Steam Systems
Many manufacturing facilities can recapture energy by installing more efficient steam equipment and processes and applying energy management practices. Use the software tools, training, and publications listed below to optimize performance and save energy.
The whole system must be considered to optimize energy and cost savings. Learn more by reading about:
- Improving Steam System Performance: A Sourcebook for Industry, Second Edition, February 2012
- Steam Generation, Distribution, Energy Use, and Recovery
Nearly 49% of all fuel burned by U.S. manufacturers is used to raise steam.
Steam heats raw materials and treats semi-finished products.
It is also a power source for equipment, facility heating, and electricity generation.
Tools
Tools to Assess Your Energy System
Scorecards and Simple Calculators
- Boiler Tune-Up
- Steam Generation Equipment Scorecard
- Mechanical Insulation Assessment and Design Calculators
Training
- DOE's Boiler MACT Technical Assistance Program
- Steam Systems Training
- Steam Tool Suite Training – 2-hour workshop (online)
- Steam End User – 1-day workshop (onsite and online)
- Qualified Steam Tool Specialist – 2½ day workshop (onsite)
- Training Calendar
- Events Calendar
Assessments
- Qualified Specialists and Energy Experts
- Energy Assessments
- Recommendations from Completed Assessments – Steam Plant Assessments
Case Studies
- Boise Inc. St. Helens Paper Mill Achieves Significant Fuel Savings, May 2008
- Chrysler: Energy Assessment Enables a Vehicle Assembly Complex to Achieve Significant Natural Gas Savings, February 2008
- Dow Chemical Company: Assessment Leads to Steam System Energy Savings, November 2007 – Repairing leaks and failed steam traps and making those activities permanent can yield substantial energy savings.
- Goodyear Tire Plant Gains Traction on Energy Savings After Completing Energy Assessment, May 2008 – By optimizing boiler operation and improving insulation, Goodyear significantly reduced fossil fuel consumption.
- J.R. Simplot: Burner Upgrade Project Improves Performance and Saves Energy at a Large Food Processing Plant, September 2005
- Longest-Serving Active Paper Mill in the Western United States Uncovers New Ways to Save Energy, Mar. 2008
- Save Energy Now Assessment Helps Expand Energy Management Program at Shaw Industries, July 2008
- Steam System Efficiency Optimized After J.R. Simplot Fertilizer Plant Receives Energy Assessment, July 2008
- Terra Nitrogen Company, L.P.: Ammonia Plant Greatly Reduces Natural Gas Consumption After Energy Assessment, Oct. 2007
Tip Sheets
- Benchmark the Fuel Cost of Steam Generation, January 2012
- Clean Boiler Water-side Heat Transfer Surfaces, January 2012
- Consider Installing a Condensing Economizer, January 2012
- Consider Installing High-Pressure Boilers with Backpressure Turbine-Generators, January 2012
- Consider Installing Turbulators on Two- and Three-Pass Firetube Boilers, January 2012
- Consider Steam Turbine Drives for Rotating Equipment, January 2012
- Considerations When Selecting a Condensing Economizer, January 2012
- Cover Heated, Open Vessels, January 2012
- Deaerators in Industrial Steam Systems, January 2012
- Flash High-Pressure Condensate to Regenerate Low-Pressure Steam, January 2012
- Inspect and Repair Steam Traps, January 2012
- Install an Automatic Blowdown Control System, January 2012
- Install Removable Insulation on Valves and Fittings, January 2012
- Insulate Steam Distribution and Condensate Return Lines, January 2012
- Improve Your Boiler's Combustion Efficiency, January 2012
- Minimize Boiler Blowdown, January 2012
- Minimize Boiler Short Cycling Losses, January 2012
- Recover Heat from Boiler Blowdown, January 2012
- Replace Pressure-Reducing Valves with Backpressure Turbogenerators, January 2012
- Return Condensate to the Boiler, January 2012
- Upgrade Boilers with Energy-Efficient Burners, January 2012
- Use Feedwater Economizers for Waste Heat Recovery, January 2012
- Use Low Grade Waste Steam to Power Absorption Chillers, January 2012
- Use Steam Jet Ejectors or Thermocompressors to Reduce Venting of Low-Pressure Steam, January 2012
- Use Vapor Recompression to Recover Low-Pressure Waste Steam, January 2012
- Use a Vent Condenser to Recover Flash Steam Energy, January 2012
Technical Publications
Sourcebook
- Unlock Energy Savings with Waste Heat Recovery, July 2011
- Achieve Steam System Excellence: Industrial Technologies Program BestPractices Steam Overview
- Steam System Opportunity Assessment for the Pulp and Paper, Chemical Manufacturing, and Petroleum Refining Industries, October 2002
- Guide to Combined Heat and Power Systems for Boiler Owners and Operators, July 2004
- Guide to Low-Emission Boiler and Combustion Equipment Selection, April 2002
- Steam System Survey Guide, May 2002
- Review of Orifice Plate Steam Traps, January 2001
- BestPractices Steam Technical Brief: Steam Pressure Reduction-Opportunities and Issues, November 2005
- BestPractices Steam Technical Brief: How to Calculate the True Cost of Steam, September 2003
- BestPractices Steam Technical Brief: Industrial Heat Pumps for Steam and Fuel Savings, June 2003
- BestPractices Steam Technical Brief: Industrial Steam System Heat-Transfer Solutions, June 2003
- BestPractices Steam Technical Brief: Industrial Steam System Process-Control Schemes, July 2003
- Save Energy Now in Your Steam Systems, January 2006
- Steam Systems Energy Efficiency Handbook, November 1997
Related System Areas
Consider improving the performance of the pumps or process heating equipment installed on steam systems.
Also review a range of projects, analyses, protocols, and strategies to reduce industrial energy intensity and carbon emissions in specific industries and technology areas.