3/6/2020 Introduction to Condensate Recovery | TLV - A Steam Specialist Company (International)

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Steam Theory Introduction to Condensate Recovery

1. Basics of Steam Contents:
What is Condensate?
2. Steam Heating
Condensate is the liquid formed when 1. What is Condensate?

3. Basics of Steam Traps
4. Steam Trap Selection
5. Steam Trap Problems
6. Steam Trap Management
steam passes from the vapor to the liquid
state.
In a heating process, condensate is the
result of steam transferring a portion of
its heat energy, known as latent heat, to
the product, line, or equipment being
a. Latent Heat vs. Sensible Heat
2. What is Condensate Recovery?
3. The Benefits of Condensate Recovery
a. Reduced Fuel Costs
b. Lower Water-related Expenses
c. Positive Impact on Safety and the

heated. Environment
7. Water Hammer 4. Condensate Recovery vs. No Recovery

8. Risk Mitigation

9. Steam Quality
Example of Steam Heating Process
10. Steam Distribution

11. Condensate Recovery

Introduction to Condensate
Recovery

Returning Condensate and When to

Use Condensate Pumps

Condensate Recovery: Vented vs.

Pressurized Systems

Condensate Recovery Piping

What is Stall?

Methods of Preventing Stall

When the latent heat of steam is transferred to heat the product, that steam condenses into
water, which is also known as “condensate”.
Cavitation in Condensate Pumps

Steam Heat Exchangers are

Underworked and Over-Surfaced Latent Heat vs. Sensible Heat

In steam-using industries, Latent Heat refers to the energy required to transform water
Allocate New Plant Focus to Steam
into steam, also known as the Enthalpy or Heat of Vaporization. By absorbing this Latent
System Design—Part 2
Heat, water becomes steam, and by releasing it, steam reverts to high temperature
12. Energy Efficiency water (condensate).

13. Compressed Air / Gas When steam condenses, at the threshold or instant of phase change, the condensate
temperature is the same as steam because only the latent heat has been lost, and the
14. Other Valves full amount of sensible heat remains. This condition is known as “Saturated Water”. Not
wasting, but rather recovering and reusing as much of this sensible heat as possible is
COSPECT® - one of the main reasons behind condensate recovery.
Troublefree Pressure
Reducing Valves Water Changing States
Product Solutions
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A change in the temperature of a solid, liquid or gas represents an increase/decrease in

sensible heat. A change in state, such as ice turning into water or water into steam, represents
an increase/decrease in latent heat.
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our bi-monthly newsletter. What is Condensate Recovery?
Sign up now If 1 t/h of steam is supplied to equipment for a heating process, then the same amount
of condensate (1 t/h) needs to be discharged from the equipment. Condensate recovery
is a process to reuse the water and sensible heat contained in the discharged
condensate. Recovering condensate instead of throwing it away can lead to significant
savings of energy, chemical treatment and make-up water.

Condensate can be reused in many different ways, for example:

As heated feedwater, by sending hot condensate back to the boiler’s deaerator

As pre-heat, for any applicable heating system
As steam, by reusing flash steam
As hot water, for cleaning equipment or other cleaning applications

The Benefits of Condensate Recovery

Reusing hot condensate can lead to considerable savings in terms of energy and water
resources, as well as improve working conditions and reduce your plant's carbon
footprint.

Reduced Fuel Costs

Condensate contains a significant amount of sensible heat that can account for about
10% to 30% of the initial heat energy contained in the steam.

Feeding the boiler with high-temperature condensate can maximize boiler output because
less heat energy is required to turn water into steam. When efficiently recovered and
reused, it can even be possible to reduce boiler fuel needs by up to 10 to 20%.

Lower Water-related Expenses

As long as any impurities picked up during condensate transport are removed,

condensate can be reused as boiler feedwater, reducing water supply and treatment
costs, as well as costs associated with cold water used to lower condensate temperatures
before sewering, where applicable.

Positive Impact on Safety and the Environment

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Reducing boiler fuel needs through condensate recovery leads to less air pollution by
lowering CO2, NOx and SOx emissions.

Additionally, condensate recovery lines can also limit vapor clouds to reduce noise
generated from atmospheric condensate discharge and help prevent build-up of water on
the ground, considerably improving a plant’s work environment.

Depending on the amount of condensate being recovered and reused, other benefits may
include a reduced need for boiler blowdown through better feedwater quality, and less
corrosion in the system as water quality becomes more consistent throughout the grid.

Condensate Recovery vs. No Recovery

No Condensate Recovery

If condensate is not recovered, its energy (sensible heat), chemical treatment, and water are
wasted, leading to greater fuel and water-related costs.

Condensate Recovery

Reusing condensate as boiler feedwater can help reduce make-up water and treatment costs.
The related energy savings can also help significantly reduce boiler fuel costs.

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Returning Condensate and

Allocate New Plant Focus to
When to Use Condensate
Steam System Design—Part 1
Pumps

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Condensate Recovery Pump for Open Systems

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