Steam recovery scheme cuts boiler costs

08 March 2011

British Bakels has reduced the combined cost of energy and water to its boiler by around 6.5%, since employing a flash steam recovery system designed and supplied by Spirax Sarco.

The system recovers the flash steam generated by blowdown from the main boiler at the company bakery.
water from a steam boiler at regular intervals to prevent contamination from building up within the system. Bakels had already minimised the amount of water released during blowdown by adopting an automated system that monitors the build up of total dissolved solids in the boiler. However, flash steam generated during the process was still being discharged, rather than recycled.

“Spirax Sarco suggested the steam recovery system” said British Bakels engineering and powder plant manager, Simon Dawson. Initial calculations predicted that the company would be able to save 5% of its boiler costs by installing a new flash vessel and associated equipment that would enable it to condense the flash steam and return it to the boiler feed tank. The feed tank is maintained at 85oC by injecting live steam, and is fed by a mixture of returning condensate and cold make-up water. The new system offsets the need for both steam injection and make-up water.

According to Mr. Dawson, since the system was installed in mid-2008, the savings have exceeded expectations: “It is vitally important that we do all we can to be as energy efficient as possible. However, as a relatively large production facility we also have a social responsibility and the Spirax Sarco system is already contributing considerably towards minimising our carbon footprint. We have been monitoring our consumption as part of a wider energy-saving initiative and we’re actually saving 6.47% per annum.”

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