High-pressure condensate service module

In the majority of steam boiler systems, any condensate that is formed is taken via open condensate containers or the feed water container back into the water-steam cycle. With condensate temperatures over 100°C, evaporation occurs. Depending on the pressure and temperature of the condensate, large quantities of condensate are lost through the roof as secondary steam. This loss of energy and water has to be made up again through the addition of more fuel and treated make-up water.

Depending on the purpose for which the steam boiler system is intended, condensate rates and condensate parameters can vary. If products are treated directly with steam, the condensate created is often not returned to the system, because it is dirty. However, in most systems, there is indirect heating via heat exchangers. To prevent foreign matter from entering, condensate monitoring devices are integrated into the condensate return flow. The monitored high-pressure condensate could then be passed into a common high-pressure condensate system without expansion steam losses. The quantity of fuel, the fresh water requirement and the use of chemical dosing agents to treat the water are dramatically reduced. In comparison with open condensate systems, fuel savings of up to 12 per cent can be realised.

The planning, production and installation of high-pressure condensate systems used to be very complicated, but LOOS has now developed a compact module. The use of the CSM-CC high-pressure condensate service module should be considered from a high-pressure condensate level of 50 per cent and above.

The module is individually dimensioned for each order and consists of a heat-insulated pressurised tank and sensors wired on a terminal strip, actuators and fittings. Pump modules and a control cabinet with an easy-to-operate touch-panel round off this component.

The condensate tank base contains a heating nozzle pipe with which the condensate temperature and pressure are maintained. Depending on fuel costs, condensate parameters and operating times of the boiler systems, the system can pay for itself in as little as a year. The module is ideal not only for new systems but also for retrofitting existing LOOS boiler systems.

The use of fewer interfaces dramatically reduces the time needed for planning, layout and assembly whilst improving planning reliability at the same time. The operator benefits from an increased level of automation, the reasonably priced Teleservice option and the potential for saving using a modular energy generating system that has been economically and ecologically optimised.

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Loos Deutschland GmbH is based in Gunzenhausen, Germany. www.loos.de