Steam technology: what sectors are we addressing?
Wherever steam is used: such as industries related to the production and processing of chemicals, textiles, food, paper etc…
What are the achievable savings?
Steam generator efficiency may be increased by 1% for every 20 °C reduction in exhaust smoke temperature (up to 5%).
Energy savings of up to 30% can be achieved by adopting regenerative burners.
What are the advantages?
Improved performance of steam generating systems resulting in reduced fuel consumption. By monitoring the operating conditions, it is possible to minimise unburnt residue and NOx.
What are the most effective solutions?
• Reduction of combustion smoke temperatures, reusing the recovered heat in the process cycle;
• Combustion air preheater with heat recovery;
• Use of regenerative burners;
• Flash vapour recycling;
• Controlling discharge-related losses and recovery of the associated heat;
• Control of the correspondence between the generated vapour pressure and the pressure actually required for the process;
• Condensate recycling;
• Installation of turbines for the recovery of excess steam energy.
What are the low CAPEX solutions?
• Burner regulation and control by monitoring fuel flow rate, oxygen levels and heat demand;
• Reduction of excess air;
• Process parameter management and optimisation;
• Reduction of heat losses by monitoring the state of insulation of combustion systems;
• Controlling distribution network losses.
What incentives are available?
The italian White Certificates Mechanism is available; it rewards savings-enhancing efficiency measures by using innovative methods or technologies.
Are there any associated risks or disadvantages?
• Preheating the combustion air can increase the formation of NOx beyond the emission limits;
• Possible increase in the visibility of the chimney exhaust smoke plumes;
• Risk of excessively low smoke temperatures and condensation of some acidic substances present, with the risk of damage to the surfaces;
• The fume heat recovery gas-gas exchangers may be bulky and occupy excessive space.