Abstract:
The hot byproduct of steam, called condensate, still retains 25% of the energy from the
original steam. Rather than draining it, it makes more sense to return it to the boiler. In
today's world, energy is a precious resource and we are facing an energy crisis. Pakistan is
currently experiencing one of the worst energy crises in its history. As a result, the textile
industry is struggling due to high production costs compared to other global markets.
However, condensate has now become a valuable resource that can significantly reduce
operating costs.
Every day, approximately 840 m3 of water is fed into the coal-fired steam boiler, which
generates 820 tons of steam. 300 tons of steam are supplied to Processing Div. II, with 80
tons used directly on machines and the remaining steam used indirectly through heat
exchangers. This leaves about 154 m3 of condensate at 80-90 ℃ that can either be wasted
or returned to the system for reuse.
This report serves as an optimized tool for conducting a cost-benefit analysis of condensate
recovery systems. Advanced techniques were used to identify the root causes of condensate
wastage. A detailed audit of the Processing Div. II was conducted, data was collected and
analyzed, and potential improvements were identified. Some repair and maintenance
activities were completed and others are currently in progress. Ultimately, a model will be
designed to find potential savings by upgrading the current condensate recovery system.
This report promotes a zero-drain approach in the textile industry, contributing to a
sustainable environment and reducing fabric costs.
