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Energy Conservation - High Temp Condensate

The document discusses methods for dealing with high temperature condensate from heat transfer systems using medium to high pressure steam to avoid energy waste from flash steam. It describes reducing steam pressure, subcooling condensate, using high temperature condensate return units with pumps, and using pressure motive pumps. It notes that systems must be designed carefully to avoid moving the flash problem downstream.

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148 views5 pages

Energy Conservation - High Temp Condensate

The document discusses methods for dealing with high temperature condensate from heat transfer systems using medium to high pressure steam to avoid energy waste from flash steam. It describes reducing steam pressure, subcooling condensate, using high temperature condensate return units with pumps, and using pressure motive pumps. It notes that systems must be designed carefully to avoid moving the flash problem downstream.

Uploaded by

Cal
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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Energy Conservation: Dealing With High Temperature

Condensate

Improperly Designed Heat Transfer Systems Using Medium to High Pressure


Steam Can Result in Energy Waste Due to Flash Steam

Flash Steam and Why it Occurs


Discharging high pressure/temperature condensate to a lower pressure receiver
results in flash steam. The amount of flash steam depends on the temperature of the high
temperature condensate and the pressure in the receiver.
The most common case occurs with atmospheric receivers (receivers that are
vented to the atmosphere, therefore operating at 0 PSIG). At 0 PSIG water can exist at a
maximum temperature of 212 °F. When condensate is discharged from a heat exchanger
at a higher temperature, the excess energy causes some of the condensate to flash into 0
PSIG steam at 212 °F, as shown below in Figure 1.

The amount that flash can be determined from the table below.
Table 1, Flash Steam
The Cost of Flash Steam
Flash steam is surprisingly costly! Each pound of lost flash steam results in a
pound of fresh water make up, which needs to be heated. The general formula for
calculating the associated cost is:

Annual Cost = PPH Flash X (Hg at Flash Pressure – Hf at make up temperature) X


HRS/YR X Energy Cost

Where:
Hg = Enthalpy in BTU/# of flash steam
Hf = Enthalpy in the make up water
Energy Cost = Net $/Million BTU

Example:
A heat exchanger operates with 60 PSIG steam. The condensate discharges to an
atmospheric receiver. The steam flow is 5,000 PPH. What is the cost of flash steam,
assuming an energy cost of $8.50/million BTU and 6,000 hours per year of operation?

Solution:
The first step is to calculate the amount of flash using the flash table. We can see
that 10% of the condensate will flash, or 500 PPH. Next we need to look up the enthalpy
of 0 PSIG steam (1151 BTU/#, from a steam table) and the enthalpy of 50 ° make up
water. Recall that 32 degree water has an enthalpy of 0, and that it takes 1 BTU to raise a
pound of water 1° F, so the enthalpy of 50 ° water is (50-32) = 18 BTU/#.

Annual Cost =
500 PPH X (1151 – 18 BTU/#) X 6000 HRS/YR X $8.50/1,000,000 BTU =
$28,893/YR

Methods of Avoiding the Cost of Flash Steam


Several methods can be used to avoid the cost of lost flash steam.

1. Use Low Pressure Steam in Heat Transfer Processes


This involves: 1) selecting the heat exchanger so that it can meet the process load
using the lowest possible steam pressure and 2) providing a pressure reducing valve to
create steam at that pressure. In certain high temperature processes, this is not possible,
as low pressure steam will have insufficient temperature to achieve the desired result.

2. Subcool the Condensate


If the use of high pressure steam is unavoidable, flash steam can be prevented by
using a secondary heat exchanger by ITT Standard called a subcooler. The subcooler is a
smaller liquid-to-liquid heat exchanger that preheats the process solution with hot
condensate. When properly selected, the subcooler will reduce the condensate
temperature below the flash temperature, thereby eliminating the flash problem. Figure 2
below shows one arrangement for a primary heat exchanger and a condensate subcooler.
Subcooling can also be accomplished in a single, vertically mounted heat
exchanger, as shown in Figure 3. In this arrangement, the placement of the pipe loop and
the trap result in condensate retention in the lower portion of the heat exchanger shell.
The retained condensate is subcooled by heat transfer with the tubes in this portion of the
heat exchanger. Careful selection of this type of heat exchanger is required, as steam-to-
liquid heat exchange occurs in the upper portion of the shell, while liquid-to-liquid heat
transfer occurs in the lower portions.

3. Use High Temperature Condensate Return Units (CRU’s)


An alternate solution is to use a pressurized condensate return unit in lieu of a
vented CRU. Shipco style “HT” units are similar in function to standard units, but they
have ASME pressurized (non-vented) receivers, which allows handling of condensate at
essentially the pressure/temperature that exists in the heat exchanger. They also have
elevated receivers and low NPSH pumps to overcome the potential NPSH problem.
Standard pump seals allow operation to 250 °F. Tungsten carbide seals allow operation to
300° F.
With high condensate temperatures, it is a good idea to consider flushing the seals
with cool water, if available. Flush coolers are available from Elanco. Note that when
sizing traps for HT units, the receiver pressure will be essentially the same as the heat
exchanger pressure. That means that the only head available across the trap is static head
in the drip leg. In other words, size the trap at a ½ to ¼ PSI differential.

4. Use Pressure Motive Pumps


Pressure motive pumps from Watson McDaniel or Shipco may be piped to handle
high temperature condensate in non-vented applications (they may also be piped to
handle vented situations). PMP’s utilize steam pressure rather than electric pumps to
move condensate, so seal life is not an issue.

System Considerations When Pumping High Temperature Condensate


If the designer is considering using high temperature condensate return units or
pressure motive pumps to return high temperature condensate, there are two important
considerations:
1. Avoid Multiple Heat Exchangers Draining to One HT or PMP Unit
When the heat exchangers are equipped with modulating valves, more than one
heat exchanger should not be drained into one pressurized condensate return unit. This is
because the condensate receiver pressure could be higher than the modulated pressure in
a given heat exchanger, which would prevent free drainage and cause water hammer
damage to the heat exchanger.

2. Heat Balance Considerations


Handling high temperature condensate may be a wonderful idea----or it may be an
expensive way to simply move the flash problem downstream. Here is the reason:
Condensate pumps generally return condensate to a boiler feed unit (BFU) or a deaerator
(DA). Most simple boiler feed units operate at atmospheric pressure (212 °F max.).
Typical pressurized DA’s run at 5-8 PSIG, which corresponds to a saturation temperature
of 227° - 235 °F. Atmospheric DA’s run at very close to 212° F.
The application of a high temperature condensate unit results in hot condensate
being returned to the BFU unit or DA. This may cause flashing at the BFU or DA unit!
To determine whether a potential problem exists, the following formula is used to
calculate the mixture temperature:

Mix Temp =(% HT Return X HT Return Temp) + (% LT Returns X LT Return


Temp) + (% Make Up X Make Up Temp)

The calculated Mix Temp must be lower than the saturation temperature at the
desired pressure in the BFU or DA vessel.
If the mixture temperature is in excess of the saturation temperature, flash steam
will result at the BFU or DA.

Summary
Heat transfer systems utilizing medium to high pressure steam must be carefully
designed to avoid energy waste. The system designer may choose from the following
methods to achieve optimal energy usage.
v Reduce the steam pressure to the lowest pressure that will achieve the desired
fluid temperature
v Subcool the condensate using a separate subcooler or a vertically mounted heat
exchanger with a subcooing section.
v Use high temperature condensate return units with electric pumps.
v Use pressure motive pumps piped for non-vented application

A fifth method, use of a flash tank, may or may not work properly when used in
heat transfer applications. Watch this WEB site for a future article on this topic, or
contact Fluid Handling to discuss it.

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