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PAPTAC Montréal February 2006

PAPTAC Montréal February 2006. Steam and Condensate Closed System (SCCS). 100 % condensate return Reality or Utopia ?. lalonde sys thermique inc The S team and C ondensate C losed S ystem Group (SCCS). Expertise in how to use steam without losses

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PAPTAC Montréal February 2006

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  1. PAPTAC Montréal February 2006

  2. Steam and Condensate Closed System (SCCS)

  3. 100 % condensate return Reality or Utopia ?

  4. lalondesysthermiqueincThe Steam and Condensate Closed System Group (SCCS) • Expertise in how to use steam without losses • A unique system technology developed & improved since 1984. • Currently installed in over 52 mills • Caddet : http://www.caddet.org/public/uploads/pdfs/Brochure/r125.pdf • 2005 Paptac Energy Award : http://oee.nrcan.gc.ca/cipec/ieep/newscentre/newsletter/cipec_vol_IX_3.cfm?attr=24#d

  5. Energy Saving Achievements • Eliminate steam & condensate losses Stop flash steam, steam trap & pump gland losses • Better control & efficiency of thermal equipmentEliminate excessive pressure, temperature & flow drops Modify steam side control Control on the condensate side • Reduce fossil fuel & green house gases More than 10 % steam savings 1000 lbs of steam = 10.8 U.S. gallon of bunker oil = 0.13 tonne of CO2 gas 1 tonne of steam = 90.2 liter of bunker oil = 0.28 tonne of CO2 gas 1 tonne of steam = 82.3 meter3 gas = 0.16 tonne of CO2 gas

  6. Basic Principles of the Steam and Condensate Closed System (SCCS) • Use of saturated steam at 0 deg superheat Usually steam enters heat exchanger with 10 ºC or more of superheat • Mechanically remove non-condensible gases on thesteam side Typically ignored or conventionally done on condensate side and amines have to be added • Return condensate to the deaerator &/or a flash tank at the highest possible pressure & temperature using mechanical force of steam pressure to return condensate Usually, condensate was vented to an atmospheric tank and pumped • No condensate tank, no pump No flash steam to atmosphere, no use of electrical power, lower maintenance

  7. SCCS METHODBENEFITS • Convert heat exchangers, evaporator, black liquor heaters etc, to full pressure steam • Control process heat exchanger on the condensate side • Control heat exchangers to less than ± 1 °F • Condensate returned under full pressure to steam plant • Better control & efficiency of thermal equipment • Control all steam system vents to atmosphere (without steam loss) with mechanical O2 &CO2 eliminators • Guaranteed boiler water make-up reduction • Up to 10 % total steam savings

  8. Last lalondesysthermique Steam and Condensate Closed System results

  9. Average Steam production per hour Before : 438 667 lbs/hour After : 400 000 lbs/hour

  10. Power Generation Before : 13.14 MW After : 14.58 MW

  11. Natural gaz consumption Before : 47 791 m3/day After : 21 678 m3/day

  12. Water regeneration Before : 6/day After : 3/day

  13. As an exemple, deaerator steam demand Before : 39 621 lbs/hour After : 17 069 lbs/hour

  14. Pulp Production Same

  15. MUCH MORE …

  16. February 2005 Energy conservation awardsare presented to individuals working in the industry who submit the best examples of energy conservation opportunities applied in Canada. Les Papetières du Québec sponsors this competition. 1st Prize : Jack Smith (Tembec – Smooth Rock Falls) for his Steam and Condensate Optimization.

  17. February 2005 Working with the mill in this effort, from the beginning, has been Systhermik Canada inc. (lalondesysthermique inc.). Their expertise revolves around closed system approaches towards handling steam and condensate. • The first prize was attributed for : • Innovation, creativity, originality • Applicability in the pulp and paper industry • Size of savings and cost-effectiveness • Installation and implementation • Environmental impact

  18. Basic Questionnaire for Energy Conservation Calculations 1. Operation in days ______ / yr 2. Steam production (approx) Summer ______ lbs/hr or ______ tons/hr Winter ______ lbs/hr or ______ tons/hr Average ______ lbs/hr or ______ tons/hr 3. Total steam production ______ lbs/yr or ______ ton/yr 4. Boiler feed water flow Summer ______ US gpm or ______ l/min Winter ______ US gpm or ______ l/min Average ______ US gpm or ______ l/min 5. Process direct steam injection in % of steam production : ____ % 6. Continuous blowdown in % of steam production : ____ % 7. Boiler water make-up in % of steam production : ____ % 8. Steam pressures in plant Pressure 1  _____ psig, or ______ KPa     Pressure 2  _____ psig, or ______ KPa   Pressure 3  _____ psig, or ______ KPa Pressure 4  _____ psig, or ______ KPa 9. Deaerator pressure : ______ psig, ______ KPa 10. Make-up water temperature in : ______ °F, or ______ °C 11. Steam production cost in $ / 1000 lbs ______ or/tons ______

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