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- 1. Proprietary content © Forbes Marshall Cross Learning for Steam Systems Forbes Marshall
- 2. Proprietary content © Forbes Marshall For more than 70 years now, Forbes Marshall has been working on Steam Usage in process plants Our approach has been to study existing setup and come up with solutions that are right and relevant for productivity and economy, given plant specific constraints This has resulted in us surveying and auditing more than 6000 plants The knowledge from Benchmarking energy consumption and its trends as well as hands on studies and improvement projects lead to development of newer products and services Today, we talk about our experience in these process plants and Paper Mills
- 3. Proprietary content © Forbes Marshall Steam That’s about 250 Tons of Extra Paper!! Accounts for 70% Consumption on Machine 20% Reduction on a 100 TPD Machine means INR 1,00,00,000 Savings in an Year
- 4. Proprietary content © Forbes Marshall A Study Conducted… 281 323 336 351 375 380 395 399 400 400 410 413 435 435 436 441 443 450 451 451 470 490 516 520 560 561 613 637 650 281 449 650 0 175 350 525 700 A C E G I K M O Q S U W Y AA AC Minimum Maximum kilogram Mill Specific Fuel Consumption Note: Though different mills use different fuels, ranging from firewood to Indian coal to imported coal, for the purpose of comparison, all mills have been converted to an equivalent of Indian coal with a gross calorific value of 4500 kcal/kg
- 5. Proprietary content © Forbes Marshall The Steam Loop Steam Generation 18 to 30% losses Energy from fuel 80 to 100% Distribution 1 to 5 % Losses Utilisation 45 to 61% Used Recovery or Drain 0 to 20 % • Energy utilised in the process is only between 45 to 61% • Losses, or opportunities, exist in all segments of the loop
- 6. Proprietary content © Forbes Marshall Breweries have seen fuel consumption go down by 40% over a decade The improvements were a result of rectification of trapping system, improvement and sustenance of boiler efficiency, reduction in leakages and heat recovery from wort vapours What are others doing? 58 35 44 28 0 15 30 45 60 75 2003 2013 Litre of Furnace Oil Per KL of Brew
- 7. Proprietary content © Forbes Marshall Textile units have seen fuel consumption go down by 15 to 40% over a decade The improvements were a result of rectification of trapping system, improvement and sustenance of condensate recovery, reduction in leakages and hot water management What are others doing? 0 0 0 0 0 0.09 0.18 0.27 0.36 0.45 2003 2013 Kg Lignite per meter cloth processed
- 8. Proprietary content © Forbes Marshall Tyre plants have seen fuel consumption go down by 18 to 32% over a decade The improvements were a result of rectification of trapping system, improvement and sustenance of boiler efficiency, reduction in leakages and hot water system management What are others doing? 210 184 162 110 0 55 110 165 220 275 2003 2013 Litre of Furnace Oil Per ton of Finished Product
- 9. Proprietary content © Forbes Marshall Opportunities in Steam Generation Perception and Reality Boiler Efficiency Ideal, Indirect & Direct Efficiency (Avg) 60% 68% 75% 83% 90% Oil Solid 86% 78% 78% 70% 74% 65% Ideal Indirect Direct 8% 4% 8% 5%
- 10. Proprietary content © Forbes Marshall Opportunities in Utilisation - Process Traps Industry Remarks SEP Trap Selection & design of CRS Textile Trap Selection + group trapping issues Paper System design; Operating practices. Brewery Bottle washer stalling of traps Pharma Selection of traps; Multiple Utility Chemical Balance not known Refineries 27% failed + no trap locations 60% 50% 25% 70% 38% 40% 45% 39% 50% 70% 30% 60% 50% 55% 0% 25% 50% 75% 100% Solvent Textile Paper* Brewery* Pharma Chemical Refineries Performing OK Not Performing Correctly
- 11. Proprietary content © Forbes Marshall Opportunities in Recovery - Condensate Recovery Industry Remarks SEP Improper design of system Textile Plant Layout, CRS+FS design Paper Flash recovery w/o affecting trap performance Brewery Bottle washer condensate recovery Beverage Sustaining CRF Tyre Flash Steam Loss highest. Water - mass & energy balance Pharma & Chem Contamination of condensate due to Multiple Utility cycles 0% 23% 45% 68% 90% 113% Solvent Paper Beverage Pharma & Chemical Actually Recovered Recoverable Condensate
- 12. Proprietary content © Forbes Marshall Example of improvement in a Refinery - Distribution Network
- 13. Proprietary content © Forbes Marshall How the Improvements came about.. • Rectifying existing stuff • Involved selection of right components • Involved rectification of installation • Does not need new knowledge, only application • 10 to 15% improvement • Modifying systems for better efficiency • Application of concepts prevalent in the industry, but not practiced in the plant • 5 to 8% improvement • Process modification • Custom solutions to the plant
- 14. Proprietary content © Forbes Marshall Potential Area in Paper Mill And Also Potential to Improve Drying Rate and Production
- 15. Proprietary content © Forbes Marshall Steam System In a Waste Paper Mill How much Steam is needed? How much fuel should be consumed? Whats the best possible recovery?
- 16. Proprietary content © Forbes Marshall Steam Loads - Good Mill A 100 TPD mill will have fuel bill in the vicinity of 5 Cr!!
- 17. Proprietary content © Forbes Marshall Comparing the two examples Parameter Average Mill Good Mill Steam Consumption on the Machine 168 TPD 138 TPD Steam Consumption in the Starch Cooker 12 TPD 10 TPD Condensate Recovery 133 TPD @ 70 to 80 deg C 133 TPD @ 100 deg C Flash Recovery 0 TPD 5 TPD Feed Water Temperature 73 deg C 100 deg C Steam to be Generated from the boiler 192 TPD 153 TPD Make up water requirement 60 TPD, 31% 15 TPD, 10% Blowdown in Boiler 2 TPD 1 TPD Distribution Losses 11 TPD 4 TPD Fuel Consumption 36 TPD 25 TPD
- 18. Proprietary content © Forbes Marshall Opportunities for Optimisation • Generation • Boiler Efficiency • Blow down optimisation • Feed water tank - Level, deaeration • Distribution • Main line trapping • Location and operation of the main pressure reducing station • Steam metering • Valve Leakages on the distribution header • Utilisation • Steam leakages from dryer isolation valves • Steam leakages from rotary joints • Reducing differential between steam and dryer surface temperature • Effective trapping or blow through system • Pressure control for groups • Temperature control for starch cookers • Recovery • Recovering condensate at high temperature • Final flash steam recovery • Others • Stock Flow Metering
- 19. Proprietary content © Forbes Marshall The Encon Triangle for a Paper Mill QCS Hoods – 5% Monitoring Sustenance - 3% Moisture Control – 4% Pulp Mill Applications Boiler Efficiency – 6% Condensate Recovery – 5%, Flash Recovery– 3% Steam Conditioning, Isolation Valves – 2% Pressure Control, Condensate Evacuation, Traps / Blow-Through – 10 %
- 20. Proprietary content © Forbes Marshall Inclusive Approach •System Design •Operating Practices •Desire from Management •Maintenance Practices •Continuous Improvement •Understanding / Training •Monitoring of parameters •Top driven •System Design •Component Selection •Maintenance Practices
- 21. Proprietary content © Forbes Marshall Happy to Assist Plant Surveys & Audits Unique approach for each plant focuses on improving specific energy consumption benchmarks, delivering generic savings or carrying out troubleshooting of the steam system to address utility related production bottlenecks. Utility Design Our approach - designing reliable, safe, energy efficient and easy to operate and maintain utility systems for process industries. Plants designed by us have been set up with the most optimized Capex and lowest Opex.
- 22. Proprietary content © Forbes Marshall www.forbesmarshall.com