Steam Recovery through condensate return

Overview and Key Components

The primary purpose of an effective condensate recovery system is to make the most effective use of all remaining steam and condensate energy after process use.

Key components include condensate return piping, flash tanks, and condensate pumps.

Key Inputs and Outputs

Key inputs include condensate from the end use system. Key outputs include condensate returned to the generation system and low-pressure steam transmitted to applications that can use it.

The low pressure steam component will consist of flash from the condensate receiver (or steam trap) plus blow-through steam that accompanies the condensate

Opportunities for Improvements

Identify how much condensate you presently recover and return to the boiler system. Determine if you can increase the amount of condensate that you return - cost savings can result from energy savings and from water treatment cost savings.

Ensure that the condensate piping is adequately sized. Condensate piping has to accommodate two-phase flow B liquid and vapor. The vapor portion of the condensate stream is more voluminous than the liquid portion. In general, condensate piping must be sized to handle the flash and blow-through steam rather than just the liquid portion. Condensate piping that is sized for the liquid portion only will be grossly undersized.

Ensure that your condensate return piping, flanges, and valves are properly insulated.

Identify if it is possible to return hot condensate to a flash recovery system, so that you can use the flash steam to supplement low-pressure steam needs.

Finding More Information:

Under Technical Resources - See Technical References and Standards, Steam Tips, Technical Tools