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Forbes Marhsal KEP
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Forbes Marhsal KEP
Steam Systems
Forbes Marshall
Our approach has been to study existing setup and come up with
solutions that are right and relevant for productivity and economy,
given plant specific constraints
This has resulted in us surveying and auditing more than 6000 plants
Today, we talk about our experience in these process plants and Paper
Mills
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Accounts for 70%
Consumption on
Machine
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A Study Conducted…
175
0
A C E G I K M O Q S U W Y AA AC Minimum Maximum
Mill
Note: Though different mills use different fuels, ranging from firewood to Indian coal to imported coal, for the purpose of comparison, all mills have been converted to an equivalent of Indian coal with a gross
calorific value of 4500 kcal/kg
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The Steam Loop
Distribution
1 to 5 % Losses
Recovery or Drain
0 to 20 %
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What are others doing?
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What are others doing?
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What are others doing?
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Opportunities in Steam Generation
68%
65%
60%
Oil Solid
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Opportunities in Utilisation - Process Traps
Industry Remarks
30%
39% Trap Selection + group
75% 50% Textile
55% trapping issues
60% 50%
70%
50% System design; Operating
Paper
practices.
70%
60%
25% 50% 45%
38% 40% Brewery Bottle washer stalling of traps
25%
0% Selection of traps; Multiple
Solvent Textile Paper* Brewery* Pharma Chemical Refineries Pharma
Utility
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Opportunities in Recovery - Condensate Recovery
Industry Remarks
45%
Bottle washer condensate
Brewery
23% recovery
0%
Solvent Paper Beverage Pharma & Beverage Sustaining CRF
Chemical
Contamination of condensate
Pharma & Chem
due to Multiple Utility cycles
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Example of improvement in a Refinery - Distribution
Network
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How the Improvements came about..
• Process modification
• Custom solutions to the plant
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Potential Area in Paper Mill
And Also
Potential to
Improve Drying
Rate and
Production
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Steam System In a Waste Paper Mill
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Steam Loads - Good Mill
A 100 TPD mill will have fuel bill in the vicinity of 5 Cr!!
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Comparing the two examples
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The Encon Triangle for a Paper Mill
QCS
Hoods – 5%
Monitoring
Sustenance - 3%
Moisture Control – 4%
Pulp Mill Applications
Boiler Efficiency – 6%
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Inclusive Approach
•System Design
•Operating Practices
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Happy to Assist
Utility Design
Our approach - designing reliable, safe,
energy efficient and easy to operate and
maintain utility systems for process
industries. Plants designed by us have
been set up with the most optimized
Capex and lowest Opex.
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www.forbesmarshall.com
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