h of steam is supplied to equipment for a heating process, then the same amount of condensate (1 t/h) needs to be discharged from the equipment. Condensate recovery is a process to reuse the water and sensible heat contained in the discharged condensate.

What do you do with condensate from a steam trap?

The discharge from a single steam trap is often worth recovering. 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.

What happens when a kilogram of steam condenses?

When a kilogram of steam condenses completely, a kilogram of condensate is formed at the same pressure and temperature (Figure 14.1.1). An efficient steam system will reuse this condensate.

How do you calculate condensate recovery? Energy Calculations for Return Condensate (hc – hm) = Energy Loss per Pound. 44,000 lbs of steam = 44,000 lbs of condensate (90 percent Return) = 39,600 lb. 39,600 lb x 157.33 (BTU/lb) = 6,230,268 BTU. 6.230268 x $15.30 = $95.32 per hour. $95.32 x 8,760 (hours/year) = $835,003.20…