Michael Hyde, Northern Europe Business Development Manager at Spirax Sarco, describes the contribution that a new generation of steam technology will make towards achieving net-carbon zero ambitions. Measures can be taken today to optimise steam systems with sustainability in mind.
As technology advances, through methods of Green Generation and Thermal Battery technology, steam will become increasingly sustainable. Steam is a long and well-proven source of energy used across a wide range of applications and sectors including healthcare, pharmaceuticals, energy, food and drink.
Understand the starting point for your plant
There should be ongoing activities to look at how steam systems are currently operating and to make sure they are operating effectively and efficiently. It is important to understand the starting point for your plant, the base-line energy consumption. Optimising the efficiency of your steam system can be realised in several ways, but where to start?
A good place is to take a look at your steam trap population, which is the most important link in the steam and condensate loop. We know that removing condensate and air from your steam system is essential whilst returning condensate to the boiler house maximises use of energy.
A healthy steam trap population allows condensate to be removed from the steam system effectively meaning it can be re-used.
A step in the right direction
Steam traps are considered to be one of the most effective resource saving measures, so how can an effective steam trap management programme help you? There are four key benefits to consider:
1. Health and safety: Correctly designed and operating steam trapping allows condensate to be effectively removed from the system, eliminating any potentially hazardous situations.
2. Productivity and process improvement: Correctly functioning steam traps allow the steam system to deliver the thermal energy required for process applications to operate efficiently.
3. Sustainable energy savings and reduced carbon emissions: Condensate typically contains around 25% of the usable energy of the steam from which it came. Returning this to the boiler feed tank can save thousands of pounds per year in energy alone.
4. Lower cost of ownership: Removing the unwanted condensate from the system ensures there is less chance of damage from issues like waterhammer and corrosion. Steam traps remove the condensate as it forms, keeping better quality steam in the system and protecting pipework and equipment from erosion and corrosion.
Effective steam trap management in practice.
Don’t just take our word for it…
Take this example of the largest food factory in Europe, the Heinz factory in Wigan which produces canned soups, baked beans, pasta and puddings. Its on-site energy centre generates up to 140 tonnes of steam per hour to keep the canning lines running.
In order to reduce carbon emissions and save energy, Heinz worked with Spirax Sarco to implement a steam trap management programme at the Wigan site following the success of a previous, one-off steam trap survey, which saved enough energy and treated water to pay for itself in less than nine months.
“When Spirax Sarco carried out the original survey they put in a conservative estimate of savings and we ended up saving much more,” says Barry Aspey, the Utilities Manager for Heinz. “That helped us decide to opt for the three-year programme. If the new savings estimates are correct, the programme offers excellent value for money and should help us achieve a 4% reduction in energy consumption and reduce our carbon emissions by 200 tonnes a year.”
Could you be achieving similar results? The first step on the road to a greener future is to ensure all systems are working correctly and fully optimised – often the quickest wins too.
Get your steam trap management recommendation at: www.surveymonkey.co.uk/r/checkmysteamtraps
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