Short-Term Opportunities (implement today for immediate results)
Mid-Term Opportunities (get results in 1 week to 6 months)
Longer-Term Opportunities (get results in 6 months or more)
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Short-Term Opportunities (implement today for immediate results)
Improve water treatment to minimize boiler blowdown -
Reduces the amount of total dissolved solids in the boiler water, which reduces blowdown and, therefore, energy loss
Estimated energy savings range: 0.5-1%
Cost: Moderate
Available Resources:
- Minimize Boiler Blowdown (PDF 221 KB)
- Boiler Blowdown Heat Recovery Project Reduces Steam System Energy Losses at Augusta Newsprint (PDF 178 KB)
- Georgia-Pacific Palatka Plant-Wide Energy Assessment (PDF 352 KB)
- Martinez Refinery Plant-Wide Energy Assessment (PDF 241 KB) (Equilon)
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Optimize deaerator vent rate -
Minimizes avoidable loss of steam
Estimated energy savings range: 0.5-1%
Cost: Low
Available Resources:
- Deaerators in Industrial Steam Systems (PDF 194 KB)
- Georgia-Pacific Palatka Plant-Wide Energy Assessment (PDF 352 KB)
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Repair steam leaks -
Minimizes avoidable loss of steam
Estimated energy savings range: 1-2%
Cost: Moderate
Available Resources:
- Martinez Refinery Plant-Wide Energy Assessment (PDF 241 KB) (Equilon)
- Rohm and Haas Knoxville Plant Assessment Sets Benchmark for Other Sites (Revised July 2003) (PDF 765 KB)
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Mid-Term Opportunities (get results in 1 week to 6 months)
Minimize vented steam -
Minimizes avoidable losses of steam
Estimated energy savings range: 2-5%
Cost: Low
Available Resources:
- Use a Vent Condenser to Recover Flash Steam Energy (PDF 198 KB)
- Martinez Refinery Plant-Wide Energy Assessment (PDF 241 KB) (Equilon)
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Implement effective steam trap maintenance program -
Promotes efficient operation of end-use heat transfer equipment and reduces live steam in the condensate system
Estimated energy savings range: 2-5%
Cost: Low
Available Resources:
- Inspect and Repair Steam Traps (PDF 196 KB)
- New Combustion Control System and Steam Traps Save $250,000 Annually (PDF 258 KB) BWX Technologies
- Improved Steam Trap Maintenance Increases System Performance and Decreases Operating Costs (PDF 235 KB)
- Rohm and Haas Knoxville Plant Assessment Sets Benchmark for Other Sites (Revised July 2003) (PDF 765 KB) Velsicol Chemical Corp.
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Use high-pressure condensate to make low-pressure steam -
Exploits the available energy in the returning condensate
Estimated energy savings range: 1-3%
Cost: Moderate
Available Resources:
- Flash High-Pressure Condensate to Regenerate Low-Pressure Steam (PDF 196 KB)
- Georgia-Pacific Palatka Plant-Wide Energy Assessment (PDF 352 KB)
- Martinez Refinery Plant-Wide Energy Assessment (PDF 241 KB) (Equilon)
- 3M: Hutchinson Plant Focuses on Heat Recovery and Cogeneration during Plant-Wide Energy-Efficiency Assessment (PDF 710 KB)
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Longer-Term Opportunities (get results in 6 months or more)
Utilize backpressure turbine instead of pressure-reducing or release valves -
Provides a more efficient method for reducing steam pressure
Estimated energy savings range: 5-8%
Cost: High
Available Resources:
- Replace Pressure-Reducing Valves with Backpressure Turbogenerators (PDF 183 KB)
- Rebuilding Steam Turbine Generator Reduces Cost at a Steel Mill(PDF 190 KB)
- New Steam Turbine Saves Chemical Manufacturer $2.3 Million Annually (PDF 402 KB)
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Optimize condensate recovery -
Recovers the thermal energy in the condensate and reduces the amount of make-up water needed
Estimated energy savings range: 1-3%
Cost: High
Available Resources:
- Return Condensate to the Boiler (PDF 188 KB)
- Appleton Papers Plant-Wide Energy Assessment (PDF 220 KB)
- Georgia-Pacific Palatka Plant-Wide Energy Assessment (PDF 352 KB)
- Martinez Refinery Plant-Wide Energy Assessment (PDF 241 KB) (Equilon)
- 3M: Hutchinson Plant Focuses on Heat Recovery and Cogeneration during Plant-Wide Energy-Efficiency Assessment (PDF 710 KB)
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