Steam
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.
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. Such as:
- Steam Generation through cogeneration applications, boiler controls, and water treatment
- Steam Distribution through checking steam leaks, installing insulation and proper steam trap maintenance
- Steam End Use through heat exchanger maintenance
- Steam Recovery through condensate return
Case Studies
- J.R. Simplot: Burner Upgrade Project Improves Performance and Saves Energy at a Large Food Processing Plant
, September 2005
Tip Sheets
- Benchmark the Fuel Cost of Steam Generation, January 2006
- Clean Boiler Water-side Heat Transfer Surfaces, January 2006
- Consider Installing a Condensing Economizer, August 2007
- Consider Installing High-Pressure Boilers with Backpressure Turbine-Generators, January 2006
- Consider Installing Turbulators on Two- and Three-Pass Firetube Boilers, January 2006
- Consider Steam Turbine Drives for Rotating Equipment, January 2006
- Considerations When Selecting a Condensing Economizer, August 2007
- Cover Heated, Open Vessels, January 2006
- Deaerators in Industrial Steam Systems, January 2006
- Flash High-Pressure Condensate to Regenerate Low-Pressure Steam, January 2006
- Inspect and Repair Steam Traps, January 2006
- Install an Automatic Blowdown Control System, January 2006
- Install Removable Insulation on Valves and Fittings, January 2006
- Insulate Steam Distribution and Condensate Return Lines, January 2006
- Improve Your Boiler's Combustion Efficiency, January 2006
- Minimize Boiler Blowdown, January 2006
- Minimize Boiler Short Cycling Losses, January 2006
- Recover Heat from Boiler Blowdown, January 2006
- Replace Pressure-Reducing Valves with Backpressure Turbogenerators, January 2006
- Return Condensate to the Boiler, January 2006
- Upgrade Boilers with Energy-Efficient Burners, January 2006
- Use Feedwater Economizers for Waste Heat Recovery, January 2006
- Use Low Grade Waste Steam to Power Absorption Chillers, January 2006
- Use Steam Jet Ejectors or Thermocompressors to Reduce Venting of Low-Pressure Steam, January 2006
- Use Vapor Recompression to Recover Low-Pressure Waste Steam, January 2006
- Use a Vent Condenser to Recover Flash Steam Energy, May 2006
Technical Publications
- Improving Steam System Performance: A Sourcebook for Industry, December 2002
- 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
- Steam Digest: Volume IV (2003): A compendium of articles published on steam system management and resources
- Steam Digest 2002: A compendium of articles published on steam system management and resources
- Steam Digest 2001: A compendium of articles published on steam system management and resources
- 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
Software Tools
The Steam System Tool Suite consists of three online software tools used to analyze energy use and savings opportunities in industrial steam systems.
- Steam Tools Fact Sheet, August 2010
- Steam System Tool Suite Introduction Guide, October 2009
- Steam System Scoping Tool
- Steam System Assessment Tool (SSAT)
- 3E Plus® Steam Quick Reference Guide, August 2009
- 3E Plus®
Training and Events
- Learn about Steam Systems Assessment training options.
- View the Training Calendar and Events Calendar.