Condensate Recovery Equipment

Condensate recovery refers to the process in which the condensate discharged after the exhaust steam from steam-using equipment is condensed enters the condensate recovery equipment under the action of the back pressure of the steam trap. The condensate undergoes flash evaporation in the equipment to generate steam. The steam is pressurized through steam injection, and then, after being boosted by high-pressure steam, it returns to the steam-using equipment. Meanwhile, the condensate is pumped by a water pump through an anti-cavitation device to the place where hot water is used for recycling and reuse.

Core Advantages

High-efficiency Condensate Recovery

  • It has an efficient separation mechanism. For example, a cyclonic separator uses centrifugal force to separate condensate from steam. The equipment also maximizes recovery rate with optimized collection trays and drainage systems, and uses sensors and valves to control condensate flow.

 Energy Conservation and Quality Improvement

  • It recovers the energy in condensate. In a power plant, hot condensate is recycled to pre-heat boiler feedwater, saving energy. It also enhances the quality of the recovered liquid through filtration and treatment to remove impurities, making it suitable for reuse in boilers and preventing scale formation and corrosiont.
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Advanced Separation

 Accurate Level Control

 Corrosion Protection

Efficient Pumping

 Automation Integration

Modular Design

Advanced Separation

  • Utilizes a combination of methods like cyclonic, coalescing, and gravity separation. Some have self-cleaning mechanisms such as ultrasonic vibrations to maintain efficiency and prevent clogging.

 Accurate Level Control

  • Equipped with precise level sensors (float, ultrasonic, or capacitive). Automatic control valves regulate condensate inflow and outflow based on sensor readings to optimize tank utilization.

Corrosion Protection

  • Constructed with corrosion-resistant materials like stainless steel. May also have a coating of corrosion-inhibiting polymers for added protection.

 Efficient Pumping

  • Pumps with variable-speed drives adjust according to demand, and impeller and piping designs minimize pressure losses for energy savings and proper condensate transfer.

 Automation Integration

  • Can interface with the industrial automation system, allowing remote monitoring and control. It can receive commands and send data to the central control unit.

 Modular Design

  • Has a modular structure that enables easy installation, expansion, or replacement of components. This flexibility is beneficial for different industrial setups and allows for quick maintenance and upgrades.

Product Specifications

Product Specification Details Product Specification Details
Heating Power 6.0 kW Energy Efficiency Rating A++
Refrigerant Type R410A Applicable Area 50-150㎡
Power Supply Voltage 220V / 50Hz Noise Level ≤25 dB
Dual Inverter Technology Supported Smart Temperature Control Supported
Remote Control Mobile App Remote Control Auto Defrost Function Supported
Operating Temp Range -15℃ to 45℃ Weight 40 kg
Dimensions (L x W x H) 850mm x 300mm x 650mm Installation Method Ceiling / Wall Mounted

condensate recovery equipment Feature and Application：

Separation 

The equipment first uses various separation techniques. It may start with a primary separation such as a cyclonic separator that spins the steam-condensate mixture. The centrifugal force drives the denser condensate to the outer walls and down into a collection chamber. Coalescing filters then further refine the separation, combining small droplets of condensate into larger ones for more efficient collection.

Collection and Storage:

the condensate is collected in a dedicated tank. The tank is designed with features to ensure proper storage. It has level sensors that accurately measure the amount of condensate. These sensors send signals to control valves which regulate the inflow and outflow of condensate. The tank is also made of corrosion-resistant materials like stainless steel to prevent degradation from the often acidic or alkaline nature of the condensate.

Energy Recovery 

The recovered condensate, which is still at a relatively high temperature, is directed towards energy recovery. It is pumped into a heat exchanger where it transfers its heat to other fluids. For example, in a boiler system, the hot condensate can preheat the incoming feedwater. This reduces the amount of fuel needed to heat the water to the boiling point. The heat exchanger is designed to maximize the heat transfer efficiency, often with features like fins or baffles that increase the surface area and turbulence of the fluids, ensuring a significant energy savings.

Economic and Social Benefits:

For businesses, condensate recovery equipment unit reduces energy costs and offers a quick return on investment. On a societal level, it aids in balancing energy demand, cutting emissions, and promoting sustainable development.

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Application:

Industrial Boilers

  • In industrial boiler systems, condensate recovery equipment is used to recycle the condensate that forms after steam gives up its latent heat. The recovered condensate is often fed back into the boiler as feedwater. This is beneficial because the condensate is already at a relatively high temperature, close to the steam’s saturation temperature. For example, in a paper mill, where large industrial boilers are used for steam – based drying processes, the condensate recovery system can reduce the energy required to heat the boiler feedwater. By reusing the condensate, the mill can save a significant amount of fuel costs and also improve the overall energy efficiency of the boiler system.

HVAC (Heating, Ventilation, and Air – Conditioning) Systems

  • In HVAC systems, especially in large commercial buildings or industrial facilities, steam is often used for heating. The condensate recovery equipment collects the condensate formed in the heating coils. This recovered condensate can be used to pre – heat the incoming water supply for the heating system. In a hotel’s HVAC system, for instance, the condensate recovery helps in reducing the energy consumption of the heating unit. It also helps in maintaining the proper functioning of the system by preventing waterlogging and corrosion in the heating coils due to accumulated condensate.

Chemical and Petrochemical Plants

Chemical and petrochemical plants have numerous processes that involve the use of steam for heating, reaction, or distillation. The condensate recovery equipment in these plants is crucial for recovering valuable chemicals that may be dissolved in the condensate. For example, in a chemical plant that manufactures fertilizers, the condensate may contain traces of ammonia or other valuable by – products. By recovering the condensate, the plant can recycle these chemicals, reducing waste and also potentially generating additional revenue.

Food and Beverage Industry

In the food and beverage industry, steam is used for processes such as sterilization, cooking, and evaporation. The condensate recovery equipment can recover the condensate from these processes. In a brewery, for example, the condensate from the boiling wort can be recovered. This condensate is usually of high quality and can be used for other non – potable applications such as cleaning or pre – heating water for the next brewing cycle.

Textile Mills

extile mills use steam for processes like dyeing, drying, and fabric finishing. The condensate recovery equipment is used to recover the condensate from these steam – using operations. The recovered condensate can be used to pre – heat the water for subsequent textile processes. For example, in a fabric – drying operation, the condensate formed can be recovered and used to heat the water for the next dyeing batch. This not only saves energy but also reduces the amount of fresh water needed, which is beneficial for both cost – saving and environmental – friendly operations.

Power Generation Plants

In power generation plants, especially those that use steam turbines, a large amount of condensate is formed. The condensate recovery equipment is used to recover this condensate and recycle it back into the power generation cycle. The recovered condensate is usually fed back into the boiler feedwater system. By doing so, the plant can reduce the amount of makeup water required and also save a significant amount of energy.

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condensate recovery equipment Details

Separator

The separator, like a cyclonic or coalescing type, separates condensate from steam/vapor. Cyclonic uses centrifugal force from a swirling motion to force condensate to chamber walls. Coalescing combines small droplets. It’s crucial for initial condensate purification

Condensate Collection Tank

  • Made of corrosion-resistant stainless steel, it collects separated condensate. With level sensors to monitor height and control inflow/outflow, and an outlet for pumping condensate for further steps.

Pump

  • A centrifugal pump (often with variable-speed drive) transfers condensate. It uses an impeller’s rotation to create force for moving condensate through pipes, adjusting flow rate based on demand.

Heat Exchanger

  • In a shell-and-tube heat exchanger, hot condensate in tubes exchanges heat with surrounding feedwater in the shell. This preheats feedwater, saving energy by reducing heating needs.

Filtration System

  • A multi-stage system removes impurities like rust and scale from condensate. The first stage… (You can continue with more details about the filtration system if needed, or leave it as is if a general overview suffices)

Control System:

Monitors and manages the operation of the entire unit, including temperature, pressure, and energy consumption, ensuring efficient performance.

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Working Principle:

Condensate recovery equipment functions on several principles. Separation occurs as a cyclonic separator’s tangential entry induces a swirl and centrifugal force for condensate collection, and coalescing separation uses media to combine droplets. Energy recovery takes place in heat exchangers where hot condensate in tubes conducts heat to pre-heat surrounding fluid. Filtration uses physical barriers and ion-exchange resins adjust condensate quality, making it apt for reuse.

Separation Mechanism

Combines cyclonic and coalescing separation. Cyclonic uses tangential entry and centrifugal force; coalescing uses media to combine droplets for condensate purity.

Energy Recovery Component:

Utilizes shell-and-tube heat exchangers. Hot condensate in tubes transfers heat by conduction to surrounding fluid, saving energy in pre-heating.

Filtration and Treatment System:

Starts with mechanical filters for particulate removal. Then uses ion-exchange resins to adjust hardness and chemical dosing to neutralize corrosives for better condensate quality.

Condensate Collection and Storage:

Has a corrosion-resistant stainless steel tank. Level sensors monitor height and control inflow/outflow. Outlet allows pumping for further steps.

Efficiency and Performance:

condensate recovery equipment are multi-faceted. It exhibits high energy efficiency by recovering hot condensate to pre-heat feedwater, potentially reducing fuel consumption by 20% or more. A significant condensate recovery rate, often 90% or higher, is achieved through efficient separation and collection systems. The system pressure drop is kept low via proper piping and component design to ensure smooth fluid flow and prevent issues like reduced flow rates and increased energy consumption. Additionally, corrosion prevention, mainly through the use of corrosion-resistant materials like stainless steel, is vital for its long-term performance, safeguarding the equipment from the corrosive nature of condensate and ensuring its reliable operation over time.

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Frequently asked questions

  • The lifespan of condensate recovery equipment can vary depending on several factors. On average, with proper maintenance and under normal operating conditions, it can last between 10 to 15 years. However, if the equipment is exposed to harsh environments, such as highly corrosive steam or extreme temperature fluctuations, its lifespan may be reduced. Regular inspections, timely replacement of worn – out parts like seals and filters, and adherence to recommended operating procedures can help extend the equipment’s longevity.
  • The space requirement depends on the size and capacity of the equipment. Smaller, more compact units designed for light industrial or commercial applications may require as little as a few square feet of floor space. Larger industrial – scale condensate recovery systems, especially those with extensive heat exchangers, storage tanks, and multiple separation stages, can take up several dozen square feet or more. It’s important to consider not only the footprint of the equipment but also the clearance needed for maintenance access, piping connections, and any ancillary components.

Most modern condensate recovery equipment is designed to handle both saturated and superheated steam. However, the equipment may need to be configured differently depending on the type of steam. For saturated steam, the focus is mainly on efficient condensate separation and energy recovery. For superheated steam, additional cooling mechanisms or pre – treatment steps might be required to bring the steam to a more suitable state for condensate recovery. Some advanced systems have built – in features to automatically adjust to different steam conditions, ensuring optimal performance regardless of the steam type.

Regular maintenance tasks include checking and cleaning the separation components such as cyclonic separators and coalescing filters to ensure proper condensate separation. The pumps should be inspected for wear and tear, and the impellers may need to be cleaned or replaced if clogged. The heat exchangers require periodic inspection for scale buildup and cleaning to maintain efficient heat transfer. Additionally, the level sensors in the condensate collection tank need to be calibrated regularly to ensure accurate measurement and control of condensate levels. Lubrication of moving parts and checking of electrical connections are also essential maintenance activities.

Condensate recovery equipment can have a positive impact on water quality. By recovering condensate and treating it, impurities such as dissolved solids, particulate matter, and some dissolved gases can be removed. The filtration and treatment processes within the equipment, like ion – exchange resins and chemical dosing, help adjust the hardness, pH, and other water quality parameters. This treated condensate, when reused, can reduce the need for fresh water intake and also prevent the introduction of new impurities into the system, which is beneficial for maintaining the overall water quality and reducing the risk of scale formation and corrosion in the associated equipment.

Yes, it is often possible to retrofit existing industrial plants with condensate recovery equipment. However, a detailed engineering assessment is required before the retrofit. The existing steam and condensate piping layout needs to be evaluated to ensure proper integration of the new equipment. Space availability for installing the recovery equipment, compatibility with the existing steam generation and usage systems, and any potential impacts on the plant’s production process during the retrofit need to be considered. In some cases, minor modifications to the existing infrastructure may be sufficient, while in others, more extensive changes might be necessary, but the potential energy savings and environmental benefits usually make the retrofit a viable option.

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