Condensate pumping station
The condensate collection and transfer station fulfils the important function of returning the condensate back to the boiler house. This process allows the condensate to be reused multiple times in steam production, which significantly reduces raw material consumption and saves significant costs. This system is used when the condensate pressure is insufficient to transport it to the boiler house or when it is necessary to separate the consumer and the condensate line in order to optimise production processes.
Technical specifications
| Name | Value |
| Material of body and/or pipework | carbon steel, stainless steel |
| Capacity, m3/h | 0,3 … 200 |
| Maximum working pressure, MPa | 0,6; 1,0; 1,6; 2,5 |
| Pump | on request |
| Condensate tank volume, litres | 100 ... 5000 |
Effect of implementation
As the steam passes through the various system components for which it is used, the vapour is converted into condensate, which is essentially high quality hot water. Except in cases where there is a possibility of contamination (e.g. due to technological reasons), this condensate represents ideal boiler feed water. It is therefore very favourable from an economic point of view to return as much condensate as possible to the boiler house for reuse.
If currently no condensate from the equipment is returned to the boiler house, there is a significant loss of energy resources as well as additional costs for preparation and heating of feed water. Consequently, it is necessary to consider the feasibility of installing a condensate collection and return system.
If we assume that installation of condensate collection and return system will allow to return to the boiler house at least 70% of condensate (in reality this amount can be increased) at a temperature of about 98°C, then in quantitative terms it will amount to approx.
1000 kg/h x 70 / 100 = 700 kg/h.
The return of this amount of condensate will reduce the consumption of water from external networks, which needs to be heated to the same temperature of 98°C (specific enthalpy 410.6 kJ/kg) from the annual average raw water temperature of 10°C (specific enthalpy 41.9 kJ/kg).
In thermal equivalent, this saving is equal to
700 kg/h x (410,6 kJ/kg – 41,9 kJ/kg) = 258 090 kJ/h.
Hence
258,090 kJ/h / (35000 kJ/m3 x 0.85) = 8.7 m3/h of natural gas
From this you can calculate the costs and, even without taking into account the cost of the water itself for steam generation, the cost of chemical water treatment and the wastewater charge, the measure is very favourable.
The possibility of pumping hot condensate without cavitation with a temperature of at least 98°C makes it possible to raise the feed water temperature, thus reducing the cost of heating cold, chemically treated water. Condensate return maximises the energy efficiency of the steam condensate system.
